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Pastomaster 120 RTX

Carpigiani Pastomaster 30 RTX, Pastomaster 120 RTX, Pastomaster 60 RTX Instruction Handbook Manual

APPLICARE
T ARGA
CARATTERISTICHE
INSTRUCTIONS HANDBOOK
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PASTOMASTER RTX
CARPIGIANI
Via Emilia, 45 - 40011 Anzola Emilia (Bologna) - Italy
Tel. 051-6505111 - Fax 051-732178
This handbook may not be reprinted, transferred, registered, recorded in a retrieval system, nor translated in other languages unless otherwise previously agreed with CARPIGIANI. The purchaser has the wright to reprint it for his own office 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.
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 certification according to the international Standard ISO 9001­94, nowadays its production has got UNI-EN-ISO 9001-2000 Certified Quality System.
Moreover, Carpigiani machines comply with following European Directives:
- “Machinery” Directive 98/37/EC,
- “Low Voltage” Directive 73/23/EEC,
- “EMC” Directive 89/336/EEC,
- “PED” Directive 97/23/EC,
- Regulation 2004/1935/EC relating to “Materials and articles in contact with foodstuffs”
PASTOMASTER RTX
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INDEX
SECT. FOREWORD .......................................................................................................... 5
INSTRUCTION HANDBOOK ................................................................................ 5
PURPOSE.................................................................................................................. 5
HANDBOOK STRUCTURE ................................................................................... 5
ADDITIONAL DOCUMENTATION ...................................................................... 5
CONVENTIONAL SYMBOLS ............................................................................... 6
SAFETY .................................................................................................................... 7
QUALIFICATION OF THE STAFF ....................................................................... 7
WARNING ................................................................................................................ 7
SECT. 1 GENERAL INFORMATION
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 USER ................................................................ 9
1.2 INFORMATION ABOUT THE MACHINE ...................................................... 9
1.2.1 GENERAL DATA ......................................................................................... 9
1.2.2 TECHNICAL FEATURES.......................................................................... 10
1.2.3 MACHINE GROUPS 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 ..................................................................................................................... 12
SEC. 2 INSTALLATION
2.1 ROOM NECESSARY TO THE MACHINE USE ........................................... 13
2.2 WATER SUPPLY CONNECTION .................................................................... 13
2.3 MACHINES WITH AIRCOOLED CONDENSER .......................................... 13
2.4 MACHINES WITH WATERCOOLED CONDENSER .................................. 14
2.4.1 WATER VALVE ADJUSTMENT............................................................. 14
2.5 ELECTRICAL CONNECTION .......................................................................... 14
2.5.1 REPLACING A POWER CABLE ............................................................. 14
2.5.2 EQUIPOTENTIAL CONNECTION ........................................................... 14
2.6 LOCATION ........................................................................................................... 15
2.7 REFILLING ........................................................................................................... 15
2.8 MACHINE TESTING .......................................................................................... 15
SEC. 3 INSTRUCTIONS FOR USE
3.1 MACHINE SAFETY WARNINGS .................................................................... 17
3.2 MACHINE CONFIGURATION ......................................................................... 17
3.3 CONTROLS........................................................................................................... 18
3.3.1 PUSH-BUTTON PANEL ............................................................................ 18
3.3.2 COMMON FUNCTIONS ........................................................................... 18
3.3.3 MANUAL FUNCTIONS ............................................................................ 18
3.3.4 AUTOMATIC FUNCTIONS ...................................................................... 2 0
3.3.5 SERIAL CONNECTOR .............................................................................. 20
3.4 AUTOMATIC WORKINGS ............................................................................... 21
3.4.1 AUTOMATIC WORKING START PROCEDURE .................................. 21
3.5 ICE CREAM MIX WORKINGS ....................................................................... 21
3.5.1 WORKING NR 01 HIGH PASTEURIZATION ..................................... 21
3.5.2 WORKING NR 02 LOW PASTEURIZATION ...................................... 22
3.5.3 WORKING NR 03 MID PASTEURIZATION ........................................ 22
3.5.4 WORKING NR 04 CHOCOLATE PASTEURIZATION ....................... 22
3.5.5 WORKING NR 05 COOLING AGEING ................................................ 22
3.5.6 WORKING NR 06 SUGAR SYRUP ....................................................... 23
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PASTOMASTER RTX
3.6 SPECIAL WORKINGS (PASTOMASTER 60, ONLY) ................................. 23
3.6.1 WORKING NR 01 INVERT SUGAR ..................................................... 23
3.6.2 WORKING NR 02 CREAM-SAUCE ...................................................... 24
3.6.3 WORKING NR 03 ZABAIONE-SAUCE ................................................ 24
3.6.4 WORKING NR 04 CHOCOLATE-SAUCE ............................................ 24
3.6.5 WORKING NR 05 FRUIT-SAUCE ......................................................... 25
3.6.6 WORKING NR 06 PUDDING ................................................................. 25
3.6.7 WORKING NR 07 PANNA COTTA ........................................................ 2 6
3.6.8 WORKING NR 08 BAVARIAN CREAM ................................................ 26
3.6.9 WORKING NR 09 LIQUID YOGURT ..................................................... 27
3.6.10 WORKING NR 10 THICK YOGURT ...................................................... 27
3.7 FREE WORKINGS .............................................................................................. 28
3.7.1 EXAMPLE OF PERSONALIZED WORKING ........................................ 29
3.7.2 NOTES TO READ THE FLOW OF A PERSONALIZED WORKING ........ 30
3.7.3 DELETING PERSONALIZED WORKING .............................................. 30
3.8 PROGRAMMING USER ..................................................................................... 30
3.9 MACHINE STARTING ....................................................................................... 31
3.9.1 AUTOMATIC OPERATION...................................................................... 31
3.9.2 MANUAL OPERATION ............................................................................ 31
3.9. 3 USE OF THE DISPENSING SPIGOT (PASTOMASTER 60 AND 120) . 31
3.9.4 USE OF THE DISPENSING SPIGOT (PASTOMASTER 30 RTX) ...... 32
3.9.5 CONVENYING THE MIX FROM PASTOMASTER 60 RTX AND
PASTOMASTER 120 RTX TO OTHER PRODUCTION UNITS .......... 32
SEC. 4 SAFETY DEVICES
4.1 MACHINE SAFETY DEVICES ......................................................................... 33
4.2 BLACKOUT .......................................................................................................... 34
SEC. 5 CLEAN OUT, DISASSEMBLING AND REASSEMBLING OF PARTS IN CONTACT WITH THE PRODUCT
5.1 EXTERIOR CLEAN OUT .................................................................................. 35
5.2 PRELIMINARY CLEAN OUT .......................................................................... 35
5.3 DISASSEMBLING THE SPIGOT PISTON ..................................................... 35
5.4 DISASSEMBLING THE TANK COVER ......................................................... 36
5.5 DISASSEMBLING THE BEATER .................................................................... 37
5.6 HYGIENE .............................................................................................................. 38
5.7 SANITIZATION .................................................................................................... 38
SEC. 6 MAINTENANCE
6.1 SERVICE TYPOLOGY ....................................................................................... 39
6.2 WATERCOOLING ............................................................................................... 39
6.3 AIRCOOLING....................................................................................................... 39
6.4 ORDERING SPARE PARTS .............................................................................. 39
6.5 TABLE OF EQUIPMENT .................................................................................. 40
SEC. 7 TROUBLESHOOT GUIDE
7.1 TROUBLESHOOT GUIDE ................................................................................. 41
PASTOMASTER RTX
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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 significant 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 Emilia (Bologna) - Italy
Tel. 051- 6505111 - Fax 051-732178
HANDBOOK STRUCTURE
This handbook is divided in sections, chapters and subchapters in order to be consulted more easily.
SECTION
A section is the part of the handbook 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.
SUBCHAPTER
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 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 maintenance.
- Wiring diagram: A diagram of wiring connections is placed in the machine.
ATTENTION
Before using the machine read carefully the instruction handbook.
Pay attention to the safety instructions.
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PASTOMASTER RTX
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: 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 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.
EQUIPOTENTIAL CONNECTION
For connecting all appliances with this type of connection.
Warning: Not intended to be used for protection earth
QUALIFICATION OF THE STAFF
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 on mechanical parts and all adjustments, as well as maintenance and repairs. He/she is qualified for interventions on electrical and refrigeration components.
CARPIGIANI ENGINEER
He/she is a skilled engineer the manufacturer assigned to field interventions for complex jobs under particular conditions or in accordance with agreements made with the machine's owner.
PASTOMASTER RTX
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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).
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.
- Be on the look out that no technician will ever carry out interventions outside his own knowledge and responsibility sphere.
QUALIFICATION OF THE STAFF
Staff attached to the machine can be distinguished according to training and responsibility as follows:
OPERATOR
- A person who has not necessarily a high technical knowledge, just trained for ordinary operation of the machine, such as: startup, stop, filling, basic maintenance (cleanout, simple blocking, instrumentation checkings, etc.).
SKILLED ENGINEER
- A person enganged on more complicated operations of installation, maintenance, repairs, etc.
IMPORTANT!
One must be on the look-out that the staff does not carry out any operation outside its own sphere of konwledge and responsibility.
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
disconnected the machine.
• 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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PASTOMASTER RTX
PASTOMASTER RTX
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1 GENERAL INFORMATION
1.1 GENERAL INFORMATION
1.1.1 Manufacturer's 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 handbook.
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 field intervention.
1.1.3 Information to the user
z The manufacturer of the machine is at user's disposal for any explanation and information
about the machine operation.
z In case of need, please call the local distributor, or the manufacturer if no distributor is
available.
z Manufacturer's 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 data
PASTOMATER RTX are pasteurizers which prepare, pasteurize, homogenize, age and
transfer ice cream mixes to other units. An electronic microprocessor steadily checks each working cycle selected. Two alphanumerical monitors display all steps of a working cycle and send audio-visible messages. The following are the main components:
z five-speed heat pump; z ergonomic display console with low voltage 24V controls; z electrical, freezing and soundproofing units complying with international standards; z graduated tank, with inside water dispenser for wash; z high resistant steel frame, treated with rust inhibitors; glazed stainless steel panels.
VHzkW
A
Gas kg
Cod.
ANZOLA EMILIA - BOLOGNA - ITALY
Matr.
AB
CDE H
FG
I
100089654588-4
Legend:
A=Serial number B= Machine type C=Voltage D= Main-switch amperometric
value
E= Gas type and weight F= Machine code G=Condensation H=Frequency I= Power input
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PASTOMASTER RTX
CARPIGIANI recommends to always use high quality ingredients for the preparation of confectionery products, 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. Bearing in mind the above statements, please take heed of the following suggestions:
z Choose high quality natural ingredients. z Follow closely instructions given by your supplier. z Do not alter your supplier's recipies, by adding, for instance, water or sugar. z Taste your products before serving and start selling only if entirely satisfactory. z Make sure your staff always keeps the machine clean. z Have your machine serviced always by companies authorized by CARPIGIANI.
1.2.2 Technical features
NOTE:
Dimensions herebelow reported may change depending on type of condensation.
Performances featured by a 25°C room temperature and 20°C cooling water temperature.
Pastomaster 30 RTX Pastomaster 60 RTX
P
L
H
P
L
H
P
H
L
Pastomaster 120 RTX
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mm
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RETSAMOTSAP
XTR03
03 51 03 1 004 05 3 4,3 retaW 53 68 301 041
RETSAMOTSAP
XTR06
0651065004053 5,6retaW5368301261
RETSAMOTSAP
XTR021
021 03 021 5 004 05 3 6,9 retaW 56 68 301 962
PASTOMASTER RTX
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1.2.3 Machine groups location
Caption
1 Tank with cover 2 Control panel 3 Dispensing spigot 4 Spout 5 Bucket holder
Note : this drawing refers to Pastomaster 60 RTX
1.3 INTENDED USE
PASTOMASTER RTX, models 30, 60, 120 must only be used conforming with contents of paragraph 1.2.1 "General Information", within the functional limits hereunder reported:
Voltage: ±10% Air min. temperature 10°C Air max. temperature 43°C Water min. temperature 10°C Water max. temperature 30°C Water min. pressure 0.1 MPa (1 bar) Water max. pressure 0.8 MPa (8 bar) Max air relative humidity: 85%
- This machine has been designed for its use in rooms not subject to explosion-proof laws; its use is thus bound to complying rooms and normal atmosphere.
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
2
3
4
5
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PASTOMASTER RTX
1.7 WEEE (Waste Electrical and Electronic Equipment)
In accordance with European Directive 2002/96/EC on WEEE (Waste Electrical and Electronic Equipment), the presence of the above symbol on the product or on its packaging indicates that this item must not be disposed of in the normal unsorted municipal waste stream. 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.
PASTOMASTER RTX
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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 all around. 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. The minimum approach room to working area should be at least 150 cm in consideration of space taken by opened doors.
ATTENTION
Machines with aircooled condenser must be installed no closer than 50 cm to any wall
in order to allow free air circulation around the condenser.
NOTE
An insufficient air circulation affects operation and output capacity of the machine.
10
60
water
air
2.2 WATER SUPPLY CONNECTION
The machine must be connected to the water supply respecting the applicable national requirements; moreover the water mains pressure must not exceed 0.8 MPa (8 bar). By aircooled machines, water connection for drinking water (for machine wash) is placed under the machine. By watercooled machines water connections (for machine wash and gas cooling) are placed on upper panel.
2.3 MACHINE WITH AIRCOOLED CONDENSER
Machines with aircooled condenser must be installed no closer than 50 cm to any wall in order to allow free air circulation around the condenser.
NOTE
An insufficient air circulation affects operation and output capacity of the machine.
dimensions in cm
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