LB1002
Carpigiani LB1002, LB1002 G, LB 302 G, LB 502 G, LB 302 User Manual
...
LB 302 • LB 502 • LB1002
LB 302 G • LB 502 G• LB 1002 G
OPERATION
MANUAL
CARPIGIANI CORPORATION OF AMERICA
3760 Industrial Drive • Winston-Salem, North Carolina 27105
336-661-9893 • 336-661-9895 (Fax)
TABLE OF CONTENTS
FORWARD........................................................................................................................................................... 3
PART 1 - INSTALLA TION......................................................................................................................................4
UNCRATING .................................................................................................................................................... 4
POSITIONING THE MACHINE ........................................................................................................................... 4
MACHINE EQUIPPED WITH AIR COOLED CONDENSER................................................................................... 5
MACHINE EQUIPPED WITH WATER-COOLED CONDENSER .............................................................................5
WATER VALVE ADJUSTMENT ..........................................................................................................................5
ELECTRICAL REQUIREMENTS ........................................................................................................................ 6
POWER SUPPLY ............................................................................................................................................ 6
WIRING ........................................................................................................................................................... 6
ELECTRICAL CONNECTIONS ........................................................................................................................... 6
BEATER ROTATION ......................................................................................................................................... 6
COMPLETING THE INSTALLATION.................................................................................................................... 7
MACHINE SAFETY SYSTEM - THERMAL RELAY .............................................................................................. 7
PROTECTION FOR THE OPERATOR ................................................................................................................ 7
PART 2 - EXPLANATION OF CONTROLS.............................................................................................................. 8
ICE CREAM DISPENSING HANDLE ................................................................................................................10
PART 3 - INITIAL CLEANING PROCEDURE ......................................................................................................... 1 1
PRELIMINARY CLEAN-OUT ............................................................................................................................ 11
BEATER DISASSEMBLY (MODELS LB 302 - LB 502 - LB 1002)....................................................................... 1 1
BEATER DISASSEMBLY (MODELS LB 302 G - LB 502 G - LB 1002 G) .............................................................12
FRONT DOOR DISASSEMBLY .......................................................................................................................12
ICE CREAM GATE DISASSEMBLY .................................................................................................................13
FILL CHUTE COVER DISASSEMBLY ..............................................................................................................13
CLEANING OPERATIONS ...............................................................................................................................13
PART 4 - ASSEMBLING THE FREEZER ...............................................................................................................14
FRONT DOOR RE-ASSEMBLY .......................................................................................................................14
BEATER RE-ASSEMBLY (MODELS LB 302 - LB 502 - LB 1002) ......................................................................14
BEATER RE-ASSEMBLY (MODELS LB 302 G - LB 502 G - LB 1002 G) .............................................................15
PART 5 - SANITIZING THE FREEZER ..................................................................................................................16
PART 6 - STARTING THE FREEZER ....................................................................................................................17
ICE CREAM PRODUCTION (PROCESSING) ....................................................................................................17
ICE CREAM CONSISTENCY ...........................................................................................................................17
CHANGING ICE CREAM CONSISTENCY .........................................................................................................17
DISPENSING ICE CREAM ..............................................................................................................................18
ICE CREAM DISPENSING HANDLE ................................................................................................................18
AFTERCOOLING............................................................................................................................................19
PART 7 - CLEANING PROCEDURE .....................................................................................................................20
PART 8 - TECHNICAL INFORMATION .................................................................................................................23
PART 9 - MANTEINANCE....................................................................................................................................24
PART 10 - TROUBLESHOOT GUIDE ...................................................................................................................25
© Copyright 1998, CARPIGIANI Corporation of America. All Rights Reserved.
CARPIGIANI Operation Manual - LB 302, LB 502, LB 1002, LB 302 G, LB 502 G, LB 1002 G
FORWARD
Thank you for selecting CARPIGIANI as your choice in equipment. CARPIGIANI machines are able to
meet today’s fast growing demands. Your CARPIGIANI freezer has been manufactured at one of the most
modern manufacturing plants and utilizes the most advanced equipment and technology available in the industry.
We at CARPIGIANI, take great pride and care in the manufacture of each and every freezer, using only the
finest components available, to provide you with years of trouble-free operation.
Over twenty-five years of experience in the manufacturing of dispensing equipment has guided us in the
preparation of this Operation Manual. PLEASE READ IT CAREFULLY. Keep it handy for future reference and
follow the instructions from the very first time your machine is put into service.
On the following pages you will find important information and procedures that describe the proper installation, sanitizing, operation, and maintenance of your CARPIGIANI machine. We feel certain that your full
compliance with these instructions will assure you of excellent performance, trouble-free operation, and profitable business for years to come.
USING THIS MANUAL
As you go through this manual, you will occasionally see special notes accompanied by this symbol:
Pay special attention to these notes - they contain special hints and precautions that are necessary for
the proper operation of your CARPIGIANI machine.
All technical data, pictures and drawings contained in this manual are not binding on the manufacturer, nor can the manufacturer be held liable
for any modification of the machine in part or whole. © Copyright 1998, CARPIGIANI Corporation of America. All rights reserved.
Page 3
Rev. 12/2002
CARPIGIANI Operation Manual - LB 302, LB 502, LB 1002, LB 302 G, LB 502 G, LB 1002 G
IMPORTANT!
Failure to follow operational and maintenance procedures may result in damage to the unit and/or
void your warranty. CARPIGIANI Corporation will
not be held responsible for any machine that is
not properly operated or maintained.
In the event this unit should malfunction, please contact
your CARPIGIANI distributor or an authorized service
agency.
PART 1
INSTALLATION
Before starting this procedure, carefully inspect the shipping case to ensure the unit has not been dropped, tampered with, or abused in such a way as to indicate the
unit may have been damaged in transit.
If you notice any damage to the outside of the ship-
ping case that may indicate possible hidden dam-
age, make a notation of the damage on the bill of
lading before signing. Contact the carrier immediately
and request an inspection of damage. If this procedure is
not adhered to you may forfeit your right to file a damage
claim and be responsible for subsequent repair costs.
• Remove the case by lifting it straight up and away from
the machine.
• The machine is also secured to the skid with strapping.
Use caution when cutting the strapping as it may spring
out injuring you or damaging the machine.
• Free the machine from the skid.
• Remove the single screw at the bottom of each side
panel.
• Remove the panels by sliding downward slightly, then
pull outward at the bottom and allow the panel to slide
down.
• You may remove the protective plastic coating that has
been laminated to the panels by peeling it off.
POSITIONING THE MACHINE
• The freezer is equipped with 2 pivoting front wheels to
allow easy location. Move the machine to the desired
location.
• The machine must stand level. Check the level condition by placing a level on the top of the freezer at each
corner.
• Lock the front wheels to prevent the freezer from moving.
UNCRA TING
• The case is secured to the skid with strapping.
Use caution when cutting the strapping as it may spring
out injuring you or damaging the machine.
Uncrating
Accurate leveling is necessary to allow for correct
drainage of the freezer barrel and to ensure correct overrun.
Positioning the machine with pivoting front wheels
Rev. 12/2002
Page 4
CARPIGIANI Operation Manual - LB 302, LB 502, LB 1002, LB 302 G, LB 502 G, LB 1002 G
MACHINE EQUIPPED WITH AIR COOLED
CONDENSER
• Machines with air-cooled condenser must be installed
at least 2 feet (24 inches) away from any wall or object
to allow the free circulation of air around the condenser
(ref. Fig. 1).
Insufficient air circulation effects the operation and
output capacity of the machine. If these clearances
are not maintained, the production capacity will
be reduced, cycling will increase, and the machine
may stop completely.
Water cooled condenser:
A ≥≥ 4 in
B ≥≥ 6 in
Air cooled condenser:
A ≥≥ 24 in
B ≥≥ 6 in
MACHINE EQUIPPED WITH WA TER-COOLED
CONDENSER
• If the unit is water-cooled, it should be located close to
the water supply and within six feet of a drain.
• Connect the fitting marked “WATER IN” to the cold water supply. Connect the fitting marked “WATER OUT” to
a drain (ref. Fig.2).
All plumbing must meet local or state codes.
WATER
INLET
WATER
OUTLET
Figure 2
A
B
Figure 1
• It is necessary to clean the condenser each month to
eliminate dust, paper, etc., which may obstruct it.
Failure to do so may result in potential damage to the
machine and improper functioning.
• The machine should be within six feet of the power supply (a plug and receptacle or unfused disconnected).
• Position the machine to allow easy access for cleaning, servicing and maintenance.
• Position the machine away from direct sunlight.
For every 2EF over 68EF, the machine’s performance
will decrease by approximately 1%.
• Once the machine is set in position, it should be leveled as accurately as possible.
WATER VALVE ADJUSTMENT
The water valve is preset at the factory.
Proceed as follows if an adjustment is required:
• To maintain a head pressure of 235-255 psi while the
compressor is running, attach a refrigeration high pressure
gauge to the compressor’s high side discharge port.
• Open the water valve clockwise to increase the pressure or
counter clockwise to decrease the pressure (ref. Fig. 3).
Figure 3
Never expose water-cooled machines to temperatures at or below 32°F. without first draining the
water from the condenser. Serious damage to the
machine can occur if it is not properly drained.
Page 5
Rev. 12/2002
CARPIGIANI Operation Manual - LB 302, LB 502, LB 1002, LB 302 G, LB 502 G, LB 1002 G
ELECTRICAL REQUIREMENTS
• The wiring used to operate this freezer must be in
accordance with the National Electrical Code and/or local electrical codes, rules and regulations.
• The machine must be properly grounded . We recommend that a licensed electrician install the power
supply.
POWER SUPPLY
The power supply must be adequate enough to meet
requirements at all times. Voltage fluctuations with the
machine in operation should not exceed plus or minus
5% of the normal or rated voltage.
WIRING
• Adequate wiring must be provided with respect to wire
size or gauge. Unless otherwise required by the local
Electrical Codes, the same gauge wire at the machine
junction box should be used for the direct power line. A
separate circuit breaker with adequate fuse protection
should be employed.
• An unfused disconnected switch or a properly sized
plug and receptacle within 6 feet of the freezer, is recommended.
ELECTRICAL CONNECTIONS
• After you remove the panel on the left side of the machine, the wiring connection box can be found on the
bottom of the frame and is labeled “Connect Power Line
Here” (ref. Fig. 4).
• Feed the power line through the access hole located at
the bottom deck directly below the wiring connection
box.
• Connect the power line to the machine’s power lines
and wiring connection box.
• After connecting, the power line should be fastened to
the wiring connection box with appropriate electrical
hardware.
• In all installations, the machine must be properly
grounded. Because all high voltage components (the
controls are 24 volts) are connected with flexible conduit or cord, adequate ground continuity is assured by
running and fastening a ground line to the machine junction box ground lug (ref. Fig. 4).
CARPIGIANI freezers are equipped with protection for the
beater motor. Should the line voltage drop, or in the unlikely event a short circuit occurs, the overload protector
will automatically disconnect the starter and the machine
will stop immediately so that no permanent damage can
be caused to the motor.
The compressor is also internally protected. If the Klixon
protector trips due to an overload, the protector must first
cool down for several minutes before the compressor can
be restarted.
Figure 4
BEA TER ROTATION
After the electrical connections have been completed
check the rotation of the beater which should be counterclockwise when facing the front of the machine.
Rev. 12/2002
Page 6
CARPIGIANI Operation Manual - LB 302, LB 502, LB 1002, LB 302 G, LB 502 G, LB 1002 G
COMPLETING THE INSTALLA TION
The following pages contain important information and
procedures that describe the proper sanitizing, operation,
and maintenance of your CARPIGIANI machine. We feel
certain that your full compliance with these instructions
will ensure the excellent performance and trouble-free
operation of the machine and a profitable business for
years to come.
Failure to closely follow set-up and maintenance
procedures can void your warranty. CARPIGIANI
Corporation will not be responsible for any machine
not properly maintained.
In the event this unit should malfunction, please contact
your CARPIGIANI Distributor or an authorized service
agency.
EXTREME CARE MUST BE TAKEN WHEN RE-
MOVING SIDE, REAR, OR CONTROL BOX PANELS. ALWAYS TURN THE MACHINE TO THE
OFF POSITION. ALSO TURN OFF THE DISCONNECT SWITCH ON THE ELECTRICAL SUPPLY LINE
BEFORE EXPOSING ANY ELECTRICAL CONNECTIONS
AND/OR MOVING PARTS, SUCH AS BELTS, PULLEYS,
FAN BLADES AND BEATER.
PROTECTION FOR THE OPERATOR
A microswitch has been placed on the door of the barrel
with the beater assembly. The switch will immediately
stop the machine when the door is opened. When the
machine stops, the monitor will display "PT." The display will blink if the machine was running when it was
stopped. The display will be steady (not blinking) if the
machine was already stopped when the door was
opened. After closing the door, the machine remains
stopped and the display resets.
Make sure the machine is stopped before opening the front door.
MACHINE SAFETY SYSTEM - THERMAL RELAY
The Thermal Relay monitors amperage draw of the beater
motor. When maximum values are reached, the machine
will stop and the monitor will blink "RT" which is the code
that indicates the THERMAL CUT-OUT has been tripped.
Upon automatic resetting of the thermal relay, the display
will stop blinking. Before restarting operation, it is
important to investigate the reason the Thermal Cut-out
tripped. To restart the machine, press the desired button.
PRESSURE SWITCH
The Pressure Switch protects the cooling system
compressor. This switch will stop the compressor in the
event of water flow interruption (water-cooled system) or
air flow obstruction (air-cooled system); resetting is automatic.
If the compressor runs too long, or the machine continually stops and restarts it may indicate cooling is insufficient. Call your authorized service technician.
Page 7
Rev. 12/2002
CARPIGIANI Operation Manual - LB 302, LB 502, LB 1002, LB 302 G, LB 502G, LB 1002 G
PART 2
EXPLANATION OF CONTROLS
4 5 6 7
1 2
00
A B
MONITORING CONSISTENCY
The ice cream consistency monitor (Hard-O-Tronic) consists of 3 parts:
3
Control Panel
00
Rev. 3/98
Ref.1 DISPLAY displaying set calibration values
Ref.2 PUSH-BUTTONS for variation of calibration values
Ref.3 LED BAR for checking all processing phases in a real time.
Page 8
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