Soren CS 800 Instruction Manual

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Soren srl

Via Pacinotti 29

20094 Corsico, MI / Italia

tel +39 02 45177.1 r.a. fax +39 02 45177.340

Email: soren@soren.it

When requesting information about your machine always state: model of

•

the machine, serial n°, order n°.

Keep this manual in a safe place for future

•

REA/CCIAA: 856472/MI

Cap. soc. € 832.000 i.v.

C.f./Iva 01720330156

INSTRUCTION MANUAL

FREEZER

Model : CS 800 (R404A)

Serial Number : F0176-00

ORDER : 0007

CUSTOMER : ALFRED & CO. LTD

•

GREAT BRITAIN

FACTORY

: Same

•

CUSTOMER ORDER : J5344 of 05-Jan-00

•

SOREN ORDER CONFIRMATION : L0005 of 10-Jan-00

•

DELIVERY : March 2000

•

FOR

reference..

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Page 1 GREAT BRITAIN FACTORY : Same • CUSTOMER ORDER : J5344 of 05-Jan-00 • SOREN ORDER CONFIRMATION : L0005 of 10-Jan-00 • DELIVERY : March 2000 • When requesting information about your machine always state: model of • the machine, serial n°, order n°.
Page 2 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO INDEX INTRODUCTION DECLARATION OF CONFORMITY CE 1. STANDARD WARRANTY 2. IDENTIFICATION OF THE MACHINE 3. SAFETY General safety information Safety first Operating zone Installation Safety inspection...
Page 3 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 10.2. Recommendation about cleaning 10.3. Circulation cleaning - C.I.P 11. MANTENANCE 11.1. Pump maintenance 11.2. Rotary pump problems 11.3. Scraper blade maintenance 11.4. Compressed air system...
Page 4 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO INTRODUCTION The purpose of this manual is to provide instructions for tha safe installation, operation and maintenance of your SOREN equipment. SOREN is committed to provide quality equipment and customer satisfaction.
Page 5: Declaration Of Conformity
Machine : FREEZER FOR CONTINUOUS ICE CREAM PRODUCTION Model : CS 800 Serial n° : F0176-00 Has been manufactured in accordance with the stipulations of the COUNCIL DIRECTIVE of the 14th June...
Page 6: Standard Warranty
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO STANDARD WARRANTY ♦ Obligations of Seller (SOREN): during the warranty period, Seller shall repair or, at Seller's option, replace parts determined by Seller to be defective in material or workmanship.
Page 7: Identification Of The Machine
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 2. IDENTIFICATION OF THE MACHINE SOREN freezers are machines for continuous ice cream production starting from ice cream mix at 4°C by refrigeration and adjustable air injection. They are...
Page 8: General Safety Information
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 3. SAFETY 3.1. GENERAL SAFETY INFORMATION The following information provides specific information on hazardous conditions which are inherent in the Continuous Ice Cream Freezer. The SOREN Continuous Ice Cream Freezer is a mechanical freezing machine which by the very nature of its design creates certain unavoidable hazards.
Page 9: Installation
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO device, the proper and safe performance of this equipment depends upon using sound and prudent operating, maintenance and servicing procedures under properly trained supervision. For your protection, and the protection of others, learn and always follow the safety rules outlined in this booklet 3.3.
Page 10: Service And Maintenance Safety
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO • Do not start the machine untill all other personnel in the area have been warned and have moved outside the operating zone. • Remove any tools or other foreign objects from the operating zone before starting.
Page 11: Electrical Hazard
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO Do not enter a confined space without first checking for toxic fumes and providing standby personnel on the site. 3.8. ELECTRICAL HAZARD DANGER ! The Continous Ice Cream Freezer is normally powered by electric motor(s) and has many other electronic controls and devices.
Page 12: Mechanical Hazard
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 3.9. MECHANICAL HAZARD DANGER ! The Continuous Ice Cream Freezer has mechanical components which operate the dasher(s) and pumps (belts, pulleys, couplings). These components are guarded and/or enclosed.
Page 13 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO - Performing any maintenance or service on the motor(s). - Removing the front door. - Disassembling the pump cover or rotors - Assembling or disassembling the dasher SCRAPER BLADES The scraper blades assembled on the dasher must be sharp to work correctly.
Page 14 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO Compressed air creates certain unavoidable hazards. Compressed air may retain the power to move objects even after the supply is turned off. Air operated mechanical devices may operate unexpectedly from a remote control signal.
Page 15 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO • Turn off air and electrical power prior to cleaning a machine. • Equip all personnel using cleaning/sanitizing solutions with protective clothing, including eye protection.
Page 16 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO • The refrigeration installation must be performed only by pipefitters trained and authorized for halocarbon refrigeration systems. • Maintenance and service of the refrigeration system must be performed only by trained and authorized service personnel.
Page 17 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO SAFETY 3.15. SAFETY LABELS...
Page 18 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO SAFETY SAFETY LABELS...
Page 19 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO . FORESEEN AND NOT FORESEEN USES OF MACHINE WARNING This machine is designed to produce ice cream to be packed in different ways (cups, cones, bulk, etc.). The SOREN freezer can also be used to cool liquid food products containing at least 1-2% of fat.
Page 20: Purpose Of The Machine
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 5. DESCRIPTION OF THE MACHINE AND SPECIFICATIONS 5.1. PURPOSE OF THE MACHINE CS “freezers” are machines for contiunuos ice cream production by dosing, mixing and refrigerating ice cream mix and air.
Page 21: Specifications
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO • To ensure a sufficient flow of detergent liquid during the CIP cycle, it is necessary to by-pass the feed plunger pump or rotor of the rotary pump/s either manually or using the pneumatic device on the pump front cover (vented cover).
Page 22: Dimension And Weight
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO DESCRIPTION OF THE MACCHINE AND SPECIFICATIONS DIMENSION AND WEIGHT DIMENSIONS TYPE CS 100 CS 200 R404 A R404 A 1200 1400 1970 K (water) SHIPPING DATA...
Page 23 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO DESCRIPTION OF THE MACCHINE AND SPECIFICATIONS DIMENSION AND WEIGHT DIMENSIONS TYPE CS 400 CS 800 CS 1100 R404 A AMMONIA R404 A AMMONIA R404 A...
Page 24: Freezer Features
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO DESCRIPTION OF THE MACCHINE AND SPECIFICATIONS POWER SOURCES AND UTILITIES REQUIRED • Electrical power: 3 x 230 V 60 Hz • Sanitary compressed air: 7 bar •...
Page 25 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 13-nov-97 CS ICE CREAM FREEZERS CS100 CS200 CS400 CS800 CS1100 CS1500 FEATURES OUTPUT ICE CREAM (min-max) 20-100 40-200 80-400 140-780 200-1060 300-1500 REFRIGERATING POWER 4.400 9.810...
Page 26: Machine Noise Emission
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 6. MACHINE NOISE EMISSION Noise sources of the machine are: dasher motor ♦ pump motor ♦ Refrigerating compressor ♦ Measurements made on freezer CS have given the following results: Machine with built in refrigerating compressor: •...
Page 27: Important Cautions
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 7. IMPORTANT CAUTIONS The following important cautions describe ways to avoid incorrect operating procedures which will cause serious damage to the FREEZER. 7.1 PROTECT CHROME CYLINDER The inside surface of the freezing cylinder is chrome plated.
Page 28 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO • Do not use any type of acid sanitizer. Acid attacks chrome. 7.4. PREVENT PUMP DAMAGE WARNING ! Incorrect operating procedures may cause damage or rapid wear to pump parts, especially the rotors and shafts.
Page 29: Installation And Assembly
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 8. INSTALLATION AND ASSEMBLY 8.1. RECEIVING AND INSPECTION SOREN equipment is run tested and inspected prior to shipment. When leaving the factory, it is well crated for normal transportation procedures.
Page 30 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO WARNING ! If the lifting equipment slips or breaks, severe injury may result. Make sure lifting equipment is rated for the weight of the unit. Only trained personnel should operate the lifting equipment.
Page 31 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO • Press forward with the right thumb while lifting the right end of the blade up and away from the dasher. Step 2 When the Scraper blade is properly assembled, the stamped letter “T”...
Page 32: Operation
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 9. OPERATION 9.1. UNIT PREPARATION Before pre start-up procedures disassemble the freezer and clean carefully all product contact surfaces (see 10.1 “FIRST CLEANING OF THE MACHINE”) 9.2.
Page 33 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 9.3. PRODUCTION 9.3.1. START-UP PROCEDURE (see “FRONT PANEL”) • Turn on the main power switch (pos. 32), push the reset button (pos. 31) and wait at least four hours before starting to allow the electric heater inside the compressor warm up the oil.
Page 34 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO • When the dasher motor load indicator reaches the first pre-set sensing level (set at 100% of the motor load) an alarm bell is sounded and the hot gas valve will automatically open.
Page 35: Front Panel
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO OPERATION : FRONT PANEL...
Page 36: Back Panel
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO OPERATION : BACK PANEL...
Page 37 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO OPERATION FRONT PANEL pos. description Pumps P0-P1 / stop Dasher D2 / stop Pumps P0-P1 / start Dasher 2 / start Pump P1 inverter / alarm...
Page 38 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 9.3.2. OVERRUN SETTING & ADJUSTMENTS For setting up or adjusting the desired overrun, please follow the instructions given below. • Press the key "w" ( pos.7 ) one time. If you have inadvertently...
Page 39 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 9.3.3. CYLINDER PRESSURE SETTING & ADJUSTMENT For setting up or adjusting the desired inner cylinder pressure (in bar) please follow the instructions given below. •...
Page 40 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 9.3.4. VISCOSITY SETTING & ADJUSTMENT For setting up or adjusting the desired viscosity of the ice cream (represented by the % of dasher motor load) please follow the instructions given below.
Page 41 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 9.3.5. STOPPING AND RESTARTING MACHINE DURING PRODUCTION Stopping • Stop refrigeration ( pos.16). • Stop pump ( pos. 1) and booster pump if used. • Stop dasher if shut-down is to be longer than 10 minutes ( pos. 2 ).
Page 42 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 9.3.7. DETERMING THE OVERRUN FACTOR To determine the overrun factor in a product, use the following formula: weight of a given volume of starting product ice cream mix minus the weight of the same volume of a finished product divided by the weight of this same volume of the finished product.
Page 43 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 9.4 OVERRUN TABLE - Metric Weight in grams of finished product Overrun percent for various densities in various sized container (grams/litres) of mix (product) input...
Page 44 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 9.5. OPERATION PROBLEM SOLVING Product too soft • Liquid refrigerant filter clogged. • Liquid refrigerant pressure too low. • No liquid refrigerant available. • Scraper blades need reconditioning.
Page 45: First Cleaning
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 1010. CLEANING AND SANITIZING DANGER ! The use of water around electronic equipment enclosures creates a hazard of electric shock which could cause severe injury or loss of life.
Page 46 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO - freezing cylinder rear door; - rotary pumps, covers, rotors, bodies. • Scrub the interior surfaces of the cylinder and all the removed product contact parts, using a brush and detergent until completely clean.
Page 47 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO WARNING ! In case the machine or part of product circuit, have been disassembled, before starting CIP operations, make sure that all parts have been correctly tightened.
Page 48 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 10.3.4. RINSE The purpose of this step is to rince the system clear of the chemical solution and removed soil. Use water at 50 -60°C: At the start of this step, route the return into the cleaning solution tank to recover the solution remaining in the system.
Page 49: Maintenance
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO 11. MAINTENANCE 11.1. ROTARY PUMPS MAINTENANCE ROLLER BEARING ADJUSTMENT Test for loose shaft roller bearings by gripping the rotor shafts firmly and attempting to move in various directions while the pump is disassembled. If the bearing show looseness by a "chucking"...
Page 50 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO SHAFT SEALS REPLACEMENT Shaft seals should be replaced monthly or when leaking occurs. • Remove worn shaft seal. • Check seal bearing and "O" rings for wear; replace if necessary.
Page 51 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO ROTORS Removal • Remove all product and mix piping from the rotary pump (1). • Remove the front cover from the pump chamber. • Remove the pump chamber (3) and the rotor (4).
Page 52 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO With the rotors removed, inspect the shafts for visible signs of wear. Installation CAUTION ! Install or assemble rotor onto shaft by hand, using caution to assemble so that dimple (match mark) on rotor corresponds with dimple (match mark) on shaft.
Page 53 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO • Seals improperly installed. EXCESSIVE BEARING WEAR • Oil contamination. • Operating at excessive pressure and at excessive speeds. • Improper bearing adjustment OIL CONTAMINATION •...
Page 54 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO • Loose bearings. • Excessive wear on shaft at contact with oil seal. • Improper oil seal installation. EXCESSIVE SHAFT WEAR AT CONTACT WITH OIL SEAL •...
Page 55 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO Dasher: the dasher assembly is heavy. This creates a hazard of severe injury for anyone handling it incorrectly. Provide enough workers or mechanical lifting assistance to enable removing, installing and servicing the dasher safely.
Page 56 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO GENERAL INFORMATION • Scraper blade are extremely hard and therefore subject to nicks when mishandled. • Blades are designed to give maximum service. Wear depends on operating conditions.
Page 57: Compressed Air System
INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO SPECIAL CLEANING INSTRUCTIONS DANGER ! ! Scraper blades can be very sharp and cause severe injury if not handled properly: use protective gloves. • he scraper blades are made from high quality hardened stainless steel.
Page 58 INSTRUCTION AND SERVICE PARTS MANUAL - FREEZER CS 800, s/n F0176-00 - ALFRED & CO Relief safety valve Weekly check the discharge pipe: in case there are product residuals, these indicate that the valve has intervened due to the defective operation of the injection valve: in this case proceed as it has been specified in the paragraph “Air injection valve”.
Page 63 FREEZER CS 800 RE : SPARE PARTS RECOMMENDED FOR 1 YEAR OR 2000 HOURS OF OPERATION DASHER & DOOR COMPONENTS Pos. Q.ty Description A4335-10 O RING X SCHIUMAT OLIO FREON adjustable take off oil bleed A4335-07 O RING X SCHIUMAT OLIO FREON...

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R404a