Technogel FREEZER 200/1 Instructions For The Installation, Use And Maintenance Download Page 3

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Instructions for unpacking the machine

FREEZER 200/1 - GROSS WEIGHT 585 KG. NET WEIGHT 460 KG.

Remove all wood packing panels from the sides
and top

Lift the machine using a fork lift truck, inserting the forks
between the base of the machine and the bottom of the
crate

Unscrew the four bolts on the base of the crate which
hold the machine locked in position

CAUTION !

Once the bolts have been removed, the bottom of the
crate will detach from the machine base.

After removing the bottom of the crate, lower the fork lift
carriage and rest the machine on the ground.

THE TYPE OF WOOD USED FOR THE CRATE IS NATURAL PINE AND DOES NOT

CONTAIN ANY CHEMICALS WHATSOEVER. IT CAN THEREFORE BE RECYCLED

Summary of Contents for FREEZER 200/1

Page 1: ...I IN NS ST TR RU UC CT TI IO ON NS S F FO OR R T TH HE E I IN NS ST TA AL LL LA AT TI IO ON N U US SE E A AN ND D M MA AI IN NT TE EN NA AN NC CE E Ed 2013 GB FREEZER 200 1 ...

Page 2: ...out prior warning CAUTION In compliance with current Standards regulating personnel safety in the workplace the instructions given in the next two sections must be followed very closely Authorized personnel Please note the symbols which appear at the side of each description of work to be carried out in installation use and maintenance of the machine Technician User Where the Technician symbol is ...

Page 3: ...d the bottom of the crate Unscrew the four bolts on the base of the crate which hold the machine locked in position CAUTION Once the bolts have been removed the bottom of the crate will detach from the machine base After removing the bottom of the crate lower the fork lift carriage and rest the machine on the ground THE TYPE OF WOOD USED FOR THE CRATE IS NATURAL PINE AND DOES NOT CONTAIN ANY CHEMI...

Page 4: ...wn in the figure positioned close to the front and rear wheels The cable used to raise the machine must be positioned exactly in the center of the machine HOW TO MOVE THE MACHINE Move the machine using a manual pallet trolley Insert the trolley forks either under the side or the front of the machine After positioning the machine make sure all four legs rest on the ground Regulate the feet so that ...

Page 5: ... point F with a cable coming from above to avoid any danger of crushing underfoot For power data please see page 7 Make sure the floor is strong enough to take the weight of the machine Check the machine is stable by making sure that the four legs are firmly resting on the floor Connect the machine to the water supply at points D and E with firmly fitted piping which will withstand a minimum press...

Page 6: ...l power type and quantity of refrigerating gas The plate is applied to the rear of the machine The plate for this machine is as indicated below When ordering spare parts and applying for technical assistance please give the data indicated on the serial plate to ensure precise identification of the machine MACHINE TYPE FREEZER 200 1 SERIAL N VOLTAGE V _____________ HZ ________ ...

Page 7: ... table A for power supply and absorption data Check that the power supply is correct for the machine details as indicated on the plate see page 6 The machine s power cable has 4 wires the yellow green wire is the earth the other three are the three phases Table A FREEZER 200 1 220 V 50 Hz 220 V 60 Hz 200 V 50 60Hz 400 V 60 Hz 380 V 50 Hz 415 V 50Hz Total power kW 8 9 8 9 8 9 Max absorption A 34 22...

Page 8: ...SSURE AND CONSUMPTION If the machine operates on mains water make sure that the water going into the machine is at least 1 Bar in pressure If the machine operates on tower water make sure that the water going into the machine is at least 2 Bar in pressure with a maximum temperature of 29 C In both cases maximum pressure for water entering the machine must not exceed 4 Bar WATER TOWER The average c...

Page 9: ... mixture connection As indicated on page 5 connect a rubber pipe with internal diameter 25 mm and max 4 metres in length to point H rubber holder supplied with machine NB Do not use a rigid steel tube If the maturation tank from which the mixture is taken is over 4 metres away it is possible to deliver the mixture using a pump providing the pressure of the mixture on arrival does not exceed 0 5 Ba...

Page 10: ... ACTIVATING THE REFRIGERATOR COMPRESSOR IF THE MACHINE IS DISCONNECTED FROM THE POWER SUPPLY FOR ONE DAY OR MORE AFTER PRESSING THE START BUTTON IT IS NECESSARY TO WAIT FOR AT LEAST 60 MINUTES BEFORE ACTIVATING THE REFRIGERATOR COMPRESSOR IF THE MACHINE IS NEVER DISCONNECTED FROM THE POWER SUPPLY NO WAITING PERIOD IS NECESSARY COMPRESS ...

Page 11: ...injection of hot gas from the remote 9 OFF Hot gas injection to stop 9 Manual valve regulating hot gas with gravitational gauge connected Turning it counterclockwise hot gas is introduced Indicative quantity is detected on the pressure gauge on the wheel 10 Alarm lamp Notice engine failure or shutdown the machine 11 Pushbutton emergency Pressing it will be for the entire machine 12 Indicator compr...

Page 12: ...worn as the knives are very sharp indeed and you could cut yourself very easily When dismantling do not drop them as they could dent CHECKING THE DIRECTION OF ROTATION Check that the EMERGENCY button 11 page 10 is ON and connect the power supply by pressing the RESET button 1 page 10 Press the stirrer button 5 and watch the hub to check which way it rotates by looking through into the inside of th...

Page 13: ...ating part 3 of the packing gland is blocked with the spring crushed it is necessary to dismantle it by removing it from the axle 4 and to grease the washer inside using vaseline 1 When re assembling the turbine in the freezer tube make sure the scraper knives are mounted correctly Correct assembly is as shown below INCORRECT ASSEMBLY CORRECT ASSEMBLY DIRECTION OF ROTATION WHEN ASSEMBLING THE TURB...

Page 14: ...quantity 200 liters of ice cream with 100 increase in volume The temperature of the ice cream produced will depend on the type of mixture used and the quantity of ice cream produced The minimum increase in volume recommended to obtain good quality ice cream is 30 THE PRODUCTION QUANTITIES INDICATED CAN BE OBTAINED WHEN THE CONDENSATION TEMPERATURE OF THE REFRIGERATING PLANT IS BETWEEN 35 C AND 40 ...

Page 15: ...ice cream with 100 overrun See Page 16 The pump flow must be associated with the injection of air into the ice cream to be made manually with the regulator See the following pages how Display of viscosity During operation of the machine display 7 gives the viscosity value for the ice cream at that particular moment in time This numerical value Ampere which is low at the start and higher as the ice...

Page 16: ...gauge G and then stop the pump unit using pushbutton Start the mixing turbine and the fridge compressor in that order Wait a few minutes and then start the pump again by pressing and inject air in the ice cream by unscrewing the handle 4 and manage to drag the ball 5 at the middle of the scale 6 While the machine is in operation make sure that the pressure of the ice cream inside the freezer as in...

Page 17: ... 0 580 kg 1 050 0 580 0 470 x 100 x 100 0 81 x 100 81 0 580 0 580 The litre of ice cream weighing 0 580 kg has an increase in volume of 81 To increase or decrease the volume increase or decrease the pressure of the air injected by the pump by turning knob E see page 15 We recommend increasing or decreasing by 0 2 Bar at a time wait for the ice cream inside the machine to be replaced and after chec...

Page 18: ...y value on the display 7 and stabilize it at the value which in your opinion is right for the product currently in production Example If prior to regulation the value of viscosity appearing on the display was 8 and the ice cream is too hard and after injecting hot gas you see that the ice cream is okay when the value displayed is 7 2 keep this value of viscosity by leaving the hot gas connected un...

Page 19: ...ecause at the start it is normal for the temperature to rise and then fall this means that the cooling water reaching the machine is insufficient Call the technical service for them to check it Low pressure gauge evaporation P This gauge measures evaporation i e the cold produced by the machine Observe the Freon scale inside the machine the temperature should vary between 26 C and 29 C CAUTION VER...

Page 20: ... IN THE MACHINE EVEN IF THERE IS WATER IN THE MACHINE THE MACHINE SHOULD NOT BE LEFT IN OPERATION AS IT WILL GIVE EXCESSIVE WEAR AND TEAR ON THE BUSHINGS AND BLADES OPERATE FOR 10 SECONDS AND THEN STOP FOR 30 SECONDS AND CONTINUE WITH INTERMITTENT USAGE UNTIL WASHING IS COMPLETE When washing is finished it is essential to empty the refrigeration pipe completely of any residual washing water Follow...

Page 21: ...arning of possible breakdown of the machine During the cold winter weather if the machine is not in operation make sure that the temperature of the room where the machine is installed does not fall below 0 C As the machine is water cooled if the temperature drops below freezing point the refrigerating system could break and this would prove costly to repair If it is not possible to ensure the temp...

Page 22: ...ves will wear out rapidly After the first month of operation Check the tension of the turbine stirrer motor belts Even if just one is worn change them all After each season of operation check the following The worm screw reduction unit 3 is oil lubricated Check the level and top up as necessary After 4000 hours operation change the oil The types of oil are as follows IP TELESIA OIL 15 OR BP ENERGO...

Page 23: ...OGEL DISCLAIMS ALL RESPONSIBILITY FOR ANY DAMAGE ARISING FROM TECHNICAL INTERVENTION CARRIED OUT BY UNAUTHORIZED PEOPLE TECHNOGEL ALSO DISCLAIMS ALL RESPONSIBILITY FOR DAMAGE CAUSED BY THE USE OF NON ORIGINAL SPARE PARTS WHICH HAVE NOT BEEN APPROVED FOR USE ON MACHINES MANUFACTURED BY THE COMPANY The next few pages give INSTRUCTIONS RESERVED FOR THE TECHNICAL SERVICE with the technical information...

Page 24: ...oesn t give the go ahead for start up The pressure switch indicating low pressure has been activated The pressure switch indicating high pressure has been activated No Freon Gas Check and top up if necessary Check and replace if broken Freon gas level low Top up The water condensation tap is closed and insufficient water is reaching the machine or it may be reaching the machine but is warm Check t...

Page 25: ... washer 22g Check the compressed air unit inside the machine Check the pressure regulator S see page 15 Check and replace O ring 22g Ice cream has too much air in it although the same pressure of compressed air was used Mixture reaching the machine is too cold and therefore stickier so that the pump in the first stage has difficulty in sucking it up The mixture storage tank is too far away more th...

Page 26: ...to wear and tear because the machine was left running during washing without any water in the freezer pipes because the machine was left running too long even though there was water inside Follow instructions given on page 12 Replace the spring of the packing gland To dismantle piece 5 remove connecting pipe 1 loosen screws 2 without removing them turn piece 5 in an anti clockwise direction and pu...

Page 27: ... 5 x 20 8A delayed type n 1 d 5 x 20 8A delayed type Fan and resistance compressor protection n 2 d 5 x 20 2A quick type n 2 d 5 x 20 2A quick type Pressure switches calibration low high pressure Set in values Low pressure threshold value 0 2 Bar High pressure threshold value 20 Bar Differential 0 7 Bar Oil pressure switch where equipped Calibration values 0 7 Differential 0 2 Bar REFRIGERATOR SYS...

Page 28: ...28 Electric system ...

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Page 31: ...31 Electric system ...

Page 32: ...32 Electric system ...

Page 33: ...33 Electric system ...

Page 34: ...machine When requesting spare parts please quote the following Type of machine Serial number of the machine Machine voltage if the spare part required is electrical Code number of the piece indicated or the number corresponding to the piece and the page number where it appears ...

Page 35: ... 9 1 Valve ball spring FR1 5672 0 10 1 Pump head FR1 3738 0 11 2 DN20 type gasket US 0099 12 4 Head blocking screws FR1 2226 0 13 1 Head plug LN 0084 15 1 Safety valve nipple FR 2061 0 16 1 Safety valve ball FR3 0074 17 1 Safety valve spring FR1 2062 0 18 1 Safety valve blocking ring nut FR1 3099 3 19 1 Rubber holder OR gasket US 0099 22 1 Complete air register valve FR1 12597 4 22a 1 US 0099 22b ...

Page 36: ...36 Pump variator assembly with connecting rod ...

Page 37: ...nal r p m indicator FR3 0239 7 Eccentric connecting rod drag FR1 19666 3 8 Complete connecting rod FR1 1793 4 20 9 Upper connecting rod cover FR1 7116 0 10 Bearing CS 7732 6 11 Snap ring SEEA 52I 12 Connecting rod casing FR1 1793 0 20 13 Spacer FR1 4462 0 14 Bearing CS 7732 6 15 Lower connecting rod cover FR1 7115 0 WARNING To replace clutch 4 disassemble first motor 1 and then the variator slide ...

Page 38: ...Bushing lock snap ring FR1 3698 0 20 5 Ice cream scraping blade 6 pieces FR1 10765 0 6 Movable stuffing box spring metallic part rubber seal spring only hard metallic part with OR only OR gasket only FR3 0027 FR3 0104 FR3 0110 AV 00133 7 Red Rulon stuffing box fixed part OR gasket OR gasket only FR3 0103 AV 00134 N B The two pieces pos 2 and pos 3 are provided with special bronze bushings ...

Page 39: ... and hot gas Light for pushbutton 30 V 50 60 Hz CC 5719 6 MXT 0017 4 Flowmeter CC 19709 6 7 Amperometric viscosity control CC 15128 6 9 HOT GAS regulator see details on page 40 10 Red ALARM warning light Bulb only FR3 0164 FR3 0166 CC 8574 6 11 EMERGENCY pushbutton CC 14776 6 CC 14777 6 12 Manometer OVVERRUN 14 Refrigeration plant condensation gauge FR6 0318 15 Refrigeration plant evaporation gaug...

Page 40: ...40 Refrigeration plant FREEZER 200 1 ...

Page 41: ...ow pressure switch TR 5714 6 9 Water pressure switch valve FR3 0095 10 Low pressure gauge evaporation FR6 0064 11 High pressure gauge condensation FR6 0065 12 Hot gas solenoid valve without electric coil electric coil only V 24 50 60 Hz VV 5614 6 VV 5616 6 13 Hot gas injection valve for details see page FR1 5158 3 14 Knob with gravitational indicator gravitational indicator only FR1 3820 0 FR3 019...

Page 42: ...ion flange FR1 3713 0 6 Complete support FR1 7257 4 7 Turbine drawing shaft FR1 1741 0 20 8 Oil protection rotating seal GU 7256 6 9 Spacer FR1 1820 0 01 10 Bearing CS 7255 6 11 Aluminium support body FR1 3717 0 20 12 Bearing CS 7254 6 13 Bearing CS 7255 6 14 Greaser attachment GU 7331 6 15 Ventilator DFA 5048 6 16 Support pulley 1st stage with 5 grooves Support pulley 2nd stage with 6 grooves FR1...

Page 43: ...oner screw 2 Top belt tensioner disk 3 Belt tensioner spring 4 Bottom belt tensioner bush 5 Stirrer motor 220 240 380 415 V 50 Hz 220 380 60 Hz 440 60 Hz MO 8301 6 MO 8301 6 6 Pulley motor 5 groove FR3 6253 0 7 Pulley locking disk FR3 6254 0 8 Transmission belts M2 0039 ...

Page 44: ...shaft FR1 5155 0 6 Rear O ring FR6 0062 7 Hot gas valve body FR1 5158 3 8 Gravitational indicator FR3 0199 9 Adjustment knob with gravitational indicator FR1 3820 0 Flange unit with turbine centering device Pos Name of component Code 1 Front flange of freezer pipe FR1 3715 3 10 2 Flange locking wheel no 3 FR1 1808 0 3 O ring FR3 0037 4 Turbine centering device FR1 1742 0 10 ...

Page 45: ...34 4 2 Faucet closure threaded pin FR1 6219 3 3 Faucet body FR1 6218 3 4 DN40 Faucet locking device R 012 40 5 Spring pusher platelet FR1 3707 0 10 6 Spring FR1 3701 0 10 7 O ring AV 00020 8 Faucet piston FR1 3708 0 21 9 O ring AV 00060 10 DN40 washer R 013 40 11 Faucet seat T connector FR1 3711 2 12 ...

Page 46: ...eezer The piping that connects the servofreezer 3 to pump 2 must be made of rubber or plastic We strongly advise not to use metallic piping In case Technogel S p a has supplied only the servofreezer and that the Client must install the pump we recommend installing a centrifugal pump with a maximum head of 10 metres thrust pressure In case the storage tank is positioned above the freezer for exampl...

Page 47: ... Spare parts forservofreezer Pos Part name Part Number 1 Stainless floating ball SF 012 2 Mixture inlet small piston seal gasket MP 0008 3 DN20 connection gasket TM 0006 4 DN25 MF throttle tap MW 00227 2 ...

Page 48: ...g box rotating part MW 0172 3 Stuffing box fixed part MW 0080 4 Fixed part OR gasket AV 00125 5 Rotating part OR gasket AV 00124 6 Complete stuffing box MW 00166 7 Pump cover OR gasket T1 0081 8 Force main DN25 gasket TM 0006 9 Pump cover closing handwheel DE 0020 10 Inlet union DN40 gasket R 013 40 11 Pump support foot BA 0002 ...

Page 49: ...e of pump safety valves 17 Checking operation of the refrigerating system 18 Washing the machine 19 Noise level Ecological warning Warning of possible breakdown of the machine 20 Maintenance 21 Technical assistance 22 Trouble shooting 23 Trouble shooting faults in the pump unit 24 Leakage from the packing gland 25 Technical characteristics 26 Electrical installation 27 28 29 Spare parts 30 Pump un...

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