Carpigiani UF 253 E Installation Manual

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

UF – 253 E Gravity and Pump

Soft Serve Freezer

Double Flavor Floor Model

OPERATION MANUAL

Foreword

Thank you for selecting Coldelite to meet your operation and growing demands. Your Coldelite freezer has been manufactured utilizing the most advanced technology and modern equipment available in the industry. We at Coldelite, 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 Coldelite freezer. We feel certain that your compliance with these instructions will assure excellent performance, trouble-free operation and profitable business for years to come.

Index

Foreword Page #

Part I Installation

A) Uncrating 4 B) Positioning the Machine 4-5 C) Electrical Requirements 5 D) Completing the Installation 5

Part II Explanation of Controls

A) Electronic Control Panel 6 B) Dispensing Handles 7 C) Proximity Switches 7 D) Dispensing Head Safety Switch 7 E) Electric Control Panel 7-8 F) Other Controls 8

Part III Initial Cleaning Procedure

A) Gravity Fed Cleaning Procedure 9 B) Pump Fed Cleaning Procedure 10 C) Disassembling the Dispensing Head 11 D) Disassembling the Beaters / Augers 12 E) Cleaning Operations 12

Part IV Assembling the Freezer

A) Assembling the Beaters / Augers 13-14 B) Assembling the Dispensing Head 14-16 C) Assembling the Gravity Feed Tubes 16-17 D) Assembling the Mix Injection Pumps 17-18

Part V Sanitizing the Freezer 19-20

Part VI Starting the Freezer

A) Gravity Fed Machines 21 B) Pump Fed Machines 22

Part VII Operating the Freezer

A) Stand By Mode 23 B) Gravity Fed Machines – How to Operate and Make Adjustments 24 C) Pump Fed Machines – How to Operate and Make Adjustments 24

Part VIII Periodic Cleaning Procedures

A) Gravity Fed Machines 25-26 B) Pump Fed Machines 26-28

Part IX Technical Information

A) Refrigeration 28 B) Beater Drive Motor 28 C) Thermal Overload 28 D) Proximity Switches 28

Part X Maintenance

A) Troubleshooting Guide 29-31

!! IMPORTANT !!

Failure to closely follow operational and maintenance procedures may result in damage to the unit and / or void your warranty. Coldelite 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.

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 pivoting casters to allow for ease of movement. When placed in its final location, lock the caster brakes to prevent unwanted movement of the freezer. (Refer to Figure 1)

2) The freezer must also be level to ensure proper drainage from the mix tanks and cylinders. To level, place a level on all corners and shim the casters as needed.

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.

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.

12"

Figure 2

3) If your freezer is air cooled, you MUST have adequate spacing on both sides and rear of the machine. You should have a minimum of 4 inches of clearance on both sides and 12 inches of clearance on the rear of the machine. This will ensure an adequate airflow is maintained. (Ref. to Figure 2)

B) Positioning the Machine

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

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

4) 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.

5) 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.

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

7) 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

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 Coldelite 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. 208 or 230 vac). Failure to wire to the correct supply voltage can result in machine malfunction.

Electrical Connection – ( Refer to Fig. 3 )

Having removed the side panels from the frame, the main power connection box is located on the 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 clockwise.

D) Completing the Installation

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

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. Coldelite 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 Coldelite Freezer. We are certain that your full compliance with instructions and procedures will result in many years of trouble free operation.

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

Part II – Explanation of Controls

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

888

L3 L4

This machine is equipped with two independent electronic touch control pads. Each electronic touch pad operates one side 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.

Push to Select – Position 571.2

By pressing this button you can select any of the

STOP

RESET

PUSH TO SELECT

AUTOMATIC STAND-BY BEATER MIX LEVEL

Figure 4

570

571.1

571.2

following machine modes:

- Automatic

- Stand-by

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

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 that more mix is needed to operate the freezer. Each mix tank has a maximum capacity of 18 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 Handles – (Refer to Figure 5)

The dispensing handles control the flow and

extraction rate of finished product. The left handle serves product from the left cylinder, the right handle serves product from the right cylinder and the center dispenses equally from both cylinders.

You should ONLY dispense product when the

machine is in the automatic mode.

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 bottom of the front panel. This control panel contains all of the machines electrical control components. ONLY a Coldelite 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 Switches -(Refer to Figure 6)

In the Automatic mode the Photo Sensor Switches

(Position #920) activate the beater / auger motors to dispense product. To activate the photo sensor switches, 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.

Figure 7

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

1) Beater Motor Contactors - (Left /Right) – 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.

Figure 6

920

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

3) Beater Motor Overload Protector - (Left/Right) – 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 Boards – (Left / Right) – These boards control and monitor ALL functions of the machine.

6) Safety Fuse – This fuse protects the high voltage side of the main transformer in the event of a short circuit. If tripped, all of the machines controls and touch pads will be inoperative.

7) Current Monitoring Transformer – (Left / Right) – These transformers monitor the current draw of the beater drive motors.

8) 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(s) will resume running.

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 Machines

Proceed with the disassembly process by removing the gravity feed tubes, which are located inside each mix storage tank. These should be pulled straight up and out of the tanks.

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 tubes must be disassembled. To disassemble, first remove the splash guard from the center of the tube.

B) Pump Fed Machines

Proceed with the disassembly of the mix injection pumps located in each 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 assemblies straight up and out of each mix storage tank.

Disassemble the mix pump assemblies as pictured below (one per side). 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 each 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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