Gami T240 User manual

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INSTRUCTION MANUAL
T240
TEMPERING MACHINE
Automatic continuous cycle
tempering machine.

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Via Lago di Lavarone, 14 Tel. [phone]
36015 Schio (Vi), Italy Fax [phone]
Cap.soc. Euro 90.000,00 www.gamitaly.com
C.F./P.I. 00932420243 [email protected]
R.I. di Vicenza 00932420243 e al R.E.A. al N. 283138
INDEX OF TOPICS
Index of topics .................................................. page 2
Using this instruction manual .............................. page 3
Plates ................................................................ page 4
Guarantee.......................................................... page 5
Software / Firmware guarantee and servicing....... page 6
Exclusion of other guarantees ............................. page 6
Exclusion of liability for indirect damage............... page 6
Overall dimensions ............................................. page 7
General outline................................................... page 8
Technical data.................................................... page 9
Compliance with standards.................................. page 9
Installation......................................................... page 10
Front panel ........................................................ page 11
How the machine works...................................... page 13
Operation sequence............................................ page 16
Electrical connection of the board........................ page 16
Board technical features ..................................... page 19
Cleaning and maintenance .................................. page 20
Alarms, possible causes and remedies ................. page 21
Spare parts list ................................................... page 22
Demolishing the machine and general notes ........ page 23
‘EC’ Compliance Statement.................................. page 25
Data record sheet............................................... page 26
Wiring diagram

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USING THIS INSTRUCTION MANUAL
Being well acquainted with the instructions set out in this manual is important
for you to gain maximum benefit from the use of the machine and is
essential for your safety.
Every machine operator must read and properly understand this entire user
and maintenance manual before starting to operate the machine.
For all problems regarding how the machine works, do not hesitate to contact
the Manufacturer where you will find technicians on hand to help.
Remember to specify the model and serial number on all correspondence
concerning this machine.
WARNING
1) Do not operate the machine under the influence of alcohol, drugs or
medicines that may alter your physical condition.
2) Keep hair and parts of the body well away from rotating parts.
3) Keep labels signalling danger and those bearing safety information
perfectly clean and in good condition.
KEEP THESE LABELS
AFFIXED TO THE
MACHINE WHERE THEY
ARE HIGHLY VISIBLE

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PLATES
Plates providing the following information are affixed to the machine:
-Data concerning production, registration, compliance with standards
and type of electricity supply required:
-Labels providing information on the type of connection:
-Labels signalling danger or which prohibit certain operations from being
performed:

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GUARANTEE

The material sold by the Manufacturer is guaranteed for 12 (twelve)
months from the date of delivery to the Customer/Dealer indicated on the
Transport Document (or on the Invoice in the case that the Invoice
accompanies the goods); electrical parts and motors are excluded.

The guarantee does not cover damage caused by improper use or
malfunctioning of the material supplied by the Manufacturer but is limited to
servicing and repairs of the said material.

The guarantee does not cover damage caused by tampering with, inexpert
repairs, negligence on the part of the Customer, or damage caused by events
beyond the control of the machine (fires, lightning, acid spills, etc.).

The technical servicing and guarantee consist of the Manufacturer sending
out as quickly as possible the spare parts requested by the Customer/Dealer
who undertakes to return the broken parts within 15 days from the request
for the new ones. In the event that the Customer/Dealer is not able to
identify the cause of the breakdown himself, the Manufacturer shall make
available his own laboratory for telephone consultations or direct repairs. The
goods in need of repair must be sent to the Manufacturer’s service centre
with carriage being paid by the customer. The Manufacturer undertakes to
repair these, or at his own discretion, replace these with new ones in the
shortest time possible.

The replaced material and labour used for repairs carried out by the
Manufacturer during the guarantee period shall be borne by the
Manufacturer; all transport charges shall be charged to the Customer.

In the event that it is necessary to call out the Manufacturer’s technicians
to the customer’s premises, the Customer shall be charged a cost for the call-
out plus travel expenses.

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SOFTWARE / FIRMWARE GUARANTEE AND SERVICING

Programmes developed by the Manufacturer are guaranteed for 90
(ninety) days from the date of delivery to the Customer/Dealer (date of
installation in the case of programmes including installation). By the end of
this period the customer must have tested that the entire programme
purchased functions properly.

Every item of SOFTWARE/FIRMWARE replaced or modified will be
guaranteed for the remaining period of the original guarantee and in all cases
for no less than 30 days.
EXCLUSION OF OTHER GUARANTEES

The Manufacturer shall not acknowledge any other Guarantee, whether
expressed or implicit for Software, accompanying written material or any
Hardware attached to this, including also the guarantee of marketability and
suitability for a particular purpose.
EXCLUSION OF LIABILITY FOR INDIRECT DAMAGE

In no case shall the Manufacturer be held liable for damage (including
without any limitations, damage for loss or lack of earnings, interruption of
business, loss of information or other financial losses) deriving from the use
of the products, even in the event that the Manufacturer has been warned of
the possibility of such damage. In all circumstances, the Manufacturer’s sole
liability (and only for the period of guarantee stated above) in accordance
with the terms of this agreement, shall be limited to a sum which
corresponds to the amount actually paid for the product purchased.

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OVERALL DIMENSIONS
950 mm.
1495 mm.
550 mm.
400 mm.

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GENERAL OUTLINE
The machine must only be used by qualified staff and must not be installed in
a place that is accessible by all.
The machine may only be used for processing confectionery products.
Residual risks
The machine has been designed to comply with the safety standards
described in the CEI (Italian Electronic Committee) regulations.
The use of the machine in situations or using methods which differ from
those envisaged by the Manufacturer may constitute unforeseeable risks that
cannot be quantified.
In particular, it is strictly forbidden for the user to tamper with and/or bypass
mechanical and electrical devices or parts, modify the structure of the
machine and loosen or remove bolts and screws.

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TECHNICAL DATA
Tank capacity 8 Kg
Diameter of tank 240 mm
Hourly production rate 30 Kg/h
Dimensions 400x550x1495h mm
Machine weight 130 Kg.
Power rating 1.9 kW
COMPLIANCE WITH STANDARDS
The machine is constructed in compliance with Machines Directive
89/392/EEC (and 91/368/EEC 93/44/EEC 93/68/EEC subsequent
modifications).
The electrical installation complies with standards EN 60204-1.
Protection devices installed
To prevent accidents involving the operator, the control panel has been fitted
with a red mushroom emergency stop button with a yellow circle around it,
which can easily be pressed from the work station.
A door-locking switch is located on the casing on the right-hand side of the
machine in order to prevent access to power circuits when connected to
mains electricity.

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INSTALLATION
Reception
Remove the packing and check that there is no damage.
Notify the carrier of any damage immediately.
Connection to electricity supply
Connection to electricity supply must be made by qualified staff.
Make sure the electricity line voltage is the same as the one indicated on the
machine’s connection plate.
The phase sequence relay inside the electric panel prevents the possibility of
the direction in which the motors rotate from being inverted; therefore, if the
message ALL FAS appears on the control panel screen when the door-locking
general disconnecting switch (on the rear casing) is switched on, just remove
the plug and invert two phases making sure never to move the earthing cable
(yellow green) and neutral cable (blue); then repeat connection to power
supply.
Electricity must be supplied through a quadruple
socket + earth.
Connection must be made in compliance with
standards in force in the Country in which the
machine is being installed.

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FRONT PANEL
The control panel is composed of the following elements:
K101 Increases tempering temperature
K102 Reduces tempering temperature
K103 Sets tempering temperature
K104 Starts up tempering cycle
K106 Starts up doser
K107 Increases doser regulation
K108 Decreases doser regulation
K109 Starts up heating of vibrating table
K110 Starts up vibration of vibrating table
K111 Starts up chocolate recirculation
K112 Starts up mixer
K113 Sets melting temperature
K114 Starts up melting
K115 Increases melting temperature
K116 Reduces melting temperature

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How push-buttons are arranged
How push-buttons are numbered

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HOW THE MACHINE WORKS
The control device provides a number of distinct function procedures which can
be selected from the keyboard.
These procedures are:
1) Machine operational
This is the machine’s standard working mode.
2) Machine setting
This function is used to set the machine configuration parameters and must
be used by our technicians only.
3) Diagnostics
This function is used to test that a number of parts controlled by the control
device (keyboard, digital inputs and digital outputs) are working properly and
must be used by our technicians only.
1.1 STANDARD OPERATION MODE
This is the machine’s normal working mode. This mode is active at all times when
the machine is under power.
During operation the two thermo-regulators can be used to regulate the
temperature of the chocolate in the tank and exit (tempering) spout. It is possible
to activate/deactivate the vibrating table and its resistor, auger, mixer and doser.
1.1.1 Thermostat 1 (Tank)
This thermostat regulates the melting temperature in the tank. Use push-button
K114 to activate or deactivate this thermostat. Deactivation can also be delayed
for a set time with respect to tempering being switched off, so as to give the
chocolate on the auger conduit time to melt completely.
If this function is deactivated, the machine stops.
Press the Set K113 button and keep it depressed to view and alter the regulation
temperature.
1.1.2 Thermostat 2 (Tempering)
This thermostat regulates the temperature of the melted chocolate at the exit
spout.
Use push-button K104 to activate or deactivate this thermostat. This thermo-
regulator can only be activated when the auger is switched on and the chocolate
in the tank has reached the SET temperature. This thermo-regulator will only
deactivate when the chocolate exiting has reached a temperature of at least 40°
C.

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1.1.3 Thermostat 3 (Auger resistor)
This thermostat regulates the auger heating temperature and it works provided
that the tank heating is switched on and tempering is switched off.
Press the SET K103 button to view and alter the regulation set-point value.
Press the two K101/K102 arrows for tempering increasing/decreasing to view the
actual temperature of the auger.
1.1.4 Mixer
This command comes directly from its own special push-button. Function state is
indicated by the LED located on the push-button itself.
The mixer will only switch on when the chocolate in the tank has reached the
SET temperature, otherwise it will not switch on even if it is enabled and the LED
flashes indicating waiting time before the mixer switches on.
1.1.5 Auger
This command comes directly from its own special push-button. Function state is
indicated by the LED located on the push-button itself.
The auger will only switch on when the chocolate in the tank has reached the
SET temperature, otherwise it will not switch on even if it is enabled and the LED
flashes indicating waiting time before the auger switches on.
The auger will only switch off when the chocolate has reached a temperature of
40° C that is the set-point value. While reaching this value the auger remains
switched on even if disabled and the LED will flash indicating to wait for some
time.
The auger may be stopped temporarily (using the pedal) for a time set by the
Manufacturer in the machine’s parameters. This stop function is simply activated
(just one stop) if the doser is switched off. If not, see doser operation described
here below (1.1.8).
1.1.6 Vibrating table vibrator
This command comes directly from its own special push-button. Function state is
indicated by the LED located on the push-button itself.
1.1.7 Vibrating table vibrator resistor
This command comes directly from its own special push-button. Function state is
indicated by the LED located on the push-button itself.

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1.1.8 Doser
The doser operates by temporarily stopping the auger to introduce the mould,
perform a timed pouring operation and stop the auger for removing the mould.
This function can be activated by using the special push-button with LED located
on the panel. The LED that lights up on the push-button indicates the state of
enablement.
This shows how the function works when it is enabled:
1) When the pedal is pressed, the auger stops for the length of time set in the
machine parameters.
2) The auger switches on again for the length of time equal to the dosing time
set on the front panel.
3) The auger stops again for the length of time set in the parameters.
4) The auger switches on again normally.
By pressing the doser activation button for 3 seconds, the display will view the
number of set doses that can also be altered as wished and recorded by pressing
the doser activation button again or by waiting 5 seconds.

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OPERATION SEQUENCE
1) Activate the door-locking device (main switch) located on the rear casing of the
machine.
2) If default data are not those required by the user, modify the melting settings; be
careful not to set the temperature too high, otherwise the organoleptic properties of
the chocolate may alter.
To change the settings, press the regulation button and then increase or decrease
the value using the up or down arrows.
3) Introduce small blocks of chocolate into the tank which has a capacity of 8 Kg
approx.
4) Press the (K114) push-button to start the melting cycle in the tank and activate
heating of the recirculation zone.
5) Press the (K112) push-button to start the mixer; the LED will flash indicating that the
mixer is enabled; the mixer will start to operate only after the chocolate in the tank
has reached the temperature set on the thermo-regulator of the tank which will be
confirmed by the LED being permanently on.
6) Press the (K111) push-button to enable recirculation which will start only after the
chocolate has reached the temperature set on the thermo-regulator (1). The LED
will flash indicating that recirculation is active and will remain permanently lit after
the preset temperature has been reached that is when the auger will start to
operate. IT IS RECOMMENDED TO START CHOCOLATE RECIRCULATION ONLY
WHEN MELTING IS ABOUT TO END.
7) After starting chocolate recirculation, it is very important to wait until the chocolate
inside the tank has completely melted and the relevant temperatures on the
thermo-regulators on the panel show the same values; from this moment, the
chocolate is ready to be tempered.
8) Press the (K103) push-button to start the tempering cycle. A special sound indicating
that the tempering temperature (±2°C) has been reached will be produced and
after a few seconds tempering can be started.
9) In order to save time, we recommend not to use all of the chocolate in the tank
completely while tempering, but to rather add small quantities of chocolate
previously melted in the tank.
10) When the cycle is completed, deactivate the tempering function (K103) and wait
until the temperatures show the same values; then switch off the auger, the mixer
and the resistors.
11) Remove the chocolate exit spout to let the chocolate come out more easily from the
conduit.
12) Deactivate the door-locking device located on the rear casing of the machine.

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ELECTRICAL CONNECTION OF THE BOARD

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POWER SUPPLY AND COMMUNICATION CONNECTIONS (J101)
Ref.No
Abbr.
Name
Notes
1
PWR
12VAC / 12VDC (Board power supply)
2
PWR
12VAC / 12VDC (Board power supply)
3
GND
0V
4
GND
0V
5
V+
12V
232
232
RS232 Serial
FC10
6
CANL
CAN Communication
7
CANH
CAN Communication
EXP
Keyb.IF
Remote keyboard interface
FC20
11
In.Com
Common for digital inputs
12
In.0
Doser pedal
13
In.1
Mixer thermal protection
14
In.2
Auger thermal protection
15
In.3
Refrigerator thermal protection
16
In.4
Door micro
17
In.5
N.C.
18
In.6
N.C.
19
In.7
N.C.
WARNING: digital inputs must be powered by voltage ranging between 12 and 24 Volts (AC/DC).
The board does not drive any inputs which must therefore use an external source of power.
21
Snd1-1
Red PT100 Tank
22
Snd1-2
Red PT100 Auger resistor
23
Snd1-3
White PT100 Tank and Auger Resistor
24
Snd2-1
White PT100 Tempering
25
Snd2-2
Red PT100 Tempering
26
Snd2-3
Red PT100 Tempering
27
Snd3-1
N.C.
28
Snd3-2
N.C.
29
Snd3-3
N.C.
30-31
Out.0
Tank resistor
32-33
Out.1
Refrigerator
34-35
Out.2
Mixer Motor
36-37
Out.3
Auger Motor
38-39
Out.4
Vibrating table vibrator
40-41
Out.5
Vibrating table resistor
42-43
Out.6
Water pump
44-45
Out.7
Auger resistor
WARNING: all relay outputs are with pure NO contact

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BOARD TECHNICAL FEATURES
-- ELECTRICAL SPECIFICATIONS:
board power supply................................................ 12 Vac/Vdc
absorption ............................................................. 1.6A max
- Digital input specifications :
number of digital inputs.......................................... 8
type of inputs ........................................................ PNP/NPN AC/DC
input voltage ......................................................... 12÷24 Vac/Vdc
input absorption..................................................... 3mA - 12mA
- Analogical input specifications :
number of analogical inputs PT100 (2 wires) .......... 2
number of analogical inputs PT100 (3 wires) ........... 1
- Analogical output specifications :
max. number of analogical outputs ........................ 2 (optional)
type of output........................................................ 0÷10V
- Digital output specifications :
max. number of digital outputs ............................... 8
type of outputs ...................................................... N.O. contact relay
max. current of single outputs ................................ 5 A
max. voltage ......................................................... 24 Vac/Vdc
- Insulation specifications :
insulation of inputs / control electronics................... 500 Vdc
insulation of digital outputs / control electronics ...... 500 Vdc
insulation of analogical outputs / control electronics .. 0 Vdc (no insulation)
-- ENVIRONMENTAL CONDITIONS:
working temperature.............................................. from 5C to 50C
storage temperature............................................... from 0C to +80C
working humidity ................................................... from 0% to 80%
without condensation

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CLEANING AND MAINTENANCE
Cleaning
To clean the machine, it is advisable to switch on the heating and empty the
tank as much as possible through the exit spout.
Open the drainage cap located on the rear casing and wait for the last
remaining residue present in the auger to drain out.
Clean the outside of the machine with a damp cloth and dry with a dry cloth.
Maintenance
As far as replacement of parts, breakdowns of the electric system, etc. are
concerned, maintenance must strictly be carried out by skilled staff.
During maintenance, the machine must not be connected to mains
electricity.
If the machine is under guarantee, the Manufacturer must be notified
immediately.
Periodically check the level of coolant by opening the cap located on the top
of the machine.