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CARPIGIANI 191 Bar PSP. Training Manual April 2008. Carpigiani 191 Bar PSP Introduction.
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CARPIGIANI 191 Bar PSP Training Manual April 2008
Carpigiani 191 Bar PSP Introduction. The 191 Bar PSP was introduced in 2004 and is Carpigiani’s first counter top self pasteurising machine. It is available in both single or three-phase, air or water-cooled. The machine benefits from state of the art electronics allowing the machine to be used for both General Market (GM) & Key Account (KA) applications just by adjusting parameters within the programming table. A self-service option is also available with the addition of a self-closing device being fitted to the door of the machine. The machine is now sited within Pizza Hut, BK, McDonalds, KFC and a vast array of GM restaurants and outlets.
Programming The Machine The programming table consists of a number of parameters with different functions that control the operation of the machine. These parameters can be individually adjusted to achieve correct operation and have a brief explanation by each one. The parameters highlighted in yellow must always be checked and those in red changed as and when required. The other parameters should then remain untouched and require little or no adjustment.
Changing Programming Table Settings…….. Before attempting to adjust ANY parameters please always make a note of what the setting was to refer back to. Remember all machines would have had a PDI completed before delivery and this sheet will be with the machine. This contains information like “Wash Days”, “Pasteurise Cycle Start Time”, “ Motor Trimmer Setting” etc which is very important.
Changing Alarm Settings. The two alarms shown that may be required are “AL11” & “AL22”, the can be switched from “YES” to “NO” if required. • AL11 is for the airflow alarm so if the machine is located in a position where restricted airflow is an issue then this should be set to “NO”. • AL22 is for the production of the machine, if the machine is in a high volume site then again this alarm should be set to “NO” to prevent nuisence triggering of this.
191 PSP Access Code “Y” Series. From the position press simultaneously the & and hold for 10 secs, on the screen “Hot” will be displayed, this is the consistency control and can be adjusted by using the button. By now pressing and holding the From the “Hot” display the technicians programming table can be accessed, using to access the next step and the to adjust the parameter.
191 PSP Access Code “COL” Series. From the position press simultaneously the & then release immediately, on the screen “Hot” will be displayed, this is the consistency control and can be adjusted by using the button. By now pressing the button “SPS” will be displayed and if pressed again “WDY” again these can be adjusted by using the button. From the mode the technicians programming table can be accessed, holding for 10 seconds then using to access the next step and the to adjust the parameter.
191 PSP Access Code “T” Series To access the “USER” function from the position you must press both & together and then release immediately; “000” will then be displayed on the screen. Now using the arrow move the figure to “012” then press “Hot” will now be displayed followed by the figure selected for this parameter, using the this figure can be adjusted as required. Pressing the button again “SPS” will be displayed where again you can adjust the Pasteurise Start Time using the advance arrow if required, then pressing the button again will display “WDY” where the Wash Days can be adjusted.
191 PSP Access Codes “T” Series For “Technicians” programming repeat the steps on the previous page entering the access code “023” instead of “12”. The attached programming table can then be accessed.
Wash Days/Cleaning Cycle This varies depending on the client but for key accounts the setting is as follows; KFC: 7 Days BK: 14 Days Pizza Hut: 8 Days McD’s: 14 Days This is the period after which the unit will lock out and require cleaning to reset. For all GM units we set to “NO” or “0”.
Standard Version Touch Pad This was used on the “Y” & “COL” series of software but has now been replaced with a touch sensitive version. The touch panel part code: IC573800638, will still be available for the foreseeable future. Should you have the need to replace an existing IC573800638 touch panel due to malfunction, then this should be ordered using the existing code and not upgraded to the newer version. If the Key Board Block is set to “YES” then the advance button must be depressed for 10 seconds before pressing when trying to exit from Production.
Colore Version Touch Pad This was only used with the “COL” version software and has the addition of the syrup system controls on the touch pad. The part code for this touch pad is IC573800657. In the programming table for this machine “P39” must be set to “YES”.
Touch Sensitive Touch Pad Commencing from serial number IC54627 (Dec 2007) this new style touch pad will be fitted coinciding with the introduction of “T” series software. This new panel has the part code: IC573.800.684 (If there is a need for replacement the authorized technician must always indicate the serial number of the machine in their spare parts order because as the new touch pad is shipped along with the front panel this will be automatically be ascertained via the units serial number)
Touch Pad Replacement • The existing touch panel part code: IC573800638, will still be available for the foreseeable future. Should you have the need to replace an existing IC573800638 touch panel due to malfunction, then this should be ordered using the existing code and not upgraded to the newer version. However if a machine with this touch pad has a cracked front panel then the new front panel will arrive equipped with the new touch sensitive panel IC573800684 and will need to be fitted following the instructions provided.
Front Panel Replacement 1(Standard) Firstly remove the two side panels to gain access to the machine. Next remove the 4 x 8mm bolts securing the front panel to the machine structure.
Front Panel Replacement 2(Standard) Once this is done the next job is to remove the two studs that hold the spigot body. This should be done using a concentric roller as supplied in the kit or 2 x 8mm nuts. Care should be taken when these are replaced not to over-tighten these as this could cause the panel to crack.
Front Panel Replacement 3(Standard) Now carefully remove the proximity sensor from the rear of the panel by unscrewing this.
Front Panel/Touch Pad Replacement (Standard) You now have full access to the control panel from the rear of the panel. Remove the four nuts securing the touch panel. If replacing the touch pad at this stage remove the touch pad ribbon cable from the CPU and replace with the new touch pad then replace the panel in reverse as desribed previously.
Front Panel/Touch Pad Replacement (Touch) For this version follow the previous steps 1 to 3 as before now in this case remove not only the ribbon cable but also the black & red wires to terminals 2 & 5 of the 5 pin connector of the CPU Board. Remove the complete front panel and replace with the new one.
Front Panel/Touch Pad Replacement Standard to Touch As described on the previous slide the same procedure must be followed when changing the front panel and the upgrade to the new touch style pad. The CPU Board can remain with no modifications to the software. The only difference is that the red wire from the pad should be fitted into terminal 13 & the black wire terminal 29 of the relay card as illustrated on the next slide.
Trimming/Calibration. This setting must be checked during the initial commissioning of a machine and when the CPU Board has been replaced as this will effect the performance of the unit. What does it do….? It sets the calibration of the beater motor to the CPU Board, ensuring that the FLC of the drive motor is never exceeded whatever the consistency setting.
How is this done? The first step is to attach you ammeter to the same phase of the beater motor that runs through the current transformer on 3-phase units, for 1-phase units refer to wiring diagram. Setting the HOT/HOD to its maximum value, i.e 120 and with a liquid mix load, place the machine into the production mode. The trimmer button must now be pressed or a link made on the CPU Board as shown on the following slides.
Final Process. Once this is done, the scale on the display will climb, once the FLC of the motor is displayed on your ammeter then the button must be pressed or the link removed. This then completes the process and the “Trimmer HOT” has now been set, thus trimming the CPU to the motor.
Electrical Box Information Every machine has a sticker located with in the electrical box which can be used as a reference for the machines original settings as shown below. The important settings on this are the EEPOT/Trimmer number, Software Version & Amperage.
Setting The Time. This is crucial especially on machines where the automatic pasteurise cycle is used as this will determine the program start time. This is done by adjusting the parameters within the programming table remember that a 24 hour clock is used.
Transformer Setting This is crucial on Carpigiani machines as the output voltage when the unit is under full load must be between 25 to 27 volts on the 24v tapping. You can adjust the output voltage be changing the incoming input windings. On the next page you can see an example of the transformer..
Adjusting the transformer. So if the incoming voltage is across terminals A & F and the link across C & E the transformer is set for 420v but if we have 23v exiting the transformer under full load, then we must decrease the input windings. To do this we would need to switch the incoming wires to A&E and the link to C&F, now the transformer is set for 400v and the output voltage on the 24v will be higher. This is critical for machines running on electrical generators.
TECHNICAL NOTES ON COL VERSION 191 AL 2 WHICH IS NORMALLY COMPRESSOR MOTOR OVERLOAD ON THIS VERSION AL2 IS THE HIGH PRESSURE SWITCH TRIPPED DUE TO THE WAY THIS MACHINE IS WIRED. ON THIS VERSION BEWARE AL1 CAN BE CAUSED BY THE LAVARTO CONTACTORS, IF THIS IS THE CASE THEY CAN BE UPGRADED TO THE ABB TYPE.
Tools for Pump Bush Replacement. In order to replace the pump shaft & bushes you will need to have the following equipment. • 14mm Adjustable reamer. • Punch bar & hammer to remove old bushes. • Bush fitting tool to insert new bushes. • Lubricating oil. • Pump Shaft 155100420 or 155102100. • JP Pump shaft bushes x 2, 157140020. • Angus oil seal 542000103
