OTT FREEZER MASTERCHEF User manual

INSTRUCTION MANUAL
MASTERCHEF
MASTERCHEF S

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MASTERCHEF
masterchef_G-07/07-ed.2
OTTFREEZER
ViaEmilia,45/A-40011AnzolaEmilia(Bologna)-Italy
Tel.[phone]-Fax[phone]
This handbook may not be reprinted, transferred, registered, recorded in a retrieval system, nor
translatedinotherlanguagesunlessotherwisepreviouslyagreedwith OTTFREEZER.
The purchaser has the wright to reprint it for his own office use.
OTT FREEZER policy pursues a steady reasearch and development, thus it reserves the right to
make changes and revisions whenever deemed necessary and without being bound to previous
statements to the purchaser.
We wish to thank you for the preference granted to us by purchasing one of OTT
FREEZER machines.
To thebest guarantee,since 1993 OTTFREEZER has submittedits own Quality
System to the certification according to the international Standard ISO 9001-94,
nowadays its production has got UNI-EN-ISO 9001-2000 Certified Quality
System.
Moreover,OttfreezermachinescomplywithfollowingEuropeanDirectives:
• 98/37/CE MachinesDirective;
• 73/23/CEE Low tension Directive;
• 89/336/CEE EMC Directive;
• 89/109/CEE Food Contact Directive.

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GENERAL INDEX
FOREWORD ......................................................................................................................3
INSTRUCTIONHANDBOOK ............................................................................................. 5
PURPOSE ............................................................................................................................ 5
HANDBOOK STRUCTURE............................................................................................... 5
ADDITIONALDOCUMENTATION................................................................................... 5
SAFETY .............................................................................................................................. 6
QUALIFICATIONOFTHE STAFF.................................................................................... 6
CONVENTIONALSYMBOLS ............................................................................................ 7
WARNINGS ........................................................................................................................ 7
1 GENERAL
1.1 GENERALINFORMATION .........................................................................................9
1.1.1MANUFACTURER'SIDENTIFICATIONDATA.................................................. 9
1.1.2CLIENT/USER'SIDENTIFICATIONDATA.......................................................... 9
1.1.3INFORMATIONABOUTSERVICE ...................................................................... 9
1.1.4INFORMATIONTOTHE USERS......................................................................... 9
1.2 INFORMATIONABOUTTHEMACHINE .................................................................10
1.2.1GENERALINFORMATION ................................................................................ 10
1.2.2TECHNICALFEATURES .................................................................................... 11
1.2.3LOCATIONOFTHEMACHINEGROUPS .......................................................... 11
1.3 INTENDEDUSE .........................................................................................................12
1.4 NOISE .........................................................................................................................12
1.5 STORINGAMACHINE .............................................................................................12
1.6 DISPOSAL OF PACKING STUFFS ........................................................................12
2 INSTALLATION
2.1 ROOMNECESSARYTOTHEMACHINEUSE .........................................................13
2.2 MACHINELOCATION ..............................................................................................13
2.3 MACHINESWITHAIRCOOLEDCONDENSER ......................................................13
2.3.1WATERSUPPLYCONNECTION FORWASH .................................................. 13
2.4 MACHINESWITHWATERCOOLEDCONDENSER ...............................................14
2.4.1WATERVALVEADJUSTMENT ........................................................................ 14
2.4.2WATERSUPPLYCONNECTIONFORMACHINEWASH ................................ 15
2.5 ELECTRICCONNECTION ........................................................................................15
2.5.1REPLACINGTHEINPUTCABLE ....................................................................... 15
2.6 REFILLING .................................................................................................................16
2.7 MACHINETESTING ...................................................................................................16
2.8 MOVEMENT-TRANSPORT .....................................................................................16
DIRECTIONSFORUSE
3.1 MACHINESAFETYWARNINGS ..............................................................................17
3.2 MACHINECONFIGURATION ...................................................................................17
3.3 CONTROLS ...............................................................................................................18
3.3.1PUSHBUTTONPANEL ....................................................................................... 18
3.3.2STOPPUSH-BUTTON ........................................................................................ 18
3.3.3BEATINGPUSH-BUTTO .................................................................................... 19
3.3.4ADJUSTINGBEATERSPEEDPUSH-BUTTON.................................................. 19
3.3.5EXTRACTIONPUSH-BUTTON.......................................................................... 20
3.3.6HEATINGPUSH-BUTTON ................................................................................. 20
3.3.7COOLINGPUSH-BUTTON ................................................................................. 20
3.3.8"GO"PUSH-BUTTON ......................................................................................... 21
3.3.9INCREMENTPUSH-BUTTON ............................................................................ 21
3.3.10DECREMENTPUSH-BUTTON ......................................................................... 21
3.3.11TIMERPUSH-BUTTON .................................................................................... 21
3.3.12WASHINGPUCH-BUTTON.............................................................................. 22
3.3.13RECIPESPUSH-BUTTON ................................................................................. 22
3.3.\4RECPUSH-BUTTON.......................................................................................... 23

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3.4 PERSONALIZEDPROGRAMS .................................................................................23
3.4.1USERPROGRAMCREATION ............................................................................ 23
3.4.2EXAMPLEOF PROGRAMCREATION ............................................................. 24
3.4.3CANCELLINGAUSERPROGRAM .................................................................... 25
3.5 READINGPROGRAMS(AUTOMATICANDUSER)...............................................25
3.6 USERPROGRAMMING .............................................................................................26
3.7 MACHINESTART ......................................................................................................26
3.7.1AUTOMATICOPERATION ............................................................................... 26
3.7.2MANUALOPERATION ..................................................................................... 26
4. ALARMS.....................................................................................................................27
4.1 NOPOWERSUPPLY ............................................................................................. 28
5. CLEANING, DISASSEMBLINGANDREASSEMBLINGPARTSINCONTACT
WITHTHEPRODUCT ...............................................................................................31
5.1 PRELIMINARYCLEANING .................................................................................. 31
5.2 DISASSEMBLINGTHE SPIGOT .......................................................................... 31
5.3 DISASSEMBLINGTHETANKCOVER ................................................................. 32
5.4 DISASSEMBLINGTHEBEATER .......................................................................... 32
5.5 HYGIENE ............................................................................................................... 33
5.6SANITATION ........................................................................................................ 33
6. MAINTENANCE .........................................................................................................35
6.1 SERVICINGTYPOLOGY ..........................................................................................35
6.2 WATERCOOLING .....................................................................................................35
6.3 AIRCOOLING ............................................................................................................35
6.4 ORDERINGSPAREPARTS ......................................................................................35
7. TROUBLESHOOTGUIDE ..........................................................................................37
7.1 TROUBLESHOOTGUIDE..........................................................................................37

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FOREWORD
INSTRUCTIONHANDBOOK
Editing this handbook, it was taken into due account community directions on safety standards
aswellasonfreecirculationofindstrialproductswithinE.C.(R.E.C.Councildirection89/392and
subsequent, known as "Machines Direction".
AIM
This handbook was edited while taking into due account needs of machine users.
Topics relevant to a correct use of the machine have been analyzed in order to keep unchanged
in the long run quality features of the worldwide OTT FREEZER machines.
A significant part of this handbook refers to the conditions necessary to the machine use and to
the necessary behaviour during cleanout as well as routine and special maintenance.
Nevertheless, this handbook cannot meet in details all demands; in case of doubts or failing
information, please apply to:
OTTFREEZER ViaEmilia,45/A-40011AnzolaEmilia(Bologna)-Italy
Tel.[phone]-Fax[phone]
HANDBOOKSTRUCTURE
This handbook is structurilized in sections, chapters and subchapters in order to consult it more
easily.
Section
A section is the part of handbook identifying a specific topic referred to a machine part.
Chapter
A chapter is that part of section describing a group or concept relevant to a machine part.
Subchapter
It is that part of a chapter detailing the specific component of a machine part.
It is necessary that each person involved in the machine running reads and clearly understands
those parts of the handbook of own concern, and particularly:
- TheOperatormust have alookatchaptersconcerning themachinestart-upandtheoperation
of machine groups.
-Askilledtechnicianemployedininstallation,maintenance,repair,etc.,must readallpartsof
this handbook.
ADDITIONALDOCUMENTATION
Along with an instruction manual, each machine is also supplied complete with further
documentation:
-Machineequipment:Alistofsparepartsdeliveredtogetherwiththemachineforitsmaintenance.
- Wiring diagram: A diagram of wiring connections put into the machine.
ATTENTION!!
Before using the machine read carefully the instruction handbook.
Pay attention to the safety instruction

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SAFETY
Whenusingindustrialequipmentandplants,onemustbeawareofthefactthatdrivemechanisms
(rotarymotion),highvoltagecomponents,aswellaspartssubjecttohightemperaturesmaycause
serious damages to persons and things.
Who is in charge of plant safety must be on the look-out that
- an uncorrect use or handling is avoided
- Safety devices must neither be removed nor tampered
- Only original spare parts are to be used especially as far as those components with safety
functions are concerned (ex.: protection microswitches, thermostats).
To achieve the above, the following is necessary:
- At working place an instruction manual relevant to the machine should be available.
- Such documentation must be carefully read and regulations must consequently be followed.
- Only adequately skilled personnel will have to be assigned to electrical equipment.
QUALIFICATIONOFTHESTAFF
Staff attached to the machine can be distinguished according to training and responsibility as
follows:
OPERATOR
- A person who has not necessarily a high technical knowledge, just trained for ordinary
operation of the machine, such as: startup, stop, filling, basic maintenance (cleanout, simple
blocking, instrumentation checkings, etc.).
SKILLEDENGINEER
-A personengangedon morecomplicatedoperations ofinstallation, maintenance, repairs,etc.
IMPORTANT!
Onemustbeonthelook-out that thestaffdoesnotcarryoutanyoperationoutsideitsownsphere
of konwledge and responsibility.
NOTE:
According to the standard at present in force, a SKILLED ENGINEER is who, thanks to
- training, experience and education,
- knowledge of rules, prescriptions and interventions on accident prevention,
- knowledge of machine operating conditions,
is able to realize and avoid any danger and has also been allowed by the person in charge of
plant safety to carry out all kinds of interventions.

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CONVENTIONALSYMBOLS
ATTENTION:ELECTRICSHOCKDANGER
The staff involved is warned that the inobsevance of safety rules in carrying out the operation
described may cause an electric shock.
ATTENTION:GENERALDANGER
The staff involved is warned that the operation described may do harm if not carried out in the
observarnce of safety rules.
NOTE
It points out significant information for the staff involved.
WARNINGS
The staff involved is warned that the inobservance of information may cause a loss of data and
damages to the machine.
MACHINEOPERATOR
It deals with an unskilled person , who has no specific competences and can only carry out easy
functions, such as the machine operation by means of controls available on push-button panel
, and filling and drain of products used during production.
MAINTENANCEENGINEER
Heisa skilled engineer for operation of themachineunderregular conditions; he is able to carry
outinterventionsonmechanicalpartsandall regulations,aswellasmaintenanceandrepairs. He
is qualified for interventions on electrical and freezing plants.
OTTFREEZERENGINEER
It deals with a skilled engineer the manufacturer puts at clients' disposal for complicated
interventionsundparticularconditionsor anyhowin accordancewithagreementstakenwith the
machine's user.
PROTECTIONS
This symbol placed by description side means that the operator must use personal protections
against an implicit risk of accident.
WARNING
Wheninstalling the machine, insertadifferential magnetothermal protectionswitchon all poles
oftheline,adequatelysizedtotheabsorptionpowershownonmachine dataplateandwithcontact
opening of 3 mm at least.
- Neverputyourhandintothemachine,alikeduringproductionandcleaningoperations.Before
carrying out any maintenance operation, make sure that the machine is in “STOP” position
and main switch has been cut out.
- It is forbidden to wash the machine by means of a bolt of water under pressure.
- Itisforbiddentoremovepanelsinordertoreachthemachineinsidebefore disconnectingthe
machine.
-OTT FREEZER is not responsible for any accident that might happen during operation,
cleaning and/or servicing of its units, if this warning has not been fully complied with.

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MASTERCHEF
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1. GENERAL
1.1 GENERALINFORMATION
1.1.1Manufacturer'sidentificationdata
The machine has a data plate carrying manufactuer's data, machine type and identification number
given when it is manufactured.
1.1.2Client/user'sidentificationdata
CLIENT: ..............................................................................................................
ADDRESS: .........................................................................................................
TELEPHONE:......................................................................................................
Machineserialnumber: ......................................................................................
Machine delivered on:........................................................................................
Instr. handbook delivered on: ............................................................................
1.1.3Informationaboutservice
All operations of routine maintenance are described in section "Maintenance" of this
handbook; any further operation requiring radical interventions on the machine must be agreed
with the manufacturer, who will also examine the possibility of a direct action on the spot.
1.1.4Informationtotheuser
- The manufacturer of the machine here described is at user's disposal for any explanation and
information about the machine operation.
- In case of need, the interlocutor is the distributor being present in user's country, or the
manufacturer if no distributor is in that market.
- Manufacturer's service department is at clients' disposal for any information about operation,
and requests of spare parts and service.
- The manufacturer reserves the right to carry out all machine changes deemed as opportune
without previous notice.
- Descriptions as well as pictures contained in this handbook are not binding.
- Reproduction rights are reserved to OTT FREEZER
VHzkW
A
Gas kg
Cod.
ANZOLA EMILIA - BOLOGNA - ITALY
Matr.
AB
CDE H
FG
I
100089654588-4
A=Serialnumber
B=Machine type
C= Voltage
D= Fuse Current
E= Gas type and weight
F= Machine code
G= Condensation
A=AirW=Water
H= Frequency
I=Power input

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1.2 INFORMATION ABOUT THE MACHINE
1.2.1Generalinformation
Masterchef machines produce ice cream and confectionery and they can work fruit and greens
in pieces.
This machine was not designed:
- to produce "pasta"
- to freeze water, i.e., to produce ice cream with high water contents
- to mix, work out, etc. explosives or substances prejudicial to the health.
OTTFREEZERrecommends toalwaysusehighqualityingredientsforconfectioneryproducts
in order to satisfy your customers, even the hardest-to-please ones. Any saving made to the
prejudice of quality will surely turn into a loss much bigger than the saving itself.
Bearing in mind the above statements, please take heed of the following suggestions:
zChoose high quality natural ingredients or buy them from reliable companies.
zClosely follow instructions given by your supplier.
zDo not alter your supplier's recipies, by adding, for instance, water or sugar.
zTaste your product before serving and start selling it if only entirely satisfactory.
zMake sure your staff always keeps the machine clean.
zHave your machine always serviced by companies authorized by OTT FREEZER.
RESIDUALRISKS
Dangerofthermalnature
By opening the cover of the tank containing high temperature product, the
operatorrunstheriskofbeingcaughtinhotsteam.
Actwithutmostcareanduseproperprotectionsbeforeopeningthe
tankcover.