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

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FREEZER 200/1
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Ed 2013
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Summary of Contents for Technogel FREEZER 200/1

  • Page 1 Ed 2013 FREEZER 200/1...

  • Page 2: Authorized Personnel

    Introduction Thank you for choosing a Technogel machine. To ensure trouble-free operation of your machine, please read the Instructions for the Installation, Use and Maintenance very carefully. The descriptions and illustrations contained in this manual are not binding. Technogel Spa reserves the right to make any changes to the machine for constructional and/or commercial reasons that the company feels necessary at any time and without prior warning.
  • Page 3 Instructions for unpacking the machine FREEZER 200/1 - GROSS WEIGHT 585 KG. NET WEIGHT 460 KG. Remove all wood packing panels from the sides Lift the machine using a fork lift truck, inserting the forks and top between the base of the machine and the bottom of the...
  • Page 4  Instructions for lifting the machine FREEZER 200/1 - NET WEIGHT = 460 kg. Raise the machine using a fork lift truck, inserting Lift the machine using belts as shown in the figure the forks under the sides of the machine between positioned close to the front and rear wheels.
  • Page 5  Positioning of different facilities CAUTION: For trouble-free operation of the machine it is not necessary for the machine to be anchored to the floor, nor are any special measures necessary to limit vibration. A number of important points should, however, be borne in mind: Leave a space of at least 50 cm around the machine.

  • Page 6: Machine Identification

    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 ._____________...

  • Page 7: Electrical Installation

    N° of wires and cross section 4 x 6 4 x 6 4 x 2,5 4 x 2,5 4 x 2,5 mm² mm² mm² mm² mm² TECHNOGEL DISCLAIMS ALL RESPONSIBILITY FOR DAMAGE ARISING FROM INCORRECT ELECTRICAL INSTALLATION OR FAULTS IN THE POWER SUPPLY...

  • Page 8: Connection Of Water Supply

    In both cases maximum pressure for water entering the machine must not exceed 4 Bar. WATER TOWER - The average consumption with the refrigerating system in operation is as follows: FREEZER 200/1 = 1800 litres/hour* *depending on the temperature of the water on entry The quantity of water (max.

  • Page 9: Pneumatic Connection

    Pneumatic connection Connect filtered and de-humidified compressed air to the special rapid connector AC (see please page 9) located on the rear of the machine at the top. The compressed air must be at least 7 Bar in pressure. The quantity of air required: suction of 11 liters per minute ...

  • Page 10: Initial Start-Up

    Initial start-up CAUTION IMPORTANT TO CARRY OUT INITIAL START-UP, PRESS THE “START” BUTTON AND THEN WAIT FOR AT LEAST 60 MINUTES BEFORE 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.
  • Page 11 Description of machine control panel Pos. Components Function white button "RESET" machine power illuminated button applied voltage Off = Power off button Potentiometer overrun Nel l'air regulator iced Push button start / stop "group bombs" Starts and for pumps Ice cream production Viewer Displays the time-liter ice cream produced Push button start / stop "agitator"...
  • Page 12 Instructions for dismantling mixer turbine:  first time then Check that the “EMERGENCY” button 11 (page 10) is off and that the power supply to the control panel is therefore disconnected. Using the appropriate spanner, dismantle faucet 2 by unscrewing ringnut 1. Unscrew handwheels 4 using the appropriate spanner and dismantle flange 5 by pulling towards you.
  • Page 13 Correct assembly of the turbine and knives Before reassembling the turbine, check that the packing gland (1) is correctly mounted: -the locking foot (2) on the spring must fit in its seat. -The rotating part (3) of the packing gland must be free to move along the axle of the turbine (4) with the force of the spring.
  • Page 14 AUTHORIZED AND UNAUTHORIZED USAGE TECHNOGEL FREEZERS are specially designed for the manufacture of ice-cream. If the machines are used for any other purpose than the production of ice-cream the Customer does so at his own risk.  Conditions of usage Quantities the machine can produce: minimum quantity is half its production rate (i.e.
  • Page 15 Operation of the machine Press the “RESET” pushbutton 1 to operate the machine and ensure that all the motors can be started up. Press pushbuttons 3 (pump), 5 (stirrer) and 6 (fridge compressor) to start the relative motors. When the pushbuttons light up, this means the relative motor has started;...
  • Page 16 Start-up of the machine Connect the Freezer pump unit to a storage mixing tank with a pipe A made of rubber or flexible plastic. The pipe must not be more than 4 meters in length. A rigid stainless steel tube should not be used. Before starting the machine, open faucet B so that the thread of the handwheel protrudes by approx.
  • Page 17  Instructions for calculating ice-cream overrun To know the exact increase in volume of the ice-cream currently in production, follow the instructions below: - Take a 1 litre container, fill with the liquid mixture and weigh it. When the tare (weight of empty container) is subtracted, the net weight of a litre of mixture is obtained.
  • Page 18 Regulation of ice-cream viscosity with the hot gas valve When the Freezer is connected to a packing machine, the quantity and viscosity of the ice-cream produced must be regulated to suit requirements. If the requirement is less than the quantity your Freezer produces, the ice-cream emerging from the machine will be too hard and it will be difficult to fill in to the cones, cups, etc.
  • Page 19  Checking operation of the refrigerating system The machine is fitted with gauges indicating the pressures and operating temperatures of the refrigerating plant. During operation it is possible to check whether the refrigerating system is operating correctly: - High pressure gauge (condensation) R This gauge measures the condensation;...

  • Page 20: Washing The Machine

    Once production of ice-cream has been terminated, connect the same mixture pipe to a tank containing water (maximum temperature 70°C) mixed with detergent and disinfectant. For the type of detergent and disinfectant Technogel advises the customer to request information from a specialized company such as DIVERSEY/LEVER or HENKEL etc. who will supply a specific product for this purpose.

  • Page 21: Noise Level

     Noise level The noise level measured 1 metre from the machine is less than 70 dB (A).  Ecological warning CAUTION !!! “This machine contains substances which may damage the ozone layer. When the machine is no longer in use it must be consigned to a specialized waste disposal center. Ask the rubbish disposal services of your town or city for information.”...

  • Page 22: Maintenance

    Maintenance After each washing operation, all accessible washers should be greased with vaseline to ensure ease of assembly and operation. Check the washers and springs on the pump unit each week and if necessary replace them. This is extremely important for trouble-free operation of the machine. Check periodically that there is not too much play (3) between the eccentric shaft (1) and...

  • Page 23: Technical Assistance

    We therefore advise you to call THE AUTHORIZED TECHNICAL SERVICE in case of any fault in the machine. TECHNOGEL 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.

  • Page 24: Troubleshooting

     Trouble-shooting The user can work on the machine without any risk or danger only when the symbol indicates he may do so. FAULT IN OPERATION CAUSES REMEDIES During operation the refrigeration No cooling water in the compressor. Check the water supply. compressor stops and starts again.
  • Page 25 Trouble-shooting faults in the pump unit FAULTS IN OPERATION CAUSES REMEDIES Leakage of mixture under the O-ring (3) are worn or broken Check and replace if necessary machine where the pump unit is located Ice-cream does not contain air Compressed air is not reaching the Check the compressed air unit inside (does not increase in volume) machine.
  • Page 26  Leakage from the packing gland FAULTS IN OPERATION CAUSES REMEDIES The mixture runs out of piece (5) The O-ring has not been Follow instructions given on page 12. when loading is being carried out lubricated on the packing gland at the start.
  • Page 27 6 A. The machine is delivered with the above-mentioned values and calibrations performed in factory. TECHNOGEL S.p.A. IS NOT RESPONSIBLE FOR DAMAGES TO OBJECTS AND/OR PERSONNEL CAUSED BY MODIFICATIONS TO THE PRE-SET VALUES, OR FROM USING FUSES THAT HAVE INCORRECT CHARACTERISTICS AND SIZE, OR IN ANY...

  • Page 28: Electric System

    Electric system...
  • Page 29  Electric system...
  • Page 30  Electric system...
  • Page 31  Electric system...
  • Page 32  Electric system...
  • Page 33  Electric system...

  • Page 34: Spare Parts

     Spare parts The next few pages describe the various units comprising the 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   Pump unit FREEZER 200/1 CLAMP Pos. # of Part name FREEZER 200/1 Pieces Part number Pump casing FR1-29480.3 Pump piston FR1-2221-3/20 Pump “OR” gasket MX-0054 Hardened piston pin FR1-2220.0/11 Piston pin snap ring SEEI-14E Check valve seat FR1-5670.0 “OR”...
  • Page 36 Pump variator assembly with connecting rod...
  • Page 37  Speed variator with connecting rod components list Pos. Part name Part number Speed variator motor:  MO-0001 220/240 V 380/415 V - 50 Hz  FR3-0101/6 220/380 V - 60 Hz  FR3-0101/2B 200 V - 50/60 Hz Speed Variator RV-14556.6/10 Variator RV-20376.6...
  • Page 38  Dasher unit with packing gland and knives FR 200/1 Pos. Part name Part number Turbine casing FR1-3798.3/30 Cam shaft FR1-4518.3/10 Cam shaft coupling with guide bushing FR1-4471.3 Bushing lock snap ring FR1-3698.0/20 Ice cream scraping blade (6 pieces) FR1-10765.0 Movable stuffing box (spring + metallic part + rubber seal) FR3-0027 - spring only...
  • Page 39  Control panel unit - FREEZER 200/1 Pos. Name of component Code Complete RESET button CC-14382.6 Light for pushbutton 30 V 50/60 Hz CC-8574.6 Potentiometer OVERRUN Pushbutton: pump – dasher – compressor and hot gas CC-5719.6 Light for pushbutton 30 V 50/60 Hz...
  • Page 40 Refrigeration plant – FREEZER 200/1...
  • Page 41  COMPONENTS LIST FOR REFRIGERATING SYSTEM FREEZER 200/1 Pos. Part name FREEZER 200/1 Part Number Freezer tube FR1-5075.3 Refrigerating compressor: CP-25034.6 - DORIN V 220/380 50 Hz CP-25035.6 V 220/380 60 Hz V 200 50-60 Hz - COPELAND V 220/240 -380/415 50 Hz...
  • Page 42  Support unit with flange and ventilator Pos. Name of component Code Aluminium freezer holder support and support FR1-3719.0/10 Freezer pipe flange FR1-4480.3/10 O-ring for flange FR3-0037 Mixture inlet mouth seal R.013.32 Stainless steel protection flange FR1-3713.0 Complete support FR1-7257.4 Turbine drawing shaft FR1-1741.0/20 Oil protection rotating seal...
  • Page 43 Dasher drawing motor unit Pos. Name of component Code Belt tensioner screw Top belt tensioner disk Belt tensioner spring Bottom belt tensioner bush Stirrer motor 220/240-380/415 V 50 Hz MO-8301.6 220/380 60 Hz 60 Hz MO-8301.6 Pulley motor – 5 groove FR3-6253.0 Pulley locking disk FR3-6254.0...
  • Page 44 “Hot gas” valve unit Pos. Name of component Code Complete hot gas valve FR1-5158.3 Valve closing nipple FR1-5154.0/10 Washer RCU-0016 Front O-ring FR6-0062 Adjuster shaft FR1-5155.0 Rear O-ring FR6-0062 Hot gas valve body FR1-5158.3 Gravitational indicator FR3-0199 Adjustment knob with gravitational indicator FR1-3820.0 ...
  • Page 45 Ice-cream outlet faucet unit Pos. Name of component Code Complete ice-cream outlet faucet FR1-8134.4 Faucet closure threaded pin FR1-6219.3 Faucet body FR1-6218.3 DN40 Faucet locking device R-012.40 Spring pusher platelet FR1-3707.0/10 Spring FR1-3701.0/10 O-ring AV-00020 Faucet piston FR1-3708.0/21 O-ring AV-00060 DN40 washer R-013.40 Faucet seat T-connector...
  • Page 46 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).
  • Page 47 Spare parts forservofreezer Pos. Part name Part Number Stainless floating ball SF-012 Mixture inlet small piston seal gasket MP-0008 DN20 connection gasket TM-0006 DN25 MF throttle tap MW-00227/2...
  • Page 48 Pos. Part name Part Number Motor 0.75 hp 1400 r.p.m.220/240-380/415 V50 Hz MO-0008 220/380 V60 Hz DFA-0029/6 Pump stuffing box rotating part MW-0172 Stuffing box fixed part MW-0080 Fixed part “OR” gasket AV-00125 Rotating part “OR” gasket AV-00124 Complete stuffing box MW-00166 Pump cover “OR”...
  • Page 49 INDEX Introduction – Authorized personnel – Installation and initial startup of machine Instructions for unpacking the machine Instructions for lifting the machine - How to move the machine Positioning of different facilities Machine identification Electrical installation Connection of water supply Pneumatic connection –...

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