Carpigiani 193 STEEL Instruction Manual
APPLY
FEATURE
PLATE
2016/03
Edition 02
INSTRUCTION MANUAL
193 STEEL
2
193 STEEL
2016/03 - Ed. 2 - EN
Via Emilia, 45
40011 Anzola dell’Emilia (BO)
ITALY
+ 39 051 6505111
+ 39 051 732178
carpigiani.com
We wish to thank you for the preference granted to us by purchasing one of CARPIGIANI machines.
Since 1993 Carpigiani produces following a Quality Management System certified according to UNI-EN-ISO 9001-2008.
Carpigiani machines comply with the 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”.
This manual contains a TRANSLATION OF THE ORIGINAL INSTRUCTIONS and may be reproduced, transmitted, transcribed,
filed in a data retrieval system or translated into other languages only with the prior written permission of CARPIGIANI.
The purchaser has the right to reprint it exclusively for his/her own office use.
Carpigiani policy pursues a steady research and development, thus it reserves the right to make changes and revisions
whenever deemed necessary and without being bound to notifying the purchaser.
EDITION DATE MODIFICATIONS
02 2016/03 sez. 1.2.3
EDITOR VERIFIED APPROVED
AM AM/AS RL
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INDEX
FOREWORD .......................................................................................... 6
Instruction manual .................................................................................................... 6
Purpose ...................................................................................................................... 6
Structure of the manual ............................................................................................ 6
Additional documentation ........................................................................................ 6
Conventional symbols ............................................................................................... 7
Qualification of the personnel .................................................................................. 7
Safety .......................................................................................................................... 8
Warnings .................................................................................................................... 8
1. GENERAL DATA .............................................................................. 9
1.1 General information ................................................................................9
1.1.1 Manufacturer identification data .................................................................. 9
1.1.2 Information on maintenance service ........................................................... 9
1.1.3 Information for users ................................................................................... 10
1.2 Information about the machine ...........................................................10
1.2.1 General information ..................................................................................... 10
1.2.2 Technical features ....................................................................................... 10
1.2.3 Machine unit location .................................................................................. 11
1.3 Intended use ..........................................................................................12
1.4 Noise ......................................................................................................12
1.5 Machine storage ...................................................................................12
1.6 Disposal of packaging materials .........................................................12
1.7 WEEE (Waste Electrical and Electronic Equipment) ..........................13
1.8 Bacterial contamination detection ......................................................13
2. INSTALLATION.............................................................................. 15
2.1 Room necessary for machine use .......................................................15
2.2 Machine with air-cooled condenser ....................................................15
2.3 Machine with water-cooled condenser ..............................................15
2.3.1 Water valve adjustment .............................................................................. 15
2.4 Electric connection ...............................................................................16
2.4.1 Replacing the power cable ......................................................................... 16
2.5 Top-ups ..................................................................................................16
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3. INSTRUCTIONS FOR USE ........................................................... 17
3.1 Machine safety warnings .....................................................................17
3.2 Machine configuration .........................................................................17
3.3 Controls .................................................................................................18
3.3.1 Keyboard ...................................................................................................... 18
3.3.2 Functions ...................................................................................................... 18
3.4
pump feed machine - “R” pump ............................................................... 22
3.5 Machines fed by gravity - feeding needle ...........................................22
3.6 Preliminary operations, washing and sanitization .............................23
3.7 Machine start-up ...................................................................................23
3.7.1 Starting machines with pump .................................................................... 23
3.7.2 Starting machines by gravity ...................................................................... 23
3.8 Production .............................................................................................24
3.9 Ice cream dispensing ...........................................................................24
3.10 Pasteurization (only for vers. “SP”) .....................................................24
3.11 Daily cleaning - cleaning procedures when starting and finishing
using the machine ............................................................................................ 25
3.11.1 Daily cleaning procedures at the end of the machine use ...................... 25
3.11.2 Daily cleaning procedures before the machine use ................................. 26
3.12 User programming ........................................................................................... 27
4. SAFETY DEVICES ......................................................................... 29
4.1 Alarms ....................................................................................................29
4.1.1 Blackout ....................................................................................................... 32
5.
REMOVING, CLEANING AND
REFITTING OF PARTS IN
CONTACT WITH THE PRODUCT .............................................33
5.1 General information ..............................................................................33
5.2 Washing conditions ..............................................................................33
5.3 Tips .........................................................................................................33
5.4 How to use cleaning/sanitizing solution .............................................33
5.5 Daily cleaning ........................................................................................34
5.6 Scheduled cleaning ..............................................................................34
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5.6.1 Machine drainage ........................................................................................ 34
5.6.2 Pump removal .............................................................................................. 36
5.6.3 Removing the feeding needle ..................................................................... 37
5.6.4 Spigot door removal .................................................................................... 38
5.6.5 Beater removal............................................................................................. 39
5.6.6 Removing the drip drawers and tray ................................................................. 39
5.6.7 Washing and sanitizing the components .................................................. 40
5.6.8 Refitting the beater hopper ....................................................................... 40
5.6.9 Reassembling the beater ........................................................................... 40
5.6.10 Reassembling the spigot door ................................................................... 41
5.6.11 Reassembling the pump ............................................................................. 42
5.6.12 Reassembling the feeding needle .............................................................. 43
5.6.13 Drip Drawer, Drip Tray and Hopper Cover Reassembly ........................... 43
5.6.14 Machine complete sanitization .................................................................. 44
6. MAINTENANCE ............................................................................ 45
6.1 Service type ...........................................................................................45
6.2 Water cooling ........................................................................................45
6.3 Ordering spare parts ............................................................................45
6.4 Supplied accessories ...........................................................................46
7. TROUBLESHOOTING ................................................................... 47
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FOREWORD
Instruction manual
The European Community directions on safety
standards as well as on free circulation of industrial
products within the E.C. were taken into due account
when editing this manual.
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 characterizing Carpigiani machines
all over the world.
A significant part of this manual refers to the conditions
necessary for the machine use and to the necessary
procedures during cleaning as well as routine and
special maintenance.
Nevertheless, this manual cannot cover any possible
need in detail. In case of doubts or missing information,
please contact:
Via Emilia, 45
40011 Anzola dell’Emilia (BO)
ITALY
+ 39 051 6505111
+ 39 051 732178
carpigiani.com
Structure of the manual
This manual is divided in sections, chapters and sub
chapters for an easy reference.
Section
A section is the part of the manual identifying a specific
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.
Sub chapter
It is that part of a chapter detailing the specific
component of a machine part.
It is necessary that each person involved in the
machine operation reads and understands those
parts of the manual of his/her own concern, and
particularly:
• The operator must read the chapters concerning
machine start-up, operation of machine components
and safety;
• A skilled engineer involved in the installation,
maintenance, repair, etc. of the machine must read
all parts of this manual.
Additional documentation
Along with an instruction manual, each machine is
also supplied with additional documentation:
• Supplied spare parts: a list of spare parts delivered
together with the machine for its routine maintenance.
• Wiring diagram: a diagram of wiring connections is
provided with the machine.
NOTE
Before using the machine read carefully the
instruction manual.
Carefully read safety instructions.
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Conventional symbols
ELECTRIC SHOCK
HAZARD
The staff involved is warned that the non-observance
of safety rules in carrying out the operation described
may cause an electric shock.
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.
MOVING PARTS
HAZARD
This warns the personnel involved about the
presence of moving parts and the hazards of
injuries if the safety norms are not complied with.
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 fingers or hands or other.
GENERAL
HAZARD
The staff involved is warned that the operation
described may cause injury if not performed
following safety rules.
NOTE
It points out significant information for the
personnel involved.
NOTE
This warns the personnel involved that the nonobservance of warning may cause loss of data
and damage to the machine.
PERSONAL
PROTECTION
This symbol on the side means that the operator
must use personal protection against an implicit
risk of accident.
Qualification of the personnel
The personnel allowed to operate the machine can
be differentiated by the level of preparation and
responsibility in:
MACHINE OPERATOR
Personnel without any specific technical
qualifications, capable of carrying out simple
jobs, such as: operating the machine using
the commands available on the keyboard,
loading and unloading of products used during
production, loading of any consumable materials, basic
maintenance operations (cleaning, simple blockages,
inspections of the instrumentation, etc.).
SKILLED ENGINEER
He/she is a skilled engineer, capable of
operating the machine under normal
conditions; he/she is able to carry out
operations on mechanical parts and all
adjustments, as well as maintenance and repairs. He/
she is qualified for operations on electrical and
refrigeration components.
CARPIGIANI ENGINEER
He/she is a skilled engineer assigned by the
manufacturer to carry out operations for
complex jobs under particular conditions or in
accordance with agreements made with the
owner of the machine.
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Safety
When using industrial equipment and plants, one must
be aware of the fact that moving parts (rotary motion),
high voltage components, as well as parts subject
to high temperatures may cause serious damage to
persons and things.
The persons in charge of safety must ensure that:
• an incorrect use or handling shall be avoided;
• the safety devices are neither removed nor tampered
with;
• the machine is regularly serviced;
• only original spare parts are used, especially in the
case of safety-related components (ex.: protection
microswitches, thermostat);
• suitable personal protective equipment is used;
• high care must be paid during hot product cycling;
• high care must be paid to moving parts.
To achieve the above, the following is necessary:
• the use and maintenance manual relating to the
machine is available at the working place;
• such documentation must be carefully read and the
instructions must be strictly followed;
• only suitably skilled personnel should be assigned to
electrical equipment;
IMPORTANT
Make sure that no technician will ever carry out operations
outside his own knowledge and responsibility sphere.
NOTE
According to the standard in force, a SKILLED
ENGINEER is a person who, thanks to:
• training, experience and education;
• knowledge of rules, prescriptions and operations
on accident prevention;
• knowledge of machine operating conditions;
is able to recognize and avoid any danger and has
also been allowed by the person in charge of plant
safety to carry out all kinds of operations.
Warnings
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 identification plate and with a contact
opening of 3 mm at least.
• Never perform operations on the machine using your
hands, both during production and cleaning. Before
carrying out any maintenance operation, make sure
that the machine is in Stop position and that the
main switch has been cut out.
• It is forbidden to wash the machine by means of a jet
of pressurized water.
• It is forbidden to remove panels in order to reach
the machine internal parts before disconnecting the
machine from the power supply.
• Carpigiani is not responsible for any accident that
might happen during operation, cleaning and/or
servicing of its units, if this warning has not been fully
complied with.
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1. GENERAL DATA
1.1 General information
1.1.1 Manufacturer identification 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 first page of this manual.
Fig. 01
V Hz kW
A
Gas kg
Cod.
ANZOLA EMILIA - BOLOGNA - ITALY
Matr.
100089654588-4
A Serial number
B Machine type
C Voltage
D Fuse current
E Gas type and weight
F Machine code
G Condensation type (A= air - W= water)
H Frequency
I Power
1.1.2 Information on maintenance service
All operations of routine maintenance are here described in section “Maintenance”; any additional operation
requiring technical operation on the machine must be agreed upon with the manufacturer, who will also examine the
possibility of a factory technician field operation.
A B F
G
IH
E
DC
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1.1.3 Information for users
• Carpigiani is at your disposal for any
necessary explanation or further
information concerning the machine
operation or possible improving
changes.
• In case of need, please call the local distributor or
the manufacturer if no distributor is available.
• The customer service department is available for any
information about operation and requests of spare
parts and service.
1.2 Information about the machine
1.2.1 General information
Electronic machine to immediately produce and
dispense soft ice cream with the following main
characteristics:
• refrigerate upper hopper;
• electronic control of the product consistency through
the "Hard-o-tronic" system;
• automatic product pasteurization system inside the
hopper and in the cylinder during the periods of
stopped production (for instance during the night)
(only for "SP" machines).
When producing ice-cream and pastry products,
Carpigiani recommends using always high-quality
ingredients to meet the requirements even of the
most demanding customers. Any saving made to the
prejudice of quality will surely turn into a loss much
bigger than the saving itself.
Bearing in mind the above statements, please
consider the following:
• choose high quality natural ingredients and create
your own mix or buy it from trustworthy suppliers;
• to prepare the mix, closely follow instructions given
by your supplier;
• do not modify the recommended recipes without
knowing the ingredient characteristics;
• taste your ice-cream before serving and start selling
only if entirely satisfactory;
• make sure your staff always keeps the machine
clean.
For any necessary repair, always contact the Carpigiani
Technical Service.
1.2.2 Technical features
MODEL
CONES
75 g / HOUR
*
HOPPER
CAPACITY
PUMPS FLAVORS
ELECTRICAL
SUPPLY***
CONDENSATE
INSTALLED
POWER
DIMENSIONS
(maximum
dimensions)
mm
NET
WEIGHT
l V Phase Hz kW L P H Kg
193
STEEL P
485 12+12 YES 2+1 400 3 50
AIR
4,7
550 875 890
210
WATER 550 800 805
193
STEEL G
415 18+18 NO 2+1 400 3 50
AIR
4,5
550 875 890
190
WATER 550 800 805
193
STEEL SP P
485 12+12 YES 2+1 400 3 50
AIR
4,7
550 875 890
210
WATER 550 800 805
193
STEEL SP G
415 18+12 NO 2+1 400 3 50
AIR
4,5
550 875 890
190
WATER 550 800 805
* The hourly production and the mix quantity for each ice cream can vary, according to the temperature and the
type of mix used and the increase in volume (overrun) desired.
Performance refers to a 25 °C room temperature and 20 °C cooling water temperature.
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1.2.3 Machine unit location
Fig. 02
1 Hopper lid
2 Control panel
3 Product spigot door
4 Drip tray
193 STEEL vers. AIR
1
1
2
2
3
3
4
4
L
L
H
P
P
H
193 STEEL vers. WATER
193 STEEL Only You vers. AIR
193 STEEL Only You vers. WATER
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1.3 Intended use
The machine must be used solely for the purpose
described in chapter 1.2.1 “General information” within
the functional limits described below.
• Voltage: ±10%
• Min. air temperature: 10°C
• Max. air temperature: 43°C
• Min. water temperature: 10°C
• Max. water temperature: 30°C
• Min. water pressure: 0.15 MPa (1.5 bar)
• Max. water pressure: 0.8 MPa (8 bar)
• Max. air relative humidity: 85%
This machine has been designed for use in rooms not
subject to explosion-proof laws; its use is thus bound to
complying rooms and normal atmosphere.
1.4 Noise
The equivalent continuous A-weighted sound pressure
level in a workplace for water-cooled as well as aircooled machines is less than 70 dB(A).
1.5 Machine storage
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 or other impurities.
1.6 Disposal of packaging materials
When opening the packing crate, divide packing stuff
per type and get rid of them according to laws in force
in machine installation country.
NOTE
IT is forbidden to dispose of the packaging materials
in the environment.
GENERAL
HAZARD
Keep packaging materials out of reach of children
as they can pose a choking hazard.
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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. Separate collection of this waste
helps to optimize the recovery and recycling of any
reclaimable materials and also reduces the impact on
human health and on 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.
1.8 Bacterial contamination
detection
A qualified expert shall analyze at regular intervals
some product samples to check the presence of
bacteria. The detected levels of bacteria must be
below the following values:
Standard Plate Count (SPC) ................................ 50.000
Coliform bacteria ....................................................... 10
Should the level of bacteria exceed the values above, this
indicates that there is a bacterial contamination source.
Such source must be promptly identified and removed.
A high level of bacteria indicates that the product is not
suitable to be consumed. To avoid product bacterial
contamination it is necessary to carefully clean and
sanitize the machine.
NOTE
Soft yogurt usually has a high level of bacteria but
this is normal and it is a feature of this product.
However, a contamination by coliform bacteria is
NEVER ACCEPTABLE. The information below will
help you avoiding coliform bacteria contaminations.
The following list shows the possible bacterial
contamination sources and how to avoid them.
SOURCE OF
CONTAMINATION
PREVENTION
Contact
with operator
• Thoroughly wash your
hands and forearms.
• Wear rubber gloves in case
of skin cuts or problems.
• Wash your hands several
times during the day.
Ingredient
residues/deposits
(milk lumps).
• Use suitable brushes.
• Rub all parts and
components to prevent the
formation of milk lumps as
they are the perfect place
for the growth of bacteria
that could contaminate
fresh milk.
Worn or
damaged parts
• Use a food grade lubricant
to lubricate all rubber parts
that come into contact with
the mix.
•
Check for damaged O-rings
and replace them with original
spare parts.
•
Check at regular intervals
the drip trays to avoid
excessive dripping.
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SOURCE OF
CONTAMINATION
PREVENTION
Inappropriate
cleaning and
hygienic
procedures.
•
The container where the
parts shall be cleaned must
be perfectly clean and
contain enough solution
(cleaning/sanitizing product)
to cover also the biggest
parts. Use brushes to clean
and sanitize the machine at
regular intervals.
• Use suitable brushes and
lubricants and, if possible,
use disposable cloths.
• Store and use the detergents
as specified on their labels.
• Have expert personnel
performing the cleaning
procedures. Make sure the
personnel can complete
the cleaning procedures
without interruptions and in
a correct way.
•
Leave the sanitizing solution in
the cylinder and hopper at least
for the time recommended by
the product manufacturer.
• Clean and sanitize the
cleaning tools and the
lubricant tube after each
use. Place the tube cap
back after the use.
• The machine components
and brushes must be left
air-dry. Do not place them
back in the machine when
they are still wet.
• Follow the daily cleaning
procedures. Use a sanitized
cloth to clean the machine
outside and the dispensers
at regular intervals.
SOURCE OF
CONTAMINATION
PREVENTION
Mix stored in an
wrong way
• First use the mix with the
oldest date. Pay attention to
the expiry date.
• Store the mix directly in
the fridge. Do not leave the
mix outside or under the
sunlight before storing it in
the fridge.
• Always leave 2-3 cm
between the mix and other
products in the fridge to
allow air circulation.
•
The mix must not remain at
ambient temperature for a
long time.
• The hopper storage
temperature must remain
at 4.4 °C (40° F). A storage
temperature above 4.4 °C
would allow the bacteria
growth at dangerous levels
in less than one hour.
•
Once the mix is poured in
the hopper, the suitable lid
must be used so as to keep
it at the correct temperature
and to minimize the risk of
contamination
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2. INSTALLATION
2.1 Room necessary for machine use
Space to access the machine must be left free to
allow the operator to operate without constraint and to
immediately leave the working area, if need be.
It is also necessary to have some room on the side
required for pulling out drip trays.
The minimum room for accessing the working area should
be at least 150 cm and about 45 cm are required on one
side of the machine to allow for pulling out drip trays.
NOTE
An insufficient air circulation affects operation and
output capacity of the machine.
Fig. 03
150 cm
50 cm
only air version
45 cm
for drawers
extraction
5 cm
air version
NOTE
Machines with an air-cooled condenser must be
installed leaving a minimum distance of at least 50
cm above the stack and of 5 cm on the machine
sides in order to allow free air circulation around
the condenser.
2.2 Machine with air-cooled
condenser
Machines with an air-cooled condenser must
be installed leaving a minimum distance of at
least 50 cm above the stack in order to allow
free air circulation around the condenser.
NOTE
An insufficient air circulation affects operation and
output capacity of the machine.
2.3 Machine with water-cooled
condenser
Machines fitted with a water-cooled condenser
need to be connected to running water supply
or to a cooling tower.
Water must have a pressure ranging between 0.15 MPa
and 0.8 MPa (1.5-8 bar), and a flow rate 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
IMPORTANT
If water valve must be reset, this operation
shall be carried out by skilled personnel, only.
NOTE
Water consumption increases if temperature of
inlet water is above 20 °C.
NOTE
Do not leave the machine in a room with
temperature below 0 °C without draining water
from the condenser.
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