Ideal AKE CALEO HOT User manual

Operating Manual
CALEO HOT/BASIC
Translation of the original
Self-contained
21A

Subject to technical changes | Valid from January 2021
2
Information on this Operating Manual
Operating Manual and Installation Guide
This Operating Manual applies to all built-in units of the Caleo Hot/Neutral type of self-service display cases, irrespective of the dierent
possible congurations regarding freestanding display cases and Gastronorm dimensions. Built-in units must be covered before they
are put into use keeping the technical requirements in mind. The possibilities described in this Operating Manual show the majority of
congurations. Due to custom designs, many other congurations of the Caleo Hot/Neutral self-service display cases are still possible.
Copyright © December 2020, AKE Ausseer Kälte- und Edelstahltechnik GmbH. All rights reserved.
This documentation is the original documentation.
No part of this publication may be reproduced, stored, or transmitted and published in any form with any means without the
prior written permission of AKE.
Document: Operating Manual_Caleo_Hot_Neutral
Revision: 21A
Valid from: January 2021

Subject to technical changes | Valid from January 2021 3
Table of Contents
1. General Information and Safety 4
1.1. Foreword 4
1.2. Flexibility 5
1.3. Scope of application 6
1.4. Warranty and liability 7
1.5. Support 8
1.6. Symbols and signal words used 9
1.7. Marking 10
1.8. General safety instructions 11
1.9. Proper use 12
1.10. Target group and prior knowledge 13
1.11. Reasonably foreseeable misuse 14
1.12. Residual hazards 15
1.13. Personal protective equipment 18
1.14. Transport and packaging 19
1.15. Disposal 20
2. Technology 22
2.1. Explanation of terms used for components 22
2.2. Technical specications 25
2.3. Safety instructions on the unit 26
2.3.1. Electrical information 27
2.4. Assembly and installation instructions 28
2.4.1. First steps 28
2.4.2. Drain connection 32
2.5. Malfunctions and causes 33
2.6. Status displays and error messages on the display 34
3. Operation - Care 36
3.1. Initial start-up 36
3.2. Operation of the units 37
3.2.1. Units with dry heat 37
3.2.2. Units with heating climate 39
3.3. Stocking the unit 41
3.4. Cleaning and care 42
3.4.1. Information on cleaning and testing 42
3.4.2. Cleaning intervals 43
3.4.3. Cleaning agents 44
3.4.4. Cleaning the steam bae (units with heating climate) 45
3.4.5. Cleaning water bath with oat (units with heating climate) 46
3.4.6. Cleaning the bottom tray (only for units with heating climate) 47
3.4.7. Filling with water (units with heating climate) 48
3.4.8. Replacing the water lter (units with heating climate) 50
3.4.9. Visual and functional check 51
3.4.10. Checking the gas damper 52
4. Service/Maintenance 53
4.1. Maintenance information 53
4.2. Purchasing spare parts 54
5. Declaration of conformity 55

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GENERAL INFORMATION AND SAFETY
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01
1. General Information and Safety
1.1. Foreword
Thank you for choosing one of our appliances. Our units with heating climate and dry heat incorporate the highest technical stan-
dards with practical operating convenience. With your unit, you have a product that is state of the art with regard to operating safety
for the start-up personnel, the operator and the user. The unit can pose hazards in the event of incorrect or improper use. We point
out dangers in Chapter 1.9 and by means of safety information throughout the document. The safety information and instructions in
this document must be complied with. All personnel who install the unit, put it into operation, and operate it must have this document
available and must have read and understood it. The operator must check and ensure this. Our unit requires correct installation,
start-up, operation and care. Non-compliance with the points mentioned above can lead to warranty, guarantee and product liability
exclusions, but also to damage and safety hazards. Always keep this document complete and in a perfectly legible condition. If ne-
cessary, request it immediately from your supplier or operator, or download it from the manufacturer’s website at www.ideal-ake.at
The manufacturer is not liable for technical or printing errors in this document. Similarly, no liability will be assumed for da-
mage that is directly or indirectly attributable to the delivery, performance or use of this document.
NOTE
The manufacturer reserves the right to change the specications and design at any time as part of ongoing
product improvemen
NOTE

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CALEO HOT/NEUTRAL
1.2. Flexibility
All Caleo units are equipped with height-adjustable feet and castors. The castors are tted exclusively for transporting and
positioning the units. The units must be mounted on height-adjustable feet and aligned horizontally. Check the stability
of the unit after it has been set up.
NOTE
Caleo Cold 60/80/120/142 Caleo Hot 60/80/120/142
Revisionsklappe
Caleo Basic 60/80/120 Caleo Neutral 60/80/120/142
Against a wall
Front side with Caleo module 142
Front side with refrigerated well with convection
cooling and boards
Front side with corner modules Four modules back to back
Side-by-side Caleo Neutral Plus 60/80/120/142
Back to back
Stand-alone solution
Corner module,
unrefrigerated, square
Corner module,
unrefrigerated, oblique
Refrigerated well with convection
cooling, square
Unrefrigerated well, square

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01
1.3. Scope of application
This Operating Manual applies to the following models as well as assignable custom models of
the Caleo series..
Model designation
Series: Caleo aaaaa bbb
Abbreviations:
aaaaa: Hot or Basic (conguration)
bbb: 60, 80, 120 and 142 (unit width)
Model designation (optional)
Caleo unrefrigerated well, front side, square
Caleo unrefrigerated corner module, square
Caleo unrefrigerated corner module, oblique
Accessories:
Caleo product basket, large with holder
Caleo product basket, small with holder
Bumper in wood eect
Cough and spit guard
Chutes
Please note that at least two persons are required to lift the unit, and at least four persons are needed from a specic size
(>60 kg) of the units. Enlist the help of another person for spotting for the installation.
The dimensions and weight specications of the units are order-based and vary depending on the conguration. For more
detailed information, please contact the operator, your supplier or our support department (see Chapter 1.5)..
NOTE
NOTE
Units with dry heat
Units with heating
climate

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CALEO HOT/NEUTRAL
1.4. Warranty and liability
Our „General Terms of Payment and Delivery“ apply. Guarantee claims and liability for personal and property damage are not possible
if they are attributable to one or more of the following reasons:
• improper use of the unit
• transport damage
• operation of the unit with defective safety components or with safety components that have not been installed
properly and are not operable
• non-compliance with the instructions in the Operating Manual regarding the correct installation, start-up,
operation, maintenance and assembly of the unit
• unauthorised mechanical or technical changes to the unit
• inadequate maintenance of used and wearing parts
• unauthorised repairs
• use of aggressive or caustic cleaning agents
• forces of nature or force majeure
Also excluded from liability are:
• breakage of glass, breakage of plastic components, seals or lighting xtures, and radiant heaters
• any damage that is demonstrably attributable to the controller being set incorrectly by an
• unqualied person
• damage or malfunctions due to incorrect assembly of the unit after cleaning or maintenance
The warranty claim may be forfeit if the information provided is not observed.
NOTE

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GENERAL INFORMATION AND SAFETY
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1.5. Support
If you have any technical questions, contact your supplier or the manufacturer.
AKE Ausseer Kälte- und Edelstahltechnik GmbH
Pichl 66
A-8984 Bad Mitterndorf
T: [phone] - 0
F: [phone] - 33
E: o[email protected]
When you contact our support department, have the serial number of your unit ready. This can be found on the
rating plate or the “AKE Certied” plate (see Chapter 1.7).
NOTE
If any malfunctions occur, switch the unit o and immediately contact your supplier, service partner or the manufacturer.
NOTE

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CALEO HOT/NEUTRAL
1.6. Symbols and signal words used
This symbol with the comment PLEASE NOTE indicates supporting information for installation, operation or alternatively
maintenance and repair. Failure to observe this information can lead to property damage
NOTE
Imminent danger to the life of persons
Safety information with the signal word DANGER indicates imminent danger to the life and health of persons. Failure to
observe these safety instructions can lead to death or serious damage.
Danger of personal injury (serious injuries) and possibly property damage in addition
Safety information with the signal word WARNING indicates a dangerous situation that can have an impact on the health
of persons. Failure to observe these safety instructions can lead to serious injuries.
DANGER
WARNING
Danger of personal injury (minor injuries) and possibly property damage in addition
Safety information with the signal word CAUTION indicates a possibly dangerous situation. Failure to observe these
safety instructions can lead to minor or slight injuries.
CAUTION

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1.7. Marking
The unit is clearly identied by the content of the rating plate. Depending on the model, the rating plate is located on the outer shell
of the bottom tray on the front side (see Chapter 2.1), or in the base on the housing of the technology box (see Chapter 2.1), or in
the base on the cover of the controller.
General technical specications can be found in Chapter 2.2. Due to the large number of models, additional technical
specications are stated on the rating plate.
NOTE

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1.8. General safety instructions
• Covers with warning signs may only be opened by authorised specialists.
• The unit must not be cleaned with a water jet.
• Supporting-heat components (radiant heaters including the housing) and primary-heat components (hotplate)
have very high temperatures when in operation and must not be touched.
• Protective covers and xtures must not be removed; otherwise there is a risk of injury.
• The controller may only be opened by an authorised specialist.
• Air ows around the unit from improperly installed fans (e.g. air conditioners) or draughts must be prevented in
order to ensure perfect operation of the unit.
• The ambient temperature must not exceed +25 °C, and the relative ambient humidity must not permanently
exceed 60%.
• The unit is not suitable for operation in entrance and outdoor areas.
• The unit must be protected against direct sunlight.
• The products displayed must be pre-heated to a core temperature of at least +85 °C or hotter before being pla-
ced in the unit.
• Sharp objects must not be kept loose in the unit; otherwise there is a risk of injury.
• All glass enclosures must be treated with the necessary care in order to prevent injuries from the glass breaking.
• Components and service uids may only be replaced with original parts.
• Do not store any combustible or explosive products in the unit or close to it.
• During the assembly or installation, the unit must be covered adequately so that no contact with live parts is
possible.
• The installation environment must be stable in order to withstand the stresses of everyday operation.
• Steering and xed-position casters must be checked and set to a stable position.
• It must not be possible to remove any coverings that are mounted during the installation without tools.
• After each cleaning, the unit must be checked for loose connections, shearing points and damage.
Any deciencies that are discovered must be rectied immediately.
• Do not use the unit for any non-designated purposes.
• The unit must be installed away from heat sources in a low-dust and well-ventilated environment.
• The outside and underside of the unit must not be cleaned with a water hose or washing brush. Running water
must always be avoided in this area.
• Do not store any objects on the unit when it is in operation.
Generally the following safety provisions and obligations apply when handling the unit:
Technical changes to the unit may only be carried out by authorised specialists. This applies in particular to work on the
electrical installation and the mechanics.
Any change must be authorised by your supplier, service partner or the manufacturer. Furthermore, liability and warranty
claims are excluded in the event of non-compliance with proper use.
NOTE

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1.9. Proper use
The units are specially intended for a freestanding CALEO island (see Chapter Flexibility), or for individual installation (on walls), or
for installation in food and serving counters. They are suitable for keeping food products hot and presenting them at controllable
temperatures (see catalogue and website). Depending on the model, the units can be used as self-service units (see Chapter 1.3).
The units only serve to keep unpackaged food hot, but not to heat it up or cook it. Units with heating climate achieve humidication
optimally with unpackaged food. For units with dry heat, care must be taken with packaged food to ensure that the packaging is
compatible with the heating components. The packaging must be suitable for the temperatures in the unit. When stocking the unit, a
minimum distance of 80 mm must be kept from the heating components (especially supporting heat, radiant heaters). The units must
be operated in a complete condition. All existing covers (depending on the model) must be mounted and closed during operation.
To save energy, we recommend switching o the units when they are not in use outside of business hours. Before stocking the units,
wait until the desired set temperature is reached.
It is mandatory for all the manufacturer’s specications to be complied with. Among others, these specications are the
ambient temperature, the quality of the installation environment, and the connections that are to be used
NOTE
Use in accordance with the intended purpose also includes observing the installation and operating guide as well as compliance
with the inspection and maintenance conditions. The operator must check and ensure this. Any other use requires the written
approval of the manufacturer. Improper use can endanger persons and result in damage to the system/unit. The unit is operated via
a controller that may only be used after reading and understanding the Operating Manual. Furthermore, liability and warranty claims
are excluded in the event of non-compliance with proper use. The unit may only be used and operated under the conditions of use
prescribed in the Operating Manual.

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CALEO HOT/NEUTRAL
1.10. Target group and prior knowledge
This Operating Manual is intended for operating personnel in the area of gastronomy (e.g.: hotel chains, restaurants, catering) as well
for the installation personnel. The unit may only be operated by trained personnel who are to be specied by the operator. Ensure
that the personnel intended to operate the unit meet the following prerequisites:
• Operators may not be visually impaired, because they must be able to easily read the safety instructions on
the unit and the information in the Operating Manual.
• Reading and understanding this Operating Manual is a requirement. The currently applicable regulations on
safety at work and accident prevention must be complied with.
• Only instructed personnel may operate and clean the appliance. Only qualied personnel who have been aut
sed by the operator may perform maintenance and repair work.
• Ensure without fail that the locally applicable safety regulations are complied with in accordance
with trade law.
To acquire the knowledge that is required to operate the unit, the following measures must be carried out by the
operator:
• product training
• regular safety instruction
This unit may be used by children aged 8 years or over, as well as persons with reduced physical, sensory or mental capabilities or
a lack of experience and knowledge, if they are supervised or have been instructed regarding safe use of the unit and the risks resul-
ting from it. Children must not play with the unit. Cleaning and maintenance must not be carried out by children without supervision.
In addition to the operating personnel, the unit may also be used by gastronomy customers for independent removal of the food.
These persons do not require any particular prior knowledge.

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1.11. Reasonably foreseeable misuse
The units must not be used as follows:
• No food may be heated up or cooked. The unit may be lled exclusively with food that displays the stipulated
core temperature (of +85 °C).
• Operation outside the specied temperature range is not reliably possible (see Chapter 1.8).
• No openings may be blocked or covered.
• Food must not touch the walls and intermediate ceilings of the unit.
• The unit must not be operated outside of buildings. Protect the unit against direct sunlight, water penetration, and
high dust pollution.
• Units for food such as seafood, sh and mussels or similar must be implemented with a higher grade of stainless
steel (V4A or AISI 316) or be equipped with suitable containers.
• Glass covers and shelves must not be used as climbing aids or for storage.

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CALEO HOT/NEUTRAL
1.12. Residual hazards
Even with maximum care during the design and manufacture of the units, and taking account of all safety-relevant circumstances,
there can still be residual hazards that have been evaluated by means of a risk assessment. All the residual risks and safety instructions
from the risk assessment are listed in this chapter.
Danger of crushing when inserting/setting-up the units in the counter cut-out
When inserting/setting-up units, be aware of the danger of crushing, including for third parties. Manual lifting of the units must
be carried out by at least four persons. These persons must be strong enough to be able to carry the units. Call in another
person for spotting if necessary. Wear protective gloves and safety shoes for installation and loading activities.
Danger of crushing and danger from falling objects when handling/aligning/positioning heavy individual components
When handling heavy objects, be aware of possible crushing dangers, including for third parties. If possible,
use both hands when you handle heavy objects. Bring in another person to help you if necessary. When handling/aligning/
positioning heavy individual components, protective gloves and safety shoes must be worn.
Danger of tripping in the entire area around the unit
Be aware of possible tripping hazards from cables/lines installed on the oor.
Lines and cables must be installed safely by the operator so that there is no tripping hazard.
Danger of slipping from spilled water
Use the lling device supplied with the unit and remove any spilled water.
WARNING
WARNING
CAUTION
CAUTION
Danger of being struck by the units during installation, cleaning and maintenance work
Be aware of possible dangers of being struck by the unit.
Danger of crushing when moving the sliding doors/hinged doors (depending on the model)
When opening and closing the sliding doors, use the handles provided for this purpose When closing the sliding doors, do
not reach between the side sections of the sliding door and the unit. Do not reach into the guide rails. When opening and
closing the sliding doors, ensure that you do this slowly. Sudden opening and closing can lead to hand injuries.
WARNING
WARNING

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Danger of tipping on an uneven or unstable subsurface
The base in which the unit is installed must have sucient stability to support the unit permanently.
Danger of crushing and from falling parts when moving the unit
The steering and xed-position casters must be locked to ensure permanent stability. This applies in particular to larger
model variants of the unit.
When lifting the unit, there may be a risk from an unergonomic posture
Bring in another person to help you if need be. This applies in particular to larger congurations of the unit.
Various dangers during the disposal of damaged parts/components
When disposing of damaged parts/components, wear protective gloves. Dispose of damaged parts/components properly
and in an environmentally compatible way. Observe country-specic laws.
Danger of burns on the inside of the display case
Do not touch any hot surfaces or products with bare hands. Use suitable aids such as tongs to remove the products. Let the
display case cool down completely before any cleaning and maintenance work.
WARNING
WARNING
WARNING
WARNING
WARNING
Danger from electrical voltage on live components
Cleaning, installation, start-up, dismantling and repair work on electrical components may only be carried out by trained
specialists when the power to the unit has been shut o.
DANGER
Danger of fire
Do not position any combustible objects or packaging materials in the eective range of the radiant heater. Observe the local
re prevention regulations. Let the display case cool down completely before any cleaning and maintenance work.
WARNING

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CALEO HOT/NEUTRAL
Danger of crushing in the area of the glass
When lifting the glass of the unit, there is a danger of crushing between the unit and glass walls. Bring in another person to
help you if need be. This applies in particular to larger model variants of the unit. Let the display case cool down completely
before any cleaning and maintenance work.
Danger of burns on the steam inlet (exclusively for units with heating climate)
Close the steam inlet on the operator side before stocking the unit with products or removing products. Let the display case
cool down completely before any cleaning and maintenance work.
Danger of burns on the collecting tray or water bath
Switch the unit o and let it cool down for at least 45 minutes before starting any cleaning work.
Crushing danger in the area of the base plate (exclusively for units with heating climate)
Check the gas dampers of the base plate regularly to ensure they work, and replace them in accordance with the
manufacturer’s specications.
Danger of burns on the steam generator (exclusively for units with heating climate)
When sliding in and removing the hinged doors from the slide-in, ensure you do not touch the steam generator.
Switch the unit o and let it cool down for at least 45 minutes before starting any cleaning work.
WARNING
WARNING
WARNING
WARNING
WARNING

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1.13. Personal protective equipment
The following protective equipment must be worn for installation, dismantling and maintenance work:
Wear safety shoes during installation and loading work.
Wear protective gloves during installation and loading work
Wear eye protection when disposing of damaged parts/components.
Wear a hard hat during installation, lifting and loading work.
When cleaning the unit, wear the respective protective equipment stipulated by the manufacturer of the cleaning agent
being used.
NOTE

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CALEO HOT/NEUTRAL
1.14. Transport and packaging
The design of the packaging is dependent on the quote submitted, and is designed individually by agreement. By default, the units are
transported with wood cladding. This cladding protects the units against major damage. Components made of glass are additionally
wrapped with packaging material. Moving parts and glass shelves are given an additional sheath of packaging material. All parts are
positioned and taped safely for transport inside this wood cladding..
Danger from falling objects during transport and installation of the unit
Use adequately dimensioned lashing and clamping devices. When securing the load, observe the permissible vehicle regu-
lations. The legal trac regulations of the specic country must be obeyed. The unit may only be transported upright. When
lifting, ensure that nobody is in the danger area. Always lift loads at the centre of gravity. Wear protective gloves and safety
shoes during installation activities.
Danger from falling objects when lifting and unpacking the units
When removing the wood cladding, be aware of possible dangers from wooden parts that might fold back. Bring in another
person to help you if necessary. The unit must be lifted with suitable load lifting equipment, e.g. a forklift. At least four persons
must be employed to manually lift the unit. These persons must be suciently strong. Wear protective gloves and safety shoes
during installation and loading activities.
WARNING
WARNING
In the event of a return shipment, the unit must be packed in the original packaging or in the same way suitable for transport.
Furthermore, the unit must be delivered unused, undamaged and complete. The return shipment must be commissioned and paid
for by the customer. Information on correct disposal of the packaging material can be found in Chapter 1.15.
All units must only be transported and stored in the position of use (horizontal). To enable damage that is caused during
loading, transport and unloading to be traced, all units are equipped with a so-called “ShockWatch® 2”. This tool makes it
possible to determine the point of the delivery chain at which the product was damaged, in order to clarify transport damage.
Information on the ShockWatch® concept is stored in the QR code (see Chapter 4.1)..
NOTE

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GENERAL INFORMATION AND SAFETY
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1.15. Disposal
Various dangers during the disposal of damaged parts/components
When disposing of damaged parts/components, wear protective gloves. Dispose of damaged parts/components properly
and in an environment-friendly way. Observe country-specic laws.
WARNING
Please note that some of the components of the unit are electronic parts. Therefore it is not possible to
dispose of them using public waste disposal companies. Check your obligations in accordance with the
national WEEE provisions. It is mandatory to sort waste before disposal is mandatory in any event
NOTE