Carpigiani LB1002, LB1002 G, LB 302 G, LB 502 G, LB 302 User Manual

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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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