Soft ice cream dispenser “K 503”
Equipment Operating Manual
Telephone:
Fax:
Issue: 8 Date: 2015/08 Changes: 2.1.1
Issued by: AM Checked by: AM Approved by: RL
Manufactured by:
Carpigiani
First Printing: Apr. ‘08
Version 8: 2015/08
Replaces:
Printed in Italy
Carpigiani K-503 Equipment Manual
Table of Contents
CONVENTIONAL SYMBOLS ................................................................................................. 4
REMOVING MACHINE FROM PACKAGING ................. ................................... ... ............. 6
WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) .............................. 7
TROUBLESHOOTING BACTERIA CONTAMINATION .................................................. 7
1. INTRODUCTION ............................................................................................................... 9
1.1 GENERAL INFORMATION .................................. .. ................................................... 9
1.1.1 MANUFACTURER IDENTIFICATION DATA ........................................................... 9
1.2 INFORMATION ABOUT THE MACHINE ............................................................. 10
1.2.1 GENERAL INFORMATION ...................................................................................... 10
1.2.2 INTENDED USE ........................................................................................................ 10
1.2.3 NOISE .............................. ............................. ................................ ............................. 10
1.2.4 TECHNICAL FEATURES .......................................................................................... 11
1.2.5 MACHINE ASSEMBLY IDENTIFICATION ......................... ..... ... ..... ...... ..... ... ..... ..... 11
1.2.6 PASTEURIZATION AUTOMATIC CYCLE (ONLY FOR PASTEURIZING
VERSIONS) ........................................................................................................................ ........ 12
1.2.7 TEMPERATURE CHECK (ONLY FOR PASTEURIZING VERSIONS) .................... 12
2. INSTRUCTIONS FOR USE ............................................................................................ 13
2.1 CONTROLS................................................................................................................ 13
2.1.1 FUNCTIONS .............................................................................................................. 14
2.2 EVENTS ............................ ................................ ................................ ......................... 18
2.3 GEAR REPLACEMENT ............................................................................................ 18
2.4 MANAGER MENU .................................................................................................... 19
2.5 OPERATION .............................................................................................................. 20
2.5.1 ICE CREAM DISPENSING ....................................................................................... 20
2.5.2 DISPENSING SPEED ................................................ ...... ..... ... ..... ..... ...... .. ...... ..... ... .. 20
2.6 PROGRAMMED CLEANING CYCLE ................................................................... . 20
2.7 POWER ON .................................. ... ..... ..... ... ..... ...... .. ...... ..... ... ..... ..... ... ..... ...... .. ...... ... 21
3. DAILY CLOSING PROCEDURES ....................................... ................................... ...... 22
PREPARE THE MACHINE FOR THE OVERNIGHT HEAT-TREATMENT CYCLE .................... 22
TOPPING PUMPS CLEANING ...................... .................................................................. ........ 22
DISASSEMBLE AND CLEAN THE COMPONENTS ................................................................ 23
CLEAN THE SPIGOT DOOR AREA. ........................................................................................ 23
4. DAILY OPENING PROCEDURES............. .................................................................. . 24
SANITIZE THE DOOR AREA ................................................................................................... 24
PREPARE THE HOT TOPPING ....................................................... ... ................................... .. 24
START THE MACHINE ............................................................................................................. 25
6. WEEKLY CLEANING .................................................. ...................................................... 27
6.1 WASHING AND SANITIZING OF THE TOPPING CONTAINERS ..................... 27
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6.1.1 CLEANING THE TOPPING CONTAINERS: ................................................................... 27
6.1.2 CLEANING THE TOPPING HOPPER ........................................................................... 27
6.2 DISASSEMBLY, WASHING AND SANITIZING OF TH E HOT TOPPING PUMPS
27
6.3 CHECK TOPPING PUMP TEMPERATURE AND VOLUME ............................... 29
7. CLEANING EVERY 14 DAYS ....................................................................................... 30
7.1 DISASSEMBLING AND CLEANING .................... ... ................................... ........... 30
7.1.1 DRAINING AND CLEANING THE ICE CREAM ..................................................... 30
7.1.2 DISASSEMBLING THE MIX PUMP ............................................... .. ........................ 32
7.1.3 DISASSEMBLING THE SPIGOT DOOR ................................................................. 33
7.1.4 BEATER REMOVAL .................................................................................................. 33
7.2 DISASSEMBLING AND CLEANING THE OTHER COMPONENTS: ................. 34
7.3 WASHING AND SANITIZING COMPONENTS ........................... ... ...................... 34
7.4 REASSEMBLY OF WASHED AND SANITIZED COMPONENTS ...................... 35
7.4.1 REASSEMBLY OF THE BEATER ............................................................................. 35
7.4.2 REASSEMBLY OF THE SPIGOT DOOR .................................................................. 36
7.4.3 REASSEMBLY OF THE MIX PUMP......................................................................... 37
7.4.4 REASSEMBLY BEATER HOPPER ............................................................................ 37
7.5 SANITIZATION OF THE WHOLE MACHINE ....................................................... 38
7.5.1 SANITIZE THE HOPPER ................................................................................................ 38
7.5.2 SANITIZE THE PUMP AND CYLINDER ................................................................. 38
7.5.3 DRAIN THE SANITIZER ................................................................................................. 38
7.5.4 PREPARING THE TOPPING AREA ............................................................................... 38
8. PREVENTIVE MAINTENANCE .................................. ... .............................................. 40
8.2 PERIODICAL CHECK-UP AND MAINTENANCE ................................................ 41
8.3 WATER COOLING .......... ... ................................... .................................. ................. 41
8.4 AIR COOLING ........................................................................................................ .. . 41
9. TROUBLESHOOTING ..................... ................................... .................................. ......... 42
9.1 ALARMS .................................................................................................................... 42
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Equipment Manual
Conventional Symbols
WARNING: ELECTRIC SHOCK HAZARD
The staff involved is warned that the in observance of safety rules in carrying out the
operation described may cause an electric shock.
WARNING: GENERAL HAZARD
The staff involved is warned that the operation described may do harm if not carried out in
the observance of safety rules.
NOTE
It points out significant information for the staff involved.
WARNING
The staff involved is warned that the in observance of information may cause a loss of data
and damages to the machine.
PROTECTIONS
This symbol placed by description side means that the operator must use personal
protections against an implicit risk of accident.
MACHINE OPERATOR
He/she is an unskilled person, who has no specific expertise and can only carry out easy
chores, such as the machine operation by means of controls available on the push-button
panel, and filling and drawing of products used during operations.
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 o n mechanical parts and all adjustments, as well
as maintenance and repairs. He/she is qualified for interventions on electrical and
refrigeration components.
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 damages to persons and things.
Who is in charge of plant safety must be on the look-out that:
- an incorrect use or handling is avoided;
- safety devices must neither be removed nor tampered;
- only original spare parts are to be used especially as far as those compo nents with safety functions are
concerned (e.g.:protection micro switches, thermostats).
To achieve the above, the following is necessary:
- an instruction manual relevant to the machine should be available at the working place;
- such documentation must be carefully read and regulations must consequently be followed;
- only adequately skilled personnel will have to be assigned to electrical equipment.
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WARNING
The machine must be exclusively installed by authorized technicians. 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. This switch is used to cut off the power supply. Any
replacement of the power cable must be carried out only by a specialized and authorized
technician.
Never put your hand into the machine, both during production and cleaning operations. 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 stream of water under pressure.
Disconnect electrical power before removing any side or rear panel.
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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Carpigiani K-503 Equipment Manual
REMOVING MACHINE FROM PACKAGING
1. Check the Shock-watch label which indicates whether the goods have been mishandled; inspect the
cardboard shipping carton for signs of damage.(
2. Cut the metal straps (be ware of snapping metal), lift t he cardboard carton up and off of the pallet (see
fig. 2).
3. Remove bag and Styrofoam protection. Inspect the machine again for signs of shipping damage or rough
handling. If damage is visible, notify the restaurant manager and/or the shipping company (see fig. 3).
Fig. 2
Fig. 1
Fig. 3
Removal from the pallet must be carried out by two qualified persons in material handling and in
compliance with the safety rules.
4. The machine i s attached to th e pallet by 4 bolts. Th e bolt heads ar e on the bottom si de of the pallet and th ey
tighten into threaded holes on the bottom of the machine. The two wooden shims, placed sideways under the
machine,
5. Now loosen the packing bolts from the bottom side of the pallet, on one side only, and let them drop to the floor.
It is not necessary to remove the side panels of the machine to do this (see fig. 4).
6. Slightly, incline the machine on one side and remove the wooden block. Please be careful. The wood blocks
keep the machine wheels off the pallet by ¼"
drop that distance (see fig. 5).
7. Repeat the same procedure on the other side.
8. After the removal of the wooden blocks, the machine will directly rest w ith its wheels on the pallet.
9. In order to unload the machine from the pallet, use the wooden ramps
enable to keep the wheels ¼" of the surface of the pallet (see fig. 4).
Place the wooden ramps against the rear side of the machine and push the machine
from the FRONT SIDE moving it to the rear. Two persons, one in front and one in the
rear, must handle and control the machine (see fig. 6).
see fig. 1).
WARNING
, therefore their removal will cause the machine to
supplied with the machine.
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Fig. 4 Fig. 5 Fig. 6
WEEE (Waste Electrical and Electronic Equipment)
In conformity with the European Directives 2006/66/EC, on batteries and accumulator s 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 pro duct 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 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 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.
Troubleshooting Bacteria Contamination
Product samples should be taken periodically by a qualified expert in order to assess the
bacteria count in the product. The bacteria count in the samples should be below the
figures given below:
Standard Plate Count (SPC)……………..50,000
Coliform …………………………………………10
Should the bacteria counts exceed the figures listed above then there is a source of bacterial
contamination. The source of contamination must be identified and corrected. High bacteria counts
indicate that a product is not safe for consumption. You must inform the machine
operator on how to prevent bacterial contamination of the product.
Note: The soft yogurt
will have high bacteria counts. This is normal and helps define the product. However,
coliform bacteria contamination is NOT ACCEPTABLE in any food product. The
information given below will help prevent coliform bacteria contamination problems.
The following
methods of prevention.
list contains possible bacteria contamination sources along with
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SOURCE OF
CONTAMINATION
1 - Contact with the operator.
2 - Mix residue/deposits (milkstone
build-up).
3 - Worn or damaged parts.
4 - Incorrect cleaning and sanitation
procedures.
PREVENTION
1a - Wash hands and forearms thoroughly.
1b - Wear rubber gloves if cuts or skin conditions exist.
1c - Wash hands periodically thro ughout the day.
2a -
Use the brushes supplied with the machine.
2b - Thoroughly brush clean all parts and components to
prevent the formation of
bacteria and contaminate fresh mix.
3a - Lubricate all rubber parts
a food grade lubricant.
3b - Inspect o-rings for damage. Only replace with factory
approved parts.
3c - Regularly check drip troughs for exces si ve leak ag e.
4a -
The container where cleaning is carried out must
be perfectly clean and contain enough solution to
cover the biggest component. Brush clean and
sanitize the freezer on a regular basis.
4b - Use the correct brushes, lubricants, and single service
towels.
4c - Store and use chemicals according to the instructions
on their labels.
4d - Use a few good employees to follow the cleaning
procedure correctly and consistently. Allow the employee
uninterrupted time to complete the cleaning procedure.
4e -
Leave the sanitizing solution in the hopper and in
the cylinder for a few minutes.
4f - Wash and sanitize the lubricant tube after each use.
Always replace the cap on the tube.
4g - Machine components and brushes should be air-dried
overnight.
Do not put them back in the machine if
they are still wet.
4h - Always follow daily cleaning procedures. Regularly wipe
down the outside of the machine and dispensing spouts
with a sanitized towel.
milk lumps, which will house
in contact with the mix with
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SOURCE OF
CONTAMINATION
5 - Improperly stored mix.
PREVENTION
5a - Use mix stock with oldest date first. Observe expiration
dates.
5b - Place the mix directly in the cooler. Do not stack mix
outside or under direct sunlight before placing it in the
cooler.
5c - Always leave one inch between the mix and ot her products
in the cooler to allow air to circulate.
5d - Mix must not remain at room temperature for long periods
of time.
5e - Hopper storage must maintain a temperature of 40°F
(4,4°C). Storage temperatures above 45°F will allow
bacteria to multiply to dangerous levels in less than one
hour.
5f - Once the mix is placed in the hopper, the hopper covers
must be used to maintain the correct temperature and
minimize mix contamination.
1. INTRODUCTION
1.1 GENERAL INFORMATI ON
1.1.1 MANUFACTURER IDENTIFICATION DATA
The machine has a plate indicating manufacturer data, machine type and serial number.
LEGEND:
=
Serial number
A
=
Machine type
B
=
Voltage
C
=
Main switch ampere rating
D
=
Gas type and weight
E
Machine code
=
F
=
Condensation type
G
=
Frequency
H
Power input
=
I
Matr.
Gas
A
B
ANZOLA EMILIA - BOLOGNA - ITALY
DE
C
V
A
kg
Cod
air
F
G
.
Hz
HI
kW
MPa
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1.2 INFORMATION ABOUT THE MACHINE
1.2.1 GENERAL INFORMATION
Electronic, heat-treatment, floor standing machine, for the production and immediate distribution of ice
cream having the following main features:
refrigerated upper hoppers;
pasteurization system to treat the mix inside the hopper and inside the cylinder during pause periods (only for
pasteurizing version);
electronic consistency control system hard-o-tronic;
two containers for hot toppings, with heating temperature control;
two containers for room temperature toppings.
1.2.2 INTENDED USE
The K-503 machine must only be used for the production of ice cream, within the functional limits listed
below:
Voltage: ±10%
Min. ambient temperature: 50°F (10°C)
Max. ambient temperature: 109°F (43°C)
Max. ambient relative humidity: 85%
This machine is designed to be used in closed places not subject to explosion-proof standards. As a matter
of fact, it shall be used in places complying with normal atmosphere.
1.2.3 NOISE
The continuous level of acoustic radiation pressure, which has been weighed and called A on working
place, turns out to be lower than 70 dB(A), both by air-cooled and water-cooled units.
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Carpigiani K-503
1.2.4 TECHNICAL FEATURES
MODEL
80 mm
Hourly
production *
80 gr.
portions
50 mm 50 mm
Hopper
capacity
liters
Flavours
Equipment Manual
1040 mm
with drip tray
Electrical supply
Volt Phase Cycle kW
In stalled
power
1470 mm
Net weight
Kg
1520 mm
1576 mm
K-503 2 x 430 2 x 18 2 + 1 400 3 50 6 398
1.2.5 MACHINE ASSEMBLY IDENTIFICATION
LEGEND:
1 Control panel
2 Cylinder front spigot door
3 Drip tub
4 Mix hopper cover
5 Topping area
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1
2
5
3
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1.2.6 PASTEURIZATION AUTOMATIC CYCLE (ONLY FOR PASTEURIZING VERSIONS)
The machine is pre-set to automatically start the heat-treatment cycle every night at 2 a.m.. The automatic
pasteurization can be set at different times (see chapter 2.3 of the Manager Menu, step U09).
1.2.7 TEMPERATURE CHECK (ONLY FOR PASTEURIZING VERSIONS)
1. When the machine is in STOP mode, the temperature in the hopper is checked: if it is equal to or
higher than 15°C (59°F) the pasteurization program is enabled.
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Equipment Manual
2. INSTRUCTIONS FOR USE
2.1 CONTROLS
The K-503 machine is equipped with a front push-button panels.
Warning light for LOW mix
DRY FILLING BUTTON
level
Flashing LCD display to
warn:
"read information on the
dis
"
MAIN FUNCTIONS:
- STOP
-
Production
Beating button/Lock button
Increase Button:
- lights on from the beginning to the end
of the heat-treatment cycle
- “+” increase button for manager menu
IMPORTANT
Push-buttons are activated keeping the finger (not the nail) pressed on it for at least 1/2 second.
WARNING
TO REDUCE BEATER BLADE WEAR (POS. 430) USE THE BEATER FUNCTION ONLY FOR THE
NECESSARY TIME.
Pasteurization LED (only for pasteurizing ve rsions)
- lights on from the beginning to the end of the
heat-treatme nt cycle
- “+” increase button for manager menu
Storage Led / Reset Button
- Lights on at the end of the
heat-treatment cycle
- “-” decrease button for
manager menu
- Push to reset alarm messages
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2.1.1 FUNCTIONS
STOP BUTTON
By pressing this push-button during operation, the machine stops (LED on).
DISPLAY Notes
10:33:21 Fri When the machine is in STOP, the display sh ows Time and Date.
10:33:21 Fri
Overload Beater
In case is an ALARM ac tivated, the ba cklight of the LCD displ ay will flas h,
and the display indicates the kind of ALAR M.
START / PRODUCTION BUTTON
Press START button to start the production mode (LED on). The motor and compresso r
are automatically controlled by HARD-O-TRONIC system.
By pressing this button from STOP, the display indicates:
KEY
1
2
3
4
5
DISPLAY Notes
Do Not Serve !
Wash In 14 days
Sundae Ready !
Wash In 14 days
Do Not Serve !
Overload Beater
Hopper +14°C
Cylinder +13°C
Set=090 Hot=085
MIR = 0
Cones today
1543
Total Cones
123456789
When the soft ice cream is not ready, the display shows: "DO NOT
SERVE".
When the soft ice cream has reached the desired co nsistency the display
shows “READY“.
In case of ALARM, it will be displayed on the second row.
While in Production mode, it’s possible to go to the next page of the
display by pushing PROD key. Temperatures are indicated.
Pushing PROD again, we move to the next pa ge showing actual
consistency and the SET to be reached. The second row shows MIR = 0
when the handle is closed and MIR=1 when the handle is opened.
Pushing PROD again, we move to the next page s howing the cones
today counter.
Pushing PROD again, we move to the next page sh owing the total cones
counter.
6
7
TEV=+10 TGV=-22
TEC=+13 TE1=-12
TET=+60 Pushing PROD again, we move to the next page showing the actual
Pushing PROD again, we move to the next page s howing the
temperature in the hopper and in the cylinder.
Topping temperature.
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