Carpigiani UC 711 E Installation Manual

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P.O. Box 4069 • Winston-Salem, NC 27115 • 336-661-9893 • 336-661-9895 (Fax)

UC – 711 E Gravity and Pump

Soft Serve Freezer

Single Flavor Counter Model

OPERATION MANUAL

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Foreword

Thank you for selecting Carpigiani to meet your operation and growing demands. Your Carpigiani freezer has been manufactured utilizing the most advanced technology and modern equipment available in the industry. We at Carpigiani, take great pride and care in the manufacturing of each and every freezer, using only the finest components available, to provide you with many years of trouble free operation.

Many years of experience in the manufacturing of soft serve dispensing equipment have guided us in the preparation of this Operation Manual. PLEASE READ IT CAREFULLY and keep it in an available place for future reference and most of all, follow the instructions carefully.

On the following pages, you will find important information and procedures, which describe the proper installation, sanitizing, operation, and maintenance of your Carpigiani freezer. We feel certain that your compliance with these instructions will assure excellent performance, trouble-free operation and profitable business for years to come.

All technical data, pictures and drawings contained in this operation manual are not binding on the manufacturer, nor can the manufacturer be held liable for any modification to the freezer in part or completely.

Part Number:

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Foreword Page #

Part I Installation

A) Uncrating 7 B) Positioning the Machine 7-8 C) Electrical Requirements 8 D) Completing the Installation

Part II Explanation of Controls

A) Electronic Control Panel 9-10 B) Dispensing Handle 10 C) Photo Sensor Switch 10 D) Dispensing Head Safety Switch 10 E) Electric Control Panel 10-11 F) Other Controls 11

Part III Initial Cleaning Procedure

A) Gravity Fed Cleaning Procedure 12 B) Pump Fed Cleaning Procedure 13 C) Disassembling the Dispensing Head 14 D) Disassembling the Beater / Auger 15 E) Cleaning Operations 15

Part IV Assembling the Freezer

A) Assembling the Beaters / Augers 16-17 B) Assembling the Dispensing Head 17-18 C) Assembling the Gravity Feed Tube 19 D) Assembling the Mix Injection Pump 20-21

Part V Sanitizing the Freezer 22-23

Part VI Starting the Freezer

A) Gravity Fed Machines 24 B) Pump Fed Machines 25

Part VII Operating the Freezer

A) Stand By Mode 26 B) Gravity Fed Machines – How to Operate and Make Adjustments 27 C) Pump Fed Machines – How to Operate and Make Adjustments 27

Part VIII Periodic Cleaning Procedures

A) Gravity Fed Machines 28-29 B) Pump Fed Machines 29-30

Part IX Technical Information

A) Refrigeration 31 B) Beater Drive Motor 31 C) Thermal Overload 31 D) Proximity Switch 31

Part X Maintenance

A) Troubleshooting Guide 33-34 B) Alarms 35

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!! IMPORTANT !!

Failure to closely follow operational and maintenance procedures may result in damage to the unit and / or void your warranty. Carpigiani Corporation will not be responsible for any machine not properly operated or maintained.

Part I – Installation

Before starting this procedure, ensure that the shipping carton does not show any evidence of damage due to dropping or mishandling. This may indicate that the freezer was damaged during transit or delivery.

!! IMPORTANT !!

Should the outside of the shipping carton give any indication of possible damage, state this on the bill of lading prior to signing. Contact the freight carrier and request an inspection of damage. If this procedure is not adhered to, you will forfeit your rights to file a damage claim and be responsible for subsequent repair costs.

A) Uncrating the Freezer

1) The outer shipping carton is secured to the shipping pallet with strapping. When cutting this strapping, do so with caution as it may spring out quickly. After cutting the strapping, lift the shipping carton straight up and off of the freezer.

Prior to choosing a location keep in mind that the freezer should be accessible for periodic maintenance and have adequate space for necessary airflow.

Figure 1

1) The freezer is equipped with adjustable legs to allow for ease of leveling. To level the freezer, turn the lower leg adjustment. The freezer must also be level to ensure proper drainage from the mix tank and cylinder.

2) Remove the protective foam boards and plastic wrapping from the outside of the freezer.

3) The freezer is also secured to the shipping pallet with strapping. Again, exercise caution when cutting this strapping since it may spring out quickly.

4) You must now remove the side panels from the freezer prior to lifting the freezer off of the pallet with a lift truck. To remove the side panels, first remove the side drip chutes and lower chute cover on both side panels. Next remove the screws in each side panel and gently pull down and away from the machine frame. Remove the protective plastic coating from the outer panel surfaces.

B) Positioning the Machine

After removing the machine from the shipping pallet, it is now ready to be located in its final location.

6" 12"

Figure 2

2) If your freezer is air cooled, you MUST have adequate spacing on both sides of the machine. You should have a minimum of 6 inches of clearance on the left side and 12 inches of clearance on the right side of the machine. This will ensure an adequate

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airflow is maintained.(Ref. to Figure 2)

Note: If these clearances are not maintained, the production capacity will be reduced, cycling will be increased and the potential will exist that the machine will stop completely

3) It is necessary to clean the air condenser each month to remove dust, paper, etc., which may obstruct airflow. Prior to cleaning the condenser from the inside, disconnect the machines power supply.

4) The machine should be connected to a fused disconnect no more than six feet away. Electrical installation MUST comply with state and / local electrical codes.

5) Never position the machine in direct sunlight or near a heat source. This will reduce its performance and possible damage the freezer.

6) Water connections (Water Cooled Only)are made at the rear of the machine. A minimum of ½ inch (ID) water supply and drain lines are recommended. Both the water inlet and outlet lines must remain unobstructed or the machine performance will be affected.

C) Electrical Requirements

main power connection box is located on the rear, right side bottom of the frame. The connection box is labeled “Connect Power Line Here”. Connect the power supply wires to the machines using the appropriate electrical hardware and strain relief devices.

Figure 3

After the electrical connections are completed, turn the power supply on. At this time you must check the beater / auger motor rotation. The correct beater rotation ( Facing the front of the machine ) should be counter clockwise.

D) Completing the Installation

1) All of the setup and calibration of this freezer should be performed by an approved Carpigiani Service Technician. Failure to calibrate this freezer properly can result in freezer damage and a voided warranty.

All wiring installed to operate the freezer must be in accordance with the National Electric Code and / or local electrical codes and regulations.

!! IMPORTANT !!

This machine must be properly grounded. Failure to properly ground the freezer may result in dangerous and / or fatal electric shock.

The main machine power supply must meet requirements at all times of operation. Voltage fluctuations must not exceed plus or minus 5% of the rated nameplate voltage.

All Carpigiani machines are equipped with step down transformers for the control circuit supply. These transformers have a “multi-tap” input which must be wired to match the inlet voltage (ie. 115 vac). Failure to wire to the correct supply voltage can result in machine malfunction.

Electrical Connection – ( Refer to Fig. 3 )

2) After installation and calibration of both electrical and refrigeration circuits, the side panels should be reinstalled.

!! IMPORTANT !!

Failure to closely follow factory setup and maintenance procedures will result in a voided warranty. Carpigiani Corporation will not be responsible for any freezer which is not setup or maintained in accordance with factory procedures.

NOTE: Always turn the machine OFF and disconnect the power supply switch to the freezer prior to exposing any electrical connections or moving parts.

On the following pages you will find important information and procedures which describe the proper sanitizing, operation, and maintenance of your Carpigiani Freezer. We are certain that your full compliance with instructions and procedures will result in many years of trouble free operation.

Having removed the side panels from the frame, the

In the event this unit should malfunction or need maintenance, please contact your local Carpigiani Distributor or Authorized Service Agent.

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Part II – Explanation of Controls

A) Electronic Touch Pad – (Refer to figure 4)

570

Push to Select – Position 571.2

By pressing this button you can select any of the following machine modes:

- Automatic

- Stand-by

- Beater The indicator light will illuminate corresponding to the mode selected with the touch pad.

571.1

571.2

L3 L4 L5

Figure 4

This machine is equipped with one electronic touch control pads. This electronic touch pad operates all controls of the freezer.

Indicator Lights – L1 through L4

These indicators illuminate to show the selected machine function. When illuminated, the machine is in that respective mode.

Indicator Light – L5

This light will illuminate when the mix tank is low or out of mix. It is also possible to activate a low mix level beeper in the programming mode.

Monitor – Position 570

This numerical monitor will display the cylinder product consistency while the machine is freezing product in the automatic mode. When not freezing the product in the cylinder, it will display mix tank temperature in ALL modes.

Stop / Reset – Position 571.1

When in this mode, the indicator light L1 will be lit and the machine functions off. From this mode you can access the programming mode or switch to operating modes.

Automatic Mode

When placed in this mode the indicator light L2 will illuminate and the machine will start the freezing process in the cylinder. During this freezing process, a number indicating the cylinder consistency will be displayed (monitor #570, the lower the number, softer the product). The machine will continue to freeze the product in the cylinder (numbers will increase) until the preset HOT number value is achieved. After achieving the preset cylinder consistency number (HOT) the machine will then start cooling the mix tank and display mix tank temperature.

Stand-By Mode

When placed in this mode the indicator light L3 will illuminate. This mode is used during prolonged idle periods. The mix temperature in both cylinder and mix storage tank is maintained below 40 degrees F by the electronic temperature probes. Product should not be served while in this mode as it will be too soft. The Monitor (#570) will only display the temperature in the mix tank while in this mode.

NOTE: If the mix level in the tank is below ½ full, a warmer than actual temperature will be displayed on the Monitor #570. The actual mix temperature will remain at a safe temperature below 40 degrees F.

Beater Mode

When placed in this mode the indicator light L4 will illuminate. This mode is used during the start-up (pump fed), cleaning and sanitizing of the machine. While in this mode the ONLY the beater / auger drive motor will operate. This mode has a built in safety device which will automatically switch the machine to the stop mode after 15 minutes of operation. This safety prevents an operator from inadvertently leaving the freezer in this mode for extended periods of time, which could damage the freezer.

Mix Tank Low Level Indicator

When low on mix in the mix storage tank, the indicator light L5 will illuminate. This will indicate

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that more mix is needed to operate the freezer. Each mix tank has a maximum capacity of 10 quarts each. DO NOT attempt to operate the freezer while low on mix or your freezer may be damaged. It is also possible to activate a beeper to sound when mix is low in the Automatic and Stand-By modes. This is done through the programming mode.

B) Dispensing Handle – (Refer to Figure 5)

The dispensing handle control the flow and extraction rate of finished product.

You should ONLY dispense product when the machine is in the automatic mode.

Figure 6

D) Dispensing Head Safety Switch

This machine is equipped with a dispensing head safety switch. With the dispensing head removed, the machine will not operate and Alarm 9 (AL9) will appear on the front touch pad monitor. Please refer to machine alarms on page 28 for more details.

E) Electrical Control Panel – (Refer to figure 7)

The electrical control panel is located on the top of

the front panel. This control panel contains all of the machines electrical control components. ONLY a Carpigiani Authorized Technician should access this control panel.

!! IMPORTANT WARNING !!

Disconnect the freezer power supply before opening the Electrical Control Panel and / or

servicing.

Figure 5

C) Photo Sensor Switch -(Refer to Figure 6)

In the Automatic mode the Photo Sensor Switch (Position #152) activate the beater / auger motor to dispense product. To activate the photo sensor switch, simply place your hand with a cone or cup under the dispensing head, pull the dispensing handle and dispense product.

NOTE: You must activate the photo sensor switch, starting the beater drive motor prior to dispensing product.

152

Figure 7

The following is an explanation of some of the components inside the electrical control panel.

1) Beater Motor Contactors - Activates the beater drive motor. In the “BEATER” mode, the contactor is energized by the front switch pad. In the “AUTO” mode, the contactor is energized by the photo sensor or 10 minute cycling timer.

2) Compressor Contactor – Activates the refrigeration compressor. When the unit is in the “AUTO” mode, the compressor contactor can be energized by the electronic HOT setting or the Tev Temperature probe.

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In the “Stand-By” mode, the contactor is energized by the Tev and Tec temperature probes.

3) Beater Motor Overload Protector - Monitors the current draw of the beater drive motor. If the motor draws excessive amperage, the overload will trip and Alarm 1 (RtA) will be displayed on the touch pad monitor.

4) Main Transformer – This transformer reduces the incoming line voltage to 24 volts for the primary control circuit.

5) Electronic Control Board – This board controls and monitors ALL functions of the machine.

6) Current Monitoring Transformer – This transformer monitor the current draw of the beater drive motor.

7) Secondary Transformer – This transformer reduces the voltage from 24 volts to 11 volts for the electronic control circuit.

F) Other Controls

1) Refrigeration Solenoid Valves – These valves are located behind the front panel. These valves are used to control the flow of refrigerant to the cylinders or mix storage tanks. These valves are designated with EVC for each cylinder and EVV for the mix storage tank. (Refer to Figure 8)

Figure 8

2) High Pressure Safety Switch – In the event of restricted airflow (Air Cooled) or restricted water flow (Water Cooled), this switch will turn off the compressor contactor. While tripped, the beater motors will continue to run until the refrigerant pressure is reduced enough to reset the safety switch. After resetting, both the compressor and motor will resume operation.

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Part III–Initial Cleaning Procedure

!! IMPORTANT !!

Before starting this procedure, place the machine in the STOP mode on the touch pad.

This is a new machine and although clean, it must be completely disassembled, washed and sanitized before adding fresh product. Please proceed as follows:

Next remove the outer regulating sleeve from the center tube by pulling straight off.

1) Remove the mix tank cover and spare parts items packed inside the mix tank. The spare parts kit will include: spatula, cleaning brushes, sanitary lubricant, oring removal tool, sanitizer packets, spare orings and seals, and operation manual. Place these items in a convenient place for future reference.

Helpful Suggestion: Before proceeding with the disassembly of the freezer, we recommend the use of a clean plastic pan or pail to place the removed parts into. This will minimize the possibility of misplacing or damaging these components.

A) Gravity Fed Cleaning Procedure

Proceed with the disassembly process by removing the gravity feed tube, which is located inside the mix storage tank. The tube should be pulled straight up and out of the tank.

Finally remove the orings on the end of the center tube using ONLY the oring removal tool included in your spare parts kit.

!! WARNING !!

Never use anything other than the oring remover provided in your tool kit. Removing the orings with other objects or tools can possibly damage the orings and plastic parts.

Once removed, the gravity feed tube must be disassembled. To disassemble, first remove the splash guard from the center of the tube.

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B) Pump Fed Cleaning Procedure

Proceed with the disassembly of the mix injection pump located in the mix storage tank. First slide the connecting tube forward away from the mix pump faceplate. This should free the feeding elbow assembly from the pump assembly. Pull the feed elbow assembly straight up and out of the mix storage tank.

Disassemble the mix pump assembly as pictured below. When disassembling the orings from the other components, use only the oring removal tool provided in the spare parts tool kit. Using other tools to remove the orings from their grooves can result in damaging both the oring and component.

Next remove the mix pump assembly by rotating clockwise until the hook stud on the rear of the pump disengages from the pump hub. After disengaging, slide the pump away from the rear of the machine and out of the mix storage tank.

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C) Disassembling the Dispensing Head

Loosen and remove the two dispensing head-retaining knobs. The knobs are removed by turning counter clockwise until loose.

Pull the handle-retaining rod out far enough to allow the handle to disengage.

Return the retaining rod to its original position. Using the metal rod as a base, lever the piston from the dispensing head with the handle.

Remove the dispensing head by pulling straight out and away from the machine.

Disassemble the dispensing head by first opening the dispensing handle.

Using the oring removal tool, remove the orings from each of the piston.

Turn the dispensing head over and remove the large oring from the rear of the dispensing head.

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D) Disassembling the Beater / Auger

Remove the beater / auger assembly from the cylinder by pulling straight out of the machine towards you.

Disassemble the beater / auger by first removing the rear rubber beater shaft seal.

Finally, remove the beater / auger end pusher by pulling straight out of the beater / auger frame. Remove the scraper blades from the beater / auger frame by gently rotating the blade out of the frame support brackets.

The machine is now completely disassembled. The removed parts must now be washed, rinsed, and sanitized.

E) Cleaning Operation

Next disassemble the center idler from the beater / auger frame. To remove, pull the idler straight out of the front of the beater / auger.

Wash the removed machine parts in luke warm (80-90 F) water and mild non-foaming detergent. Scrub each of the parts with the cleaning brushes provided in the machines spare parts kit.

!! IMPORTANT !!

DO NOT use hot water on any of the plastic parts as this may result in damaging these parts.

4) Air Dry

3) Sanitize

2) Rinse

1) Wash

Using your three-tank sink, wash rinse, and sanitize all of the disassembled machine parts. Mix the sanitizing solution to a 200ppm concentration with warm water. Allow the parts to soak in the sanitizing solution for 35 minutes before removing. Allow the parts to air-dry on the clean, sanitized counter at the end of the sink. DO NOT towel or sponge dry these parts.

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Part IV - Assembling the Freezer

A) Assembling the Beater / Augers

After completing the Cleaning Operation, you are now ready re-assemble the freezer. First locate the parts needed to assemble the beater / auger. A) End pusher, B) Beater frame, C) Idler, D) Beater seal, E) Scraper Blades (2per), F) Blade bumpers (2 per blade)

Install the idler into the beater frame by placing it through the end pusher.

NOTE: When installed correctly, the idler should rotate freely inside the beater frame. If the idler does not rotate freely, it is incorrectly installed and MUST NOT be installed into the machine. Repeat the above instructions until the idler is installed correctly .

Next, lubricate the rear of the metal washer on the beater frame with three 3/8 ” drops of the sanitary lubricant spaced equally on the washer.

Install the rubber bumpers into each scraper blade.

NOTE: Keep the large end of the bumper opposite the blade groove.

Assemble the scraper blades onto the beater frame by inserting the blade into the support and rotating downward. Install the end pusher into the beater frame making sure to engage the alignment notch of both the beater and end pusher.

Slide the rubber beater seal onto the beater frame end. Using the sanitary lubricant, place three more 3/ 8” drops of lubricant on the flat side of the beater seal (next to the beater shaft). DO NOT lubricate the “V” groove of the seal as this is not the sealing surface of the seal.

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Insert the beater assembly into the freezing cylinder. Holding the beater horizontal, gently slide it straight into the cylinder until it can go no farther.

B) Assembling the Dispensing Head

Locate the parts that will be needed to assemble the dispensing head. These parts include: A) Dispensing head oring, B) Dispensing head, C) Piston orings (2), D) Piston, G) Handle retaining rod, H) Dispensing handle, and I) Retaining rod oring.

Once installed, rotate the beater assembly to engage the beater frame into the drive coupling in the transmission. This engagement will allow the beater frame to go another ¾” into the cylinder. Push the beater frame until it can go no further.

After locating all of the required parts, start by assembling orings onto the piston.

After installing and engaging the beater assembly, rotate the center idlers to a vertical position. This will ensure that they will correctly engage the pins on the rear of the dispensing head.

Once the orings have been installed onto the piston, place a bead of lubricant between the orings.

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Spread the lubricant to lightly coat the piston surface between and including the orings. This will ensure free movement of the pistons and dispensing handle.

Insert the piston into the chamber of the dispensing head. When installing, align the square handle recess with the rectangular cut out of the head.

Install the dispensing handle onto the head by placing the rounded side of the metal cam into the piston notch. Insert the metal retaining rod into the dispensing head and piston cams. When the handle is installed, affix the small oring into the metal retaining rods oring groove.

You are now ready to install the dispensing head assembly onto the front of the freezer.

Turn over the dispensing head and insert the two large orings into the grooves in the dispensing head. Lightly lubricate the outside of these orings.

Finger tighten the two metal dispensing head-retaining knobs.

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C) Assembling the Gravity Feed Tube

Lightly lubricate both orings on each tube with the

sanitary lubricant. When finished, place a feed tube

Locate the parts needed to assemble the gravity feed tubes. This should include: A) Splash guard, B) Orings (2per), C) Outer regulating sleeve, D) Center gravity feed tube

Insert the splash guard into the top hole of the gravity feed tube.

Next, slide the two orings onto the center gravity feed tube oring grooves.

uninstalled at the bottom of each mix tank.

Lubricate

The machine is now completely assembled and ready to be sanitized.

Slide the outer regulating sleeve onto the center feed tube. Make sure that the two finger hooks are at the top of the feed tube (farthest away from the orings at the bottom).

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D) Assembling the Mix Injection Pump

Before assembling the mix injection pump, locate all of the parts that will be required. (See Below)

207

1117

1197

105

1126

550

248

1178

245

206

1126

38A

202

Install the two orings (#1126) into the bottom grooves of the feeding elbows (#32) then lightly lubricate.

Install the assembled pressure relief plunger into the feed elbows, small end first. Next install the assembled connecting tube into the mix feed elbow, check valve first. The feeding elbows are now completely assembled and can be placed into the bottom of the mix storage tanks.

271

1126

First install the small oring (#31) onto the pressure relief plunger (#105) and lightly lubricate the oring.

NOTE: Oring #1126 is slightly smaller than the other orings used on this assembly. Locate these orings first and install.

Assemble the connecting tube (#207) with the check valve (#1126) and orings (#1126) and (#1117). Lightly lubricate the check valve before installing into the connecting tube. Lightly lubricate both orings.

To assemble the mix pumps, first locate the pump gears (#38&A) and pump body (#39). Lightly lubricate the top, bottom, and inside bore of the gears. Install the gear into the appropriate gear well. Install and lubricate oring (#1178) into the pump body (#39).

NOTE: DO NOT lubricate the gear teeth since this is removed when the pump starts running.

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Install the mix pump drive shaft seal into the rear of the mix pump body. Lightly lubricate the inside of the shaft seal then install the drive shaft into the pump seal engaging it into the drive gear.

Assemble the plastic suction tube (#271) by installing the oring (#1126) into the groove and lightly lubricate. Next lightly lubricate the base (flat part) of the relief valve (#245) and install into the well of the mix pump cover (#202). Install the spring (#206) onto the relief valve in the pump well. Install the suction tube with lubricated oring into the pump cover well engaging the spring into the suction tube recess. To lock the suction tube onto the pump cover, rotate, the tube until the adjustment lever is pointed away from the pump cover (6 o’clock position).

Install the pump body assembly into the rear hub inside of each mix storage tank. Slide the drive shaft into the rear hub and rotate the pump until the hook stud engages the pin on the rear hub. At this point, you must ensure that the drive shaft is engaged into the rear drive coupling by turning the drive gear until it completely engages.

You are now ready to install the pump cover with suction tube onto the pump body assembly, which is installed on the rear pump hub in the mix storage tank. To install the cover, first ensure that the oring (#1178) is installed into the pump body (#39). Next, affix the pump cover onto the pump body using the two metal retaining knobs (#8).

The freezer is now completely assembled and must be sanitized prior to adding fresh mix and operating.

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Part V - Sanitizing the Freezer

Prior to filling the machine with fresh liquid mix, the assembled machine must be sanitized. The frequency of cleaning and sanitizing must comply with your local and / or state health regulations. If uncertain of these regulations, contact your local Health Departments or Department of Agriculture.

Sanitizing your freezer is very important. This procedure will retard the growth of bacteria and insure excellent product bacteria test results performed by your local inspectors.

To begin, you will need the sanitizer, spatula, large cleaning brush, (all included in the start up kit), and clean pail.

Mix the sanitizer (Stera Sheen green label or equivalent) into the clean pail with at least two gallons of warm water. Mix the sanitizer and water to make a 200-PPM. concentration of sanitizer solution. Using the spatula, stir the solution until the sanitizer is completely dissolved.

With the dispensing handle closed, pour an even amount of the sanitizer solution into the mix tank. With the large cleaning brush, clean all surfaces of the mix storage tank with the sanitizing solution.

With the cylinder full of the sanitizer solution, push the “Push to Select” button on the front touch pad (#571.2) until the beater mode is selected. Allow the machine to run in the beater mode for approximately 30 seconds.

!! IMPORTANT !!

Do not exceed the formula recommended by the sanitizer manufacturer as it will not add to the sanitizing effectiveness. DO NOT use straight chlorine bleach since it does not clean properly and will damage plastic components. Do not leave the sanitizing solution in the freezer longer than one hour as it can corrode some parts.

Do not select the “Automatic” or “Stand-By” modes while sanitizer is in the machine as this can possibly damage your freezer. Select only the “Beater “mode while cleaning or sanitizing the freezer.

571.2

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Press the “Stop – Reset” button (#571.1) and place the machine in the OFF / Stop mode. Allow the sanitizer to remain in contact with all of the product surfaces for 3 to 5 minutes.

“Push to Select” button on the front touch pad (#571.2) until the beater mode is selected. Allow the machine to run in the beater mode for approximately 10 seconds then push the “Stop” button on the touch pad. This will remove any of the remaining sanitizer from the cylinder.

571.1

Place the clean pail under the dispensing head and pull the handles, allow the sanitizer to completely drain from the freezer.

After the sanitizer has completely drained, close the dispensing handle.

!! IMPORTANT !!

With your spatula, direct any remaining liquid in the bottom of the tank to the cylinder feed hole.

The freezer is now sanitized and ready to be filled with fresh liquid mix. Do not wipe out any residual sanitizing solution from the bottom of the mix storage tanks as this will contaminate the machine with bacteria. Prior to dumping the sanitizing solution from the pail, submerse your hands to sanitize since you must next install the Gravity Feed Tube or Pump Feed Elbow into the cylinder feed hole.

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Part VI – Starting the Freezer

Only after completing the cleaning and sanitizing procedures should you fill the machine with fresh mix. The mix being used MUST be free of ice, seeds, pulp, and completely dissolved if made from powder. The products used in these freezers must be a homogenous liquid.

You may now start the freezing process by pressing the “Select” button (#571.2) and selecting the Automatic mode.

571.2

A) Gravity Fed Machine

The cylinder of this freezer are designed to allow for simple start up and minimal product loss due to improper overrun.

Fill the mix tank with fresh liquid mix. The mix tank has a maximum capacity of 10 quarts. The minimum recommended mix quantity is 3 quarts.

The initial freeze time is approximately 4-7 minutes. Do not dispense product until the machine has cycled off. Before dispensing product you must also open the outer regulating sleeve on the feed tube. The draw rate, portion size, and mix viscosity will determine the final regulating sleeve setting. Our standard setting is 2 or 3 notches up from the bottom. Adjust for your specific application.

Allow the cylinder to fill with mix. When the air bubbles stop coming out of the cylinder feed hole, mix has filled the cylinder to its maximum capacity. Install the assembled gravity feed tube into the cylinder feed holes. Set to the closed position (bottom).

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B) Pump Fed Machines

With your clean, sanitized hands, install the feeding elbow into the cylinder feed hole. Next slide the elbow connecting tube into the pump cover hole.

Holding the connecting tube inside the pump cover hole, slide the feeding elbow away from the pump. This will seat the tube and elbow to prevent the tube from sliding out when under pressure.

With the mix tanks filled with liquid mix and the elbows connected to the pumps, you can now prime the cylinders. To prime the cylinders, press the “Select” button on the touch pad, selecting the “Beater” only mode. Allow the machine to run for approximately one minute the press the “Stop” button.

570

571.1

571.2

Carefully push the plastic bleed plunger, which extends from the front of the feeding elbow. This will allow the air to escape from the cylinder.

Fill each mix tank with fresh liquid mix. Each mix tank has a maximum capacity of 10 quarts. The minimum recommended mix quantity is 3 quarts.

When all of the pressure is released, press the “Select” button and switch to the “Beater” only mode for one minute. After one minute, press the “Stop” button and carefully push the plastic bleed plunger, which extends from the front of the feeding elbow.

Repeat this process until a steady stream of mix only is flowing from the bleed hole on the feeding elbow.

You may now start the freezing process by pressing the “Select” button (#571.2) and selecting the Automatic mode.

The initial freeze time is approximately 4-7 minutes. Do not dispense product until the machine has cycled off. The draw rate, portion size, and mix viscosity will determine the final regulator tube setting. Adjust for your specific application.

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Part VII – Operating the Freezer

A) Stand-By Mode

The machine will automatically stop the freezing process after achieving the pre-set “consistency” value (number displayed on the touch pad monitor). This will indicate that the product is ready to be served. At this time the compressor will continue to run and automatically switch to cooling the mix storage tanks.

To serve product, simply place a cup, container, or cone under the dispensing spout and slowly pull the dispensing handle down. At this time the beater / auger drive motor should start and product start coming out. As the product begins to flow, move the container in a circular fashion to create a tapering tower if frozen product.

During long pauses between servings, press the “Push to Select” button (#571.2) and select the “Stand-By” mode of operation. In this mode, you will significantly reduce the energy consumption of the freezer. When placed in this mode the indicator light L3 will illuminate. The mix temperature in both cylinders and mix storage tanks are maintained below 40 degrees F by the electronic temperature probes. Product should not be served while in this mode as it will be too soft. The Monitor (#570) will only display the temperature in the mix tank while in this mode.

570

571.1

571.2

When the desired portion has been dispensed, close the handle and pull the container with product straight down to add a peak.

Dispense the product without exceeding the freezers production capacity. If you do not exceed this pace and are careful to refill the machine with fresh mix, you can be sure you will rarely have to pause in selling product, even during peak times. A standard draw rate is ¾ to 1 ounce of product dispensed per second. The larger the portion size, the slower it should be drawn.

When you want to begin serving product again, press the “Push to Select” button (#571.2) and select the “Automatic” mode. Allow the machine to cycle off on the consistency control before serving product.

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B) Gravity Fed Machines

C) Pump Fed Machines-Operation

The gravity feed tube consists of two tubes, one sliding inside of the other, and a center splash guard. The inner tube blends the flow of air and mix into the freezing cylinder. Air enters through the top of the tube, mix through the bottom. (Refer to figure 9)

Air Intake

Max. Fill Level

Mix Intake

Maximum

Standard

The mix injection pump runs whenever the beater drive motor is turning. To regulate the amount of mix being injected into the cylinder, pivot the pump suction tube either to the right (less mix/more air) or to the left (more mix/ less air). (Refer to figure 10)

min

max

271

Figure 9

The outer tube is actually a regulating valve. Lifting or closing this outer tube changes the hole opening size on the inner tube which allows more or less mix to enter the freezing cylinder. Since the air inlet hole size does not change, the air inlet is constant.

You can vary the overrun (yield) by allowing more or less mix to enter the cylinder by changing. You do this by opening or closing the outer regulator sleeve setting on the inner feed tube.

The inner splash guard keeps mix from splashing the underside of the mix tank cover as well as eliminate clogging of the feed tube.

The draw rate, portion size, and mix viscosity will determine the final regulating sleeve setting. Our standard setting is 2 to 3 notches up from the bottom. Open the outer tube to increase the mix amount. Close the outer tube to decrease the mix amount. Adjust for your specific application.

Figure 10

The air intake is through the front two holes of the pump cover. Since the two air inlet holes are fixed, the air intake is constant. To adjust your overrun (yield) you must regulate the amount of mix being pumped into the cylinders. The mix pump suction tube will change the orifice size on the tube to allow either more or less mix to be pumped into the cylinder.

You will also have to adjust your pump suction tube during daily operation to either a larger (Left) or smaller (Right) orifice setting depending on your draw rate and product viscosity.

For heavy draw rates and / or thick viscosity mixes, a setting of center, one, two, or three positions to the left of center will be necessary in order to operate the machine properly.

For light draw rates and / or thin viscosity mixes, a setting of center, one, or two positions to the right of center will be necessary.

The “Normal” operating position for the suction tubes on this freezer is either one position to the left, center, or one position to the right.

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Part VIII – Periodic Cleaning

Procedures

Cleaning and sanitizing schedules for your freezer are determined by your local Health Department and / or Department of Agriculture and must be followed accordingly. Check with your local organization prior to determining your cleaning schedule.

After determining your schedule, proceed as follows:

A) Gravity Fed Machine

With frozen mix in the machine, select the Beater mode on the front touch pad by pressing the Push to Select button (#571.2) until pilot light #L4 illuminates. Allow the machine to operate in the beater mode for 4 to 5 minutes. This will soften the product and allow for easier product removal.

With the machine still in the Beater mode, place a pail under the dispensing head. Slowly pull the handle and allow all of the product to drain from the machine.

After the product has drained, press the Stop / Reset button (#571.1) on the front touch pad. This will turn the machine to the OFF mode.

570

571.1

571.2

Remove the gravity feed tube assembly from the mix tank by pulling straight up and out of the tank.

571.1

Fill the mix tank with luke warm (80-90F) water and a non-foaming dish washing detergent solution.

Press the Push to Select button on the front touch pad (#571.2), and carefully select the Beater mode. Allow the machine to run for 1 – 2 minutes then push the Stop / Reset button (#571.1) on the touch pad. Drain all of the water and soap solution from the machine. Repeat this process until the water drained is clear. Prior to draining the last time, brush clean all surfaces of the mix storage tanks with the cleaning brushes provided with the freezer.

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Drain the remaining water and soap solution from the freezer.

You are now ready to disassemble and clean your freezer. Please refer to Part III – Initial Cleaning Procedure of this operation manual for instructions on how to proceed.

B) Pump Fed Machines

With frozen mix in the cylinder, select the Beater mode on the front touch pad by pressing the Push to Select button (#571.2) until pilot light #L4 illuminates. Allow the machine to operate in the beater mode for 4 to 5 minutes. This will soften the product and allow for easier product removal.

571.2

Place a pail under the dispensing head, holding it up against the bottom of the head as high as possible and slowly pull the dispensing handle. This will allow the mix to drain from the machine.

!! IMPORTANT !!

You MUST disassemble the machine after draining and follow the described cleaning and sanitizing procedures as described in this operation manual in order to maintain acceptable hygienic levels in your product.

After the frozen product is removed and liquid mix is dispensing from the machine, press the Stop / Reset button (#571.1) on the touch pad. Placing the machine in the OFF mode, close both of the dispensing handles. Slowly push in on the pressure relief plungers to remove any remaining pressure from the cylinders.

571.1

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Remove the feeding elbow assembly from the mix tank by first sliding the connecting tube away from the pump cover, Then turn the elbow assembly slightly and pull the assembly straight up and out of the mix tank.

Remove the mix pump assembly from the mix tank by rotating the pump clockwise until the hook stud disengages from the rear pump hub. After disengaging the hook stud, pull the pump assembly straight forward and out of the mix storage tank. Please ensure that the mix pump drive shaft and seal must also be removed at this time.

571.2

Prior to draining the last time, brush clean all surfaces of the mix storage tank with the cleaning brushes provided with the freezer.

After removing the parts from the mix storage tank, fill the mix tank with luke warm (80-90F) water and a non-foaming dish washing detergent solution.

Drain the remaining water and soap solution from the freezer.

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You are now ready to disassemble and clean your freezer. Please refer to Part III – Initial Cleaning Procedure of this operation manual for instructions on how to proceed.

!! IMPORTANT !!

Part IX – Technical Information

A) Refrigeration:

Compressor – Hermetic / Low Temperature Suction Pressure (Cylinder) – 18-21 psig.

(Mix Tank) – 20-25psig. Discharge Pressures – 250 to 260psig. Refrigerant Type – R-404A ONLY Cooling Type – Air or Water Cylinder valve type – TXV w/equalizer Mix tank valve type – AXV Refrigerant Charge- See Machine Data Plate

D) Proximity Switch

The sensitivity of this switch can be adjusted with a small screwdriver. The trimmer location is on the switch body nearest the front panel. To adjust, the adjustment screw should be turned

very carefully either in a clockwise direction to increase the range or counter clockwise to decrease the range of operation.

B) Beater / Auger Drive Motors

Motor Type – Leeson - ODP with C flange Beater Rotation-(facing front of freezer)-CCW H.O.T Amps – 7.0 single phase Minimum Operating Voltage – 110vac. Maximum Operating Voltage – 130vac.

C) Thermal Overload

Overload Setting – 8.0 single phase Overload Ranges – 7.5-11 amps – single phase Thermal Overload – Calibrations and Settings

(Top View)

AMP. CALIBRATION

MAN AUT

ALWAYS IN R POSITION

Page 32

Part X – Maintenance

Your Carpigiani freezer has been designed, engineered, and manufactured to achieve high performance and long durability. The life expectancy of any machine depends not only on the quality of engineering, and components used, but also on the basic maintenance procedures.

It is important for you to become familiar with a few of the basic operating procedures.

OFF mode and disconnect power to the freezer.

If your machine is Water Cooled, it is important that it is not stored at a temperature below 32 degrees F. Before storing at a temperature below 32 degrees you must remove all liquids from the freezer and winterize the water condenser coil. This should be performed by an authorized service technician to avoid damage to the freezer.

• Only remove orings with the oring extractor

provided in the machine spare parts kit.

• Clean and sanitize the freezer in accordance with

the instructions in this operation manual.

• Lubricate all orings and seals as instructed.

• The wearing or the improper cleaning of the

beater shaft seals will result in product leakage into the rear of the machine. Check the side drip chutes frequently and replace seals when necessary.

• Replace any oring that is leaking or damaged.

• When all of the spare parts supplied in the spare

parts kit are used, re-order immediately. Do not wait until the part is urgently needed or causes

the machine to be inoperative without it.

• NEVER use the Automatic or Stand-By mode in the cleaning, sanitizing or initial filling of the

freezer. This can damage the freezer and its components.

• During the washing, cleaning and sanitizing

procedures, operate the machine in the BEATER mode as little as possible. This will minimize

component wear on the freezer.

• When removing and installing the freezer parts,

handle these with care. DO NOT drop or bang

together as this will damage the parts and affect

the freezers performance.

• NEVER use HOT WATER when washing,

cleaning, or sanitizing your freezer or its parts.

ALWAYS use luke warm water (80-90F).

The following is a recommended wearable parts replacement schedule. This is for normal operation of the freezer and will vary based on the volume and type of product served as well as operational and cleaning procedures.

Replacement Schedule

Orings and Seals – Every 6 months or as needed Beater Scraper Blades - Every 6 months or as needed Beater End Pusher – Every year or as needed

(Maximum

of 3 Seasons of Operation)

Drive Belts – Every 2 years or as needed Pump Gears – Every 3 years or as needed Pump Drive Bearings – As needed Plastic Parts - As need when leaking, scratched, or broken Rebuild Mix Pumps – Every 5 years or as needed Check Gearbox Grease Levels – Annually Electrical Components – When malfunctioning.

!! IMPORTANT !!

Prior to opening any of the machines outer panels, place both sides in the STOP / OFF mode and disconnect the machines power supply. Failure to do so can result in serious injury and or death.

!! IMPORTANT !!

If your machine is Air Cooled, its efficiency depends on a clean air cooled condenser. The fins of the condenser must be straight and cleaned a minimum of every two or three months. Prior to cleaning the air condenser, place the machine in the STOP or

Page 33

b) H.O.T. control set too low for product b) Set H.O.T. Setting to a higher value

c) Low on refrigerant c) Contact Authorized Service Agent

A) Trouble Shooting Guide – Gravity Fed Freezers

Problem Possible Cause Suggested Solution

1) Product too soft a) Drawing faster than the machine can produce a) Slow down draw rate

b) Gravity feed tube setting too small b) Open the feed tube setting to a larger hole opening

c) Beaters / augers assembled incorrectly c) Disassemble the freezer and reassemble (refer to Part IV)

2) No product dispenses from head a) No mix in mix tank a) Add Mix to mix tanks

b) Gravity feed sleeve open too wide b) Adjust the outer sleeve to a smaller opening

3) Low product overrun a) Defective / leaking oring on feed tube a) Replace all orings on feed tubes

b) Alarm #1 (RTA) on display monitor b) Motor has drawn excessive amps, press Stop/Reset on touch pad.

c) Control pad does not function c) Contact a Carpigiani Authorized Service Technician

d) Alarm #9 (IMS) on display monitor d) Assemble dispensing head on freezer or Contact Service Tech.

e) Power to the freezer but no functions work e) Contact a Carpigiani Authorized Service Technician

4) Machine will not start a) No power to the machine a) Check plug, disconnect, fuses or breaker for the machine

b) Low on refrigerant b) Contact a Carpigiani Authorized Service Technician

c) H.O.T. setting too high for product used c) Set the H.O.T. setting to a lower value

d) Scraper blades worn out d) Replace the beater scraper blades with new parts

e) Not enough mix in cylinder to reach H.O.T. e) Open feed tube and allow more mix in the cylinder

5) Machine Runs Continuously a) Restricted air flow (Air Cooled) a) Clean air condenser or contact a Carpigiani Authorized Service

Tech.

b) Low on refrigerant b) Contact a Carpigiani Authorized Service Technician

c) Compressor not functioning c) Contact a Carpigiani Authorized Service Technician

d) Insufficient power supply (low voltage) d) Contact a Carpigiani Authorized Service Technician

e) Insufficient water flow (water cooled) e) Contact a Carpigiani Authorized Service Technician

6) Machine will not Freeze product a) Restricted air flow (Air Cooled) a) Clean air condenser or contact a Carpigiani Authorized Service

Tech.

Page 34

b) Suction tube setting too large for draw rate b) Reset the suction tube to a smaller orifice setting (rotate CCW)

c) H.O.T. control set too low for product c) Set H.O.T. Setting to a higher value

d) Low on refrigerant d) Contact Authorized Service Agent

A.1) Trouble Shooting Guide – Pump Fed Freezers

Problem Possible Cause Suggested Solution

1) Product too soft a) Drawing faster than the machine can produce a) Slow down draw rate

b) Mix Pump assembled incorrectly b) Disassemble and reassemble pump accordingly (refer to Part IV)

c) Mix Pumps loosing prime c) Change pump gears or Contact Authorized Service Agent

d) Beaters / augers assembled incorrectly d) Disassemble the freezer and reassemble (refer to Part IV)

e) Pressure loss in mix feed system e) Change all machine orings and seals

2) No product dispenses from head a) No mix in mix tank a) Add Mix to mix tanks

b) Mix Pump suction tube setting too large b) Adjust the suction tube (rotate tube lever ccw)

3) Low product overrun a) Defective / leaking orings on mix feed system a) Replace all orings on freezer