Carpigiani XVL 1 Instruction Manual

INSTRUCTION MANUAL

XVL 1

COUNTER

APPLICARE

TARGA

CARATTERISTICHE

2015/10

Edition 01

Via Emilia, 45

40011 Anzola dell’Emilia (BO)

ITALY

 + 39 051 6505111

 + 39 051 732178

carpigiani.com

XVL 1 COUNTER

We wish to thank you for purchasing one of Carpigiani’s machines.

Since 1993, Carpigiani manufactures utilising the Quality Control Management System that is today certified ac­cording to UNI-EN-ISO 9001-2008.

Carpigiani’s machines conform to the requirements of the following European Directives:

• “Machinery” Directive 2006/42/EC;

• “Low Voltage” Directive 2006/95/EC;

• “EMC” Directive 2004/108/EC;

• “PED” Directive 97/23/EC;

• Regulation 2004/1935/EC relating to “Materials and articles in contact with foodstuffs”.

This manual contains the ORIGINAL INSTRUCTIONS and can be reproduced, transmitted, copied and filed in a
retrieval system or translated in other languages ONLY by prior written agreement with Carpigiani.

The purchaser has the right to reproduce copies only for his/her own use.

Carpigiani’s policy pursues constant research and development and therefore it reserves the right to make changes
and revisions whenever deemed necessary and without being bound to the purchaser for any previous statements.

EDITION DATE MODIFICATIONS

01 2015/10

EDITOR VERIFIED APPROVED

AM DN/EZ RL

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GENERAL INDEX

FOREWORD ..........................................................................................7

Instruction manual ....................................................................................................7

Purpose ...................................................................................................................... 7

Manual structure ....................................................................................................... 7

Additional documentation ........................................................................................7

Standard symbols ...................................................................................................... 8

Qualification of the personnel ..................................................................................8

Safety ......................................................................................................................... 9

Warning ...................................................................................................................... 9

1. GENERAL INFORMATION ...........................................................10

1.1 General information .............................................................................10

1.1.1 Manufacturer’s identification data .............................................................10

1.1.2 Information about maintenance ................................................................. 10

1.1.3 Information for the user ..............................................................................11

1.2 Information about the machine ..............................................................11

1.2.1 General data ................................................................................................. 11

1.2.2 Technical features ....................................................................................... 11

1.2.3 Location of machine groups ....................................................................... 12

1.3 Intended use ......................................................................................... 12

1.4 Noise ..................................................................................................... 12

1.5 Storing a machine ................................................................................ 12

1.6 Disposal of packing materials ............................................................12

1.7 WEEE (Waste Electrical and Electronic Equipment) .........................13

1.8 Bacterial contamination detection ..................................................... 13

2. INSTALLATION.............................................................................. 15

2.1 Space necessary to use the machine ................................................ 15

2.2 Machine with air-cooled condenser ...................................................15

2.3 Machines with water-cooled condenser ........................................... 15

2.3.1 Water valve adjustment ..............................................................................15

2.4 Electrical connection ........................................................................... 16

2.4.1 Replacing the power cable ......................................................................... 16

2.5 Refilling ................................................................................................. 16

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3 INSTRUCTIONS FOR USE ........................................................... 17

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 Functions ...................................................................................................... 19

3.4 Dispensing handles ............................................................................. 31

3.4.1 Modifica quantità prodotto erogato ...........................................................31

3.4.2 Self closing ................................................................................................... 32

3.5 Machines fed by pump and semi-submersible pump ............................32

3.6 Gravity-fed machines - feeding needle ..............................................32

3.7 Preliminary operations, washing and sanitising ............................... 33

3.8 Commissioning the machine .............................................................. 33

3.8.1 Avviamento macchine con pompa ............................................................. 33

3.8.2 Avviamento macchine a gravità ................................................................. 33

3.8.3 Dry Filling ......................................................................................................34

3.9 Production ............................................................................................ 34

3.10 Pasteurisation ...................................................................................... 35

3.11 Daily cleaning – Opening and closing procedures ...............................36

3.11.1 Daily closing procedures ...........................................................................36

3.11.2 Daily opening procedure ............................................................................. 38

4. SAFETY DEVICES .........................................................................40

4.1 Alarms ...................................................................................................40

4.1.1 Blackout ....................................................................................................... 42

5.

DISASSEMBLY, CLEANING AND REASSEMBLY OF THE

PARTS IN CONTACT WITH THE PRODUCT ............................43

5.1 General description ............................................................................. 43

5.2 Washing conditions .............................................................................43

5.3 Suggestions ..........................................................................................43

5.4 How to use cleaning/sanitising solution ............................................ 43

5.5 Daily cleaning ....................................................................................... 44

5.6 Scheduled cleaning ............................................................................. 44

5.6.1 Machine Drainage ....................................................................................... 44

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5.6.2 Pump feed machine - removal from Hopper ............................................. 44

5.6.3 Gravity fed machines - removing feeding needle from hopper ............... 45

5.6.4 Mix Beaters Removal from Hopper............................................................45

5.6.5 Hopper Washing .......................................................................................... 45

5.6.6 Pump feed machine - disassembly of the pump ...................................... 47

5.6.7

5.6.8 Disassembly of the door .............................................................................49

5.6.9 Disassembly of beaters .............................................................................. 51

5.6.10 Disassembly of the drip drawer, the drip tray and the hopper lid ........... 52

5.6.11 Cleaning and sanitising of the components ............................................. 52

5.6.12 Reassembly of the tank beater ................................................................. 52

5.6.13 Reassembly of the beater ......................................................................... 53

5.6.14 Reassembly of the dispensing door .......................................................... 53

5.6.15 Pump feed machine - Reassembly of the pump .....................................54

5.6.16 Gravity fed machines - refitting the feeding needle .....................................56

5.6.17 Drip Tray and Hopper Cover Reassembly ............................................................ 56

5.6.18 Complete sanitisation of the machine ....................................................... 57

Gravity fed machines - disassembling the feeding needle .......................... 49

6. MAINTENANCE ............................................................................58

6.1 Maintenance ......................................................................................... 58

6.2 Water-cooling ....................................................................................... 59

6.3 Ordering spare parts ........................................................................... 59

6.4 Supplied accessories .......................................................................... 60

7. TROUBLESHOOTING GUIDE ...................................................... 61

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FOREWORD

Instruction manual

In writing this manual, the European Community direc­tions on safety standards as well as on free circulation
of industrial products within the E.C. were taken into
due account.

Purpose

This manual was conceived taking machine users’
needs into due account.

Issues regarding the correct use of the machine have
been analysed in order to keep the longstanding quality
features characterising Carpigiani’s machines all over
the world unchanged.

A significant part of this manual refers to the conditions
required for using machine and, above all, to the nec­essary procedures to follow while cleaning and during
routine and special maintenance.

Nevertheless, this manual cannot meet all demands in
details. In case of doubts or missing information, please
apply to:

Manual structure

This manual is divided in sections, chapters and
subchapters in order to be consulted more easily.

Section

A section is the part of the manual 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.

Any person employed to use the machine must have
first read and fully understood the parts of the manu­al that refer to his/her competence and in particular:

• the Operator must have read the chapters regarding

starting the machine, the functioning of the machine
units and the prescribed safety precautions;

• a skilled technician involved in the installation, main-

tenance, repair, etc., of the machine must read all
parts of this manual.

Via Emilia, 45

40011 Anzola dell’Emilia (BO)

ITALY

 + 39 051 6505111

 + 39 051 732178

 carpigiani.com

Additional documentation

Along with an instruction manual, each machine is
also supplied with additional documentation:

• Spare parts list: a list of spare parts provided with

the machine for its maintenance.

• Wiring diagram: a diagram of wiring connections

placed in the machine.

WARNING

Before using the machine read the instruction
manual carefully.
Pay attention to the safety instructions.

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Standard symbols

ELECTRIC SHOCK

DANGER

This warns personnel concerned that the opera­tion described could cause electric shock if not
carried out while respecting safety norms.

PROTECTION

This symbol located next to description means
that the operator must use personal protection
against an implicit risk of accident.

DANGER FROM HIGH

TEMPERATURES

This warns personnel concerned that the opera­tion described could cause burns and scalds if not
carried out while respecting safety norms.

DANGER

MOVING PARTS

This warns personnel concerned about the pres­ence of moving organs and the risk of physical in­jury if safety norms are not respected.

CRUSHING

HAZARD

This warns personnel concerned about the risk of
having a finger, hand or other body part crushed
if the described operation is not carried out while
respecting safety norms.

GENERAL

HAZARD

This warns personnel concerned that the opera­tion described may cause injury if not carried out
respecting safety norms.

NOTE

This points out significant information for the per­sonnel concerned.

Qualification of the personnel

Personnel using/working on the machine can be dif­ferentiated according to training and responsibility as
follows:

OPERATOR

This term identifies unqualified personnel who
have no specific technical qualifications and
who can carry out only simple tasks such as

operating the machine using the controls on
the keyboard, loading and unloading product utilised
during production, loading of any consumable materi­als, basic maintenance operations (cleaning, removing
simple obstruction, controlling instrumentation, etc.).

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 me-

chanical 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 that the manufac-

turer has assigned to field interventions for

complex jobs under particular conditions or in

accordance with agreements made with the

machine’s owner.

WARNING

This warns the personnel involved that the non­observance of warning may cause loss of data
and damage to the machine, or cause risks
for noncompliance with any applicable law/
regulations.

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Safety

When using the machine be aware that drive mecha­nisms (rotary motion), high voltage components and
parts subject to high temperatures may cause serious
injury/damage to persons and things.

The person in charge of plant safety must check
that:

• any incorrect use or handling is avoided;

• safety devices are not removed or tampered with;

• the machine is regularly maintenanced;

• only original spare parts are used especially with

regards to those components with safety functions
(e.g., protection microswitches, thermostats, etc.);

• suitable personal protective equipment is worn;

• great care is taken during hot product cycles;

• particular attention is paid to organs in movement.

To achieve the above, the following is necessary:

• at the work station an instruction manual relevant to

the machine must be available;

• the documentation must be carefully read and re-

quirements must consequently be met;

• only adequately skilled personnel should be as-

signed to electrical equipment.

Warning

When installing the machine, insert a differential ther­momagnetic 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 leas.

• Never put your hand into the machine during pro-

duction and cleaning operations. Before carrying out

any maintenance operation, make sure that the ma-

chine is in the Stop position and the main switch has

been switched OFF.

• Using a jet of pressurized water to wash the machine

is forbidden.

• Removing panels in order to reach the machine in-

side before the machine has been disconnected is

forbidden.

• Carpigiani will not respond to accidents that might

happen during the use, cleaning and/or maintenance

of its machines if the specified safety norms have not

been complied with.

IMPORTANT

Ensure that technical personnel do not carry out opera­tions that are not within their capabilities, knowledge
and responsibility.

NOTE

According to the norms in force, a SKILLED ENGI­NEER is a person who, thanks to his/her:

• training, experience and education;

• knowledge of rules, prescriptions and interven-

tions on accident prevention;

• knowledge of machine operating conditions.

Is able to recognize and avoid any danger and has
also been authorised by the person in charge of
plant safety to carry out all types of interventions.

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1. GENERAL INFORMATION

1.1 General information

1.1.1 Manufacturer’s identification data

The machine has a data plate that was assigned to the machine when it was manufactured, showing the manufac­turer’s data, machine type and serial number.

A copy of the machine data plate can be found on the first page of this manual.

Fig. 01

A B F

100089654588-4

Matr.

ANZOLA EMILIA - BOLOGNA - ITALY

Cod.

V Hz kW
A
Gas kg

DC

E

IH

G

A Serial number
B Machine type
C Voltage
D Main-switch amperometric value
E Gas type and weight

F Machine code
G Condensation (A= Air - W= Water)
H Frequency
I Power input

1.1.2 Information about maintenance

All operations of routine maintenance are hereby described in the section “Maintenance”. Any additional operation
requiring a technical intervention on the machine must be cleared with the manufacturer who will also examine the
possibility of a factory technician field intervention.

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1.1.3 Information for the user

• Carpigiani is at the disposal of the user

for any clarification or necessary/inte­grative information regarding the func­tioning of the machine or any improve­ment modifications to the machine.

• Contact the area distributor in the event of any prob-

lems or the manufacturer if a distributor is not available.

• The customer assistance service is available at any

time to respond to customer requirements regarding
the functioning of the machine, requests for spare
parts or technical assistance that may eventually be
necessary.

1.2 Information about the machine

1.2.1 General data

It is an electronic machine for the production and in­stant distribution of variegated ice cream that has the
following main characteristics:

• refrigerated upper tank;

• electronic control of product consistency via the

“Hard-o-tronic” system;

• automatic pasteurisation system of the product con-

tained in the tank and cylinder during non-produc­tion periods (e.g., at night);

• Dry Filling;

• mixer for mixing the dressing with the ice cream;

Carpigiani recommends using top quality raw materials
always in the production of ice cream and confectionery
products to satisfy the most demanding requirements
of customers. Any cost saving of the mix utilized affects
the quality and much greater losses will occur apart
from the economic losses.

Taking into account everything mentioned above,
the following recommendations should be taken
into account:

• only you produce the mix using top quality natural

products, or receive supplies from serious and trust-

worthy companies;

• scrupulously follow the mix preparation instructions

that are supplied by the supplier;

• Do not modify suggested recipes without knowing

the characteristics of the ingredients;

• taste the final product and place it on sale only if you

are completely satisfied;

• advise your personnel that the machine must always

be kept clean.

Contact only the Carpigiani Technical Assistance Ser­vice for any repairs to the machine.

1.2.2 Technical features

INSTALLED

POWER

OUTPUT

NET

WEIGHT

DIMENSIONS

mm

MODEL

XVL 1

COUNTER P

XVL 1

COUNTER G

CYLINDER

75g

CONES

HOUR **

310 1,75 1 400 3 50 Air/Water 2,4 170 400 744 909

265 1,75 1 400 3 50 Air/Water 2,4 160 400 744 909

CAPACITY

/

l V Phase Hz kW Kg L P H

FLA-

VOURS

ELECTRICAL

POWER SUPPLY ***

CONDENS-

ER

** The hourly production and mix quantity for each ice cream can vary depending on the temperature and type of

mix utilised and on the increase in volume (overrun) required.

*** Also available with a water-cooled condenser and other types of electrical power supply.

Performances refer to room temperature of 25°C at a water temperature of 20°C in the condenser.

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1.2.3 Location of machine groups

Fig. 02

P

1 Tank lid
2 Control panel

1.3 Intended use

The machine must only be used for the production of ice
cream and patisserie products, in compliance with what
has been stated in paragraph 1.2.1 “General information”,
and within the operating limits indicated here below.

• Voltage: ±10%

• Min. air temperature: 10°C

• Max. air temperature: 43°C

• Min. water temperature: 10°C

• Max. water temperature: 30°C

• Min. water pressure: 0,15 MPa (1,5 bar)

• Max. water pressure: 0,8 MPa (8 bar)

• Max. relative humidity: 85%

L

1

H

2

3

4

3 Product dispensing door
4 Drip tray

1.5 Storing a machine

The machine must be stored in a dry and damp-free
environment.

Before storing the machine, cover it with a sheet to pro­tect it against dust and dirt.

1.6 Disposal of packing materials

When removing the machine from its packaging, sub­divide the packing materials into the various types and
dispose of them in accordance with the norms in force
in the destination country.

WARNING

This machine has been designed for use in rooms not
subject to explosion-proof laws and therefore it can
only be utilised in rooms that conform to a normal at­mosphere.

1.4 Noise

Continuous acoustic pressure level equivalent to
Weighting A in the working place is less than 70 dB(A)
for both water-cooled and by air-cooled machines.

12

It is forbidden to dispose of packaging materials
in the environment.

GENERAL

HAZARD

Do not leave packaging materials within reach of
children because they could cause suffocation.

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1.7 WEEE (Waste Electrical and
Electronic Equipment)

In conformity with the European Directives
2006/66/EC, on batteries and accumulators
and waste batteries and accumulators, and
2002/96/EC, also known as WEEE, the pres­ence of this symbol on the side of the product
or packaging means that the product must not

be disposed of with normal urban waste. Instead, it is
the user’s responsibility to dispose of this product by
returning it to a collection point designated for the recy­cling/treatment of electrical and electronic equipment
waste.

Differentiated collection of this waste material helps to
optimise 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.

1.8 Bacterial contamination
detection

A qualified bacteriologist must periodically analyse
samples of the product to check for the presence of
bacteria. The bacteria count in the samples should be
below the following figures:

Standard Plate Count (SPC) ................................ 50,000

Coliforms .................................................................... 10

The following list indicates the possible sources of bac­terial contamination and the methods to prevent it.

SOURCES OF

CONTAMINATION

Operator contact.

Residues / deposits of
material (milk clots).

Worn or damaged
parts.

HOW TO PREVENT

CONTAMINATION

• Wash hands and forearms

thoroughly.

• Wear rubber gloves if they

are cut or have skin prob­lems.

• Wash hands several times a

day.

• Utilise the appropriate brush-

es.

• To clean thoroughly, scrub

the parts and components
to prevent the formation of
milk clots because milk clots
are fertile material for the
proliferation of bacteria that
could contaminate the fresh
milk.

• Lubricate all rubber parts

that come into contact with
the mix using a food-grade
lubricant.

• Replace damaged O-rings

only with original spare
parts.

• Systematically check the

drip drawers to avoid exces­sive dripping.

If the bacteria count exceeds the above-mentioned fig­ures, there is a source of bacterial contamination. This
source must be immediately identified and eliminated. A
high bacteria count means that the product is not fit for
consumption and a correct cleaning and sanitization of
the machine must be carried out to eliminate the contin­ued bacterial contamination of the product.

NOTE

Soft yogurt normally has a high bacteria count and
therefore it is necessary to highlight the product. In
any case, coliform bacteria contamination IS NOT
ACCEPTABLE in any type of product. The follow­ing information will help you to prevent coliform
bacteria contamination problems.

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SOURCES OF

CONTAMINATION

Cleaning and
wrong hygienic
procedures.

HOW TO PREVENT

CONTAMINATION

• The container in which the

pieces are washed must be
perfectly clean and contain
enough detergent/sanitis­ing solution to completely
cover even the largest com­ponents. Use the brushes to
clean and sanitise the ma­chine regularly.

• Utilise the appropriate

brushes, lubricants and dis­posable cloths.

• Store and utilize the deter-

gents as per the manufac­turer’s instructions.

• Follow expert personnel’s

cleaning habits. Ensure the
personnel can complete
cleaning procedures coher­ently, correctly and without
interruption.

• Leave the sanitising solution

in the cylinder and tank at
least for the time suggested
by the manufacturer of the
sanitising solution.

• Each time after using, wash

and sanitise the utensils
used for cleaning and the
tube containing the lubri­cant. Always replace the cap
on the tube.

• The machine components

and the brushes must be left
to dry in the open. Do not
put them back into the ma­chine whilst they are wet or
damp.

• Always carry out the daily

cleaning procedure. Regu­larly clean the outside of the
machine and the dispenser
with a sanitized cloth.

SOURCES OF

CONTAMINATION

Wrong method of
storing the mix.

HOW TO PREVENT

CONTAMINATION

• Utilise leftovers of mixes

with the oldest date first. Be
careful of the expiry date.

• Put the mix directly in the

fridge. Do not accumulate
mix outside in direct sunlight
before putting it in the fridge.

• In the fridge, leave at least

2-3 cms of space between
the mix and other products
to allow air to circulate.

• The mix must not be left at

ambient temperature for
long periods of time.

• The storage temperature of

the tank must be maintained
at 4.4°C (40°F). Storage
temperatures above 4.4°C
would permit the multiplica­tion of bacteria to dangerous
levels within less than one
hour.

• Once the mix has been

placed inside the tank, place
the lid on the tank to store
the mix at the correct tem­perature and minimise the
possibility of contamination.

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2. INSTALLATION

2.1 Space necessary to use the
machine

Space for access to the machine must be left free in or­der to enable the operator to act without constraint and
also to immediately leave the working area if necessary.

The machine also requires free space on the side to ex­tract the drip trays.

It is also advisable to have a minimum access to the
operating area of the machine of at least 150 cm, and
about 45 cm. of space on the side of the machine to al­low fro extracting drip trays.

NOTE

Insufficient air circulation affects the operation
and the output capacity of the machine.

Fig. 03

50 cm only for

air-cooled condenser

2.2 Machine with air-cooled con­denser

Machines with an air-cooled condenser must
be installed leaving a minimum distance (at
least 50 cms) above the chimney for the free
circulation of the condensate air.

NOTE

An insufficient air circulation affects operation and
output capacity of the machine.

2.3 Machines with water-cooled
condenser

A water-cooled machine must be connected
to a mains water supply or to a cooling tower
to operate it.

The water must have a pressure of between

0.15 MPa and 0.8 MPa (1,5-8 bar) and a flow capacity at

least equal to the estimated hourly consumption.

Connect the inlet pipe marked by the “Water Inlet” plate
to the water supply by installing a shut-off valve and
the outlet tube marked by the “Water Outlet” plate to a
drainage pipe by installing a shut-off valve.

1 cm

1 cm

150 cm

WARNING

Machines with an air-cooled condenser must be
installed leaving a minimum distance (at least 50
cms) above the chimney for the free circulation of
the condensate air.

2.3.1 Water valve adjustment

IMPORTANT

If the water valve needs be reset, this opera­tion must be carried out only by skilled per­sonnel.

NOTE

Water consumption increases if the temperature of
the inlet water is above 20°C.

WARNING

Do not leave the machine in a room with a tem­perature below 0°C without first draining the wa­ter from the condenser.

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2.4 Electrical connection

Before connecting the machine to the mains
supply, check that the machine voltage indi­cated on the data plate corresponds with the
mains supply voltage.

Position a class D section thermomagnetic circuit
breaker switch correctly rated to the absorption power
required and with a contact aperture of at least 3 mm.
The machines are delivered with a 5 wire cable: the blue
wire must be connected to the neutral lead.

IMPORTANT

The yellow/green ground wire must be connected to an
adequate ground plate.

2.4.1 Replacing the power cable

Should the machine’s power cable become
damaged, it must be replaced immediately by
one with similar characteristics.

The replacement must be carried out only by a skilled
technician.

2.5 Refilling

The type of motor installed in the machine is a
lubricated-for-life motor. No checking/replac­ing or topping up is necessary.

The correct quantity of gas for the refrigeration circuit
is put in by Carpigiani when testing the machine. A new
machine does not need any topping up or refilling.

If it becomes necessary to top up or fill the system with
gas, the procedure must be carried out in conditions of
safety and by a qualified technician capable of estab­lishing the cause of the anomaly prior to topping up.

2.6 Machine testing

The machine is tested by Carpigiani at the end
of the assembly procedure. The foreseen op­erational and production functions are checked.

Machine testing on the end user’s premises
must be carried out by skilled technicians or
by one of Carpigiani’s engineers.

After positioning the machine and making the correct
connections, carry out all operations necessary for func­tionality check and operational testing of the machine.

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3 INSTRUCTIONS FOR USE

3.1 Machine safety warnings

When using industrial equipment and plant, be aware
that drive mechanisms (rotary motion), high voltage
components, as well as parts subject to high tempera­tures may cause serious injury/damage to persons and
things.

The person in charge of plant safety must check
that:

• any incorrect use or handling is avoided;

• safety devices are not removed or tampered with;

• the machine is regularly maintenanced;

• only original spare parts are used especially with

regards to those components with safety functions
(e.g., protection microswitches, thermostats, etc.);

• suitable personal protective equipment is worn;

• great care is taken during hot product cycles.

To achieve the above, the following is necessary:

• at the work station an instruction manual relevant to

the machine must be available;

• the documentation must be carefully read and re-

quirements must consequently be met;

• only adequately skilled personnel should be as-

signed to electrical equipment;

• ensure that technical personnel do not carry out op-

erations that are not within their capabilities, knowl­edge and responsibility.

3.2 Machine configuration

The machine is composed of a motor for operating the
beater unit, a cooling system with a water-cooled or air­cooled condenser and electronic management of the
main functions.

The preparation of soft ice cream occurs by plac­ing the cold mix (+4°C) inside the tanks and start­ing an automatic production cycle until the set pro­grammed optimum consistency of the ice cream is
reached.

The mix enters into the whipping cylinders already
mixed with air. The ice cream is produced only at the
moment in which it is served.

By using the ice cream dispensing levers positioned on
the front of the machine, a portion of soft ice cream re­quested will be dispensed.

Simultaneously, an equal quantity of mix passes from
the upper refrigerated tanks to the whipping cylinder.

DANGER FROM HIGH

TEMPERATURES

Be extremely careful during pasteurisation phase;
contact could cause burns.

Fig. 05

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17

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3.3 Controls

3.3.1 Push-button panel

The machine is equipped with a push-button panel fitted on the front panel; each button is marked by an explana­tory symbol of the assigned function.

Fig. 06

1 32

1 Stop the machine from functioning
2 Production
3 Information
4 Touch screen display
5 Increment/Decrement.
6 Confirm

4

7 Cleaning
8 Storage/Alarm Reset
9 Pasteurisation

NOTE

6 7 8 95

18

The display is touch screen with 7 sensitive zones:

NOTE

The keypad emits an acoustic signal when the key pressed has been accepted.

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3.3.2 Functions

BUTTONS DESCRIPTION OF FUNCTIONS

STOP In Stop mode, with the Stop key back lit, the machine is at stop.

From the Stop position any machine function can be accessed.

To change function, returning first to Stop IS ALWAYS REQUIRED.

The display indicates the time, date and the indication of the tank.

XVL 1 COUNTER

WHY IN STOP ??

With the machine in
Stop mode for more
than 30 seconds.

WASH TODAY!

With the machine in
Stop mode for more
than 24 hours.

If the machine is left in Stop mode with the level covered, after 30 seconds the message
“Why in STOP ??” is visualised to alert the user to put the machine into Production,
Pasteurisation or Storage mode.

Press the key to cancel the alarm message from the display. Refer to alarms.

From Stop mode, there is a time countdown if the tank level is covered.
If this time exceeds 24 hours, the display visualises the message “Wash today!”.

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The user must carry out machine washing procedure before restarting Production.

Press the

key to cancel the alarm message from the display. Refer to alarms.

19

XVL 1 COUNTER

BUTTONS DESCRIPTION OF FUNCTIONS

INFO whilst in Stop
mode

Pressing the Info

key whilst in Stop mode, the display visualises the following

functions that can be selected directly on the touch screen:

• Pasteurisation history

• Events history

Functions that can be
selected from INFO
whilst the machine is in
Stop mode:

• Pasteurisation

history (for SP
versions, only)

• Events history

• Key locking

• Settings

INFO –
PASTEURISATION
HISTORY

With the machine in

Stop mode press:

• INFO

• PASTEURISATION

HISTORY

• Key locking

• Settings

.

Press the

Pressing the Pasteurisation History

key to go back to the previous page.

key the display visualises the list of pasteuri-

sations carried out successfully.

Utilise the and arrow keys to scroll the different events.

INFO – EVENTS
HISTORY

With the machine in

Stop mode press:

• INFO

• EVENTS HISTORY

20

Pressing the Historical Events

key the display visualises the list of events that

include function changes, alarms and pasteurisation steps.

Utilise the and arrow keys to scroll the different events.

NOTE

The maximum number of memorizable events is 1000.

A further event deletes the earliest one.

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BUTTONS DESCRIPTION OF FUNCTIONS

INFO – KEY
LOCKING

The key locking button is present in all functions of the machine. Pressing and holding the

Lock icon

for about 10 seconds (wait for the visualisation of the display to return to
the current function) will lock the touchpad, except for those inside the display, so that it
can be cleaned without accidentally activating a different function.

With the machine in

Stop mode press:

• INFO

• KEY LOCKING

To re-enable the keys press any key; The window with a lock will re-appear: press it for 10
seconds to enable the keys.

INFO - SETTINGS

Pressing the Settings

key, the display visualises the following functions that can be

selected directly on the touch screen:

• Setting the time

With the machine in

Stop mode press:

• INFO

• SETTINGS

• Display

• Setting the machine

•

Functions that can be
selected from SETTINGS
mode:

• Setting the time

• Display

• Setting the machine

XVL 1 COUNTER

INFO – SETTING
THE TIME

With the machine in

Stop mode press:

• INFO

• SETTINGS

• SETTING THE TIME

Pressing the Setting the time

key, the display visualises:

Pressing on the hour the background of the key becomes grey and the and ar­row keys light up so that the hour can be modified. To confirm press the button on the
display to deselect it.

To modify minutes and date follow the same procedure.

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21

XVL 1 COUNTER

BUTTONS DESCRIPTION OF FUNCTIONS

INFO - DISPLAY

With the machine in

Stop mode press:

• INFO

• SETTINGS

• DISPLAY

Pressing the Display

The display luminosity bar (intensity of the backlight) of the display appears when press-

key, the display visualises:

ing on the display and the

Confirm using the key.

and arrow keys light up to allow modification.

22

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BUTTONS DESCRIPTION OF FUNCTIONS

INFO – MACHINE
SETTING

With the machine in

Stop mode press:

• INFO

• SETTINGS

•

MACHINE SETTING
(PROGRAMMING)

Pressing the Machine setting key, access is gained to the first step of user
programming.

To scroll the various steps, utilise the and arrow keys. The display visualises
the first step of user programming. E.g., U07 - Language: Eng. The value is modifiable
using the left and right arrow keys visualised on the touch screen. Refer to the Program­ming table.

XVL 1 COUNTER

Step

U07 Linguaggio Language Ita Esp Ita
U08 Ora Avvio Prod. Start Prod. Time 00 23+no+auto 08
U09 Ora Avvio Pas-Con Start Pasto Time 00 23+no 02
U10 Abilita Beep Liv Lev. Beep Enable No Yes Yes
U12 Tempo Mixer Mixer Time 0 20 0
U15 Extra Agitaz.Vas Extra Hop.Agit. No Yes Yes

U07 - Language: Set language among Italian, English, German and Spanish.
U08 - Start Prod.Time: Set the time at which Production will automatically start. If set

to “no”, automatic Production is disabled. If set to “auto”, Production will start as soon
as Pasteurisation is completed.

U09 - Start Past-Stor.Time:

For Pasteurising machines: Set the time at which Pasteurisation will automatically start.
If set to “no”, automatic Pasteurisation is disabled.

Display ITA Display ENG Min Max Default Notes

ADVERTÊNCIA

User takes full responsibility for the manual control of pasteurization, complying
with prevailing local regulations on mix handling in case mixes are not pasteurized.

For non-Pasteurising machines: Set the time at which Storage will automatically start. If
set to “no”, automatic Storage is disabled.

U10 - Lev. Beep Enable: If set to “YES”, the machine will beep intermittently when the
level is less than half full, except in Stop mode, when it will not beep even if the function
is enabled.

U14 - Mixer Timer: The amount of time in seconds the mixer will run when the
corresponding key is pressed.

U15 - Hopper Extra Beat.: Enable/disable hopper rotor periodical activation in
Production and Storage functions

To exit from user programming, do not press any key for approximately 30 seconds or

2015/10 - Ed. 01 - EN

press
On exiting user programming, if the table has been updated, the message “Table Up­dated M.” appears on the display.

on the display. At this point the machine returns to the previous menu.

23

XVL 1 COUNTER

BUTTONS DESCRIPTION OF FUNCTIONS

INFO from
Production mode

Pressing the

key whilst in Production mode, the display visualises the following

functions that can be selected directly on the touch screen:

• Cones and Software Versions

Functions that can be
selected from INFO
whilst the machine is in
Production mode:

• Cones and Software

Versions

• Setting

• Modify Set Hot

• Key locking

INFO – CONES AND
SOFTWARE VERSIONS

With the machine
in production mode
press:

• INFO

• CONES AND SOFT-

WARE VERSIONS

• Setting (if present)

• Modify Set Hot

• Key locking

Use the key to return to the previous page.

Pressing the Cones and Software Versions
read page that reports the following data:

• Daily cones

• Total cones

• SW versions

key, the display visualises the only

INFO - SETTING
(if present)

With the machine
in production mode
press:

• INFO

• SETTINGS

24

To return to the previous function press the key.

Pressing the Setting

key, access is gained to the whipping cycle selection menu

(if present).

To return to the previous function press the key or wait 15 seconds.

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BUTTONS DESCRIPTION OF FUNCTIONS

INFO – MODIFY
SET HOT

Pressing the Modify Set Hot

key, the background of the key becomes grey

XVL 1 COUNTER

With the machine

in production mode
press:

• INFO

• MODIFY SET HOT

INFO - KEY LOCKING

With the machine

in production mode
press:

• INFO

• KEY LOCKING

and the

After having set the desired value, to confirm press the button on the display to deselect
it.

If the

Pressing the Key locking
leaning of the front panel without accidentally activating any functions.

To re-enable the keys, press any key and the window with the lock appears. Pressing the
Key locking key for 10 seconds, all keys are re-enabled.

and arrow keys light up to permit the modification of the value.

key isn’t pressed again, the value is not memorised.

key for 10 seconds all keys are disenabled to permit the

INFO whilst in
Cleaning mode

Functions that can be
selected whilst in INFO
mode with the machine
in Cleaning mode:

• Key locking

Pressing the
functions that can be selected directly on the touch screen:

• Key locking

Pressing the Key locking key for 10 seconds all keys are disenabled to permit the
cleaning of the front panel without accidentally activating any functions.

To re-enable the keys, press any key and the window with the lock appears. Pressing the
Key locking key for 10 seconds, all keys are re-enabled.

Using the

key whilst in Cleaning mode, the display visualises the following

key the menu returns to the previous page.

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25

XVL 1 COUNTER

BUTTONS DESCRIPTION OF FUNCTIONS

INFO whilst in
Pasteurisation mode

Pressing the

key whilst in Pasteurisation mode, the display visualises the follow-

ing functions that can be selected directly on the touch screen:

• Key locking

Functions that can be
selected whilst in INFO
mode with the machine
in Pasteurisation mode:

• Key locking

INFO whilst in
Storage mode

Functions that can be
selected whilst in INFO
mode with the machine
in Storage mode:

• Key locking

CLEANING

Pressing the Key locking key for 10 seconds all keys are disenabled to permit the
cleaning of the front panel without accidentally activating any functions.

To re-enable the keys, press any key and the window with the lock appears. Pressing it for
10 seconds, all keys are re-enabled.

Using the

Pressing the

key the menu returns to the previous page.

key whilst in Storage mode, the display visualises the following

functions that can be selected directly on the touch screen:

• Key locking

Pressing the Key locking key for 10 seconds all keys are disenabled to permit the
cleaning of the front panel without accidentally activating any functions.

To re-enable the keys, press any key and the window with the lock appears. Pressing the
Key locking key for 10 seconds, all keys are re-enabled.

Using the

Pressing the Cleaning

key the menu returns to the previous page.

key the display visualises the following functions that can

be selected directly on the touch screen:

Functions that can
be selected whilst in
Cleaning mode:

• Beating

• Heated beating

• Pump

• Water dispensing

• Beating

• Heated beating

• Pump

• Water dispensing (if present)

The last line visualises the temperature of the cylinder and the consistency of the product

.

The keys that can be activated have a coloured icon (blue or red) and once pressed the
background becomes grey.

The keys that cannot be activated have a grey icon. Refer to the key

on the above

display.

The 2

and functions can be activated simultaneously.

26

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BUTTONS DESCRIPTION OF FUNCTIONS

CLEANING – BEATING

Pressing the Beating

key the beater motor is activated/deactivated.

When the motor is functioning, the background of the relative function becomes grey.

Press:

• CLEANING

• BEATING

After 3 minutes the symbol returns to a white background and the motor switches off.

The Beating function is utilised to wash the cylinder and facilitate the emptying of the
product from the cylinder.

CLEANING - HEATED
BEATING

Pressing Heated Beating the beater motor with heating is activated/deac­tivated.

When Heated Beating is activated the background of the function becomes grey.

The cylinder is heated until a set temperature is reached.

On reaching this temperature the symbol changes back to the white background and

Press:

•

CLEANING

•

HEATED BEATING

Heated Beating is deactivated.

XVL 1 COUNTER

CLEANING – PUMP

Press:

• CLEANING

• PUMP

CLEANING - WATER
DISPENSING

Press:

•

CLEANING

•

WATER DISPENSING

Pressing the Pump

key (only machines with a pump), the pump motor is activated/

deactivated.

When the motor is functioning, the background of the relative function becomes grey.

After 30 seconds the symbol returns to a white background and the pump switches off.

The function is utilised to load the mix from the tank to the cylinder and to pressurize the
cylinder to facilitate the dispensing of the product.

Pressing the Water Sprayer key activates/deactivates (only if present) the dis­pensing of water via the Water Sprayer positioned inside the cabinet of the machine. The
maximum dispensing time is 3 minutes. To stop the water dispensing before 3 minutes,
press the Water Sprayer key again.

When Water Sprayer is active, the background of the function becomes grey; when it is
deactivated the symbol changes back to the white background.

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27

XVL 1 COUNTER

BUTTONS DESCRIPTION OF FUNCTIONS

PRODUCTION

Production can be accessed only when the minimum level is covered.

Pressing the key

Where:

The tank level.

minimum uncovered.
Number of cones that can be dispensed with the level uncovered. It ap-

pears only if the minimum level becomes uncovered.

Temperature in the tank. If <40°C the temperature visualised is blue.

If >=40°C the temperature visualised is red.
Arrow lit: when the tank is cooling.

Set consistency to be reached.

the display visualises:

: minimum and medium covered, : medium uncovered, :

Product cannot be sold yet.

When it reaches consistency it becomes
Current consistency.

Arrow lit: if the cylinder is cooling.

Number of days left to Cleaning.

14

The machine brings set ice cream in the cylinder to the right consistency every 10 min-

utes. Press the
set value.

key to force this time. The consistency will conform to the

.

28

2015/10 - Ed. 01 - EN

BUTTONS DESCRIPTION OF FUNCTIONS

PRODUCTION
VERSIONS WITH
WATER DISPENSING
AND MIXER

VERSIONS WITH WATER DISPENSING AND MIXER

The display third line (at the bottom), shows what follows:

Basic machine.

The cone indicates that the machine is
in Production mode.
The key is not active.

Machine with a water dispenser.

The cone indicates that the machine is
in Production mode. The key is not ac­tive. The water sprayer is not active key
(gray). .

Machine with a mixer.

The cone indicates that the machine is
in Production mode.
The grey key is not active.
The mixer is an active (blue) key.

Machine with a mixer and a water
dispensing.

The cone indicates that the machine is in
Production mode. The key is not active.
The mixer is an active (blue) key.
The water sprayer is not active key
(gray).

XVL 1 COUNTER

STORAGE/ALARM
RESET

Storage has the function of bringing the product in the tank and the cylinder to a tem­perature of 4°C.

Once entering the Storage cycle the display shows as follows:

To start Storage manually press the key .

The button allows also to reset the alarms that might be shown on the display.

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29

XVL 1 COUNTER

BUTTONS DESCRIPTION OF FUNCTIONS

PASTEURISATION Pasteurisation can be accessed only when the medium level is covered.

Pressing the Pasteurisation

Where:

The tank level.

: minimum and medium covered, : medium uncovered,

: minimum uncovered.

Temperature in the tank. If <40°C the temperature visualised is blue.

If >=40°C the temperature visualised is red.

Arrow lit to one side of the temperature: Up if the tank is in heating
mode and Down if in cooling mode.

Temperature in the cylinder. If <40°C the temperature visualised is
blue.

If >=40°C the temperature visualised is red.

Function active: heating. Do not remove product.

key for 5 seconds, the display visualises:

Water Sprayer where applicable.

If the machine pasteurises, the Pasteurisation cycle occurs automatically every
day at a predetermined time (if set in User Programming).

When the machine is in Production or Storage mode at the time set for pasteurisation, it
automatically goes into Pasteurisation mode.

To activate Manual Pasteurisation, keep the

If the Pasteurisation cycle is not successfully completed, the machine CANNOT gain ac­cess to Production mode until a Pasteurisation cycle is completely carried out.

During the Pasteurisation cycle, the product in the tank or in the cylinder is heated to
65°C, maintained at this temperature for 30 minutes (fixed) and then cooled until the
storage temperature is reached.

At the end of the cycle, the display visualises
week, which means that the pasteurising process has been carried out correctly.

key pressed for 5” seconds.

with the hour and the day of the

30

2015/10 - Ed. 01 - EN

XVL 1 COUNTER

3.4 Dispensing handles

To dispense the product, place a cup or a
cone underneath the dispensing door and,
with the machine in production mode, slowly
lower the dispensing handle.

As soon as the product starts to come out, move the
cup or cone with a circular motion to give the ice cream
a conical shape.

Once a sufficient amount of product has been dis­pensed, close the dispensing handle and move the
cup or cone quickly downwards to give the portion a
pointed tip.

The product dispensing handle can also be easily re­moved by lifting it upwards. In this way it can also be
used as a key to stop the machine being used.

Fig. 07

3.4.1 Modifica quantità prodotto erogato

To modify the quantity of dispensed product from the
different handles, proceed as follows:

• Disassemble spigot door covering panel

 Press the two keys on the side of the panel

 Push the panel downwards

 Pull the panel from the front and remove it from

the machine.

Fig. 08

1

2

3

2015/10 - Ed. 01 - EN

31

XVL 1 COUNTER

• Turn knob counter clockwise to reduce the quantity

of dispensed product, or clockwise to increase it.

Fig. 09

3.4.2 Self closing

The machine is equipped with an automatic return sys­tem that brings the ice cream dispensing handle to rest
automatically.

This occurs via a spring system connected to the dis­pensing piston.

NOTA

In production, when symbol is displayed, di­spense a cone by lowering dispensing handle all the
way down, then take handle back to closed position.

3.5 Machines fed by pump and
semi-submersible pump

The pump allows a variation in the proportion of air/mix
sent to the cooling cylinders. Therefore, within certain
limits, it allows to adjust the volume increase (overrun)
suitable to the type of mixed used. By turning the mid­dle handle counter-clockwise the overrun is increased.

Fig. 10

3.6 Gravity-fed machines - feed­ing needle

How to obtain and how to keep quality performances.

• Maintain a big mix level inside the hopper (above the

half of the hopper itself). Mix storage temperature
inside hopper is +4°C, both during production and
storage.

• During the day the mix must periodically be stirred

by use of a plastic spatula to avoid separation,
particularly when product has not been dispensed
over a long period and the machine has been in
“storage” mode for a long time.

• A fluid mix without particles has to be used. A very

thick mix with big particles could close the slot of
the feeding needle thus blocking mix from entering
the cylinder.

• Keep the feeding needle slider (pos. 52) in a position

as to allow for a smooth mix flow from the hopper
to the cylinder. By rotating the slider slot to the hole
with smaller diameter, the quantity of mix to the tank
will decrease, and vice versa.

• Set the feeding needle in such a way that inlet hole is

turned towards the middle of the hopper.

• Never exceed production limit specified in paragraph

1.2.2 and dispense cones and cups in the most
regular way. If the indicated production limits are
reached the machine could block and the display
shows the alarm signal “ICE”. If this occurs, please
operate as follows to reset the machine operation:

 stop the machine (in STOP position);

 remove the feeding needle to enable a quick drop

of mix into the cylinder;

 set machine in “cleaning” mode for a few minutes;

 make sure that the product dispensed from the

spigot body is liquid;

 position the feeding needle again making sure the

slider is sufficiently open;

 start the machine setting it in Production mode,

wait until it stops before start dispensing again.

32

Fig. 12

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XVL 1 COUNTER

3.7 Preliminary operations,
washing and sanitising

Before using the machine for the first time, thorough-

ly clean all component parts as well as sanitising the
parts that come into contact with the ice cream.

Refer to section 5 of this manual for machine disassem­bly and cleaning procedures.

NOTE

Cleaning and sanitisation are operations that must
be carried out with maximum care to ensure pro­duction quality and compliance with required hy­gienic norms.

3.8 Commissioning the machine

After installing the machine in compliance with the in­structions contained in the “Installation” chapter of this
manual and after thoroughly washing and sanitising the
machine, proceed as follows:

3.8.1 Starting machines with pump

Take pressure pipe from tray and plunge it into the
cleaning/sanitising solution for the time indicated by the
manufacturer of the product used.

Loading the tank:

• Take a tub of mix from the refrigerator.

N.B. Load a mix that has a temperature of 4-5°C.

• Place a pail under the spigot door, and pour a small

quantity of mix (approximately 100 ml.) into the
tanks, lower the ice cream dispensing levers and
dispose of a small amount of mix poured so as to
eliminate any residues of water and detergent/sani­tising solution. Bring the ice cream dispensing levers
back to the original position and continue to pour the
mix so that it fills the cylinder by gravity.

•

When the cylinder is full and the tank almost empty,

Assembling the compression tube:

•

With clean and sanitised hands (or wearing disposable
gloves), take compression pipe out of the cleaning/
sanitising solution making sure that pipe is empty,
then insert it on hopper bottom.

• Rotate the compression tube counter-clockwise in or-

der to align it with the pump. Insert the connecting tube
(pos. 207) into the pump and rotate it until it is fastened.

• Pour the mix into the tank until it is full.

NOTE

The level of mix in the tank must not exceed the
maximum level indicated on the tank wall.

Fig. 12

MAX

MIN

• Place the tank lid.

• Place the machine in Production mode by pressing

the

• After few minutes the product can be dispensed.

3.8.2 Avviamento macchine a gravità

Take the feeding needle from tray and plunge it into the
cleaning/sanitizing solution for the time indicated by the
manufacturer of the product used.

key.

press the
verify the correct functioning of the pump (the mix
must flow at over 15 mm). In the event of malfunction­ing, refer to paragraph 6.1. To deactivate the function

press the

Fig. 11

2015/10 - Ed. 01 - EN

key and then press the key to

key again.

Prime Hopper:

• Retrieve one bag of mix from the refrigerator.

NOTE: Mix to be poured at a temperature of 4-5°C.

• Place a bucket under the spigot door and pour a

small quantity of mix (about 100 ml) in the hoppers,
lower the ice cream dispensing handles and let a little
bit of mix come out in order to eliminate any water
and cleaning/sanitizing solution residues. Bring the
ice cream dispensing handles back to the original
position and pour the mix so that it fills the cylinder
by gravity.

•

In this phase it is necessary to fill the cylinders only,
the hopper must remain almost empty in order to
carry out the following procedures.

Feeding needle assembly:

•

With clean and sanitized hands (or wearing disposable
gloves), take feeding needle out of the sanitizing
solution making sure that pipe is empty, then insert it
in hopper bottom.

33

XVL 1 COUNTER

• Pour mix in the tanks until filling them completely.

NOTA

Il livello di miscela nelle vasche non deve mai su­perare l’altezza dell’ago di alimentazione.

• Refit hopper lid.

• Set the machine to Production mode by pressing the key

• By pressing the key the display shows:

• After a few minutes it will be possible to dispense

ice cream.

3.8.3 Dry Filling

WARNING

The machines predisposed for the dry filling func­tion must have an exclusive connection to the
drinking water mains system. If the microbiologi­cal characteristics of the water are not periodically
checked and/or the powdered food preparatives
utilised are not sterile, CARRYING OUT PASTEURI­SATION HEAT TREATMENT IS HIGHLY RECOM­MENDED each time they are loaded and topped up.

LOADING THE MIX - How to carry out a Dry Filling
after cleaning and sanitising machine

Carrying out a DF procedure must take place only once
the machine has been cleaned. The DF procedure is
enabled if the Medium level or the Minimum level is un­covered (and consequently the Medium level).
With clean, sanitised hands (or wearing disposable
gloves) proceed as described below.

• Turn shut-off valve located onto machine upper side

towards hopper.

• The and keys lights up to allow the modifi-

cation of the quantity in litres shown on display.

• The quantity is therefore modifiable by using the

and arrow keys in steps of 0.1 litres.

• To start the DF procedure, press the

• At this point add the powdered mix. In the meantime,

clean the upper part of the machine with a sanitised
cloth and close the lid of the tank.

• If the DF procedure is carried out with the minimum

level uncovered (and the previous function was
Stop), after completing the DF procedure, the mix­ing and the loading for 30” with pump, the display
visualised as follows:

to indicate to bleed the cylinder by pulling its lever.

• After pulling the lever, on the display is shown:

key.

• The machine is in Stop mode. Press the key.

The display visualises:

• By pressing the key the display shows:

34

• After a few minutes the beating stops and the ma-

chine is ready for production.

2015/10 - Ed. 01 - EN

XVL 1 COUNTER

3.9 Production

Production can be accessed only when the mini­mum level is covered.

Pressing the key

Where:

The tank level.

mum uncovered.
Number of cones that can be dispensed

with the level uncovered. It appears only
if the minimum level becomes uncovered.

Temperature in the tank. If <40°C the
temperature visualised is blue.
If >=40°C the temperature visualised is red.

Arrow lit: if the tank is cooling.

Set consistency to be reached.

Product cannot be sold yet. When it reach-

the display visualises:

: minimum and medium covered,

: medium uncovered, : mini-

Machine with a mixer.

The cone indicates that
the machine is in Pro­duction mode.
The grey key is not ac­tive.
The mixer is an active
(blue) key.

Machine with a mixer
and a water dispenser.

The cone indicates that
the machine is in Produc­tion mode. The key is not
active.
The mixer is an active
(blue) key.
The water sprayer is not
active key (gray).

NOTE

During production, it is recommended to enable
the “Touchpad Lock” function described in
paragraph 3.3.2 of this manual.

NOTA

If level indicator turns on, machine will allow you
to dispense the set number of portions, only; then
dispensing keys will be locked until hopper is filled
with mix.

es the consistency it becomes
Actual consistency (HOT).

Arrow lit: if the cylinder is cooling.

Number of days left to Cleaning.

14

Versions with water dispenser and mixer

Where:

Basic machine.

The cone indicates that the
machine is in Production
mode. The key is not active.

Machine with a water
dispenser.

The cone indicates that
the machine is in Produc­tion mode. The key is not
active. The water sprayer
is not active key (gray). .

.

In production, when symbol is displayed, di­spense a cone by lowering dispensing handle all the
way down, then take handle back to closed position.

NOTA

3.10 Pasteurisation

The machine is equipped with a system that allows to
carry out Pasteurisation automatically every day at an
established time.

Pasteurisation can also be activated manually by press­ing the pasteurisation key.

The product, whether in the tank or the cylinder, is heat­ed to 65°C and maintained at this temperature for 30
minutes. Then it’s cooled until the storage temperature
has been reached.

At the end of the cycle the display visualises “ - Pasto
End - ” which means that the pasteurisation process
has been carried out correctly.

Pasteurisation cannot be started if the mix in the tank is
less than half full.

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3.11 Daily cleaning – Opening and
closing procedures

NOTE

3.11.1 Daily closing procedures

With clean, sanitised hands (or wearing disposable
gloves) carry out the following procedures.

• Keep the machine in Production mode.

Disassembly and cleaning of the components:

• Remove the tank cover, then wash, sanitise and

rinse it in a container.

• Clean the outside part of the tank by using a clean,

sanitised cloth.

Fig. 13

• Replace the cover onto the tank after having sani-

tised it.

Notify an authorised technician if any mix leaks
from the drip tray.

• Disassemble spigot door covering panel

 Press the two keys on the side of the panel

 Push the panel downwards
 Pull the panel from the front and remove it from

the machine.

Fig. 16

1

Fig. 14

• Remove the drip drawers on the side of the machine,

then wash, sanitise and rinse them.

Fig. 15

2

3

36

• Disassemble ice-cream dispensing handle.

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• Using the suitable supplied tool, unscrew the spigot

door nozzle unit (260), remove it from the spigot door
and pull the O-Ring (1140) out.

Fig. 19

1140

260

• Clean and sanitize the spigot door covering panel,

the ice cream dispensing handle, the spigot door
nozzle unit and the relevant O-Rings.

• Fill a bucket with cleaning/sanitising solution. Im-

merse the supplied brush into the cleaning/sanitising
solution and clean the door dispenser and the area
of the door plunger several times.

Fig. 19

any humidity, product or cleaning/sanitising solution
residues.

• Fit the O-Ring (1140) inside the spigot door nozzle

unit and, using the suitable supplied tool, screw the
nozzle unit back on the spigot door.

Fig. 19

1140

260

• Reassemble the spigot door covering panel and the

dispensing handle.

• Remove the drip tray and its cover; wash, sanitise,

rinse it and then reassemble the machine.

Fig. 22

• Spray the cleaning/sanitising solution on the door

dispenser and the door itself, particularly in the
plunger area.

Fig. 20

• Using a clean and sanitised cloth, clean spigot door

area, the steel area underneath, machine front side
and any other “splash” area, making sure to remove

2015/10 - Ed. 01 - EN

Prepare the machine for the pasteurisation night
cycle (for “SP” machines)

• Open the lid of the tanks to check the level of the mix.

• Fill the tanks with mix at least up to the medium level.

• Keep the machine in Production mode.

WARNING

If the mix in the tank is below the medium level the
Pasteurisation cycle will not start.

The Pasteurisation cycle is automatic and occurs over­night at the set time.

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3.11.2 Daily opening procedure

With clean, sanitised hands (or wearing disposable
gloves) carry out the following procedures.

Disassembly and cleaning of the cover:

• Remove the tank cover, wash, sanitise and rinse it in

a container.

• Clean the outside part of the tank by using a clean,

sanitised cloth.

Fig. 23

Door area sanitising:

• Disassemble spigot door covering panel

 Press the two keys on the side of the panel

 Push the panel downwards

 Pull the panel from the front and remove it from

the machine.

Fig. 25

1

• Reposition the lid onto the tank after sanitization.

Fig. 24

2

3

38

• Remove ice-cream dispensing handle.

• Wash and sanitise the spigot door covering panel

and the dispensing handle.

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• Fill a bucket with cleaning/sanitising solution. Im-

merse the supplied brush into the cleaning/sanitising
solution and clean the door dispenser and the area
of the door plunger several times.

Fig. 28

XVL 1 COUNTER

• Spray the cleaning/sanitising solution on the door

dispenser and the door itself, particularly in the
plunger area.

Fig. 29

• Clean the door area, and the machine front with a

clean, sanitised cloth, carefully removing any kind of
dampness and remains of product or cleaning/sani­tising solution.

• Reassemble the front panel and the dispensing han-

dle.

• Make sure the machine is in Production mode and

ready to serve.

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4. SAFETY DEVICES

4.1 Alarms

The machine signals possible alarms visualising them on the display with a flashing triangle.

If an alarm is triggered but then correct functioning is restored, the alarm remains visible on the display, as does the
fixed (not flashing) warning triangle.

To delete the alarm message from the display press the

The machine can be used in Production mode even if an alarm message is being visualised . If it is a critical alarm,
the machine stops access to Production mode. In this case, press Stop and do not use the machine until the ma­chine has been repaired.

The list of alarms is reported in the following table:

ALARM

Mix Out

Add Mix

Safety Therm.Cyl

(TESC)

Safety Therm.Hop

(TESV)

Overload Beater

(PTMA)

The display indicates

When the medium level is uncovered the display visualises its symbol

Cylinder safety thermostat released.

The machine goes into Stop mode.

Tank safety thermostat released.

The machine goes into Stop mode.

Bi-metal circuit breaker switch of the beater motor released.

The machine goes into Stop mode.

when the minimum mix level is uncovered.

key.

DESCRIPTION

.

Pressure Switch

(PR)

Overload Compres

(RTC)

Overload MP

(ptmp)

Al.Hopper Probe

(TEV)

40

Pressure switch released.

The machine goes into Stop mode:

• after established number of interventions.

• if the contact of the pressure switch remains open for as long as 2 minutes at a time.

Repeat pasteurisation if the machine is in Pasteurisation mode.

Compressor motor thermal relay released.

The machine goes into Stop mode.

Pump motor thermal relay.

The machine sets to Stop mode.

Faulty Tank sensor.

Being a critical alarm the machine goes into Stop mode whether in Production mode,
Storage mode or Pasteurisation mode.

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ALARM

Al. Cylind.Probe

(TEC)

Al. IceHop.Probe

(TGV)

Spigot Opened

(IMS)

Al. Evapor.Probe

(TE)

Power On

Ice Cylinder

(ICE)

Timeout Prd.

DESCRIPTION

Faulty Cylinder sensor.

Being a critical alarm the machine goes into Stop mode whether in Production mode,
Storage mode or Pasteurisation mode.

Faulty Tank evaporator sensor.

The alarm places the machine into Stop mode.

Magnetic circuit breaker safety switch.

Cylinder evaporator sensor alarm.

The alarm places the machine into Stop mode.

Voltage return after a blackout.

Checking of No Voltage table in Pasteurisation and Production.

The event is recorded in any function.

Anti-ice cylinder.

The alarm may appear due to poor feeding into the cylinder.

Refrigeration problems; the product does not harden.

Check loading of mix into cylinder, the tank pump and the refrigeration implant.

Al.Heat.Exchange

(DELTA TGV-TEV)

Wash in n days

(Wash)

Do Not Serve !

Switch Phases

Pasto Needed!

Why in STOP ??

The tank beater does not rotate.

Check the insertion of beater in its seat.

“
example) left before cleaning machine.

The Wash can be activated even with the machine in Stop mode with the level covered
for 24 hours (1 hour for Japan version).

See sec. 5.

In Production mode, every time the consistency drops below the programmed value, the

symbol on the display becomes

It is necessary to cut machine power and invert the two phases on the three-phase cable
so that the beater turns in the correct direction.

When the machine is positioned in Stop mode for more than 60 minutes with the low
level covered, the temperature is checked. If it is greater or equal to 15°C, a Pasteuri­sation cycle is required. Pressing the Production key, the machine goes automatically
into Pasteurisation mode (per le vers. Giappone l’allarme Pastorizzare ! viene generato
anche quanto trascorrono più di 24 ore dall’ultima pastorizzazione).

If the machine is left in Stop with mix in the hopper, after 1 minute (20 minutes for Japan
version) the flashing message “Why in STOP ??” will appear on the display, accompa­nied by a periodic beeping sound. This alerts the operator to select either Production,
Pasteurization, or Storage mode.

The message disappears when Storage is pressed.

” is visualised in Production mode which means there are nth days (14 for

.

Table Updated M.

2015/10 - Ed. 01 - EN

Message shown every time the programming table is changed.

41

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ALARM

Table Updated R.

Communic.Error P

Pasto Fail

(For Japanese version

only)

MWG OK

NO MWG

The message disappears when Storage is pressed.

Communication problems with the keypad.

In production, when the symbol on the side is displayed, dispense a cone by lowering
dispensing handle all the way down, then take handle back to closed position.

If pasteurization is not completed in 4 hours, the machine stops, a beep is emitted and
the “Past fail” alarm is displayed.

For the machines featuring the TEOREMA teleservice system, upon machine installation,
in STOP function, press the increase key for 10” in order to check the connection to the
teleservice control unit. Message “MWG OK” indicates successful operation.
This check can be repeated every time the data transmission check between TC
control unit and teleservice control unit, also known as MWG control unit, proves to be
necessary and operator must make sure to turn machine power off and back on before
carrying out this test.

It indicates that the aforementioned test has been unsuccessfully performed.

DESCRIPTION

4.1.1 Blackout

When the electricity returns after a blackout occurring while the machine was in Cleaning mode, the machine goes
into Stop mode.

When the electricity returns while the machine is in Heating mode of a Pasteurisation cycle or Pause during a Pas­teurisation cycle, the machine restarts in the function it was in before the blackout (with “Power On” written on the
display).

If the machine was in Cooling mode of a Pasteurisation cycle, when electricity comes back the machine checks the
TEV temperature and the duration of the blackout. If the time is more than that indicated in the table, the machine
completely repeats the pasteurisation cycle and memorises the alarm “Power On” in its ‘events list’.

If the time is less than that indicated in the following table, the machine returns to the function it was in before the
blackout.

TEMPERATURE TEV TIME

68°C ÷ 50°C 30 minutes
49°C ÷ 15°C 10 minutes

14°C ÷ 10°C 20 minutes

9°C ÷ 4°C 2 hours

If the machine was in Production or Storage mode, check the TEV temperature when the electrical power supply
returns and if it is less than the threshold set by the manufacturer the machine returns to the same function visual­izing the “Power On” alarm. If the TEV is greater than the threshold set by the manufacturer and the time exceeds
that of the above table, the Pasteurisation cycle is repeated.

42

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5.

DISASSEMBLY, CLEANING
AND REASSEMBLY OF THE
PARTS IN CONTACT WITH
THE PRODUCT

5.1 General description

Cleaning and sanitisation are operations that
must be carried out with utmost care on a rou­tine basis and at the end of each production
run to guarantee production quality and com­pliance with required hygienic norms.

Letting soiling dry out can greatly increase the risk of
ringmarks, spots and damage to surfaces.

Removing soiling is much easier if it is done immediate­ly after use some elements containing acid and saline
substances can corrode the surfaces. Prolonged soak­ing is recommended.

5.2 Washing conditions

Avoid using solvents, alcohol or detergents that
could damage the component parts, the machine or
pollute the functional production parts.

Use drinking water (bacteriologically pure) to rinse the
parts.

To sanitise, leave the disassembled parts in sanitised
tepid water for the time recommended by the manu­facturer of the sanitising product (utilise the sanitising

product following the instructions of the manufac­turer) and rinse them before reassembling.

When the washing procedure has been completed and
before reassembling components, dry each one thor­oughly with a clean, soft cloth suitable for use with
foodstuffs, in order to remove any traces of humidity
rich in mineral salts and chlorine that could attack the
metal surfaces and leave opaque traces.

Carpigiani recommends the use of a cleaning/sani­tisIng solution to wash the machine.

The use of a cleaning/sanitising solution optimises the
washing and sanitising procedures in that it eliminates
two phases of the procedure (a rinse and a washing
phase). Basically the use of a cleaning/sanitising solu­tion saves time by facilitating and simplifying washing/
sanitising procedures.

During the cleaning procedures, Carpigiani recom­mends to use the supplied brushes that must be washed
and sanitized before and after use

When manually washing never utilise powder or abrasive
products, abrasive sponges or pointed utensils which can
dull surfaces, remove or deteriorate the protective film
that is present on the surface thus scoring the surface.

Never ever use metal scouring pads or synthetic abra­sives whose scouring action could remove ferrous parts
and risk causing oxidisation or making the surfaces vul­nerable.

Avoid using detergents that contain chlorine and its com­posites. The use of these detergents such as bleach, am­moniac, hydrochloric acid and decalcifiers can attack the
composition of the steel, marking it and oxidising it ir­reparably and causing damage to the “plastic” parts.

Do not use dishwashers and their detergent products.

The use of a cleaning/sanitising solution allows to opti­mize the washing and sanitising process

since it avoids two procedure phases (i.e. a rinse and
a washing phase); in substance the use of a cleaning/
sanitising solution allows saving time by facilitating and
simplifying washing/sanitising procedures.

5.3 Suggestions

Use a non-aggressive detergent solution to wash the
parts.

Manually wash the parts in water (max 60°C) using a
non-aggressive detergent and the provided cleaning
brushes.

WARNING

Every time the machine is washed and its parts that
come into contact with the ice cream mix are disas­sembled, it is essential to carry out a visual control
of all its parts in thermosetting materials; plastics,
elastomers,silicone and metal (for example, scrap­ers, pump gears, beaters, etc…). All parts must be
whole, not worn, without cracks or splits, or opaque
if originally polished/ transparent.
Carpigiani declines all responsibility for any dam­age caused by imperfection and/or undetected
breakages and not promptly solved by the substitu­tion of original spare parts and is available for con­sultation and for any specific request made by the
customer.

5.4 How to use cleaning/sanitis­ing solution

Follow the instructions on the label of the
product used to prepare the cleaning/sanitis­ing solution.

Washing/sanitisation by immersion of components

• Manually remove the bulk residues utilising the sup-

plied brushes.

• Remove finer residues with a jet of water.

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• Dip the parts to clean into the solution.

• Leave the solution to act for the time indicated by

the manufacturer of the sanitising product.

• Rinse the parts with care, using plenty of clean drink-

ing water.

5.5 Daily cleaning

Cleaning and sanitising procedures have to be carried
out on a daily basis at every opening and closing with
the utmost care to ensure production quality and com­pliance with hygienic norms by following the instruc­tions in section 3.10 scrupulously.

5.6 Scheduled cleaning

The machine is equipped with an automatic system
which activates cleaning of the parts in contact with the
product at scheduled times.

Such system, called “WASH”, inhibits the dispensing
function when the scheduled time comes.

5.6.1 Machine Drainage

• Place a bucket under the dispenser door.

• Press the button .

• Lower the dispensing handle and drain out all the

product from the cylinder.

Fig. 31

• Select the function and then select .

WARNING

Cleaning and sanitising procedures have to be car­ried out with the utmost care on a regular basis ac­cording to the scheduled date shown on the ma­chine display to ensure production quality and the
compliance with the necessary hygienic rules.

In Production mode the days left until the next wash are
visualised as follows:

On the day when the machine is to be washed, Produc­tion mode is blocked and the machine does not accept
the function. The visualisation becomes:

NOTE

It is recommended to select the Beating Heating

to make emptying the cylinder easier if ice

cream is still inside.

• When mix coming out is liquid, press key and

continue draining it.

• Remove hopper cover.

5.6.2 Pump feed machine - removal from
Hopper

• Rotate the connection tube (207) until its notch is

aligned with the pin on the pump, pull it forward so as
to disconnect it from the pump.

• Remove the compression tube (32) by rotating it 90°

and removing it from its seat in the tank. Continue
draining the remaining mix by opening the dispensing
handle.

Fig. 32

207

To reset the number of days to the programmed value
(Wash Days), machine must be washed.

44

32

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• Disassemble the pump by rotating it of 45° clock-

wise and by taking it out frontally.

• Remove pump shaft (96) and seal, sliding them out

from machine front side.

Fig. 33

96

• Insert the plug and its O-ring provided with the kit

into the pump housing hole so as to close the tank.

Fig. 34

5.6.4 Mix Beaters Removal from Hopper

• Remove the beaters in the tank by pulling them upwards.

Fig. 35

5.6.5 Hopper Washing

• Pour clean warm water into the tank.

5.6.3 Gravity fed machines - removing
feeding needle from hopper

• Remove the feeding needle from the bottom of the

hopper.

Fig. 37

WARNING

Never exceed the maximum level indicated on the
tank.

• Use the supplied brushes to clean the sides of the

tank, the level sensor, the beater shaft and its inter­stice and the tank. Using the smallest brush, clean
the compression tube seat on the bottom of the
tank. Discharge the water from the hopper using the
dispensing handle and repeat the operation several
times until clean water is obtained.

• Repeat the two previous procedures by using a

cleaning/sanitising solution.

Fig. 36

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45

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• Position a bucket underneath the door, lower the

dispensing handle and allow the solution to flow.

Fig. 37

• Select the function and then select .

Let the machine function for 10 seconds.

• Press the button and discharge the water from

the machine.

• Rinse with warm water until clean water comes out.

• Remove the plug from the pump housing hole.

Fig. 38

• Spray the cleaning/sanitising solution around the

pump housing hole. Immerse a fine brush in the
cleaning/sanitising solution and clean the pump
housing hole several times.

NOTE

The plug and its O-ring must be washed and
sanitised.

46

2015/10 - Ed. 01 - EN

5.6.6 Pump feed machine - disassembly of the pump

Fig. 39

236

1270

XVL 1 COUNTER

1270

96

1138

39

243

38

1178

1107

202

99A

1131

271

38A

245

206

99

99A

1107

1131

1117

8

207

1126

8

8 Pump knob
31 Membrane valve
32 Compression hose
38 Driven gear
38A Driving gear
39 Pump body
96 Pump shaft
99 Suction pipe
99A Air inlet pipe
202 Pump cover
206 Spring
207 Connection pipe

32

1131

31

236 Plug
243 Pump body seal
245 Pump valve
271 Pump regulator
1107 O-ring
1117 O-ring
1126 O-ring
1131 O-ring
1138 O-ring
1178 O-ring
1270 O-ring

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• Remove the seal (243) and the two O-rings (1138).

Fig. 40

243

1138

• Remove the pump regulator (271) from the pump

cover (202) by rotating it clockwise until the notch is
aligned with the pin situated on the pump cover lo­cated on the regulator and pull it out. Use the O-ring
extractor to remove the two O-rings (1131) located
on the pump regulator.

• Remove the spring (206) and the pump valve (245).

Fig. 41

• Keep the suction pipe (99) vertical, rotate it until the

notch is aligned with the pin situated on the pump.

• Use an O-ring extractor to take the O-ring (1131) out

from the suction pipe (99).

Fig. 43

1131

99

• Unscrew the two knobs (8) and separate the pump

cover (202) from the pump body (39).

• Use an O-ring extractor to remove the O-ring (1178).

• Remove the gears (38-38a).

271
1131

245

206

202

• Remove the two air inlet pipes (99A) from the pump

cover (202) by pulling and rotating them until the
notches on the pipes are aligned with the pins situ­ated on the pump cover and take them out.

• Remove the plugs (236) and O-ring (1270) from the

air inlet pipes (99A).

• Remove the O-rings (1107) from the air inlet tubes (99A).

Fig. 42

236

1270

1270

Fig. 44

39

38a

202

38

1178

• Remove the connection tube (207) from the com-

pression tube (32).

• Remove the O-rings (1117), (1126), (1131) and the

valve (31).

Fig. 45

1117

207

1126

48

99A

1107

202

32

1131

31

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5.6.7

Gravity fed machines - disassem­bling the feeding needle

To disassemble the feeding needle proceed as follows:

• Remove the feeding needle slider (52).

• Remove the O-ring from the needle (1131).

Fig. 49

52

1131

5.6.8 Disassembly of the door

Fig. 46

214

30

1147

1188

7

5

1140

8

260

5 Dispenser levers
7 Dispensing door
8 Knob
30 Piston

214 Adjusting screw
260 Spigot door nozzle unit
1140 O-ring
1147 O-ring
1188 O-ring

WARNING

Before disassembling the dispensing door, make
sure the hoppers and the cylinders are empty and
the machine is STOPPED.

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• Disassemble spigot door covering panel

 Press the two keys on the side of the panel

 Push the panel downwards

 Pull the panel from the front and remove it from

the machine.

Fig. 47

1

•

Using an ice cream dispensing handle (5), push
adjuster screw (214) up so as to release ring from its
seat on piston (30) and remove the complete screw.

Fig. 50

•

Loosen the two knobs (8a) and remove dispensing
spigot door.

Fig. 51

2

3

• Remove ice-cream dispensing handle.

8a

50

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• Take the plunger out.

• Using the suitable supplied tool, unscrew the spigot

door nozzle unit and remove it.

• Use an O-ring extractor to take out:

 The two O-rings (1147) of the plunger.

 The O-ring of the dispensing door (1188).

 Spigot door nozzle unit O-Ring (1140).

Fig. 52

30
1147

1188

• Remove the beaters (21) from its seat in the cylinder,

being careful not to knock the walls of the cylinder.

Fig. 54 with terminal

21

• Let the seal (28) slide on the beater axle and remove it.

Fig. 55

28

1140

260

5.6.9 Disassembly of beaters

Fig. 53

28

21

WARNING

The seal is very important for cylinder tightness.
Check its wear on a regular basis according to the
maintenance plan (Refer to paragraph 6.1). Fur­thermore always lubricate the seal properly during
washing operations.

• Remove the idler (24) from the shaft.

Fig. 56

24

24

21 Beater
24 Idler
28 Seal

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5.6.10 Disassembly of the drip drawer, the
drip tray and the hopper lid

• Use the brush provided (washed and sanitized) to

clean the dripping tubes on the front of the machine.

Fig. 58

•

Remove the drip tray and relevant cover.

Fig. 59

5.6.11 Cleaning and sanitising of the com­ponents

WARNING

As regards the use of cleaning/sanitising solution,
refer to the manufacturer’s instructions on the la­bel of the solution used.

WARNING

To carry out the following operations, your hands
must be clean and sanitized, or you must wear di­sposable gloves.

• Fill a sink with a cleaning/sanitising solution prepared

according to th

• Use the provided brushes and vigorously brush all

components and holes found on the same compo­nents (the holes on the pump, suction pipes, non­return valves, pump seal and its interstice, beater
flaps, etc...)..

• Dip the components into the cleaning/sanitising so-

lution and let it work for the time indicated by the
manufacturer.

• Rinse the parts with care by using plenty of drinking water.

• Place the components onto a clean, sanitised tray

and let them dry in air.

• Dip a big brush into the cleaning/sanitising solution

and clean the cylinder.

• Immerse a brush in the cleaning/sanitising solution

and clean the pump housing holes, the compression
tubes on hopper bottom, and the sides of the
hoppers.

• Spray the cleaning/sanitising solution on the bottom

of the cylinders and on the tank surface.

• Repeat the last three steps some times.

e manufacturer’s indications.

• Remove the tank cover.

Fig. 60

52

5.6.12 Reassembly of the tank beater

• Reposition the beater (pos. 162) into its seat and

make sure it is inserted properly.

Fig. 61

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5.6.13 Reassembly of the beater

• Insert the idler (24) into the beater.

Fig. 63

24

C

• Lubricate the inner sides of the seal (28) and its seat on

the beater shaft. Let the seal slide onto the beater shaft.

Fig. 64

28

5.6.14 Reassembly of the dispensing door

• Lubricate and fit the O-Ring (1140) on the spigot

door nozzle unit.

• Using the suitable supplied tool, screw the nozzle

unit back on the spigot door.

• Lubricate and fit piston O-rings (1147) .

• Lubricate piston (30) and insert it inside its seat on

spigot door, making sure that piston square notch
matches with spigot door front rectangular opening.

• Lubricate and fit O-ring (1188) onto spigot door.

Fig. 66

30
1147

NOTE

Check the beater seal for integrity. Replace if worn
or damaged.
out the replacement.

• Insert the beater assemblies into the cylinders, turn-

ing and pushing them until they engage in rear hub.

Fig. 65

Refer to the maintenance plan to carry

21

1188

1140

260

• Insert the door assembly onto the two front panel pins

and tighten it properly using the two knobs (8a).

Fig. 67

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8a

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• Using a dispensing handle (5), refit adjuster screw

(214) so as to correctly position ring inside its seat
on piston

Fig. 68

• Refit spigot door covering panel.

• Reassemble the dispensing handles onto the door.

5.6.15 Pump feed machine - Reassembly
of the pump

• Lubricate and insert the O-rings (1117) on the con-

nection tube (207).

Fig. 70

• Insert the connection tube (207) assembly in the

pressure pipe (32).

Fig. 72

207

32

• Leave the pressure tubes on the clean tray. They will

be sanitised and mounted during the “mix prepara­tion procedure”.

• Lubricate and insert the O-rings (1138) onto the body

of the pump (39).

• Lubricate and insert the seals (243) into the body of

the pump (39).

Fig. 73

1117

207

• Lubricate and insert the O-rings (1126), (1131) and

the duck bill valve (31) on the pressure pipe (32).

Fig. 71

1126

32

1131

243

1138

54

31

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• Lubricate and insert the O-rings of the body of the

pumps (1178).

• Lubricate the surface of the pump gears (38-38A)

and insert them into the pump bodies (39).

WARNING

Do not lubricate gear teeth and carry out checking
of wear refering to par. 6.1.

Fig. 74

39

38a

38

1178

• Insert the spring (206) and the pressure relief valve

(245) into the pump cover (202).

Fig. 77

245

206

• Insert the pump regulator (271a) on the pump cover

(202) aligning the pump regulator notch to the pin on
the pump cover and turning to lock it.

Fig. 78

• Lubricate and insert the two O-ring (1131) on the

feeding tube (271).

Fig. 75

271

1131
1131

• Lubricate and insert the O-ring (1131) on the feeding

tube (99).

• Holding the pump cover (202) insert the feeding tube

(99) by pushing and turning it counterclockwise.

Fig. 76

1131

271a

• Lubricate and insert the O-rings (1107) onto the air

inlet tubes (99A).

• Insert the two plugs (236) and the O-rings (1270) on

the air intake tubes valve holder (99A).

• Insert the two air intake tubes valve holders (99A) on

the pump cover (202) aligning the tube notch to the
pin on the pump cover and turning the tubes until
they are locked.

Fig. 79

236

1270

1270

99A

2015/10 - Ed. 01 - EN

99

1107

55

XVL 1 COUNTER

• Make sure that machine is in Stop mode, and

lubricate pump shaft (96). Fit shaft inside mix hopper
rear hole, push it and slightly turn it so that it engages
with driving hub. Hold pump body with locking pin
hook on the right side and keep pump gears in their
positions with your thumbs, then push and turn
pump clockwise to align shaft with gears. Then turn
pump counter-clockwise so as to lock it onto pin.

Fig. 80

96

5.6.16 Gravity fed machines - refitting the
feeding needle

• Lubricate O-ring (1131).

• Reassemble the feeding needle

Fig. 86

• Leave the sanitized feeding needles on the tray. They

will be assembled during the “mix preparation pro­cedure”

5.6.17 Drip Tray and Hopper Cover Reas­sembly

•

Refit drip tray and cover.

• Assemble the pump cover (202) with the feeding

tube downwards onto the pump body and turn the
two knobs (8) tightly.

Fig. 81

Fig. 83

• Refit hopper cover.

Fig. 84

• Reassemble the drip drawer, the drip tray and its

cover and the tank cover previously washed and
sanitised.

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2015/10 - Ed. 01 - EN

XVL 1 COUNTER

5.6.18 Complete sanitisation of the ma­chine

The machine must be sanitised before mix is poured
into the tank.

NOTE

After having cleaned and sanitised the machine
and, more precisely, after having closed the front
door of the machine, operate the machine in

Production mode (by pushing
60 minutes. After 60 minutes, the machine does

not accept the
cally passes to the pasteurisation function. In
other words, carry out the “Complete sanitisation
of the machine“ and “Mix Preparation“ within 60

minutes, then push the

• With the machine in Stop mode, fill the cleaning/

sanitising solution into the tank up to the maximum
level so that it drains into the cylinder.

• Using the brush, clean the mix level sensors, the

whole surface of the mix hopper, the surface of the
mix pump and the outside of the tank beater.

• Press the key and then press and let the

beater operate for approximately 5 seconds. Press

the

• Pour a little cleaning/sanitising solution into a bucket.

• Open the spigot door covering panel, dip the

provided brush into the pail of the cleaning/sanitising
solution and brush the dispensing spout clean.

• Wipe the exterior of machine with clean, sanitised

cloth. Repeat the operation twice and close the
spigot door covering panel.

• Leave the cleaning/sanitising solution in the tank for

the time indicated by the manufacturer.

key to stop beating.

key anymore and automati-

key.

key) within

Draining the cleaning/sanitising solution

• Place an empty bucket underneath the door and

lower the dispensing handle.

Fig. 85

• Drain all cleaning/sanitising solution, then press key

and then to let also the last solution

residues flow out of the machine. Do not leave beater

enabled for more than 5 seconds, then press

• Fill hopper with drinkable water to thoroughly

rinse it, then repeat the above-described drainage
operation.

.

WARNING

Do not keep the beater running for more than
the time strictly needed to complete washing
and sanitisation. Mix butterfat lubricates beater
blades; without this lubrication the beater blades
wear out quickly.

• Refer to the paragraph 3.8 of this manual for filling

the tank and starting production.

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57

XVL 1 COUNTER

6. MAINTENANCE

WARNING

Never put your hands into the machine while it is
in Production or Cleaning modes. Before perform­ing any maintenance, make sure the machine has
been placed in Stop mode and the main switch has
been switched OFF.

6.1 Maintenance

WARNING

Any maintenance operation requiring that the ma­chine’s protective panels be opened, must be per­formed with the machine in Stop mode and with
machine disconnected from the electrical power
supply! The cleaning or lubricating of moving parts
is forbidden! “Repairs on the machine or its elec­trical, mechanical, pneumatic or refrigeration sys­tem must be performed by authorised, qualified
personnel and in accordance with scheduled and
unscheduled maintenance as agreed with the cus­tomer with regards to specific service methods on
the basis of destination of use of the machine”.

How to check condition of gears:

This check must be carried out during the periodical
cleaning of the machine.

Disconnect the compression tube after depressurising
the cylinder. If all parts of the pump are correctly as­sembled and the gears are OK the pump produces a
strong stream of mix (fig. 86), If all parts of the pump are
correctly assembled but the gears are worn the stream
of mix is very weak (fig. 87).

Fig. 86

Procedures necessary for the good operation
of the machine are such that most mainte­nance is completed during the Production cy­cle.

Maintenance operations, such as the cleaning of parts
coming into contact with the product and disassem­bling the beater, are to be normally all carried out at the
end of each work shift, thereby keeping maintenance
effort at a minimum.

Below is a list of normal maintenance operations:

• Cleaning and replacement of beater seal

Cleaning must be carried out on the set date indicat­ed on the display. The part should be substituted if
it is noticeably worn and mix is leaking into drip tray.

• Cleaning of the beater assembly

Cleaning must be carried out on the set date indi­cated on the display.

• Cleaning of the dispensing head

Cleaning must be carried out on the set date indi­cated on the display.

• Cleaning of the pump unit

Cleaning must be carried out on the set date indi­cated on the display.

Fig. 87

How to avoid wear of the gears:

• Do not operate the pump without mix inside the tank

or only with water for more than a few seconds: the
fat/grease content of the mix acts as a lubricant for
the gears (like the oil of a car). Without the mix the
gears would wear much quicker.

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2015/10 - Ed. 01 - EN

• No foreign object or food piece must enter the pump,

not even a little piece of plastic, a tomato skin, a
piece of straw that may have accidentally fallen into
the tank; they could block the feed and damage the
gears.

• During cleaning operations handle the gears with

care. Their correct functioning could be jeopardised
if they are accidentally dropped.

• Cleaning of blades, drip drawer and tray support

shelf.

It must be performed daily utilizing neutral soaps
and ensuring that detergents never be used inside
the beater unit.

• Cleaning and sanitisation:

It must be carried out on the set date indicated on
the display according to the procedures indicated in
section 5 of the manual.

WARNING

To clean the machine and its parts never use abra­sive sponges which could scratch the surfaces.

XVL 1 COUNTER

6.2 Water-cooling

For those machines equipped with a water­cooled condenser, all water must be drained
out of condenser at the end of selling season
to avoid any trouble should the machine be
stored in an environment where the tempera­ture may drop below 0°C.

After closing the water inlet pipe, withdraw drain pipe
from its seat and let water flow out from circuit.

6.3 Ordering spare parts

When one or more parts are worn out or broken, place
the order through your local distributor.

2015/10 - Ed. 01 - EN

59

XVL 1 COUNTER

6.4 Supplied accessories

Fig. 88

1433 1178

028

031

1138

236

072

236A

1270

772

55

1107

1126

1129

1131

1140

1147

830

475

243

840

93

Legend:
28

Beater shaft seal

31 Membrane valve
55 Rubber hose fitting
72 O-ring extractor
93 Nozzle unit key
236 Blanking plug for pump hole
236A Plug
243 Body pump seal
475 Kit case

Brushes

772
830 Carpilube tube
840 Cleaning spatula

60

1224

1107 O-ring
1126 O-ring
1129 O-ring
1131 O-ring
1138 O-ring
1140 O-ring
1147 O-ring
1178 O-ring
1188 O-ring

1224 O-ring
1270 O-ring

1433 O-ring

2015/10 - Ed. 01 - EN

7. TROUBLESHOOTING GUIDE

IRREGULARITY CAUSE PROCEDURE TO FOLLOW

XVL 1 COUNTER

Compressor starts and then
stops after a few seconds.

Mix or ice cream leaks out
from above and/or below the
plunger even though the door
is closed.

Mix leaks out of the drip draw­er.

The dispensing handle is hard
to operate.

• If it’s a water-cooled machine: the water
is not circulating.

• If it’s an air-cooled machine: the air is not
circulating.

• Piston without O-ring or the O-ring is
worn out.

• Stuffing box missing or worn out.

• Dry sugar on piston.

• Open water inlet cock and check that
pipe is not squashed or bent.

• Check that the machine is positioned so
that there’s enough space for air to circu­late freely upwards from below (at least
50 cms of space above the chimney).

• Check the condenser is not blocked by
dust or other things and eventually call
the customer service for cleaning.

• Call for service assistance if necessary.

• Stop the machine and insert or replace it
with a new one if worn out.

• Stop the machine and install it if missing.
If worn out, replace it with a new one.

• Stop the machine and wash thoroughly
and grease the plunger and the O-ring
with edible fat.

Ice cream comes out from
front lid.

Low ice cream overrun.

• O-ring missing or not properly fitted.

• Front lid knobs not tightened evenly.

• Pump not adjusted correctly.

• Stop the machine and check then act ac­cordingly.

• Stop machine, loosen and tighten them
again.

• Adjust the position of the central knob of
the pump.

2015/10 - Ed. 01 - EN

61

CARPIGIANI

Via Emilia, 45

40011 Anzola dell’Emilia (BO) Italy

[phone]

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[phone]

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