CARPIGIANI LB202-G Gelato Batch Freezer Instruction Manual
- June 13, 2024
- CARPIGIANI
Table of Contents
LB202-G Gelato Batch Freezer
Product Information
The LB 202 G is a machine manufactured by Carpigiani, a renowned
company in the industry. Carpigiani has been committed to providing
high-quality products since 1993 and has obtained certification
according to the international Standard ISO 9001-94. The production
of Carpigiani machines is backed by a UNI-EN-ISO 9001-2000
Certified Quality System.
In addition to meeting international quality standards,
Carpigiani machines also comply with the Machines Directive and
other European Directives.
Product Usage Instructions
Section 1: General Information
-
1.1 GENERAL INFORMATION: This section provides
manufacturer’s identification data, information about service, and
information to the users. -
1.2 INFORMATION ABOUT MACHINE: This section
includes general data about the machine, technical features, and
the location of machine groups. -
1.3 INTENDED USE: This section explains the
intended use of the machine. -
1.4 NOISE: This section provides information
about the noise produced by the machine. -
1.5 STORING A MACHINE: This section provides
guidance on how to store the machine. -
1.6 DISPOSAL OF PACKING STUFFS: This section
explains how to dispose of packing materials properly.
Section 2: Installation
-
2.5.1 REPLACING THE POWER CABLE: This section
provides instructions on how to replace the power cable. -
2.6 LOCATION: This section explains how to
choose an appropriate location for the machine. -
2.7 REFILLING: This section provides guidance
on how to refill the machine. -
2.8 MACHINE TESTING: This section explains how
to perform testing on the machine.
Section 3: Direction for Use
-
3.1 MACHINE SAFETY WARNINGS: This section
highlights safety warnings related to machine usage. -
3.2 MACHINE CONFIGURATION: This section
provides instructions on how to configure the machine. -
3.3 CONTROLS: This section explains the
various controls of the machine.
Please refer to the complete user manual for detailed
instructions and information on operating the LB 202 G machine.
INSTRUCTION HANDBOOK
LB 202 G
LB 202 G
We wish to thank you for the preference granted to us by purchasing one of
CARPIGIANI machines.
To the best guarantee, since 1993 CARPIGIANI has submitted its own Quality
System to the certification according to the international Standard ISO
9001-94, nowadays its production has got UNI-EN-ISO 9001-2000 Certified
Quality System.
Moreover, Carpigiani machines comply with following European Directives:
· 98/37/CE
Machines Directive;
· 73/23/CEE LowtensionDirective;
· 89/336/CEE EMCDirective;
· 89/109/CEE Food Contact Directive.
CARPIGIANI CORPORATION OF AMERICA
3760 Industrial Drive · Winston-Salem, North Carolina 27105
336-661-9893 ·
336-661-9895 (Fax)
This handbook may not be reprinted, transferred, registered, recorded in a
retrieval system, nor translated in other languages unless otherwise
previously agreed with CARPIGIANI. The purchaser has the wright to reprint it
for his own office use. CARPIGIANI policy pursues a steady reasearch and
development, thus it reserves the right to make changes and revisions whenever
deemed necessary and without being bound to previous statements to the
purchaser.
lb 202 g_G – 04/05 – ed. 2
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GENERAL INDEX
INSTRUCTION HANDBOOK …………………………………………………………………………… 5 PURPOSE
……………………………………………………………………………………………………………. 5 HANDBOOK STRUCTURE
……………………………………………………………………………….. 5 ADDITIONAL DOCUMENTATION
………………………………………………………………….. 5 CONVENTIONAL SYMBOLS
…………………………………………………………………………… 6 SAFETY
………………………………………………………………………………………………………………. 7 QUALIFICATION OF THE STAFF
……………………………………………………………………. 7 WARNING
…………………………………………………………………………………………………………… 7
SECTION 1 GENERAL INFORMATION
1.1 GENERALINFORMATION ………………………………………………………………. 9
1.1.1 MANUFACTURER’S IDENTIFICATION DATA ……………………………………………….. 9 1.1.2
INFORMATION ABOUT SERVICE ……………………………………………………………………. 9 1.1.3 INFORMATION TO
THE USERS ………………………………………………………………………. 9
1.2 INFORMATIONABOUTMACHINE …………………………………………………… 9
1.2.1 GENERAL DATA ………………………………………………………………………………………………. 9 1.2.2 TECHNICAL
FEATURES ……………………………………………………………………………………. 10 1.2.3 LOCATION OF MACHINE GROUPS
………………………………………………………………… 11
1.3 INTEDEDUSE …………………………………………………………………………………. 11 1.4 NOISE
……………………………………………………………………………………………. 11 1.5 STORINGAMACHINE
……………………………………………………………………. 11 1.6 DISPOSALOFPACKINGSTUFFS
…………………………………………………….. 11
SECTION 2 INSTALLATION
2.1 ROOMNECESSARYTOTHEMACHINEUSE ……………………………………… 13 2.2 WATERSUPPLYCONNECTION
………………………………………………………. 13 2.3 MACHINESWITHAIRCOOLEDCONDENSER …………………………………… 13
2.4 MACHINESWITHWATERCOOLEDCONDENSER …………………………….. 14 2.4.1
WATERVALVEADJUSTMENT ………………………………………………………… 14 2.5 ELECTRICCONNECTION
……………………………………………………………….. 14
2.5.1 REPLACING THE POWER CABLE …………………………………………………………………….. 14
2.6 LOCATION ……………………………………………………………………………………. 15 2.7 REFILLING
…………………………………………………………………………………….. 15 2.8 MACHINETESTING
………………………………………………………………………… 15
SECTION 3 DIRECTION FOR USE
3.1 MACHINESAFETYWARNINGS ……………………………………………………….. 17 3.2 MACHINECONFIGURATION
…………………………………………………………… 17 3.3 CONTROLS …………………………………………………………………………………… 18
3.3.1 PUSH-BUTTON PANEL …………………………………………………………………………………….. 18 3.3.2 CHECKING
MONITOR ……………………………………………………………………………………… 18 3.3.3 PUSH-BUTTON FUNCTIONS
……………………………………………………………………………. 18 3.3.4 SERIAL CONNECTOR
………………………………………………………………………………………… 19
3.4 ICECREAMPRODUCTION(PROCESSING) ………………………………………. 19
3.4.1 ICE CREAM CONSISTENCY ……………………………………………………………………………… 20 3.4.2 CHANGING
ICE CREAM CONSISTENCY ………………………………………………………… 20 3.4.3 DISPENSING ICE CREAM
………………………………………………………………………………….. 21 3.4.4 USE OF ICE CREAM DISPENSING HANDLE
……………………………………………………. 21 3.4.5 AFTERCOOLING
……………………………………………………………………………………………….. 21
3.5 CREMOLATAPRODUCTION …………………………………………………………… 22
3.5.1 VARIATION OF CREMOLATA PRODUCTION TIME …………………………………….. 22 3.5.2
CREMOLATA EXTRACTION ……………………………………………………………………………. 22
3.6 SICIALIANSLUSH ………………………………………………………………………….. 23
3.6.1 VARIATION OF SICILIAN SLUSH PRODUCTION TIME ………………………………… 23 3.6.2
DISPENSING SLUSH …………………………………………………………………………………………… 23
LB 202 G
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lb 202 g_G – 04/05 – ed. 2
LB 202 G
SECTION 4 SAFETY DEVICES
4.1 ALARMS ……………………………………………………………………………………….. 25 4.2 MACHINESAFETYDEVICES
……………………………………………………………. 25
SECTION 5 CLEANOUT DISASSEMBLING AND REASSEMBLING OF PARTS IN CONTACT WITH THE
PRODUCT
5.1 OUTSIDECLEANOUT ……………………………………………………………………… 27 5.2 PRELIMINARYCLEANOUT
……………………………………………………………… 27 5.3 BEATERDISASSEMBLY ………………………………………………………………….
27
5.3.1 STUFFING BOX ………………………………………………………………………………………………… 28
5.4 FRONTLIDDISASSEMBLY …………………………………………………………….. 29 5.4.1
ICECREAMDOORDISASSEMBLY ……………………………………………………. 29 5.4.2 HOPPERCOVERDISASSEMBLY
………………………………………………………… 29 5.4.3 ICECREAMSLIDEDISASSEMBLY
…………………………………………………….. 29 5.5 SANITIZATION ………………………………………………………………………………. 30
5.5 HYGIENE ……………………………………………………………………………………….. 30
SECTION 6 MAINTENANCE
6.1 SERVICINGTYPOLOGY ………………………………………………………………….. 31 6.2 WATERCOOLING
…………………………………………………………………………… 31 6.3 AIRCOOLING
………………………………………………………………………………… 31 6.4 ORDERINGSPAREPARTS
……………………………………………………………… 31 6.5 ACCESSORIESKIT ………………………………………………………………………….
32
SECTION 7 TROUBLESHOOT GUIDE
7. TROUBLESHOOTGUIDE ………………………………………………………………… 33
lb 202 g_G – 04/05 – ed. 2
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FOREWORD
INSTRUCTION HANDBOOK
Editing this handbook, it was taken into due account European Community
directions on safety standards as well as on free circulation of industrial
products within E.C.
PURPOSE
This handbook was conceived taking machine users’ needs into due account.
Topics relevant to a correct use of the machine have been analyzed in order to
keep unchanged in the long run quality features charachterizing CARPIGIANI
machines all over the world. A significant part of this handbook refers to the
conditions necessary to the machine use and to the necessary procedure during
cleanout as well as routine and special maintenance. Nevertheless, this
handbook cannot meet all demands in details. In case of doubts or missing
information, please apply to:
CARPIGIANI CORPORATION OF AMERICA
3760 Industrial Drive · Winston-Salem, North Carolina 27105
336-661-9893 ·
336-661-9895 (Fax)
HANDBOOK STRUCTURE
This handbook is divided in sections, chapters and subchapters in order to be
consulted more easily.
SECTION A section is the part of the handbook identifying a specific topic
related to a machine part. CHAPTER A chapter is that part of a section
describing an assembly or concept relevant to a machine part. SUBCHAPTER It is
that part of a chapter detailing the specific component of a machine part.
It is necessary that each person involved in the machine operation reads and
clearly understands those parts of the handbook of his/her own concern, and
particularly:
– The Operator must read the chapters concerning the machine star-up and the
operation of machine components.
– A skilled technician involved in the installation, maintenance, repair,
etc., of the machine must read all parts of this handbook.
ADDITIONAL DOCUMENTATION
Along with an instruction manual, each machine is supplied also with
additional documentation: – Part list: A list of spare parts which is
delivered together with the machine for its maintenance. – Wiring diagram: A
diagram of wiring connections is placed in the machine.
LB 202 G
ATTENTION Before using the machine read carefully the instruction handbook.
Pay attention to the safety instructions.
– 5 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
CONVENTIONAL SYMBOLS
CAUTION: ELECTRIC SHOCK DANGER The staff involved is warned that the non-
obsevance of safety rules in carrying out the operation described may cause an
electric shock.
CAUTION: GENERAL HAZARD The staff involved is warned that the operation
described may cause injury if not performed following safety rules.
NOTE It points out significant information for the staff involved.
WARNINGS The staff involved is warned that the non-observance of warning may
cause loss of data and damage to the machine.
PROTECTIONS This symbol on the side means that the operator must use personal
protection against an implicit risk of accident.
QUALIFICATION OF THE STAFF
MACHINE OPERATOR He/she is an unskilled person, who has no specific expertise
and can only carry out easy chores, such as the machine operation by means of
controls available on the push-button panel, and filling and drawing of
products used during operations.
MAINTENANCE ENGINEER He/she is a skilled engineer for the operation of the
machine under normal conditions; he/she is able to carry out interventions on
mechanical parts and all adjustments, as well as maintenance and repairs.
He/she is qualified for interventions on electrical and refrigeration
components.
CARPIGIANI ENGINEER He/she is a skilled engineer the manufacturer assigned to
field interventions for complex jobs under particular conditions or in
accordance with agreements made with the machine’s owner.
lb 202 g_G – 04/05 – ed. 2
– 6 –
SAFETY
When using industrial equipment and plants, one must be aware of the fact that
drive mechanisms (rotary motion), high voltage components, as well as parts
subject to high temperatures may cause serious damage to persons and things.
Who is in charge of plant safety must be on the look-out that – An incorrect
use or handling shall be avoided – Safety devices must neither be removed nor
tampered with – The machine shall be regularly serviced – Only original spare
parts are to be used especially as far as those components with safety
functions are concerned (ex.: protection microswitches, thermostats).
To achieve the above,the follow ing isnecessary: – A tthe w orking place an
instruction m anualrelevantto the m achine should be available. – Such docum
entation m ustbe carefully read and requirem entsm ustconse quently be m et. –
O nly adequately skilled personnelshould be assigned to electricalequipm ent.
– Be on the look out that no technician will ever carry out interventions
outside his own
knowledge and responsibility sphere.
QUALIFICATION OF THE STAFF
Staff attached to the machine can be distinguished according to training and
responsibility as follows:
OPERATOR – A person who has not necessarily a high technical knowledge, just
trained for ordinary operation of the machine, such as: startup, stop,
filling, basic maintenance (cleanout, simple blocking, instrumentation
checkings, etc.).
SKILLED ENGINEER – A person enganged on more complicated operations of
installation, maintenance, repairs, etc.
IMPORTANT! One must be on the look-out that the staff does not carry out any
operation outside its own sphere of konwledge and responsibility.
NOTE: According to the standard at present in force, a SKILLED ENGINEER is
who, thanks to – training, experience and education, – knowledge of rules,
prescriptions and interventions on accident prevention, – knowledge of machine
operating conditions, is able to realize and avoid any danger and has also
been allowed by the person in charge of plant safety to carry out all kinds of
interventions.
WARNING
When installing the machine, insert a differential magnetothermal protection
switch on all poles of the line, adequately sized to the absorption power
shown on machine data plate and with contact opening of 3 mm at least.
· Never put your hand into the machine, alike during production and cleaning
operations.
Before carrying out any maintenance operation, make sure that the machine is
in “STOP” position and main switch has been cut out.
· It is forbidden to wash the machine by means of a bolt of water under
pressure. · It is forbidden to remove panels in order to reach the machine
inside before having
disconnected the machine.
· CARPIGIANI is not responsible for any accident that might happen during
operation,
cleaning and/or servicing of its units, if this warning has not been fully
complied with.
LB 202 G
– 7 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
lb 202 g_G – 04/05 – ed. 2
– 8 –
1 GENERAL INFORMATION
1.1 GENERAL INFORMATION
1.1.1 Manufacturer’s identification data
The machine has a data plate carrying manufacturer data, machine type and
serial number, assigned when it is manufactured. Copy of machine data plate to
be found on first page of this handbook.
LB 202 G
AB
FG
Matr.
ANZOLA EMILIA – BOLOGNA – ITALY
Cod.
100089654588-4
V
Hz
kW
A
Gas
kg
Legend:
A= Serial number B= Machine type C= Voltage D= Main-switch amperometric
value E= Gas type and weight F= Machine code G= Condensation H= Frequency I=
Power input
CD E
H
I
1.1.2 Information about service
All operations of routine maintenance are here described in section
“Maintenance”; any additional operation requiring technical intervention on
the machine must be cleared with the manufacturer, who will also examine the
possibility of a factory technician field intervention.
1.1.3 Information to the user
l The manufacturer of the machine is at user’s disposal for any explanation
and information about the machine operation.
l In case of need, please call the local distributor, or the manufacturer, if
no distributor is available. l Manufacturer’s service department is available
for any information about operation, and
requests of spare parts and service.
1.2 INFORMATION ABOUT THE MACHINE
1.2.1 General data
LB 202 G are batch freezers for the production of ice cream. They have a
horizontal barrel which facilitates the extraction of ice cream. These
machines are electronically controlled to ensure a professional use and best
quality of ice cream. It is possible to personalize ice cream production
programs in order to get any kind of ice cream and other specialities; only
with the LB 202 G can you really produce an extraordinary variety of ice
cream, exclusively tasty cremolata fruit; the “G” version offers the option of
producing a perfect “Sicilian” slush.
– 9 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
CARPIGIANI recommends to always use high quality mix for ice cream production
in order to satisfy your customers, even the hardest-to-please ones. Any
saving made to the prejudice of quality will surely turn into a loss much
bigger than the saving itself. Bearing in mind the above statements, please
take heed of the following suggestions:
· Make your mixes yourselves from high quality natural ingredients or buy them
from reliable
companies.
· Follow closely instructions given by your mix supplier for the preparation
of the mixes. · Do not alter your mix supplier’s recipies, by adding, for
instance, water or sugar. · Taste ice cream before serving it and start
selling it only if entirely satisfactory. · Make sure your staff always keeps
the machine clean. · Have your machine serviced always by companies authorized
by CARPIGIANI.
1.2.2 Technical features
MODEL
ICE-CREAM
Quantity per batch
Hourly output
mix batch ice cream Mix per ice cream
kg
litres
batch kg
litres
Min Max Min Max Min Max Min Max
Cremolata
Quantity per cycle
kg
Slush optional
Quantity per
cycle kg
beater motor speed nr
Power supply Volt Hz Ph
rated output
kW
Dimensions cm
Condenser
base
Width. Depth
(L)
(P)
Height (H)
Net weight
kg
LB 202 G 1,5 5 2 7 10 30 12 42
4
4
2
400 50 3 3.2
Water
50
65 140 230
L
H P
lb 202 g_G – 04/05 – ed. 2
– 10 –
1.2.3 Location of machine groups 5 1
2 4
1 Controlpanel 2 Barrel front lid 3 Shelf 4 Dripdrawer 5 Water dispenser
3
LB 202 G
1.3 INTENDED USE
The LB 202 G must only be used for the production of ice cream, cremolata
fruit and slush (“G” option) with the respect of what indicated in 1.2.1
“General information”, within the limits indicated here under.
Voltage Min air temperature Max air temperature Min water temperature Max water temperature Min. water pressure Max water pressure Max relative humidity
±10% 10°C 43°C 10°C 30°C 0,1 MPa (1 bar) 0,8 MPa (8 bar) 85%
– This machine has been designed for its use in rooms not subject to explosion-proof laws; its use is thus bound to complying rooms and normal atmosphere.
1.4 NOISE
The steady acoustic pressure level weighed A in a working place alike by
watercooled and by aircooled machines is less than 70 dB(A).
1.5 STORING A MACHINE
The machine must be stored in a dry and dump-free place. Before storing the machine, wrap it in a cloth in order to protect it against dust and else.
1.6 DISPOSAL OF PACKING STUFFS
When opening the packing crate, separate packing stuffs per type and get rid
of them according to laws in force in machine installation country.
– 11 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
lb 202 g_G – 04/05 – ed. 2
– 12 –
2. INSTALLATION
2.1 ROOM NECESSARY TO THE MACHINE USE
The machine must be installed in such a way that air can freely circulate all
around. Rooms for the approach to the machine must be left free in order to
enable the operator to act without constraint and also to immediately leave
working area, if need be. The minimum approach room to working area should be
at least 150 cm in consideration of space taken by opened doors.
ATTENTION Machines with aircooled condenser must be installed no closer than
50 cm to any wall in order
to allow free air circulation around the condenser. NOTE An insufficient air
circulation affects operation and output capacity of the machine.
50 cm.solo ad aria
LB 202 G
150 cm.
2.2 WATER SUPPLY CONNECTION
The machine must be connected to running water which pressure must not be
higher than 0,8 MPa (8 bars). By aircooled machines, water connection for
drinking water (for machine wash) is placed under the machine. By watercooled
machines water connections (for machine wash and gas cooling) are placed on
upper panel.
2.3 MACHINE WITH AIRCOOLED CONDENSER
Machines with aircooled condenser must be installed no closer than 50 cm to
any wall in order to allow free air circulation around the condenser.
NOTE An insufficient air circulation affects operation and output capacity of
the machine.
– 13 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
2.4 MACHINES WITH WATERCOOLED CONDENSER
To make the machine run, a watercooled machine must be connected to running
water supply, or to a cooling tower. Water must have a pressure of 0.1 MPa and
0.8 MPa (1-8 bar) at least, and a delivery at least equal to the estimated
hourly consumption. Connect inlet pipe marked by plate “Water Inlet” to water
supply installing a shut-off valve, and outlet pipe marked by plate “Water
Outlet” to a drain pipe, installing a shut-off valve.
2.4.1 Water valve adjustment
IMPORTANT If water valve needs be reset, this operation will have to be
carried out by skilled personnel, only. Valve adjustment must be carried out
in such a way that no water flows when machine is off and lukewarm water flows
when machine is on.
NOTE Water consumption increases if temperature of entering water is above
20°C.
ATTENTION: Do not leave the machine in a room with temperature below 0°C
without first draining water from the condenser.
2.5 ELECTRIC CONNECTION
Before connecting the machine to the mains, check that machine voltage
indicated in data plate corresponds with the mains. Insert a differential
magnetothermal protection switch adequately sized to absorption capacity
required and with contact opening of 3 mm at least. The machines are delivered
with a 5 wire cable: blue wire must be connected to the neutral lead.
IMPORTANT Yellow/green ground wire must be connected to an adeguate ground
plate.
2.5.1 Replacing the power cable
Should the machine main cable be damaged, it must be replaced immediately
through one with similar features. Replacement shall be carried out by skilled
technicians, only.
IMPORTANT Direction of rotation Beater rotation is anticlockwise
NOTE By threephased machines, it is necessary to check that axial pulley A has
clockwise rotation: to do that, watch through slits of rear panel (see
picture).
A
Reversal of rotation Should direction of rotation be wrong, reverse it by exchanging two of the three phases which start at the differential magnetothermal protection switch.
lb 202 g_G – 04/05 – ed. 2
– 14 –
2.6 LOCATION
The machine is provided with castors for an easy positioning; a mechanical
block system, once engaged, prevents machine from moving and keeps it
standstill.
LB 202 G
2.7 REFILLING
Motor installed in the machine is of the type with lubrication for life; no
action of checking/replacing or topping up is necessary. Gas filling necessary
to the freezing system is carried out at CARPIGIANI works during machine
postproduction testing. If a gas addition happens to be made, this must be
carried out by skilled technicians, only, who can also find out trouble
origin.
2.8 MACHINE TESTING
A postproduction test of the machine is carried out at CARPIGIANI premises;
Operation and output functionality of the machine are thoroughly tested.
Machine test at end user’s must be carried out by skilled technicians or by
one of CARPIGIANI engineers. After the machine positioning and correct
connections, also carry out all operations necessary to functional check and
test of the machine.
– 15 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
lb 202 g_G – 04/05 – ed. 2
– 16 –
3. DIRECTIONS FOR USE
3.1 MACHINE SAFETY WARNINGS
When using industrial equipment and plants, one must be aware of the fact that
drive mechanisms (rotary motion), high voltage components, as well as parts
subject to high temperatures may cause serious damages to persons and things.
Who is in charge of plant safety must be on the look-out that
– An uncorrect use or handling is avoided – Safety devices must neither be
removed nor tampered – Only original spare parts are to be used especially as
far as those components with safety
functions are concerned (ex.: protection microswitches, thermostats).
To achieve the above, the following is necessary: – At working place an
instruction manual relevant to the machine should be available. – Such
documentation must be carefully read and regulations must consequently be
followed. – Only adequately skilled personnel will have to be assigned to
electrical equipment.
3.2 MACHINE CONFIGURATION
The machine consists of motor drive for beater assembly drive, a cooling
system with water- or aircooled condenser. Ice cream is made by pouring mix
into the barrel and starting the automatic production cycle which ends when
right consistency of ice cream as set by CARPIGIANI is reached. To this
purpose, minum and maximum quantities of mix per batch must be followed, as
shown in table Sec. 1.2.2. When cycle is over, ice cream is ready for being
taken out from ice cream door and poured directly in ice cream cups and
containers.
LB 202 G
Ice cream mix
Ice cream (end product)
– 17 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
3.3 CONTROLS
3.3.1 Push-button panel
The machine has a push-button panel on its front side; each push-button has a
symbol representing the corresponding function.
3.3.2 Checking monitor
Ice cream consistency checking monitor (HARD-O-DYNAMIC) consists of 3 parts:
C
B
B
A
A DISPLAY displaying set values B PUSH-BUTTONS for variation of setting values
C LED BAR for checking that working steps go ahead
3.3.3 Push-buttonfunctions
STOP When pressing it, the machine stops.
lb 202 g_G – 04/05 – ed. 2
ICE CREAM PRODUCTION (EC-SP) When pressing it, operation of the beter motor
and compressor is automatically controlled. It is possible to select 2
production types, i.e., EC (Excellent Ice cream) to obtain an excellent ice
cream , SP (Ice cream Speed) and the production cycle is faster. Ice cream
consistency is controlled by the exclusive electronic system CARPIGIANI,
HARD-O-DYNAMIC, to reach the best production values.
DISTRIBUTION When pressed, it controls beater rotation at high speed for an
easy distribution of the product. Attention Three minutes after selecting this
function, the machine automatically sets to “STOP” in order to avoid an
excessive wear of beater and cylinder
CREMOLATA FRUIT (CF) When pressed , it controls the production of Cremolata by
switching the compressor on; the beater runs instead ON/OFF at intervals
during the whole production time. The production time must be selected on the
display by the user. SICILIAN SLUSH (GS) By selecting the slush production
program, the compressor is on and the beater runs at very slow speed, special
for slush. The production time unit shall be selected on the display by the
users.
– 18 –
CLEANING When pressed, it just controls beater rotation, whilst freezing
system is off. Attention 3 minutes after inserting this function, the machine
automatically sets to “STOP” in order to avoid an excessive wear of beater and
barrel.
SHOWER When pressing it, water inlet is activated by means of the shower onto
the machine front side.
3.3.4 Serial connector
LB 202 G units are provided with a serial connector to be found on the machine
rear. Connection of your PC to the machine allows to look at, to download and
to print the machine events. The connection of your machine to a modem allows
to receive and thence to transfer operation data to the service department,
directly, in order to have technical diagnosis and remote repairs.
NOTICE To connect the machine to your PC, it is necessary to place an order of
an Easydloader kit
toCarpigiani. Code is nr 193.013.520 and includes connection and CD cable with
the program allowing PC-
machine dialog. To connect the machine to modem, use the cable usually
supplied with modem.
LB 202 G
3.4 ICE CREAM PRODUCTION (PROCESSING)
After washing, sanitizing and thoroughly rinsing the machine just before its
use, as per instructions in Section 5, take the mix from pasteurizing unit,
pour the desired quantity of mix into the cylinder through front lid hopper,
while following minimum and maximum quantities shown in the table (Sec.
1.2.2). Before filling the machine with mix, make sure front lid and ice cream
door are perfectly closed.
On pressing the push-button PRODUCTION ice cream, the display will show the
message EC that can be changed into SP with the arrows-buttons. The two
monograms mean the two different kinds of production programs, namely:
GELATO EXCELLENT: it indicates the program to obtain an”eccellent” product,
i.e., a well made, smooth and creamy ice cream with a high overrun, suitable
for long display. This program is particularly suitable for small batches and
fruit ice cream.
GELATO SPEED: This program is faster; ice cream is compact and dry; suitable
for highest outputs.
– 19 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
The lighting-up sequence of all LEDS on the bar of HARD-O-DYNAMIC monitor shows ice cream status during its processing. The blinking of LED bar, as well as an ear signal mean that the cycle is over and ice cream is ready for dispense.
NOTE If ice cream is not dispensed soon after its preparation due to a temporary engagement of the operator, ice cream is kept under beating and HARD-O-DYNAMIC steadily checks its consistency. On a decrease in ice cream consistency, HARD-O-DYNAMIC starts up compressor again and processing automatically restarts, thus bringing ice cream back to its best thickness conditions.
IMPORTANT If a boiling mix at +85°C is used, it is necessary to press push-
button “PRODUCTION”
before pouring it into the barrel.
3.4.1 Ice cream consistency
CARPIGIANI sets the best consistency value to 10. HARD-O-DYNAMIC constantly
secures a perfect ice cream in relation to the mix used, and yet the operator
can set personalized processing cycles through LB 202 G. Particularly creamy
ice cream may require a higher consistency, whilst ice cream with low fat
contents, such as sherbets, requires a lower consistency degree
3.4.2 Changing ice cream consistency
To vary final ice cream consistency, press push-button processing ice cream.
while machine is
In order to get a harder ice cream, increase setting value displayed on monitor A by pushing arrow
.
To get a smooth ice cream, decrease setting value displayed on monitor A, by pushing arrow
.
Example: To vary consistency value from 10 to 8: l Press push-button for ice cream processing
l Press repeatedly push-button arrow
so decreasing value until number 8 is displayed;
the new set value of consistency is immediately stored. l At the end of
processing cycle, i.e. when buzzer will ring and LED bar will blink, ice cream
consistency value will be 8 instead of 10.
Typical value is 10, the new value set will be stored until it is not changed again.
The above described operation can be carried out on both EC and SPprograms. By EC cycle, the machine control system is able to automatically recognize whether the operator has filled the machine with minimum or maximum batched and whether it is working a fruit or cream product; consistency value can be modified 8 to 12. In SP program, the consistency value can be set 1 to 12.
IMPORTANT LB 202 G hourly output may vary depending on:
· roomandcoolingwatertemperature · kind and quantity of mix used · set value
of consistency
lb 202 g_G – 04/05 – ed. 2
– 20 –
3.4.3 Ice cream distribution
When production cycle is over, as it is shown by blinking of LED bar and by
the buzzer simultaneously, ice cream can be dispensed from the cylinder as
follows:
l Place a container on the shelf, under ice cream door. l Turn the lid by
unlocking lever towards the left (ref. 1). l Lift handle together with ice
cream door (Fig. C). l Press push-button “DISPENSE”. l Last, press “STOP”.
SAFETY NOTE To avoid a useless wear of sliding shoes and barrel, the machine
returns to STOP after 3
minutes uninterrupted running in distribution.
LB 202 G
1
3.4.4 Use icre cream dispensing handle
Locking Lock ice cream door turning the handle (rif. 1) rightwards till the
stop.
Opening Turn the handle (rif. 1) 90°C leftwards. Lift handle and ice cream
door. Lock ice cream door on top turning the handle (rif. 1) rightwards till
the stop.
Closing Repeat in the opposite direction opening sequence described above.
3.4.5 Aftercooling
This function, which is a peculiarity of LB 202 G, is particularly useful by
those models with a bigger output capacity (2 containers per cycle or more).
As a matter of facts, if ice cream in each container needs further
preparation, such as garnish and variegation or else before storage, ice cream
still inside the machine being left at high speed of dispense may loose its
original thickness. At any moment during DISTRIBUTION and upon operator’s
choice, it is also possible to press push-button PRODUCTION in order to cool
ice cream again. The result is a steady consistency of ice cream, from
beginning to the end of distribution. Starting Post-Cooling from SP (Speed)
production program, makes the compressor run 20 seconds only.
– 21 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
3.5 CREMOLATA PRODUCTION
Through front lid hopper, pour slush mix into the barrel.
From “STOP” position, press push-button “CREMOLATA PRODUCTION”
in order to
start cooling intermittently. Monitor A displays production time set in minutes. All lighted LEDS on bar C dynamically show how many minutes are to cycle ending. The machine is set with a production time of 12 minutes.
20 19 18 17 16 15 14 13 12 11
minutes
1 2 3 4 5 6 7 8 9 10
minutes
When the number set is over 10, LED bar decreases from left to right. If, on the contrary, the number set is below 10, it decreases from right to left.
3.5.1 Variation of cremolata production time
The user can vary production time between 2 and 20 minutes, depending on final
product he would like to obtain. In order to change cremolata production time,
it is necessary to act on push-buttons arrow of MONITOR, with the machine in
CREMOLATA PRODUCTION. In order to obtain a drier cremolata,
the time must be increased by pressing
, and vice versa decreased by pressing
.
New time set is displayed on MONITOR.
NOTE By power failure, time setting remains memorized on last value stored.
3.5.2 Cremolata extraction
When the porduction cycle is over, as indicated by the LED bar blinking and
the buzzer sound, the machine sets to STOP. You can take the “cremolata” out,
now, by opening the lid and using the special spatula.
NOTE The best FRUIT CREMOLATAS are obtained when using same or bigger
quantities than the ones to be found in table on page 10.
lb 202 g_G – 04/05 – ed. 2
– 22 –
3.6 SICILIAN SLUSH
Through front lid hopper, pour slush mix into the cylinder From “STOP”
position, press push-button “SLUSH PRODUCTION” cooling cycle with low speed
beating so that slush is not emulsified. The display will show:
in order to start
which means CREMOLATA
which means SICILIAN SLUSH
Select “GS” by means of
button.
Monitor displays production time set in minutes. All lighted LEDS on bar C dynamically show how many minutes are to cycle ending. The machine is set with a production time of 16 minutes. When the number set is over 10, LED bar decreases from left to right. If, on the contrary, value is below 10, it decreases frorm right to left.
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7 8 9 10
minutes
minutes
3.6.1 Variation of Sicialian Slush Production Time
The user can vary production time between 2 and 20 minutes, depending on final
product he would like to obtain. In order to change slush production time, it
is necessary to act on push-buttons arrow of MONITOR, with the machine in
SLUSH PRODUCTION. In order to obtain a drier slush, times should be
extended by pressing
, and vice versa shortened by pressing
.
New time set is displayed on MONITOR.
NOTE By power failure, time setting remains automatically on datum last stored.
3.6.2 Slushdistribution
When the porduction cycle is over, as indicated by the LED bar blinking and
the buzzer sound, the machine sets to STOP. You can take the slush out, now,
by opening the lid and using the special spatula.
NOTE The best SICILIAN SLUSHES are obtained when using same or bigger
quantities than the ones to be found in table on page 10.
LB 202 G
– 23 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
lb 202 g_G – 04/05 – ed. 2
– 24 –
4. SAFETY DEVICES
4.1 ALARMS
LB 202 G have been provided with a series of safety devices to machine and
operators’ safeguard. Any tripping of a safety device coincides with an alarm
signal on control panel display. Hereunder an ALARMS list:
ALARM Er It trips when the machine does not cool the product.
ALARM Pt It trips when the machine lid is open.
ALARME rt Thermal relay has tripped. If the alarm blinks it means thermal
relay has not yet reset. When fixed, it means the thermal relay had tripped
but it has also reset. To reset the alarm, press “STOP”.
ALARM EE Call an engineer.
ALLARME tt Call an engineer.
ALARM AG It trips if the beater is not inserted into its seat or if there is
no mix in the cylinder.
4.2 MACHINE SAFETY SYSTEMS
The diagram with location of above mentioned safety devices is hereunder
illustrated. Safety devices can be seen on right and left sides of the
machine, after removing side panel.
LB 202 G
(4) (1)
(3) (2)
Symbolizes the parts inside the machine.
WARNING IT IS ABSOLUTELY FORBIDDEN TO REMOVE AND TO TAMPER WITH DEVICES TO
OPERATOR’S SAFETY.
CAUTION CARPIGIANI will not be resposnsiblefor any damages to people and/or to
the machine, if
safety devices turn to be tampered with or removed.
– 25 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
THERMAL RELAYS (1) They take overheating of beater motor and motorcompressor; maximum values of setting bring
about machine stop and the machine sets to “STOP”, whilst MONITOR blinks,
meaning
that THERMAL CUT OUT has tripped. On automatic resetting of thermal relay, display stops blinking. Before resetting operation, it is necessary to find out reason of tripping. In order to restart the machine, press desired push- button.
FUSES (2) They protect control electric circuit against overloads. If they trip, check and eliminate causes of trouble, before replacing them.
NOTE To identify values and features of fuses, refer to machine wire diagram.
PRESSURE SWITCH (3) It is a protection ofor cooling system and make the circuit cooling compressor stop in the event the circuit has no water (watercooled machines) or in the event of insufficient air circulation in the condenser (aircooled machines). Reset follows automatically.
WARNING Too long running of compressor as well as stop and restart over and
over again mean that
cooling is insufficient; check reasons.
PROTECTIONS FOR THE OPERATOR (4) Magnet switch On the closing lid of the cyclinder in which you find the beater assembly, there is a magnet switch which immediately controls the machine stop on lid opening. The machine sets to “STOP” and on
DISPLAY the message
will be blinking in case the machine was operating, will be steadily
on if the machine was already in “STOP”. Reclosing the lid keeps the machine in “STOP” and makes the alarm on display off.
WARNING Before opening front lid, make sure the machine is in STOP position.
lb 202 g_G – 04/05 – ed. 2
– 26 –
5. CLEANOUT DISASSEMBLING AND REASSEMBLING OF PARTS IN CONTACT WITH THE
PRODUCT
IMPORTANT Cleanout and sanitation must be carried out at the end of every
working day as a habit and with utmost care in order to guarantee the
production quality in the observance of necessary healthy rules.
WARNING Ideal water temperature for washing and sanitizing the machine is
55°C. Water temeprature must never be higher than 60°C and lower than 45°C.
Wash the disassembled parts by hands: do not use automatic washing machines.
WARNING Never use solvents, alcohol, or detergents that can damage the machine
parts or pollute
production functional parts.
5.1 OUTSIDE CLEANOUT
Clean the machine from dust and material its has been strewed with before
shipment. Use water only and add a mild detergent, such as soap and a smooth
cloth.
5.2 PRELIMINARY CLEANOUT
With machine off and beater front lid closed, let water in the barrel by means
of the hose placed on machine front side and opening shut-off valve. Press
push-button “CLEANOUT” and let beater run for the time strictly necessary. The
machine runs about 3 minutes and then it automatically sets to “STOP”
position, in order to avoid a useless wear of sliding shoes and barrel.. Drain
all waterfrom barrel, open the lid so as to remove beater.
5.3 BEATER DISASSEMBLY
Remove beater with care, paying attention not to damage the sliding shoes.
WARNING Carry out this operation with utmost care, since beater may be damaged
in case it falls to the
ground.
LB 202 G
When reassembling the beater, catch it with both hands and push the sliding shoes in order to insert it easily. Push to the beater to the bottom and at the same time let it turn in order to fully insert the beater shaft into its seat.
– 27 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
l Fully disassemble the sliding shoes pos. 431; l Withdraw the stuffing box
from its seat on the beater shaft pos. 28. l Wash all parts with water and a
cleansing solution, then rinse. l Reassemble all parts previously
disassembled, minding to grease the stuffing box with a film
of edible fat.
431
28
21
5.3.1 Stuffing box
On disassembling beater also check wholeness of stuffing box; depending on
machine operation length, it is necessary to replace it through the spare one
to be found in the accessory kit inside machine packing.
l Remove beater assembly l Remove stuffing box from its seat l Lubricate spare
stuffing box l Mount the new stuffing box l Clean and lubricate the old
stuffing box and put it away for recovery of its elasticity.
IMPORTANT Stuffing box must be replaced each time ice cream drops are found on
withdrawing drip drawer placed at the machine side. Keeping on operating the
machine after finding ice cream drops brings about a bigger leakage from
stuffing box, thence a malfunctioning of the machine which consequently
affects production.
CAUTION When you do not use the machine, leave beater lid open in order to
avoid stuffing box buckling.
lb 202 g_G – 04/05 – ed. 2
– 28 –
5.4 FRONT LID DISASSEMBLY
l Lift lid locking lever and shift it towards right. l Open the lid by
rotating it on its hinge. l Remove lid while lifting it. l To carry out
cleaning operations, remove all movable parts and seal with barrel. l Wash all
parts previously disassembled with water and a cleansing solution, then rinse.
l Reassemble all parts previously disassembled, minding to grease the OR and
the support rif. 362
with a film of edible fat.
290
350
6 291
338
289
960 363
502 304 7 501 362 1126
5.4.1 Ice cream door disassembly
l Lift the lid by turning the lever (ref. 1) by 90° towards the left. l Lift
the lever and the door and lock the lid upwards by turning the lever
rightwards till its stop. l Remove the OR from the lid sliding rod, now, and
take it out, in order to release the lever, as well. l Remove the OR of the
lid itself. l Wash all disassembled parts with water and a cleansing solution,
then rinse. l Reassemble all parts previously disassembled, minding to grease
the OR with a film of edible fat.
LB 202 G
1
2
5.4.2 Hopper cover disassembly
To clean the mix filling area, withdraw the cover fixing rod (pos. 6) and
remove it. The cover is provided with a small panel to prevent ice cream from
going back to the hopper, which must be disassembled to be cleaned. Wash all
disasembled parts with water and a cleansing solution, then rinse.
5.4.3 Ice cream slid disassembly · Release the slide from its fixing knobs by
rotating it. · Wash the slide with water and soap, then rinse.
– 29 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
5.5 SANITIZATION
l With machine off and beater assembly lid closed, pour a NON CORROSIVE
sanitizing solution into the the freezing barrel.
l Push push-button “CLEANOUT”. Let the machine run 10/15 seconds.
WARNING Too long running at “CLEANOUT” position with empy barrel or with water
and cleansing
solutions will wear out beater sliding shoes very quickly.
l Let the sanitizing solution act into the cylinder about 10/15 minutes
according to the instructions given by the manufacturer.
l Fully draining the sanitizing solution from the freezing cylinder.
ATTENTION Do not touch sanitized parts with hands, napkins, or else.
WARNING Before starting again with ice cream production, rinse thoroughly with
just water, in order to
remove any residue of sanitizing solution.
5.6 HYGIENE
Ice cream fat contents are ideal fields for proliferation of mildew and
bacteria. To eliminate them, parts in contact with mix and ice cream must be
thoroughly washed and cleaned. Stainless steel materials as well as plastic
and rubber ones used for the construction of these parts and their particular
design make cleaning easy, but cannot prevent the growth of mildew and
bacteria if not properly cleaned.
lb 202 g_G – 04/05 – ed. 2
– 30 –
6. MAINTENANCE
CAUTION Never put your hands into the machine, either during the operation or
during cleaning. Before servicing, make sure the machine has been set in
“STOP” position and the main
switch has been cut out.
6.1 SERVICING TYPOLOGY
ATTENTION Any servicing operation requiring the opening of machine panels must
be carried out
with machine set to stop and disconnected from main switch! Cleaning and
lubricating moving parts is forbidden!
Repairs of electrical and freezing plants must be carried out by skilled
engineers!
Operations necessary to proper machine running are such that most of servicing
is completed during production cycle. Servicing operations, such as cleaning
of parts in contact with the product, replacing of stuffing box, disassembling
of beater assembly are to be carried out at the end of a working day, so as to
speed up serving operations required. Herebelow you can find a list of routine
servicing operations: – Cleanoutandreplacementofstuffingbox
Cleaning should be carried out at the end of a working day, whilst replacement
only after checking of stuffing box and in the event product drips inside drip
drawer. – Cleanout of beater assembly At the end of a working day – Cleanout
of sliding shoes At the end of a working day – Cleanout of panels To be
carried out daily with neutral soap, seeing to it that cleaning solution never
reaches beater assembly at its inside. – Cleanoutandsanitization At the end of
each working day, according to procedures described in section 5 of this
manual.
WARNING Never use abrasive sponges to clean machine and its parts, as it might
scratch their surfaces.
6.2 WATERCOOLING
By machines with watercooled condenser, water must be drained from condenser
at the end of selling season in order to avoid troubles in the event that the
machine is stored in rooms where temperature may fall under 0°C. After closing
water inlet pipe, withdraw drain pipe from its seat and let water flow out
from circuit.
6.3 AIRCOOLING
Clean condenser, periodically, so as to remove dust, paper and what can
prevent air from circulating. For cleanout, use a brush with long bristles or
a bolt of compressed air.
ATTENTION When using compressed air, put on personal protections in order to
avoid accidents;
put on protective glasses!
Note: nevere use sharp metal objects to carry out this operation. Good working
of a freezing plant mostly depends on cleaning of condenser.
6.4 ORDERING SPARE PARTS
When one or more parts are worn out or broken, place the order through your
local distributor.
LB 202 G
– 31 –
lb 202 g_G – 04/05 – ed. 2
LB 202 G
6.5 ACCESSORIES KIT
772A 28
431
255 304
830
291 840
72
LB 202 G ACCESSORY KIT
Description
Beater stuffing box O-ring extractor Hose adapter Lid gasket Gaskets for hose
adapter Brush Food-grade lubrificant tube Ice cream spatula
Position number
28 72 287 291 352 772A 830 840
lb 202 g_G – 04/05 – ed. 2
– 32 –
7. TROUBLESHOOT GUIDE
IRREGULARITY
CAUSE
Machine does not start
Main switch is off Machine unplugged
PROCEDURE Switch it on Check and plug in
Machine is not set at PRODUCTION
Front lid is not closed well
Check push button for PRODUCTION is lit
Check front lid closure
Compressor starts and then stops after a few seconds without ice cream being thick
Watercooled machine: water does not circulate
Aircooled machine: air does not circulate
After 15 minutes processing No gas mix has not frozen and the machine returns
to Stop
Pressure switch has broken down
Machine runs but no ice cream comes from ice cream door
No sugar in the mix
Machine works but ice cream is too soft
Too much sugar in the mix
Mix in drip drawer
Stuffing box missing or ruined
Ice cream comes out from behind front lid
Gasket missing or not properly installed
Bacteria tests show too high bacteria charge
Too high bacteria charge in the mix
Machine not clean enough
Open water tap
Check that hose is neither squashed nor doubled up.
Check that rear ofmachine is at least 50 cm from wall
Clean condenser from obstructions
Check leakage and weld
Check connection and replace, if need be
Allow to thaw, then modify
or replace the mix
Modify or replace the mix
Install if missing Replace if ruined
Check and fix or replace
Improve preparation procedure by sanitizing all containers, spoons, etc., and
have mix analyzed before pouring it into the machine Empty and thoroughly wash
the machine. Carry out sanitization as per chapter 5 of manual.
LB 202 G
– 33 –
lb 202 g_G – 04/05 – ed. 2