Diamond TGV/5D-N Operating And Maintenance Manual
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Diamond TGV/5D-N Operating And Maintenance Manual

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03/2019
Mod: TGV/5D-N
Production code: PRATICA 9-12 AIR-(400/50/3)

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Summary of Contents for Diamond TGV/5D-N

  • Page 1 03/2019 Mod: TGV/5D-N Production code: PRATICA 9-12 AIR-(400/50/3)
  • Page 2 Operating and maintenance manual TGV / 5D - N 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...

  • Page 5: Table Of Contents

    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 MACHINE OPERATION 5.1 Controls 5.2 Switching on and starting the machine 5.3. Programming • 5.3.1 Adjusting the temperature-based cycle (P1) • 5.3.2 Adjusting the time-based cycle (P2) • 5.3.3 Adjusting the buzzer (P3) • 5.3.4 Adjusting the granita program (P4) 5.4 Temperature-based cycle production •...
  • Page 7 Declaration of Conformity (according to 2006/42/EC, Annex II, No.1 A) Supplier:........... Address:....................... Tel:............ Fax:........... We hereby declare that the Gelato reezer Type of machine TGV / 5D - N Name of the model Year of production Serial number FULFILS All relevant provisions of Directive 2006/42/EC.

  • Page 8: General Information

    Chapter 1 General Information 1 GENERAL INFORMATION 1.1 General safety instructions Before using the machine, carefully read all of this manual, which is an integral part of the machine. Knowing the information and instructions in this manual is essential for users to use the machine correctly and safely. The manufacturer declines all responsibility in the event of modifications, tampering or any operations carried out in a way that does not coincide with what is specified in this manual, since they may put the health and safety of personnel and/or objects at risk.

  • Page 9: Testing, Guarantee And Liability

    Guarantee DIAMOND guarantees the machines put on the market for 12 months from the date of delivery. During the guarantee period the seller undertakes to substitute, free of charge ex works, any parts which may develop a fault due to obvious manufacturing defects or poor quality materials.

  • Page 10: Modifications And Additions

    DIAMOND reserves the right, should it deem it appropriate and for valid reasons, to update the manuals already on the market, sending its customers sheets of technical and/or operating updates which must be considered and kept in the manual.

  • Page 11: Ordering Spare Parts

    1.5.3 Downloading the technical manual Hard copy technical manuals are replaced by “PDF” files which can be down-loaded directly from this address: http://www.diamond-europe.com A new window is opened, containing step by step instructions for registering and then for downloading the “TECHNICAL MANUAL”.

  • Page 12: Intended Uses

    Plus, using a specific program with a temperature-based operating cycle, it is possible to make granita. THE MACHINE CANNOT BE USED FOR OTHER PURPOSES WITHOUT DIAMOND'S AUTHOR- ISATION. DIAMOND WILL NOT BE RESPONSIBLE FOR DIRECT OR INDIRECT DAMAGES DUE TO IMPROPER USE OF THE MACHINE.

  • Page 13: Packaging, Transportation And Storage

    OPERATOR: a person trained for routine operation of the machine, that is to say, loading products to be processed, running recipes, cleaning and routine maintenance. QUALIFIED TECHNICIAN: a person whose training and professional education gives him a knowledge of machine service conditions, and who is able to work on the machine and recognise and avoid any dangerous conditions.

  • Page 14: Technical Specifications

    2.1 General description of the machine range of machines covered by this manual are vertical batch freezers for making gelato, sorbet and granita. TGV/5D-N Processing of the mixes or ready-packaged foods is performed in a single vertical cylinder which is: "easy to fill, the product is always visible and the ingredients can be added at any time".

  • Page 15: Illustration Of The Machine As A Whole And Its Components

    2.2 Illustration of the machine as a whole and its components Cover Control panel Cylinder Mixer Food-safe plastic paddle scrapers Extraction door lever Extraction door Extraction opening Extraction door chute Basin support Outer panels Air cooled condenser Supporting feet...
  • Page 16 Chapter 2 Technical Specifications...

  • Page 17: 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 TGV/5D-N Net weight Coolant gas (type)

  • Page 18: Noise

    80 dB(A) and 135 dB(C). Test documents and certificates for the instruments used for the measurements are filed at DIAMOND and are available to monitoring authorities. TEST DOCUMENTS AND CERTIFICATES FOR THE INSTRUMENTS USED FOR THE MEASUREMENTS...

  • Page 19: Items Supplied With The Machine

    2.6 Items supplied with the machine The machine is supplied together with the following items: 1. Operating and maintenance manual. 2. Kit of gaskets and packet of food-safe lubricating grease 3. Spatula for gelato/ice cream 4. Tube brush for cleaning. 6.
  • Page 20 Chapter 3 Safety regulations 16. Do not put fingers and/or objects in the machine slots or holes. 17. Do not use the machine with damp or wet hands. 18. Always wear suitable gloves and a hair cover for hygiene. 19. Pay maximum attention to all caution and danger signs on the machine. 20.

  • Page 21: Safety Devices Present On The Machine

    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.

  • Page 22: Safety Symbols And Stickers

    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.

  • Page 23: Installation Instructions

    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. Remove the documents and accessories located on the outside of the machine.

  • Page 24: Spaces Needed For Use Of The Machine

    Chapter 4 Installation 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 circu- lation around it.

  • Page 25: Electricity Supply

    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. Connect the machine only to a power supply using a suitable earth connection. 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.

  • Page 26: Air-Cooled Machine

    Chapter 4 Installation 4.6 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.

  • Page 27: Machine Operation

    5 MACHINE OPERATION 5.1 Controls The control panel functions are illustrated below: ON/OFF button For switching the machine on and off. The digital display (2) shows the temperature of the cylinder. Power LED Power ON light. When lit the LED indicates that the machine is supplied with electricity.
  • Page 28 Chapter 5 Using the machine 7. “TEMPERATURE-BASED CYCLE” button Button for starting a machine “temperature”-based operating cycle. When the cycle is ON the warning light (7a) in the button is lit. When this button is pressed the mixer in the cylinder and the machine cooling system are switched on automatically.

  • Page 29: Switching On And Starting The Machine

    5.2 Switching on and starting the machine 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 power LED (1) is lit.

  • Page 30: Programming

    Chapter 5 Using the machine 5.3. Programming DURING ITS FACTORY INSPECTION, THE MACHINE HAS BEEN PROGRAMMED WITH OPTIMAL TIME AND TEMPERATURE PARAMETER VALUES FOR THE OPERATION CYCLES. DO NOT CHANGE PROGRAMMING UNLESS IT IS STRICTLY NECESSARY. IF PARAMETER VALUES DO NEED TO BE ALTERED, MAKE ANY NECESSARY MACHINE PRO- GRAMMING CHANGES BEFORE STARTING PRODUCTION.

  • Page 31: Adjusting The Temperature-Based Cycle (P1)

    5.3.1 Adjusting the temperature-based cycle (P1) ▪ Having pressed the + Programming/Adjustment button (B), the P1 code appears on the digital display. ▪ A few seconds after the code P1 flashes on the display, a numer- ical value indicating the cooling temperature set appears on the display.

  • Page 32: Adjusting The Buzzer (P3)

    Chapter 5 Using the machine 5.3.3 Adjusting the buzzer (P3) ▪ When the code P3 flashes on the display, you can modify the du- ration of the buzzer at the end of the production cycle. The factory set value is 10 seconds. ▪...

  • Page 33: Temperature-Based Cycle Production

    ▪ Several seconds after entering the operating time, the display □□ shows two zeroes again “ ”. Now you can set a numerical value corresponding to the mixer pause time. ▪ Use the adjustment buttons (C) and (D) to set the mixer pause time.
  • Page 34 Chapter 5 Using the machine - Before starting the production check that the extraction door is closed and pour the pasteurised mixture or the pre-packaged food products in the cylinder. Note: The suitable quantity of product which can be pro- cessed is indicated in sec.

  • Page 35: Modifying The Cooling Temperature With The Temperature-Based Cycle Started

    5.4.1 Modifying the cooling temperature with the temperature-based cycle started If, during the processing cycle, you want to modify the cooling temperature, this can be done by accessing the programming section. Follow the instructions in section 5.3.1 of this manual. –...

  • Page 36: Modifying The Churning Time With The Time-Based Cycle Started

    Chapter 5 Using the machine - At the end of processing, that is to say, when the churning time set has elapsed, the operator is alerted by a buzzer. Once the cycle has ended the cooling system switches off automatically whilst the clockwise mixing of the mixer continues to prevent the formation of ice on the sides of the cylinder.

  • Page 37: Temperature-Based Cycle Granita Production

    5.6 Temperature-based cycle granita production Granita can only be made using a temperature-based cycle. You can set the mixer to operate with intermittent motion and clockwise rotation, with pause times, expressed in seconds. THE RECOMMENDED COOLING TEMPERATURE FOR MAKING GRANITA IS -2°C. MODIFY THE COOLING TEMPERATURE SET IN THE MACHINE.

  • Page 38: Washing

    Chapter 6 Washing 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 39 – 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 ¼ full. Note: Use a specific food-safe detergent, normally alka- line.

  • Page 40: End Of Day Washing And Sanitising

    Chapter 6 Washing 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 41 2. W AShInG 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 42 Chapter 6 Washing You must also: - Thoroughly clean the inside of the mixer component drive using the tube brush supplied (F). - Remove product residues from the mixer's scrapers using the tube brush supplied (F) or a suitable brush. - Thoroughly wash and degrease with a disposable cloth (E) soaked in detergent the gasket (11) of the mixer fixing knob.
  • Page 43 3. R InSInG 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 44 Chapter 6 Washing c) Refitting the components: After washing, re-fit all of the machine components as described below: • Re-fitting the mixer scrapers - Position the paddle scrapers (7) on the mixer and use a suit- able tool (hex socket screwdriver) (8) to partially tighten the fixing screws (9), so that the position of the paddles inside the cylinder can be adjusted afterwards.
  • Page 45 • Re-fitting the extraction door chute - Insert the chute gasket (11) in its seat. - Position the chute (10) below the extraction door and secure it by tightening the clamp screw (9) to the front panel. TIGhTEn ThE FIXInG SCREWS, ChECKInG ThAT ThERE IS nO PLAY In ThE ChUTE. ThE InCORRECT InSTALLATIOn OR COnTACT FAILURE OF ThE mAGnET On ThE COVER ACTI- VATES A mAChInE ALARm, PREVEnTInG IT FROm STARTInG.
  • Page 46 Chapter 6 Washing 5. R InSE 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.

  • Page 47: Routine Maintenance

    7 ROUTINE MAINTENANCE 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. 7.2 Maintenance work Maintenance is the set of organised operations which must be carried out on machine parts in a regular, systematic way.

  • Page 48: Maintenance Sheets

    Chapter 7 Maintenance 7.4 Maintenance sheets Substituting the paddle scrapers installed on the mixer CHECKING INTERVAL: 500 hours or quarterly AUTHORISED OPERATOR: 1 Operator TIME NEEDED: 15 minutes TOOL: Flat-tip screwdriver 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 49 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. - The machine is supplied with a full set of spare gaskets.

  • Page 50: Checks On Safety Devices

    Chapter 7 Maintenance 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:...

  • Page 51: Troubleshooting

    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 possible,...
  • Page 52 Chapter 8 Troubleshooting...
  • Page 54 Chapter 8 Troubleshooting...

  • Page 55: Troubleshooting - Flowchart

    8.2 Troubleshooting – flowchart In abnormal conditions the machine may malfunction, as specified below: MACHINE DOES NOT OPERATE OR OPERATION IS INTERRUPTED THE MAIN SWITCH IS IN THE ON POSITION (1), THE POWER WARNING LIGHT DOES NOT SWITCH ON. The plug is not inserted in the Insert it correctly.
  • Page 56 Chapter 8 Troubleshooting MACHINE REPEATEDLY TRIPS THE ELECTRIC OVERLOAD SWITCHES OR BLOWS THE MAINS FUSES. Contact the Technical assistance The capacity of the electrical service. system is not sufficient to power the machine. The electrical specifications of the Contact the Technical assistance overload switches or fuses are not service.
  • Page 57 UNUSUAL NOISE The fixing knob for the movable pad- Check the condition of the gasket (sub- dle (if present) has worked loose. stitute it if necessary) and tighten the knob again. Stop the machine and wait a few min- The mixer and/or the cylinder utes until normal operating conditions have been subjected to a jump in are restored.
  • Page 58 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 59 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 in Contact the Technical assistance is higher than that indicated in the service.

  • Page 60: Inactivity

    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 button, power down at the mains master switch and take the plug out of the socket.

  • Page 61: Decommissioning The Machine

    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 62 Illegal disposal of the product by the owner shall be subject to the administrative sanctions provided for under the regulations in force. DIAMOND EUROPE...
  • Page 63 Notes:...
  • Page 64 Notes:...
  • Page 65 Made in Italy...

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