Page 1
MOD : PCT/10-35WT Production code : PASTOGEL T 3-6 WATER 12 /2023...
Page 2
Operating and maintenance manual Operating and maintenance manual PCT 10-35 T - PCT 20-60 T PCT 10-35 T - PCT 20-60 T Translation of the original instructions...
Page 4
All of the staff at DIAMOND and its dealers hope that you will enjoy working with our machines! This operating and maintenance manual is part of the machine and must always be kept with it, even...
CONTENTS 1 GENERAL INFORMATION 1.1 General safety instructions 1.2 Information about precautions, specific warnings and symbols 1.3 Testing, guarantee and liability 1.4 Purpose of the manual • 1.4.1 Structure of the manual • 1.4.2 Modifications and additions 1.5 Manufacturer identification •...
Page 6
Introduction Contents 5 STARTING THE MACHINE AND USING THE PROGRAMS SET 5.1 Setting the language and temperature unit of measurement 5.2 Machine programs reset 5.3 Starting the machine 5.4 List of programs set 5.5 Managing the heating and cooling system 5.6 Example of program set 5.7 Starting the program 5.8 Modifying parameters and phases of the programs set...
Chapter 1 General Information 1 GENERAL INFORMATION 1.1 General safety instructions Before using the machine, carefully read this manual, which is an integral part of the machine. Knowing the information and instructions in this manual is essential for operators to use the machine correctly and safely. The manufacturer declines all responsibility in the event of modifications, tampering or any operations that may put the health and safety of people and/or objects at risk, carried out in a way that does not coincide with what is specified in this manual.
Guarantee DIAMOND guarantees the machines put on the market for 12 months from the date of delivery. During the guarantee period the manufacturer undertakes to substitute, free of charge ex works, any parts which may develop a fault due to obvious manufacturing defects or poor quality materials.
DIAMOND reserves the right, should it deem it appropriate and for valid reasons, to update the manuals already on the mar- ket, sending its customers sheets of technical and/or operating updates which must be considered and kept in the manual.
1.5.2 Ordering spare parts When requesting spare parts, contact your dealer or consult the up-to-date list of authorised service centres on the official DIAMOND S.A. : https://www.diamond-eu.com/ 1.6 Machine identification data - CE marking The data plate with CE marking is located at the top of the machine rear panel and shows all of the data needed for ma- chine identification.
Chapter 1 General Information 1.7 Intended uses The PCT T range of machines are designed for: 1. Mixing and heating/cooking ingredients or pre-packaged foods placed inside the machine cylinder. 2. Chilling, churning and freezing the ingredients processed for making gelato, creams, jams, sauces, granita and sorbet. This processing takes place in a vertical cylinder using a mixer and retaining paddle supplied with the machine.
1.8 Information for personnel authorised to use the machine This manual contains the information needed by authorised personnel to correctly use the machine. A knowledge of and compliance with the general safety instructions and danger warnings contained in this manual are the conditions for proceeding, in minimal risk conditions, with installation, putting into service, operating and routine mainte- nance of the machine.
Chapter 2 Technical Specifications 1.9.1 Transportation, lifting and handling THE PACKAGE MUST ONLY BE HANDLED BY QUALIFIED TECHNICAL PERSONNEL. When the machine is delivered, check that during transportation in addition to visible damage no other damage was caused which could compromise correct operation. On the delivery note, write “Subject to approval” to show that acceptance of the machine is subject to checks.
2 TECHNICAL SPECIFICATIONS 2.1 General description of the machine The machines in the PCT T range covered by this manual are multi-function combined machines for mixing, pasteurising, churning and freezing various ingredients such as: milk, cream, flour, fruit, sugar, eggs, etc. necessary for making gelato and ice cream, creams, jams, sauces, granita and sorbet.
2.2 Illustration of the machine as a whole and its components Shower unit for washing the cylinder (optional) Cover Cylinder Mixer Retaining paddle Touch-screen Extraction door Extraction door lever Extraction door chute Rear wheels Basin support Front wheels with brake Outer panels Connector for inflow of condensation water (water version machines) Connector for outflow of condensation water (water version machines)
2.3 Working and control position The operator must stand in front of the machine and load the ingredients, programme the recipe, start the processing and unload the processed product at the end of the recipe. 2.4 Machine technical data Model PCT 10-35 T PCT 20-60 T Net weight...
Page 20
Chapter 2 Technical Specifications PCT/10-35 T PCT/20-60 T Model PCT 10-35 T PCT 20-60 T Dimensions L (mm) D (mm) H (mm) 1100 1150 H2 (mm) D2 (mm) For air version E (mm) For water version E (mm) RATED POWER / RATED CURRENT Power supply voltage (Volts) Frequency (Hz) Phases...
2.5 Noise The machine is designed and built to conform to the requirements of the regulations in force. The A-weighted sound pressure level at the working positions does not exceed 70 dB (A). The C-weighted instantaneous peak sound pressure level at the working positions does not exceed 63 Pa (130 dB re 20 µPa). Test documents and certificates for the instruments used for the measurements are filed at te manufacturer and are avail- able to monitoring authorities.
Page 22
Chapter 3 Safety regulations Every day, check that all safety devices on the machine are operating correctly (see sections 3.2 and 8.5 of this man- ual). Safety devices must not be removed or bypassed for any reason. Any tampering with or modification of the machine not authorised in advance by the manufacturer shall release the manufacturer from any responsibility for injury/damage to people and/or objects.
3.2 Safety devices present on the machine The term safety device refers to: “a component specially designed by the manufacturer and also sold separately from the machine in order to be able to perform safety functions. Therefore, a safety component will be considered a device whose failure to function compromises the safety of exposed persons.
Chapter 3 Safety regulations 3.2.3 Safety symbols and stickers On the machine there are symbols/stickers for highlighting: what you must not do, important information and warnings: This symbol indicates the presence of an electric shock hazard. It indicates to the relevant personnel that they risk an electric shock if they do not work in compliance with safety regulations.
3.3 Personal Protective Equipment (PPE) The employer must inform personnel about the following safety-related issues: 1 Accident risks. 2 Operator safety equipment. 3 General accident-prevention rules envisaged by the regulations in place in the country for which the machine is intended. The operator must always: 1.
Chapter 4 Installation 4 INSTALLATION INSTRUCTIONS 4.1 General requirements INSTALLATION MUST ONLY BE PERFORMED BY QUALIFIED TECHNICAL PERSONNEL. Once the package is near to the machine installation location, cut the straps (A) and remove the cardboard (B) by pushing it upwards.
4.3 Spaces needed for use of the machine The machine must be positioned on a solid, level and even floor. It must not be directly exposed to sunlight or near to heat sources. Keep the machine air inlets clear to allow adequate air cir- culation around it.
Chapter 4 Installation 4.4.1 Assembling the shower unit Water version machine – Place the bracket (A) on the back of the machine approx. 6 cm from the outer edge and secure it with the screws supplied (B). – Insert the tap (1) in the hole in the bracket (A), making sure that the upper and lower washers (2) adhere to the bracket.
4.5 Electricity supply WORK ON ELECTRICAL CONNECTIONS MUST ONLY BE CARRIED OUT BY QUALIFIED TECHNICAL PERSONNEL. The machine must be powered at the voltage shown on the data plate at the top of the rear panel. The machine is supplied with a power cable to which a qualified technician must connect a plug suitable for the technical data (voltage, current) on the data plate.
Chapter 4 Installation 4.6 Water-cooled machine For machines with a water-cooled condenser, a water supply tube and a water drainage tube have to be fitted. Connect a valve or tap (1) before the delivery tube. The threaded connectors are on the back of the machine, in the lower area. Each connector is marked with a label indicating its purpose, as below: A.
4.7 Air-cooled machine Air-cooled machines must be installed with a minimum distance from the rear wall of at least 500 mm to allow free circulation of condensation air. Every day, clean the area around the machine to prevent foreign bodies (for example: build-up of dust, bits of paper, etc.) from blocking the regular inflow of air.
Chapter 5 Using the machine 5 STARTING THE MACHINE AND USING THE PROGRAMS SET 5.1 Setting the language and temperature unit of measurement Home page, press the screen to continue. Select "SETTINGS". Select "General operating parameters settings". Press "Language selection". Use the arrows to select the desired language.
Page 33
Press the icon to confirm the desired language. Press the icon to return to the previous screen page. Use the arrows to display the "Unit of measurement selection" parameter. Press "Unit of measurement selection". Select the desired Unit of measurement. Press the confirm icon.
Chapter 5 Using the machine 5.2 Machine programs reset Select "Extra". Press "Program data reset". Press "Start" to restore the factory data in the programs. Wait until the Reset is complete. To return to the previous screen pages press the "Back" icon.
5.3 Starting the machine Press "START PROGRAM" to select the programs. Use the arrows to select the desired program. Icons legend: Buzzer Program Start Configuration menu, for modifying parameters and STOP, program stop control phases set in the program Machine switch ON / OFF Mixer clockwise rotation in manual mode Mixer anti-clockwise rotation in manual mode Selection arrows...
Chapter 5 Using the machine 5.4 List of programs set The following programs are saved in the machine: GELATO HOT COLD +85°C -8°C GELATO HOT COLD +65°C -8°C GELATO HOT COLD +92°C -8°C GELATO -8°C GELATO -9°C GELATO -10°C SORBET -7°C GELATO MIX PASTEURIZATION +85°C +4°C FRUIT SYRUP +65°C +5°C CRÈME PÂTISSIÈRE...
5.5 Managing the heating and cooling system The machine manages the heating and cooling system independently, based on the operating temperature set. The heating is started automatically when the operating temperature set in the first phase is higher than the product temperature measured in the cylinder, or when the operating temperature set in one phase is higher than the product temperature in the previous phase.
Chapter 5 Using the machine 5.6 Example of program set In "Program 1" there are 4 phases configured. PHASE 1: Heating the mix to +85 °C. PHASE 2: Cooling to -8 °C. PHASE 3: Extraction at 190 rpm. PHASE 4: Second extraction at 240 rpm.
5.7 Starting the program Press the icon to start the program. Heating the mix to +85 °C (PHASE 1). Cooling the mix to -8 ° C (PHASE 2). At the end of the cooling cycle, press the flashing extraction icon to unload the product.
Page 40
Chapter 5 Using the machine Press the flashing extraction icon to start the second extraction for unloading remaining product. The extraction icon turns green and the direction of rotation of the mixer is inverted, with a speed of rotation of 240 rpm (PHASE 4).
5.8 Modifying parameters and phases of the programs set Premere il "Menu di configurazione". Press the "Configuration menu". Selezionare "IMPOSTAZIONI". Select "SETTINGS". Selezionare "Parametri di lavoro". Select "Operating parameters". Each Program is made up of "Phases". In each "Phase" it is possible to set parameters such as: - TYPE OF PHASE OPERATION - TYPE OF MIXER OPERATION - BUZZER...
Chapter 5 Using the machine 5.8.1 Type of operation of the phase Select the "Operating temperature" parameter. Use the arrows to select the type of operation of the Phase: - "Operating time" - "Operating temperature" - "Preservation" (*) - "Product extraction" (*) (*) The preservation and the extraction can be set only in the phases at the end of the working cycle.
Page 43
If you select "Preservation", you can only set the "type of mixer operation" and the "product maintaining temperature delta". Press the confirm icon. Set the relative parameters by selecting the boxes for the type of mixer operation and the product maintaining temperature delta.
Chapter 5 Using the machine 5.8.2 Type of mixer operation Select the "Type of Mixer operation" parameter. Possible choices: Continuous anti-clockwise mixing Continuous clockwise mixing Intermittent anti-clockwise mixing Intermittent clockwise mixing Alternate mixing with pause Alternate mixing No mixing Continuous clockwise mixing Select the speed of rotation box and use the arrows to set the desired value.
Page 45
Intermittent anti-clockwise mixing Select the boxes and use the arrows to set the desired values. The speed of rotation adjustment range is 0 to 250 rpm. The mixing time and pause time adjustment range is between 0 and 1250 seconds. Press the confirm icon.
Chapter 5 Using the machine 5.8.3 Buzzer Select "Buzzer". The buzzer can be set for both of these phases: "Operating time" "Operating temperature". Press the "Buzzer" icon, then use the arrows to select Buzzer On. Press the buzzer duration box to set the value. Use the arrows to set the desired value.
5.8.4 Product maintaining temperature delta in the phase Select "Product maintaining temperature delta in the phase". The Delta is the temperature range within which the compressor will be switched on or off to return the temperature to the value set. Press the temperature value box.
Chapter 5 Using the machine 5.8.5 Compressor configuration Select "Compressor configuration". Use the arrows to select the type of cooling: Continuous compressor Intermittent compressor, with settable operating and pause times No compressor If you select "Continuous compressor", the machine compressor is activated in continuous mode. Press the confirm icon.
5.8.6 Add or delete a phase Select the "Configuration menu". NOTE:: Use the "yellow navigation arrows" to move to the various phases set in the program. From the "Configuration menu", for every phase set, you can: Add a phase BEFORE Add a phase AFTER Delete a phase Select the desired option and press the confirm icon.
Chapter 5 Using the machine 5.9 Configuring a free program Press "START PROGRAM" to select the programs. Use the arrows to display the "FREE PROGRAM" (Position 19). Press the "Configuration menu". Select "SETTINGS". Select "Name".
Page 51
Select the "FREE PROGRAM" text box and change the Name. Enter the desired Name using the keyboard (e.g.: "WHITE BASE MIX"). Press the confirm icon. Select "Operating parameters". The screen page for the new phase added is displayed, with the operating parameters to be set: Type of operation of the phase Type of mixer operation Buzzer...
Chapter 5 Using the machine 5.10 Adding a new program Press "START PROGRAM" to select the programs. Use the arrows to display the "FREE PROGRAM" (Position 19). Press the "Configuration menu". In addition to the "SETTINGS" icon, you will see these icons: Add Program BEFORE...
Page 53
Press the confirm icon to confirm the addition of a new program. Use the arrows to display the new FREE PROGRAM added. (Position 22). Press the "Configuration menu". The screen page with these icons appears: - SETTINGS for entering the name and operating parameters of the new FREE PROGRAM - Add Program BEFORE...
Chapter 5 Using the machine 5.11 Modifying parameters with program started Changes made to parameter values, once the program has started, are temporary and will not be saved. When the program restarts, the parameters will return to the original setting. For example, "Program 1"...
Page 55
PHASE 2 Select the "Operating temperature" value box. Use the arrows to modify the value. Select the "Mixer speed of rotation" box. Use the arrows to modify the value.
Page 56
Chapter 5 Using the machine PHASE 3 Select the box for "Mixer speed of rotation" in the product extraction phase. Use the arrows to modify the value. PHASE 4 Select the box for "Mixer speed of rotation" in the second product extraction phase. Use the arrows to modify the value.
5.12 Production EVERY DAY, WHEN YOU SWITCH ON THE MACHINE, CHECK THAT THE SAFETY DEVICES ARE OPERATING CORRECTLY AS DESCRIBED IN DETAIL IN SECTION 7.5 OF THIS MANUAL. Connect the machine power cable to a socket and check that the screen is on. Press the machine screen to prepare it for operation.
Page 58
Chapter 5 Using the machine – By pressing the arrow symbols you can select one of the programs al- ready in the memory, or use the free programs to customise a recipe of your own. – When you have selected the desired program and added the ingredi- ents in the cylinder simply touch the “START"...
6 WASHING 6.1 Rinse or complete wash When switching from one production cycle to another, a simple rinse or a “complete” wash may be needed, depending on the ingredients or the types of mixes used. The washing methods can be summarised as follows: 1) No washing: for recipes using products that are com- patible with each other, with no fats and strong flavours THERE IS NO NEED FOR WASHING between one...
Page 60
Chapter 6 Washing – Check that the extraction door is closed, open the machine cover (A) and pour in a solution of hot water at 50° C and de- tergent until the cylinder is ½ full. Use a highly effective, neutral detergent. It should be a professional grade detergent specifically for the food sector.
6.2 End of day washing and sanitising Sanitising includes all of those activities intended to make the inner surface of the cylinder and the removable components that come into contact with foods hygienic. Aims of sanitising: To remove all traces of product residues To reduce the microbial load without leaving chemical residues of the products used on the surface treated.
Page 62
Chapter 6 Washing 2. Washing with detergent phase: Before thoroughly washing with detergent, remove all components installed on the machine as follows: a) Removing components: • Removing the cover – Pull the fixing pin (1) out of the block horizontally and remove the cover (2).
Page 63
b) Washing with detergent: For the washing use a highly effective, neutral detergent. It should be a professional grade detergent specifically for the food sector. Do not use products which cause oxidation or corrosion, or which are too alkaline or acidic. The doses used and contact times must com- ply with the instructions on the detergent label.
Page 64
Chapter 6 Washing 3. Rinsing phase to remove detergent: After washing with detergent, a thorough rinse of the processing cylinder with cold water is needed to completely remove any detergent residues still present in it. - Position the special water collecting basin (A) under the prod- uct extraction door chute and use a container of water (C) or the shower (optional) to rinse the cylinder.
Page 65
c) Refitting the components: After washing, re-fit all of the machine components as described below: • Re-fitting the mixer scrapers - Re-fit the side scrapers (11) by fitting them onto the pins (20) on the mixer. - Fit the mixer’s lower scraper (13) in its seat. •...
Page 66
Chapter 6 Washing • Re-fitting the extraction door chute - Insert the extraction door chute gasket (16) in its seat. - Position the chute (15) below the extraction door and secure it by tightening the clamp screws (14) to the front panel. TIGHTEN THE FIXING SCREWS, CHECKING THAT THERE IS NO PLAY IN THE CHUTE.
Page 67
5. Rinse to remove disinfectant phase: Follow the instructions on the disinfectant packaging and if necessary thoroughly rinse the machine to completely remove disinfectant residues. - Position the special water collecting basin (A) under the product extraction door chute, open the cover (B) and use a container of water (C) or the shower (optional) to rinse the cylinder.
Chapter 7 Maintenance 7 ROUTINE MAINTENANCE ONLY PURCHASE AND USE ORIGINAL SPARE PARTS, WHICH ARE GUARANTEED BY THE MANU- FACTURER. CONTACT THE DEALER OR THE NEAREST SERVICE CENTRE TO REPLACE FAULTY OR DAMAGED COMPONENTS. 7.1 Type of checks and interval between them Regular checks of the operation of the parts of the machine most subject to stresses and wear can prevent faults and help to maintain maximum productivity levels, guaranteeing lasting constant operation.
7.4 Maintenance sheets Substitution of scrapers installed on mixer CHECKING INTERVAL: 500 hours or quarterly AUTHORISED OPERATOR: 1 Operator TIME NEEDED: 15 minutes TOOL: Tool supplied Optimum scraping of the cylinder allows good machine performance and product quality. Substitute the mixer scrapers when they show signs of wear which are obvious when looking at their scraping profiles and also indicated by the formation of streaks of product residue on the surface of the cylinder.
Page 70
Chapter 7 Maintenance Replacing the gaskets CHECKING INTERVAL: 500 hours or quarterly AUTHORISED OPERATOR: 1 Operator TIME NEEDED: 5 minutes TOOL: Non-metallic pointed tool ! - Regularly check the integrity of the gaskets and substitute them if they are broken, worn or swollen. ! - Only use original gaskets, made of food-safe rubber.
Page 71
Replacing the mixer guide bushing CHECKING INTERVAL: 500 hours or quarterly AUTHORISED OPERATOR: 1 Operator TIME NEEDED: 5 minutes TOOL: - - Periodically check that the mixer guide bushing is intact and replace it if damaged or worn. - Only use original spare parts. Replace the bushing for the mixer component drive when there are signs of wear.
Chapter 8 Troubleshooting 7.5 Checks on safety devices Safety devices CHECKING INTERVAL: DAILY (AT MACHINE SWITCH ON) AUTHORISED OPERATOR: 1 Operator TIME NEEDED: 5 minutes TOOL: - DO NOT USE THE MACHINE IF ONE OR MORE SAFETY DEVICES MALFUNCTION OR ARE DAMAGED! 7.5.1 Checking the safety device installed on the cover Checking procedure: Phase 1...
8 TROUBLESHOOTING Most faults and problems during machine operation are promptly automatically indicated by the machine. ALARMS STOP THE MACHINE, WITH AN EMERGENCY STOP MESSAGE DISPLAYED ON THE CON- TROL PANEL. TO RESTART THE MACHINE, YOU MUST ELIMINATE THE CAUSE OF THE EMERGENCY. People involved in troubleshooting: Operator: person trained in the ordinary operation of the machine who performs initial fault-finding and if...
8.2 Troubleshooting – flowchart In abnormal conditions the machine may malfunction, as specified below: MACHINE DOES NOT OPERATE OR OPERATION IS INTERRUPTED THE TOUCH-SCREEN DOES NOT COME ON OR IT SUDDENLY SWITCHES OFF. The plug is not inserted in the sock- Insert it correctly.
Page 80
Chapter 8 Troubleshooting MACHINE REPEATEDLY TRIPS THE ELECTRIC OVERLOAD SWITCHES OR BLOWS THE MAINS FUSES. Contact the Technical assistance The capacity of the electrical sys- service. tem is not sufficient to power the machine. The electrical specifications of the Contact the Technical assistance overload switches or fuses are service.
Page 81
UNUSUAL NOISE The fixing knob for the movable Check the condition of the gasket (sub- paddle (if present) has worked stitute it if necessary) and tighten the loose. knob again. The mixer and/or the cylinder Stop the machine and wait a few min- have been subjected to a jump utes until normal operating condi- in temperature, which caused...
Page 82
Chapter 8 Troubleshooting COOLING IS INSUFFICIENT OR SWITCHES OFF IN A FAULTY WAY AIR-cooled machine Contact the Technical assistance The air condenser fan is faulty. service. Contact the Technical assistance Fault in the refrigerating system or service. control electronics Contact the technical assistance service COOLING IS INSUFFICIENT OR SWITCHES OFF IN A FAULTY WAY WATER-cooled machine...
Page 83
COOLING IS INSUFFICIENT OR SWITCHES OFF IN A FAULTY WAY WATER-cooled machine Contact the Technical assistance The water pressure switch valve service. needs adjusting again, or it is faulty. The temperature of the water fed Contact the Technical assistance in is higher than that indicated in service.
9 INACTIVITY 9.1 Keeping the machine efficient if it remains inactive If the machine will not be used for a lengthy period, follow these instructions: Sanitise the machine as described in sec. 6.1. Switch off the machine using the I/O - ON/OFF icon, power down at the mains master switch and take the plug out of the socket.
10 DECOMMISSIONING THE MACHINE 10.1 Description of method of disposal The lifetime of the machine estimated by the manufacturer is 20,000 hours (10 years) of operation under normal operating conditions, described in this operating manual. At the end of its lifetime the machine must be disposed of in accordance with the regulations in force in the country where it was used, concerning the disposal of waste electrical and electronic equipment.
Page 86
INFORMATION FOR USERS In accordance with Directives 2011/65/EU and 2012/19/EU and subsequent amendments and additions, on the restriction of the use of certain hazardous substances in electrical and electronic equipment (EEE) and waste electrical and electronic equipment (WEEE), we hereby inform you that: “the crossed bin symbol on the device or on its packaging indicates that, at the end of its life, the product must be disposed of separately from other waste”.
Need help?
Do you have a question about the PCT/10-35WT and is the answer not in the manual?
Questions and answers