Carpigiani 191 PSP N Installation Manual

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APPLICARE
TARGA
CARATTERISTICHE
INSTRUCTIONS - HANDBOOK
191 SP/USA
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191 SP USA P
We wish to thank you for the preference granted to us by purchasing one of CARPIGIANI machines.
To the best guarantee, since 1993 CARPIGIANI has submitted its own Quality System to the certifi cation according to the international Standard ISO 9001, nowadays its production has got UNI-EN-ISO 9001-2008 Certifi ed Quality System.
Moreover, Carpigiani machines comply with following European Directives:
- “Machinery” Directive 2006/42/EC,
- “Low Voltage” Directive 2006/95/EC,
- “EMC” Directive 2004/108/EC,
- “PED” Directive 97/23/EC,
- Regulation 2004/1935/EC relating to “Materials and articles in contact with foodstuffs”
CARPIGIANI
Via Emilia, 45 - 40011 Anzola dell'Emilia (Bologna) - Italy
Tel. +39 051 6505111 - Fax +39 051 732178
This manual contains a TRANSLATION OF THE ORIGINAL INSTRUCTIONS and may not be reproduced, transmitted, transcribed, fi led in a data retrieval system or translated into other languages, without the prior written permission of CARPIGIANI. The purchaser has the wright to reprint it for his own offi ce use. CARPIGIANI policy pursues a steady reasearch and development, thus it reserves the right to make changes and revisions whenever deemed necessary and without being bound to previous statements to the purchaser.
Issued by: AM Checked by: RF Approved by: RV
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INDEX
FOREWORD ....................................................................................................................... 5
INSTRUCTION HANDBOOK ................................................................................. 5
PURPOSE ...................................................................................................................5
HANDBOOK STRUCTURE .................................................................................... 5
ADDITIONAL DOCUMENTATION ....................................................................... 5
CONVENTIONAL SYMBOLS ................................................................................ 6
SYMBOLOGY QUALIFICATION OF THE STAFF ............................................... 6
SAFETY ..................................................................................................................... 7
WARNING ................................................................................................................. 7
SECT. 1 GENERAL
1.1 GENERAL INFORMATION ................................................................................. 9
1.1.1 MANUFACTURER'S IDENTIFICATION DATA ......................................... 9
1.1.2 INFORMATION ABOUT SERVICE ............................................................. 9
1.1.3 INFORMATION TO THE USERS ............................................................... 9
1.2 INFORMATION ABOUT THE MACHINE ......................................................... 9
1.2.1 GENERAL DATA ........................................................................................... 9
1.2.2 MACHINE LAY-OUT .................................................................................. 10
1.2.3 TECHNICAL FEATURES ........................................................................... 10
1.2.4 MACHINE SETS LOCATION .....................................................................11
1.3 INTENDED USE .....................................................................................................11
1.4 NOISE ......................................................................................................................11
1.5 STORING A MACHINE ........................................................................................11
1.6 DISPOSAL OF PACKING STUFFS .....................................................................11
1.7 WEEE.......................................................................................................................11
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SECT. 2 INSTALLATION
2.1 ROOM NECESSARY TO THE MACHINE USE .............................................. 13
2.2 MACHINE WITH AIRCOOLED CONDENSER .............................................. 13
2.3 MACHINE WITH WATERCOOLED CONDENSER ....................................... 14
2.3.1 WATER VALVE ADJUSTMENT ................................................................ 14
2.4 ELECTRIC CONNECTION ................................................................................ 14
2.4.1 REPLACEMENT OF POWER SUPPLY CORD ......................................... 14
2.5 REFILLING ........................................................................................................... 14
2.6 MACHINE TESTING ........................................................................................... 14
SECT. 3 DIRECTION FOR USE
3.1 MACHINE CONFIGURATION .......................................................................... 15
3.2 ELECTRONIC CONTROL KEYBOARD AND BUTTON FUNCTION ........ 15
3.3 SPIGOT HANDLE ................................................................................................ 17
3.4 "R" PUMP .............................................................................................................. 17
3.5 PRELIMINARY OPERATION, WASHING AND SANITIZATION ............... 18
3.6 STARTING THE MACHINE ............................................................................... 18
3.7 PRODUCTION ...................................................................................................... 18
3.8 PASTEURIZATION .............................................................................................. 19
3.9 OPENING PROCEDURES .................................................................................. 19
3.9.1 SANITIZATION OF THE LID AREA ......................................................... 19
3.9.2 DISASSEMBLY AND CLEANING OF COMPONENTS .......................... 19
3.9.3 REASSEMBLY OF COMPONENTS .......................................................... 19
3.9.4 EXTERNAL CLEANING OF THE MACHINE ......................................... 20
3.10 CLOSING PROCEDURES................................................................................... 20
3.10.1 PRE-ARRANGE THE MACHINE FOR A PASTEURISATION
CYCLE OVERNIGHT ................................................................................. 20
3.10.2 DISASSEMBLY AND CLEANING OF THE TANK COVER ................... 20
3.10.3 CLEANING THE TANK ZONE .................................................................. 20
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3.10.4 DISASSEMBLY AND CLEANING THE OIL DRIP DRAWERS .............. 20
3.10.5 SANITIZATION OF THE LID AREA ......................................................... 20
3.10.6 CLEANING AND SANITISATION OF THE OIL DRIP TRAY ................ 20
3.10.7 EXTERNAL CLEANING OF THE MACHINE ......................................... 20
SECT. 4 SAFETY DEVICES
4.1 ALARMS ................................................................................................................ 21
4.1.1 BLACK-OUT ............................................................................................... 22
SECT. 5 CLEANOUT DISASSEMBLING AND REASSEMBLING OF
PARTS IN CONTACT WITH THE PRODUCT
5.1 GENERAL DESCRIPTION ................................................................................. 23
5.2 WASHING CONDITIONS ................................................................................... 23
5.3 SUGGESTIONS ..................................................................................................... 23
5.4 HOW TO USE DETERGENT/SANITIZER ....................................................... 24
5.5 DAILY CLEANING ............................................................................................... 24
5.6 PROGRAMMED CLEANING TIME ................................................................. 24
5.7 DRAINING AND CLEANING ............................................................................. 24
5.8 DISASSEMBLING OF THE TANK MIXER ..................................................... 25
5.9 DISASSEMBLING MIX PUMP ........................................................................... 25
5.10 DISASSEMBLING OF THE DISPENSING DOOR .......................................... 26
5.11 DISASSEMBLING OF THE BEATER ............................................................... 26
5.12 WASHING AND SANITIZING OF COMPONENT PARTS ............................ 27
5.13 REASSEMBLING OF THE HOPPER MIXER ................................................. 27
5.14 REASSEMBLING MIX PUMP ............................................................................ 28
5.15 REASSEMBLING OF THE BEATER ................................................................ 29
5.16 REASSEMBLING OF THE DISPENSING DOOR ........................................... 29
5.17 SANITIZING THE WHOLE MACHINE ........................................................... 30
5.18 MIX PRIMING ...................................................................................................... 30
SECT. 6 MAINTENANCE
6.1 SERVICING TYPOLOGY ................................................................................... 31
6.2 WATERCOOLING ................................................................................................ 32
6.3 AIRCOOLING ....................................................................................................... 32
6.4 TABLE OF SPARE PARTS EQUIPMENT ......................................................... 33
SECT. 7 TROUBLESHOOT GUIDE
7.1 TROUBLESHOOT GUIDE .................................................................................. 35
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FOREWORD
INSTRUCTION HANDBOOK
Editing this handbook, it was taken into due account European Community directions on safety standards as well as on free circulation of industrial products within E.C.
PURPOSE
This handbook was conceived taking machine users' needs into due account. Topics relevant to a correct use of the machine have been analyzed in order to keep unchanged in the long run quality features charachterizing CARPIGIANI machines all over the world. A signifi cant part of this handbook refers to the conditions necessary to the machine use and to the necessary procedure during cleanout as well as routine and special maintenance. Nevertheless, this handbook cannot meet all demands in details. In case of doubts or missing information, please apply to:
CARPIGIANI Via Emilia, 45 - 40011 Anzola dell'Emilia (Bologna) - Italy
Tel. +39 051 6505111 - Fax +39 051 732178
HANDBOOK STRUCTURE
This handbook is divided in sections, chapters and subchapters in order to be consulted more easily.
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Section
A section is the part of the handbook identifying a specifi c topic related to a machine part.
Chapter
A chapter is that part of a section describing an assembly or concept relevant to a machine part.
Subchapter
It is that part of a chapter detailing the specifi c component of a machine part.
It is necessary that each person involved in the machine operation reads and clearly understands those parts of the handbook of his/her own concern, and particularly:
The Operator must read the chapters concerning the machine star-up and the operation of
machine components.
A skilled technician involved in the installation, maintenance, repair, etc., of the machine must
read all parts of this handbook.
ADDITIONAL DOCUMENTATION
Along with an instruction manual, each machine is supplied also with additional documenta­tion:
Part list: A list of spare parts which is delivered together with the machine for its mainte-
nance.
Wiring diagram: A diagram of wiring connections is placed in the machine.
Before using the machine read carefully the instruction handbook.
Pay attention to the safety instructions.
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CONVENTIONAL SYMBOLS
CAUTION: ELECTRIC SHOCK DANGER
The staff involved is warned that the non-obsevance of safety rules in carrying out the operation described may cause an electric shock.
CAUTION DANGER FROM HIGH TEMPERATURES
This warns the staff involved that failure to abide by safety rules in carrying out the operation described involves the risk of burns and scalds.
WARNING DANGER FROM MOVING PARTS
This informs the staff concerned of the presence of moving parts and the risk of injury from failure to comply with safety regulations.
CAUTION CRUSHING HAZARD
This warns the staff involved that failure to abide by safety rules in carrying out the operation described involves the risk of suffering crushed fi ngers or hands.
CAUTION: GENERAL HAZARD
The staff involved is warned that the operation described may cause injury if not performed fol­lowing safety rules.
NOTE
It points out signifi cant information for the staff involved.
WARNINGS
The staff involved is warned that the non-observance of warning may cause loss of data and damage to the machine.
PROTECTIONS
This symbol on the side means that the operator must use personal protection against an implicit risk of accident.
SYMBOLOGY QUALIFICATION OF THE STAFF
The staff allowed to operate the machine can be differentiated by the level of preparation and respon­sibility in:
MACHINE OPERATOR
Identify unqualifi ed personnel, those without any specifi c technical abilities who are capable of carrying out simple jobs, such as: operating the machine using the commands available on the keypad, the loading and unloading of products used during production, the loading of any con­sumable materials, basic maintenance operations, (cleaning, simple blockages, controls of the instrumentation, etc.).
MAINTENANCE ENGINEER
He/she is a skilled engineer for the operation of the machine under normal conditions; he/she is able to carry out interventions on mechanical parts and all adjustments, as well as maintenance and repairs. He/she is qualifi ed for interventions on electrical and refrigeration components.
CARPIGIANI ENGINEER
He/she is a skilled engineer the manufacturer assigned to fi eld interventions for complex jobs under particular conditions or in accordance with agreements made with the machine's owner.
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SAFETY
When using industrial equipment and plants, one must be aware of the fact that drive mechanisms (rotary motion), high voltage components, as well as parts subject to high temperatures may cause serious damage to persons and things. Who is in charge of plant safety must be on the look-out that:
an incorrect use or handling shall be avoided; safety devices must neither be removed nor tampered with; the machine shall be regularly serviced; only original spare parts are to be used especially as far as those components with safety
functions are concerned (ex.: protection microswitches, thermostats);
suitable personal protective equipment is worn; high care must be payed during hot product cycling.
To achieve the above, the following is necessary:
at the working place an instruction manual relevant to the machine should be available; such documentation must be carefully read and requirements must conse quently be met; only adequately skilled personnel should be assigned to electrical equipment;
IMPORTANT!
One must be on the look-out that the staff does not carry out any operation outside its own sphere of knowledge and responsibility (refer to “Symbology qualifi cation of the staff”).
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NOTE: According to the standard at present in force, a SKILLED ENGINEER is who, thanks to:
- training, experience and education,
- knowledge of rules, prescriptions and interventions on accident prevention,
- knowledge of machine operating conditions, is able to realize and avoid any danger and has also been allowed by the person in charge of plant safety to carry out all kinds of interventions.
WARNING
When installing the machine, insert a differential magnetothermal protection switch on all poles of the line, adequately sized to the absorption power shown on machine data plate and with contact opening of 3 mm at least.
Never put your hand into the machine, alike during production and cleaning operations. Before
carrying out any maintenance operation, make sure that the machine is in “STOP” position and main switch has been cut out.
It is forbidden to wash the machine by means of a bolt of water under pressure. It is forbidden to remove panels in order to reach the machine inside before having discon-
nected the machine.
CARPIGIANI is not responsible for any accident that might happen during operation, clean-
ing and/or servicing of its units, if this warning has not been fully complied with.
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1. GENERAL INFORMATION
1.1 GENERAL INFORMATION
1.1.1 Manufacturer's identif cation data
The machine has a data plate carrying manufacturer data, machine type and serial number, as­signed when it is manufactured. Copy of machine data plate to be found on fi rst page of this handbook.
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1.1.2 Information about service
All operations of routine maintenance are here described in section "Maintenance"; any additional operation requiring technical intervention on the machine must be cleared with the manufacturer, who will also examine the possibility of a factory technician fi eld intervention.
1.1.3 Information to the user
The manufacturer of the machine is at user's disposal for any explanation and information
about the machine operation.
In case of need, please call the local distributor, or the manufacturer if no distributor is avail-
able.
Manufacturer's service department is available for any information about operation, and re-
quests of spare parts and service.
1.2 INFORMATION ABOUT THE MACHINE
1.2.1 General data
Counter-top machine to immediately produce and distribute soft express ice cream in one fl avor available with pump to ensure a grater increase of volume. CARPIGIANI recommends to always use high quality mix for ice cream production in order to satisfy your customers, even the most hard-to-please ones. Any saving made to the prejudice of quality will surely turn into a loss much bigger than the saving itself.
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Bearing in mind the above statements, please take heed of the following suggestions:
- Make your mixes yourselves from high quality natural ingredients or buy them from reliable companies.
- Follow closely instructions given by your mix supplier for the preparation of the mixes.
- Do not alter your mix supplier's recipies, by adding, for instance, water or sugar.
- Taste ice cream before serving it and start selling it only if entirely satisfactory.
- Make sure your staff always keeps the machine clean.
- Have your machine serviced always by companies authorized by CARPIGIANI.
1.2.2 Machine layout
8
0
m
m
m
0
8
)
n
i
3
(
m
m
0
8
)
n
i
3
(
m
(
3
i
n
)
710 mm (28 in)
5
6
0
m
m
(
6
7
5
2
2
i
m
m
n
(
)
2
6
,
5
i
n
)
m
5
0
5
)
n
i
0
2
(
m
Fig. 1
1.2.3 Technical features
Hourly
MODEL
production *
120 ml - 0,03 gal
portions
191 P/SP N 250 12 1 380 3 60 2,1 143
* Hour output may vary depending on mix used Performances featured by a room temperature of 25°C and a water temperature of 20°C.
Hopper
capacity
liters/gal
Flavors
Electrical supply
Installed
power
Volt Phase Cycle kW/Hp
Net
weight
Kg/lb
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1.2.4 Machine sets location
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Caption:
1 Control panel 2 Freezing cylinder front lid 3 Drip tray shelf 4 Mix tank cover 5 Oil drip drawer
5
Fig. 2
4
1
2
3
1.3 INTENDED USE
The machines must be used solely for the purpose described in chapter 1.2.1, "General informa­tion" within the functional limits decribed below.
Voltage: ±10% Min air temperature °C: 10°C Max air temperature °C: 43°C Min water temperature: 10°C Max water temperature: 30°C Min. water pressure: 0,1 MPa (1 bar) Max water pressure: 0,8 MPa (8 bar) Max relative humidity: 85%
The machine has been designed for its use in places which are not subject to explosion-proof standards; its use is thus bound to conforming places and normal atmospher.
1.4 NOISE
The steady acoustic pressure level weighed A in a working place alike by watercooled and by aircooled machines is less than 70 dB(A).
1.5 STORING A MACHINE
The machine must be stored in a dry and dump-free place. Before storing the machine, wrap it in a cloth in order to protect it against dust and else.
1.6 DISPOSAL OF PACKING STUFFS
When opening the packing crate, divide packing stuffs per type and get rid of them according to laws in force in machine installation country.
1.7 WEEE (Waste Electrical and Electronic Equipment)
In conformity with the European Directives 2006/66/EC, on batteries and accumulators and waste batteries and accumulators, and 2002/96/EC, also known as WEEE, the presence of the symbol on the side of the product or packaging means that the product must not be disposed of with normal urban waste. Instead, it is the user’s responsibility to dispose of this product by returning it to a collection point designated for the recycling/treat­ment of electrical and electronic equipment waste. Differentiated collection of this waste material helps to optimize the recovery and recycling of any reclaimable materials and also reduces the impact on human health and the environment. For more information concerning the correct disposal of this product, please contact your local authority or the retailer where this product was purchased.
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2. INSTALLATION
2.1 ROOM NECESSARY TO THE MACHINE USE
The machine must be installed in such a way that air can freely circulate allaround. Rooms for the approach to the machine must be left free in order to enable the operator to act without constraint and also to immediately leave working area, if need be.
ATTENTION
Machines with aircooled condenser must be installed no closer than 8 cm to any wall
in order to allow free air circulation around the condenser.
NOTE
An insuffi cient air circulation affects operation and output capacity of the machine.
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8
0
m
m
m
0
8
)
n
i
3
(
m
m
0
8
)
n
i
3
(
m
(
3
i
n
)
2.2 MACHINE WITH AIRCOOLED CONDENSER
Fig. 3
Machines with aircooled condenser must be installed no closer than 8 cm to any wall in order to allow free air circulation around the condenser.
NOTE
An insuffi cient air circulation affects operation and output capacity of the machine.
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2.3 MACHINES WITH WATERCOOLED CONDENSER
To make the machine run, a watercooled machine must be connected to running water supply, or to a cooling tower. Water must have a pressure of 1 Bar at least and a delivery at least equal to the estimated hourly consumption. Connect inlet pipe marked by plate "Water Inlet" to water supply installing a shut-off valve, and outlet pipe marked by plate "Water Outlet" to a drain pipe, installing a shut-off valve.
2.3.1 Water valve adjustment
WARNING
If water valve must be retarded, this operation will have to be carried out by skilled personnel, only. Valve adjustment must be carried out in such a way that no water fl ows when machine is off and lukewarm water fl ows when machine is on.
NOTE:
Water consumption increases if temperature of entering water is above 20°C.
ATTENTION:
Do not leave the machine in a room with temperature below 0°C
without f rst draining water from the condenser.
2.4 ELECTRIC CONNECTION
Before connecting the machine to the mains, check that machine voltage indicated in data plate corresponds with the mains (see sec. 1.1.1 point C). Insert a differential magnetothermal protection switch adequately sized to absorption capacity required (see sec. 1.1.1 point D) and with contact opening of 3 mm at least.
WARNING
Yellow/green ground wire must be connected to a good ground outlet.
Rotation direction by three-phased machines
The beater rotates anticlockwise. By gravity-feed machines, it is necessary to remove the plate and check the direction of rotation, whereas by machines with pump you shall check whether the mix comes out from delivery hole when removing the compression pipe.
Reversing rotation direction
To reverse the direction rotation, when wrong, it is necessay to interchange two of the three leads coming from the circuit breaker.
2.4.1 Replacement of power supply cord
If the machine main cable is damaged, it must be replaced through a cable with similar fea­tures. Replacement will have to be carried out by skilled technicians only.
2.5 REFILLING
Motor installed in the machine is of the type with lubrication for life; no action of checking/re­placing or topping up is necessary. Gas fi lling necessary to the freezing system is carried out at CARPIGIANI works during machine postproduction testing. If a gas addition happens to be made, this must be carried out by skilled technicans, only, who can also fi nd out trouble origin.
2.6 MACHINE TESTING
A postproduction test of the machine is carried out at Carpigiani premises; Operation and output functionality of the machine are thoroughly tested. Machine test at end user's must be carried out by skilled technicians or by one of CARPIGIANI engineers. After the machine positioning and correct connections, also carry out all operations necessary to functional check and test of the machine.
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3. DIRECTION FOR USE
3.1 MACHINE CONFIGURATION
The machine has a motor to drive the beater, and a cooling system with water or air condenser.
Soft ice cream is prepared by f lling the tank with cold mix (+4°C) and starting the automatic production cycle, until the ideal ice cr eam consistency set by CARPIGIANI is r eached.
Thanks to the pump or to the feeding needle, the mix enters the freezing cylinder already mixed with air; ice cream is produced only when it needs to be served. The spigot head allows a single portion of soft ice cream to be distributed. At the same time, the same amount of mix moves from the hopper into the freezing cylinder.
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Fig. 5
3.2 ELECTRONIC CONTROL KEYBOARD AND BUTTON FUNCTIONS
Details of the panel are shown in the picture below.
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Fig. 6
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STOP button
STOP function selected and light indicator on: the machine is ready to receive all the functions. From Production, Storage and Pasteurization it is necessary to press Stop 2 seconds, in order to have the machine in STOP and so avoid "touch" problems with the touch­sensitive panel.
PRODUCTION function (Prd)
When selecting this function the led lights up and the mix into the cylinder is freezed until its set consistency (pre-set HOT setting) is reached.
CLEANING function (CLE)
When selecting this function, led lights up, the beater and the mix pump run, while the refrigeration unit is off. This function is timed and ends automatically when the set time (usually 3 minutes) is reached.
LOCK button
To clean the keyboard panel with a clean towel it is recommended to block the keys of the keyboard as follows: Push for 3 second the LOCK button, the respective led will fl ash indicating that the keyboard is blocked. At this stage you can clean the keyboard without any risk. To reactivate the keyboard push for 3 seconds the LOCK button, the led will get off.
PASTEURIZING function (PAS)
Pasteurization cycle will not start if the mix inside the hopper is below the minimum level. The mix, both in hopper and in cylinder, is heated up to 65°C, held at this temperature for 30 minutes, then cooled down to the storage temperature.
STORAGE function (Sto)
When selecting this function, led lights up and the machine stores the mix both in hopper and cylinder at a pre-set temperature of +4°C. The display indicates mix temperature in the hopper.
MIX LEVEL INDICATOR On display you'll be able to see:
1. Mix Out
2. How many cup is as still possible to delivery (last cones)
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3.3 SPIGOT HANDLE
In order to dispense the product, place a cup or a cone under the spout and slowly pull down the disepnsing handle (pos. 5). As son as the product comes out, twist the cup or the cone to form a cone-shaped serving. When the portion has reached the desired size, close the dispensing handle and quickly pull the cone or the cup down in order to sharpen the tip.
WARNING
It is important to keep the sensor (pos. 920) clean.
5
920
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Fig. 7
3.4 "R" PUMP
"R" pump allows, by changing position of regulator pos. 271, to vary proportions between air and mix conveyed to the freezing cylinder; so, within certain limits, it allows overrun regulation depending on mix used. "R" pump regulator should be set to the middle position. If, after dispensing a signifi cant number of cones, ice cream is too heavy and wet, you may move the R pump regulator a notch at a time towards the right. If ice cream comes out of spigot mixed with air bubles, then turn R pump regulator a notch at a time towards the left.
271
Fig. 8
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3.5 PRELIMINARY OPERATIONS, WASHING AND SANITIZATION
Before starting the machine for the fi rst time, it is necessary to thoroughly clean its parts and sanitize all parts coming into contact with the mix. To perform these operations see section 5 of this manual.
3.6 STARTING THE MACHINE
After installing the machine according to the instructions contained in the chapter INSTALLA­TION, and after carefully cleaning and sanitizing the machine, proceed as follows:
Remove the compression pipe from bottom of the tank and place it in the sanitizing solution.
Prime Hopper:
Retrieve 1 bag of mix from the walk-in refrigerator.
NB.: Mix to be poured at a temperature of 4-5°C.
With the draw handle open, pour one bag of mix into the hopper and allow the mix to pass also into the freezing cylinder. The mix level in the tank must never reach the pump (see photo) and more mix must be added when the level goes below approximately 2 cms from the tank bottom.
When only a full strength mix is fl owing from the draw spout, bringing with it eventual residues of sanitizer, close the draw handle.
Fig. 16
Connect the mix pressure pipe:
When the mix stops bubbling from the bottom of the hopper, take the mix pressure pipe from the sanitizing solution and insert it in its position in the bottom of the hopper. Make sure your hands are clean and sanitized.
Rotate the compression tube in a clockwise direction towards the pump and connect it to the pump and rotate the connection tube (pos. 207) to block it. The level of the mixture in the vat must never reach the pump (see fi gure). It is also necessary to add mixture when the level has dropped to approximately 2 cms from the bottom.
Reposition the vat cover.
Select the production function.
3.7 PRODUCTION
Dispense icecream without exceeding the machine production rate as shown in the table on page
13. If you do not exceed it, and provide to refi ll the machine with fresh mix, you can be sure you will never have to stop selling, even during peak hours. While your store is closed, set the machine to STORAGE mode. You will save signifi cantly on energy consumption, as the compressor runs only for the time strictly necessary in order to keep product at its correct temperature. When you reopen the store, assure that the heat-treatment has been correctly completed and no malfunction has occurred, set the machine to STOP and then to PRODUCTION. Within a few minutes icecream will be back at the correct consistency for sale. It is essential that you carry out CLEANING and SANITIZATION of the machine, every few days, depending on bacteriological quality of your mix as well as on health regulations in force in your country. If the machine has been stopped a long time due to a power failure, it is necessary that you check product temperature before starting the sale again; if the temperature is over +6°C, the machine must be emptied, cleaned and sanitized, and fi lled up with new fresh mix at +4°C.
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3.8 PASTEURIZATION
When you stop production, mix in tank and in cylinder must be pasteurized: to do that, press STOPand then SELECTION till the led relevant to PASTEURIZATION function switches on. The machine can also be programmed to carry out pasteurisation automatically whilst the premises are closed and on a time scale set in the programme of the machine (by the technician). It is anyway necessary that the mix inside the tank is over the half of tank capacity (mean level should be thus covered). The machine automatically executed heating and cooling programs and then stores the product at +4°C. In the event of a black-out during the pasteurization cycle, the machine will automatically carry out the program. On reopening your shop, assure that the heat-treatment has been correctly com­pleted and no malfunction has occurred, press STOP and then select the production function; within a few minutes ice cream will reach its right consistency to be served. In the event of extended power failure, it is utmost necessary that, before dispensing ice cream again, the temperature of the mix inside the tank is checked, so as to pasteurize the mix in case it is beyond 6°C. If the power failure lasts several hours, it is then necessary to clean the machine and refi ll with fresh mix.
3.9 OPENING PROCEDURES
ATTENTION
Ensure that your hands are thoroughly clean and sanitized before proceeding with the
following operations.
191 SP USA P
• Check that the Pasteurisation cycle has been totally completed and that the message “END” has appeared on the display. This message indicates that the pasteurisation process has been completed correctly without interruptions and the machine is ready for production. Press the Stop key and put the machine into production.
ATTENTION
If the Pasteurisation cycle has not been completed, the machine is blocked and access
cannot be gained to production. The mix has not been correctly pasteurized.
Check why the pasteurization has not been carried out by reading the alarm messages
on the display.
If necessary, contact Technical Assistance.
Press the Stop key and the arrow key to select the pasteurization function and carry out
a manual pasteurization cycle. If the pasteurization cycle is completed successfully, the
blockage automatically resets and the machine is ready to start production. No product
can be dispensed during the pasteurization cycle.
3.9.1 Sanitization of the lid area
• Fill a bucket with detergent/sanitizing solution. Immerse the brush into the
solution and accurately clean the dispenser zone, the dispenser spout, the handle and the area surrounding the piston; then rinse with clean water.
• Spray detergent/sanitizing solution over the tap zone, handle, dispenser
spout and inside the lid hole; then rinse with clean water
ATTENTION
Do not spray sanitising solution directly onto the photocell
underneath the door.
3.9.2 Disassembly and cleaning of components
Remove the oil drip tray, the oil drip drawers and the tank cover. Wash, sanitise and rinse them. Reassemble the components after sanitisation.
3.9.3 Reassembly of components
Reassemble the oil drip tray, the oil drip drawers and the tank cover after sani­tization.
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191 SP USA P
3.9.4 External cleaning of the machine
Using a clean and sanitised cloth, clean the door area, the front panel and any other areas that come into contact with the product.
3.10 CLOSING PROCEDURES
ATTENTION
Ensure that your hands are thoroughly clean and sanitized before proceeding with the
following operations .
3.10.1 Pre-arrange the machine for a pasteurisation cycle overnight
- Open the lid and check the level of mix in the tank.
- Add mix if necessary. The LED of the tank level indicator must be off. The level of the mix in the tank must never reach the pump.
- Ensure that the machine is in Distribution mode (the relative LED must be alight).
3.10.2 Disassembly and cleaning of the tank cover
Disassemble the tank cover and wash, sanitise and rinse it.
3.10.3 Cleaning the tank zone
Using a clean and sanitized cloth, accurately clean the external zone of the tank. Ensure that no debris drops into the tank. Reposition the sanitized tank cover on the tank.
3.10.4 Disassembly and cleaning the oil drip drawers
Remove the two oil drip drawers from the side of the machine. Wash, sanitise, rinse and reassemble them.
3.10.5 Sanitization of the lid area
• Fill a bucket with detergent/sanitizing solution. Immerse the brush into the sanitising solution and accurately clean the dispenser zone, the dispenser spout, the handle and the area surrounding the piston.
• Spray sanitizing solution over the tap zone, handle, dispenser spout and inside the lid hole.
• Rinse with clean water
ATTENTION
Do not spray sanitising solution directly onto the photocell
underneath the door.
3.10.6 Cleaning and sanitisation of the oil drip tray
After sanitising the door area, remove the oil drip tray and wash, sanitise and rinse it. Replace it on the machine.
3.10.7 External cleaning of the machine
Using a clean and sanitised cloth, clean the door area, the front panel and any other areas that come into contact with the product.
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4. SAFETY DEVICES
4.1 ALARMS
The machine is provided with a self- “CHECK“ indicating possible troubles with your machine. The “CHECK” led (the spot down on the right side of the display ) blinks when an alarm is active, and it stays on as a reminder of an alarm occurred and reset. When an alarm is displayed, check which one through the table below.
The machine can be used in the distribution mode also when an alarm has occurred, provided that it is non critical one; otherwise the machine will not allow to enter in the distribution function; if this is the case, press STOP and do not use the machine till its repair. Press Selection in order to delete the writing with reset alarm.
In the table below you can fi nd list of available alarms:
ALARM DESCRIPTION
A01 (PTMA) Thermal protection tripped.
191 SP USA P
A02 (RTC/PTMC)
A03 (TESV) Tank Safety thermostat tripped.
A04 (TESC) Cylinder Safety thermostat tripped.
A05 (TEV)
Above 5 critical alarms cause machine to set at STOP, while led blinks if the alarm is still active and is fi xed on if reset.
ALARM DESCRIPTION
A06 (TEC)
A07 (TGV)
Compressor thermal relay or Compressor thermal protection tripped.
Tank sensor faulty (interrupted or under short circuit). You can only enter in Cleaning function. The machine set at Stop.
Cylinder sensor faulty (interrrupted or under short circuit). If tripping comes from Pasteurization or Storage, the machine will set at Stop. If it comes instead from Cleaning or Production, the machine will remain in that function: relevant led blinks and A06 will be displayed.
Tank evaporator sensor faulty (interrupted or under short circuit). The alarm will cause check led blinking but will not stop the machine (this remains in the same function).
A09 (IMS)
A11 (PRESS)
A12 (TE1)
A15 (BLACK OUT)
A20 (BELT)
Safety magnet switch. Front lid open.
High pressure switch tripped. After 3 times or when it trips 2'consecutively, the machine sets at Stop.
Cylinder evaporator sensor faulty (interrupted or under short circuit). The alarm will cause check led blinking but will not stop the machine (this remains in the same function).
Blackout. The machine returns to the function where it was , excepted for Cleaning, where it returns to Stop or Pasto Cooling according to the Blackout Table.
DELTA TGVTEV In Heating of Pasteurization, if TGV temperature becomes >= TEV as to the value programmed in step DELTA TGVTEV, A20 is displayed and the machine sets back at STOP.
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191 SP USA P
ALARM DESCRIPTION
In Production: the beater motor is controlled and if staying ON more
A22 (TIME OUT)
A24 (MIX OUT)
than 15' without reaching HOT, the machine sets at "Hot reached" status, with alarm A22. If, instead, the consistency value is below HOB (HOT Block) 15', the machine sets at Stop.
When the minimum level is on (level LED on) and in Production we dispense a number of portions same as or higher than the value set in step t23 (Last Cones), A24 is displayed and the machine sets at Stor­age mode. Top up in order to reset the alarm.
A30
Wnn - WAS
Stb
PHS
LOW
If TEV is over 15°C in Stop, a Pasteurization cycle will be forced and the display shows A30.
In production, everytime the beater motor starts, if we press the pro­duction key or we dispense an ice cream portion, Wnn is displayed, this means that there are still nn days to the machine wash. See WEEKLY CLEANING. The last days to cleaning, the display is WAS, which will be reset through the Selection key once the machine has been washed. Also when: the machine has been left 24 hours in Stop with mix level covered, Cleaning is forced (WASH) and the alarm resets soon after the ma­chine wash (IMS).
In production, it may be displayed STB, meaning Stand By or ice cream not yet ready for distribution.
Phase controller. Machine is left in Stop. It is necessary to invert 2 phases in order to enable its functioning again. On turning the ma­chine on, the alarm resets.
"LOW" blinks mix is out and reserve led is on. The alarm is active in all functions but Cleaning. An acoustic signal is activated in models PIZZA HUT and it plays till mix topping up.
4.1.1 Black-out
In case of a blackout, if the machine was:
- in Stop or Cleaning, on power return it sets at STOP.
- Production, Storage or Heating or Pause during Pasteurization: on power return, the machine
sets back at the function where it was before blackout and alarm A15 will be displayed.
- Cooling step from Pasteurization,
on power return, the machine checks TEV temperature, as well as how long the blackout lasted; if time turns to be longer than the one shown in the table, the machine will executed the full pasteurization program again, whereas CHECK led is on and A15 is both on the display on and events list. If, on the contrary, time is shorter than the one shown in the following table, the machine will set back at Cooling step from Pasteurization and A15 will be displayed.
Temperature TEV Time
65°C - 50°C 30 minutes
49°C - 15°C 10 minutes
14°C - 10°C 20 minutes
9°C - 4°C 2 hours
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5. CLEANOUT DISASSEMBLING AND REASSEMBLING OF PARTS IN CONTACT WITH THE PRODUCT
5.1 GENERAL DESCRIPTION
Cleaning and sanitisation are operations that must be carried out habitually and with maximum care at the end of each production run to guarantee the production quality and respect the necessary hygienic norms. Giving dirt the time to dry out can greatly increase the risk of rings, marks and damage to surfaces. Removing dirt is much easier if it is done immediately after use because there is the risk that some elements containing acid and saline substances can corrode the surfaces. A prolonged soaking is recommended.
5.2 WASHING CONDITIONS
Avoid using solvents, alcohol or detergents that could damage the component parts,
the machine or pollute the functional production parts.
• When manually washing never utilise powder or abrasive products, abrasive sponges or pointed utensils; there is a risk of dulling the surfaces, removing or deteriorating the protective fi lm that is present on the surface and scoring the surface.
• Never ever use metal scouring pads or synthetic abrasives to stop any scouring action that could remove ferrous parts that could cause oxidisation or make the surfaces vulnerable.
• Avoid using detergents that contain chlorine and its composites. The use of these detergents such as bleach, ammoniac, hydrochloric acid and decalcifi ers can attack the composition of the steel, marking it and oxidising it irreparably and causing damage to the “plastic” parts.
• Do not use dishwashers and their detergent products.
191 SP USA P
5.3 SUGGESTIONS
• Use a non-aggressive detergent solution to wash the parts.
• Manually wash the parts in water (max 60°C) using a non-aggressive detergent and the cleaning brushes supplied as standard.
• Use drinking water (bacteriologically pure) to rinse the parts.
• To sanitise leave the disassembled parts in sanitised tepid water for the time specifi ed by the manufacturer of the product used (use the sanitising product following the instructions of the manufacturer) and rinse them before reassembling.
• When the washing procedure has been completed and before the reassembly of each component dry thoroughly with a clean and soft cloth that is suitable for coming into contact with foodstuffs, to avoid leaving any humidity rich in mineral salts and chlorine that could attack the metal surfaces and leave opaque traces.
Carpigiani recommends the use of sanitising detergent to wash the machine. The use of detergent/sanitizer permits optimising the washing and sanitising process inasmuch that it eliminates two phases of the procedure (a rinse and a washing phase). Substantially, the use of detergent/sanitizer saves time facilitating and simplifying the washing/sanitising procedures.
ATTENTION
It is also essential that each time the machine is washed and parts in contact with the ice
cream mix are removed, to make a visual check of all parts in thermosetting materials,
plastics, elastomers, silicone and metal that come into contact with the product (for
example, scrapers, pump gears, beaters, etc…).
Each part must be whole, not worn and without cracks or splits, or opaque, if originally
polished/transparent.
Carpigiani refuses to accept any liability for damage caused through imperfection and/
or failures not found and promptly solved, including with the use of original replacement
parts, and is happy to provide help and consultation for all specif c customer requests.
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191 SP USA P
5.4 HOW TO USE DETERGENT/SANITIZER
Prepare a water-based solution and detergent/sanitizer following the instructions on the label product used.
Washing/sanitizing by soaking
- Remove larger residues by hand.
- Remove fi ner residues with a jet of water.
- Soak the parts to be cleaned in the detergent/sanitizer solution.
- Leave the solution to act for the time specifi ed by the manufacturer of the product used.
- Rinse the parts with care, using plenty of clean drinking water.
5.5 DAILY CLEANING
Refer to the opening procedures (par. 3.9) and closing procedures (par. 3.10).
5.6 PROGRAMMED CLEANING TIME
The machine is equipped with an automatic system wich calls for washing of the parts in contact with the product for example every 14 days. This system, identifi ed as "WASH", disables the dispensing function at the end of the fourteenh day after the latest cleaning. On the display, the message " " appears. Every time the product is dispensed or the beater motor is activated, the display shows the number of days to the next cleaning date, as follows:
DAY MESSAGE
3 days before -3
2 days before -2
1 day before -1
Disabling day
WARNING
Cleanout and sanitization must be carried out at the programmed date indicated on the
display (for example every 14 days), as a habit and with utmost care, in order to secure
quality of production in the observance of healthy rules.
5.7 DRAINING AND CLEANING
1. Place a empty pail under the spout.
2. Press the STOP button.
3. Pull the dispensing lever and drain the ice cream.
4. Select CLENOUT function.
5. When the product coming out becomes liquid, push STOP button and leave the spout open.
6. Remove the hopper cover.
7. In the hopper, disconnect pressure pipe from the mix pump, turn it sideways, remove it pull­ing it up from its seat and let the product fl ow completely out. Grasp the pump an turn it in a clockwise direction of 45° then pull it out towards you.
8. Remove the hopper agitator by pulling it upwards.
9. Close the spout handle, pour 10 litres of cool and clean water into the mix hopper. Use the white hopper brush to scrub the mix hopper, mix level sensor and the outside the agitator shaft. Use the small brush to clean the mix inlet hole and the drive hub of the mix pump.
10.
Place an empty pail under spout. Open the spigot piston and let the water drain out.
11. Rinse with warm water until the solution runs clear.
12. Select CLENOUT function and let the beater run for 10 seconds.
13. Turn the machine off by pushing the button and let the water fl ow out.
Fig. 19
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Page 25
5.8 DISASSEMBLING OF THE TANK MIXER
Remove the hopper agitator (pos. 162) by pulling it upwards.
162
Fig. 20
5.9 DISASSEMBLING MIX PUMP
1.
Keeping the feeding tube (pos. 271) upward turn it counterclockwise and pull it out.
2. Pull the spring (pos. 206) and the back fl ow valve (pos. 245) out. Using the o-ring extractor, remove the o-ring (1126).
3. Unscrew the 2 knobs (pos. 8) and separate the cover (pos. 202) from the pump body (pos.
39).
4. Tapping the pump body against the palm of your hand, remove the pump gears (pos. 38 and 38A). Using the o-ring extractor, remove the large o-ring (pos. 1178).
5. Remove the pump body seal (pos. 243).
6. Pull the connection tube (pos. 207) from the pressure pipe. Remove the o-rings (pos. 1117, 1126 and 1131).
191 SP USA P
96
39J
39
243
248J
248
1178
38A
202
1117
207
1126
550
38
245
206
1126
271
8B
32
1131
Fig. 21
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Page 26
191 SP USA P
28
21
24
25P
430
5.10 DISASSEMBLING OF THE DISPENSING DOOR
CAUTION
Before disassembling the dispensing head, make sure that the hopper
and the cylinder are completely drained.
1. Remove the two retaining knobs (pos. 8A) and pull the door assembly towards you sliding it off the two front panel studs.
2. Pull the dispensing handle (pos. 5) so the piston (pos. 30) raises in its housing.
3. Remove the pivot pin o-ring (pos. 1285) and the pivot pin (pos. 6) out releasing the dispensing handle (pos. 5).
4. Using the dispensing handle lever pull the piston (pos. 30) out completely.
5. Using the o-ring extractor, remove the two piston o-rings (pos. 1153), and the large dispensing door o-ring (pos. 1188).
30
1188
1153
1285
7
8A
6
5
Fig. 23
5.11 DISASSEMBLING OF THE BEATER
Pull the beater (#21) out of the cylinder. Slide the beater seal (#28) out of the beater shaft. Pull out and remove the end pusher (#25P) and the idler (#24). Remove the 3 beater blades (#430). Carpigiani suggests to replace the blades each 6 months.
191 SP USA P_EN - 2012/09 - Ed. 03
WARNING
The beater seal is very important. It must be checked regularly for wear and tear. It must
always be on the beater shaft and properly lubricated, during operation, otherwise mix
will leak in the drip tray.
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5.12 WASHING AND SANITIZING OF COMPONENT PARTS
1. Manually remove the bulk of the residue.
2. Remove the rest of the residue with a jet of water.
3. Wash the parts in the detergent/sanitizer solution.
4. Immerse the parts in the detergent/sanitizing solution for the time specifi ed by the manufac- turer of the product used (use the detergent/sanitizing product following the instructions of the manufacturer).
5. Rinse with clean water.
7. Place the components on a clean tray and let them dry naturally.
8. Immerse a brush in the detergent/sanitizing solution and clean the cylinder.
9. Immerse the brush in the detergent/sanitizing solution and clean the pump housing hole and the compression tube.
10. Spray the sanitizing solution on the rear of the cylinder and on the walls of the tank.
Repeat operations 8, 9 and 10 several times, then rinse with clean water.
191 SP USA P
Fig. 26
5.13 REASSEMBLING OF THE HOPPER MIXER
Replace the hopper agitator (pos. 162) back in its seat: pay attention to angage it onto its shaft correctly.
162
Fig. 28
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191 SP USA P
5.14 REASSEMBLING MIX PUMP
1. Lubricate and replace the o-ring (pos. 1117) on the connection tube (pos. 207).
2. Lubricate and replace the o-rings (pos. 1126 and 1131) on the pressure pipe (pos. 32).
3. Insert the connection tube assembly in the pressure pipe (pos. 32).
4. Lubricate and replace the punp body o-ring (pos. 1178) and the pump body seal (pos. 243).
5. Lubricate the sides as well as the center of the pump gears (pos. 38 and 38A) with a thin fi lm of lubrifi cante insert them into the pump body (pos. 39). Do not lubricate the teeth of the
pump gears.
6. Lubricate and replace the o-ring (pos. 1412) on the feeding tube (pos. 271).
7. Hold the pump cover (pos. 202) upside down and insert the back fl ow valve (pos. 245) and spring (pos. 206) in their pump cover housing.
8. Insert the feeding tube (pos. 271) in the pump cover: push and turn it clockwise.
9. Assemble the pump cover (pos. 202) with the feeding tube downwards onto the pump body and turn the two knobs (pos. 8) tightly; install the mix pump in the hopper with the blocking pin hook on the right, pushing and turning the pump in a clockwise direction and then in an anticlockwise direction until it locks onto the hopper blocking pin.
96
243
550
39J
39
248J
248
1178
38A
202
1117
207
1126
38
245
206
1126
271
8B
32
191 SP USA P_EN - 2012/09 - Ed. 03
1131
Fig. 29
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Page 29
5.15 REASSEMBLING OF THE BEATER
28
21
24
25P
430
1. Insert the 3 beater blades (#430) onto the beater frame. Carpigiani suggests to replace the blades each 6 months.
2. Insert the end pusher (#25P) onto the beater frame.
3. Insert the end of the idler shaft (#24) in the rear housing of the beater, through the end pusher. Push the idler into position.
4. Lubricate the sides of the beater seal (#28) and slide it onto the beater shaft.
IMPORTANT
Check the beater seal for integrity. Replace if worn or damaged.
It should be replaced rather frequently.
5. Insert the beater assembly into the cylinder. Push it while turning it clockwise until it engages in its rear hub, otherwise the dispensing head cannot be fastened properly, mix can fl ow out and serious damage may occur.
191 SP USA P
5.16 REASSEMBLING OF THE DISPENSING DOOR
1. Lubricate and slide the 2 piston o-ring (pos. 1153) into their seats.
2. Insert the piston (pos. 30), pointed end down, in the dispensing head (pos. 7) making sure that the piston square notch lines up with the rectangular opening on the spigot front.
3. Position the dispensing handle (pos. 5) on the door (pos. 7) and insert the pivot pin (pos. 6) in its housing through the handle lever hole. Lubricate and insert the pivot pin o-ring (pos.
1285). Lubricate and slide into its seat the large dispensing door o-ring (pos. 1188).
4. Insert the dispensing door assembly onto the two front panel studs and fasten it with the two knobs (pos. 8A) hand tight.
30
1188
1153
1285
6
5
7
8A
- 29 -
Fig. 32
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191 SP USA P
5.17 SANITIZING THE WHOLE MACHINE
The machine must be sanitized before mix is poured in. Procede as follows:
1. Fill the hopper to the maximum level with detergent/sanitizing solution prepared following the instructions on the label product used, and allow to drain into the cylinder.
2. Using the brush, clean the mix level probes, the entire surface of the mix hopper, the surface of the mix pump and the outside of the hopper agitator.
3. Select CLENOUT function and let the beater run for about 10 seconds. Press the STOP button. The cylinder and the pump are now fi lled with the detergent/sanitizing solution.
4. Return to the machine with a small amount of detergent/sanitizing solution in a pail.
5. Dip the door spout brush in the pail of detergent/sanitizing solution and brush clean the dis­pensing spout. Repeat the operation 2 times.
6. Wiper the exterior of machine with clean sanitized towel. Repeat the operation 2 times.
7. Wait for at least 5 minutes before proceeding with the next instructions.
8. Place an empty pail under the draw spout and pull the handle.
9. Allow all of the sanitizier to drain. If the sanitizing solution does not fl ow out completely, keep the spigot open and select CLENOUT function, keep the beater runnig for 5 seconds so that the last solution residues fl ow out then push STOP.
CAUTION
Do not keep the beater running for more than the time strictly needed to complete
washing and sanitization. Without the lubrif cation of mix butterfatu
the beater wear out quickly.
10. Rinse by fi lling the cylinder with drinking water.
11. Drain the water from the cylinder by lowering the distribution lever.
5.18 MIX PRIMING
Prime Hopper:
Take a bag of mixture from the refrigerator. Insert the mixture at a temperature of 4­5°C.
Lower the distribution level and start to pour the mixture into the vat, permitting the mix to pass also into the cylinder. The level of the mixture in the vat must never reach the pump or the height of the feed needle; furthermore, it will be necessary to add mixture when the level has dropped to approximately 2 cms from the bottom.
Wait until a small quantity of mixture discharges from the opening, bringing with it any sanitising residues and place the distribution level back in its original position, thereby closing the opening.
Connect the mix pressure pipe:
Continue to pour in mixture and wait until the fi lling of the cylinder has fi nished (during the fi lling process, bubbles in the vat are visible). With clean and hygienic hands, take the feed needle from the sanitised solution and insert it into the bottom of the vat.
The level of the mixture in the vat must never exceed the height of the feed needle (see gure); furthermore, it is also necessary to add mixture when the level has dropped to approximately 2 cms from the bottom.
Reposition the vat cover.
Select the production function.
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Page 31
6. MAINTENANCE
28
21
24
25P
430
6.1 SERVICING TYPOLOGY
ATTENTION
Any servicing operation requiring the opening of machine panels must be
carried out with machine set to stop and disconnected from main switch!
Cleaning and lubricatingmoving parts is forbidden!
“Repairs to the wiring, mechanical, air supply or cooling systems, or to parts of same
must be carried out by qualif ed personnel with permission to do so and if necessary,
according to the routine and extraordinary maintenance schedules as envisaged by the
customer with reference to specif c intervention methods, according to the use for which
the machine is destined”.
Operations necessary to proper machine running are such that most of servicing is completed during production cycle. Herebelow you can fi nd a list of routine servicing operations:
- Cleanout and replacement of stuff ng box
If the prodduct drips from the side drip drawer, it means that the stuffi ng box(pos. 28) has no tightness. When dismantling the beater, check the status of the stuffi ng box; based on how long the
machine has been used, replace it if necessary, alternating it with the second stuffi ng box, provided with the accessories packet included in the packing. If the stuffi ng box has no defects, it can still be used after washing it, i.e., when at room tem- perature, it has again its original shape. To replace the stuffi ng box, proceed as follows. Remove the beater unit. Remove the stuffi ng box from its slot. Lubricate the replacement stuffi ng box. Mount the new stuffi ng box. Clean and lubricate the replaced stuffi ng box and store it to allow it to regain fl exibility.
191 SP USA P
WARNING
If you continue to work after noting traces of product in the drawer, you further
accentuate the leakage of the stuff ng box; this can lead to a malfunction
of the machine serious enough to halt production.
drip drawer
Fig. 34
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191 SP USA P
WARNING
Like all moving parts, the complete beater is also subject to wear and tear. For this
reason, we recommend checking the amount of wear to parts in direct contact with one
another (beater/beater idler and beater/cylinder walls) on a regular basis during
scheduled cleaning operations and in any case, every six months of machine operation.
In particular, make sure that the wear on the bushing on the beater idler is no more than
2 mm, as indicated by the marking on the bushing itself. If there is more than 2 mm
wear, it is necessary to replace the beater idler.
- Cleanout of beater assembly, cleanout of pump or feeding needle, cleanout and sanitiza­tion of the all machine
According to procedures described in section 5 of this manual.
- Cleanout of panels
To be carried out daily with neutral soap, seeing to it that cleansing solution never reaches
beater assembly at its inside.
WARNING
Never use abrasive sponges to clean machine and its parts,
as it might scratch their surfaces.
6.2 WATERCOOLING
By machines with watercooled condenser, water must be drained from condenser at the end of selling season in order to avoid troubles in the event that the machine is stored in rooms where temperature may fall under 0°C. After closing water inlet pipe, withdraw drain pipe from its seat and let water fl ow out from circuit.
6.3 AIRCOOLING
Clean condenser, periodically, so as to remove dust, paper and what can prevent air from circulating. For cleanout, use a brush with long bristles or a bolt of compressed air.
ATTENTION!
When using compressed air, put on personal protections in order to avoid accidents;
put on protective glasses!
NEVER USE SHARP METAL OBJECTS TO CARRY OUT THIS OPERATION. GOOD WORKING OF A FREEZING PLANT MOSTLY DEPENDS ON CLEANING OF CON­DENSER.
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Page 33
6.4 TABLE OF SPARE PARTS EQUIPMENT
191 SP USA P
1188
475
772 772A 772C 772D
28
1117
1266
1178
1126
830
Pos. Description
28 Beater stuffi ng box 72 O ring extractor 475 Accessories 772 Swab D 8x250 772A Swab D 15x350 772C Swab D 20x450 772D Swab D 30x640 830 Food-grade lubrifi cant tube
840
1131
1153
72
Fig. 37
Pos. Description
840 Cleaning spatula 1117 Gasket OR 1126 Gasket OR 1131 Gasket OR 1153 Gasket OR 1178 Gasket OR 1188 Gasket OR 1266 Gasket OR
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191 SP USA P_EN - 2012/09 - Ed. 03
Page 34
191 SP USA P
191 SP USA P_EN - 2012/09 - Ed. 03
- 34 -
Page 35
7 TROUBLESHOOT GUIDE
191 SP N
IRREGULARITY
Compressor starts and then stops after a few seconds.
Mix or ice cream come out above or below piston though it is closed.
Mix coming out of drip drawer
Piston hard to operate.
Ice cream comes out fr om front lid .
Low ice cream overrun
CAUSE
1. If machine is watercooled: water is not circulating.
2. If machine is aircooled: air is not circulating.
1. Piston without OR or OR is worn­out.
1. Stuffi ng box missing or worn-out.
1. Dry sugar on piston.
1. OR missing or not properly fi t.
2. Front lid knobs not tightened evenly.
1. "R" pump not properly adjusted
PROCEDURE TO FOLLOW
1. Open water inlet cock and check that pipe is not squashed nor bent.
2. Check that machine clearance is at least 80 mm from wall.
2. Call for service if necessary
1. Stop the machine and insert or replace it with a new one if worn-out.
1. Stop the machine and install it if missing. If worn-out, replace it with a new one.
1. Stop the machine and wash thoroughly and grease piston and OR with edible fat.
1. Stop the machine and check and put remedy.
2. Stop machine. loosen and tighten them again.
1. Change regulator (Pos. 271).
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191 SP N_EN - 08/06 - Ed. 07
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