file + vers.

SW date changes

Meaes503ka1.doc 03/06/2003 First version

ka19.bin
st6ka2.hex
Meaes503ka1.doc 31/07/2003
ka25.bin - added wash
st6ka2.hex - inserted Storage
- inserted new MMV operation
Meaes503kamd1.doc 22/01/2004
kamd02.bin - inserted MD pads with relevant operation
st6ka2.hex - deleted storage
Meaes503kamd2.doc 30/04/2004 - MMV running anticlockwise in the function DF
- inserted DF bloc time.
kamd04.bin - water delivery independent from medium level (60” fixed time delivery)
st6ka2.hex - IMS open resets any possible pasteurization flags.
On reclosing, timer is set at 60’ within which it is allowed to enter in
production without conditions (exception made for “wash” and alarms).
After 60', the temperature will be tested and if it is over 10°C or same,
pasteurization flag of involved section is issued, and as a consequence, the
machine is forced to execute a pasteurization program.

AES 503 KA MD
AES 503 KA MD Topping
AES 503 KA MD DF
AES 503 KA MD DF Topping

ELECTRONICS HANDBOOK

1
This handbook gives information and procedures to assist technicians in setting up and repairing the
machine. This is the reason why this handbook is reserved for TECHNICIANS, only.
When turning the machine on, it carries out an operating self-test of the display and all leds light up.

General note:
when mentioning MA1, MC1 or parts with final digit “1”, they are always parts of the machine
LEFT side, looking at its front side. When mentioning MA2, MC2 etc., we are instead talking about
parts of the machine RIGHT side.

SOFTWARE VERSION

When switching the machine on, the display indicates the software version.

FOR EXAMPLE:
KAM02 means version 02

On display:

followed by the machine model, for instance 400/50/3 or 230/50/3 .......

MOD01 means machine model 01

If the machine fails to work, your Technician will always have to specify this number (software
version), as well as the machine serial number you will find on data plate, so as to take the best
advantage of Carpigiani Technical Service.

2
DISPLAY

The display normally indicates the temperature in the tank (if in STOP on both sides real time is also
displayed).
In Production, it is normally displayed the CONSISTENCY (when MA is running) on 2 figures,
only, 0 to 12, and HOT set is reached, the temperature in tank TEV will be displayed.
During heating or cooling cycles, sensors TEC and TEV alternatively, depending on whether the
cylinder or the tank are heated or cooled. TEC sensor is displayed through a spot down on the
display right side not to mistake it for the TEV one.

Pasteurization has no particular displays:

Tank heating, left side

On central display figure led switches on to indicate
Pastuerization Heating on left side.
TEV is displayed on both left displays.

Cylinder heating, left side

On central display figure led switches on to indicate
Pastuerization Heating on left side.
TEC is displayed on both left displays and spot down on
the right side switches on.

Heating pause, left side.

On central display figure led switches on to indicate
Pastuerization Pause on left side.
TEV is displayed on both left displays.
If cylinder heating starts, it will displayed TEC
temperature.

Tank cooling left side

On central display figure led switches on to indicate
Pastuerization Heating on left side.
TEV is displayed on both left displays.

Cylinder cooling, left side

On central display figure led switches on to indicate
Pastuerization Cooling on left side.
TEC is displayed on both left displays and spot down on
the right side switches on.

3
Tank heating, right side
On central display figure led switches on to indicate
Pastuerization Heating on right side.
TEV is displayed on both rightside displays.

Cylinder heating, right side

On central display figure led switches on to indicate
Pastuerization Heating on right side.
TEC is displayed on both rightside displays and spot
down on the right side switches on
Heating pause, right side.
On central display figure led switches on to indicate
Pastuerization Pause on right side.
TEV is displayed on both rightside displays.
If cylinder heating starts, it will displayed TEC
temperature.
Tank cooling right side
On central display figure led switches on to indicate
Pastuerization Heating on right side.
TEV is displayed on both left displays.

Cylinder cooling, right side

On central display figure led switches on to indicate
Pastuerization Cooling on right side.
TEC is displayed on both left displays and spot down on
the right side switches on

Negative temperatures

Negative temperatures display is also particular, as well and explanation given herebelow apply to
both right and left sides:

0 to –9°C the temperature shown is on 2 displays,

one for sign “-“, the other one for the temeprature
value.
For example: –9°C:

For temperatures –10°C to –19°C the display “-“ is

on the same monitor as decimal.
For example: –19°C:

For temperatures below –19°C, the display is as

follows:

4
AVAILABLE CONTROLS

AES 503 KA MD AES 503 KA MD DF

192.114.360 (573.800.651) 192.114.370 (573.800.652)

AES 503 KA MD Topping AES 503 KA MD DF Topping

192.114.210 (573.800.642) 192.114.350 (573.800.650)

Code of the Complete Pad in brackets.

5
ENABLING PROGRAMMING KEYS

this key is used to activate keys which coincide

with

. Starting from the left, the first key belongs to Programming,

the second one to Enter, the third one to Decrement and the fourth one to Increment.

Press the key 5” in order to enable them.

The led below on display right side lights at intervals and it switches off by pressing again the same
key (or after 255”), so disabling a.m. keys.
Every time this handbook makes reference to those keys, please take heed of following note.

If your machine is not a topping one, key TOPPING will not be displayed on the machine pad
but it can be activated through its pressure.
Topping key is thence invoked for special executions.

6
SENSORS LOCATION

LEFT SIDE SENSORS

BACK⇒

RIGHT SIDE SENSORS

FRONT ⇒

7
CLOCK SETTING

When installing the machine, it is necessary to check exact time and set it again, if need be.
In order to adjust the machine inside clock, set the machine to STOP.

By pressing the monitor will display SET HOURS (HOUR), then press

(SX=Enter) to display the value of real time and through (DX=Decrement)

and (Increment) set the exact value.

By pressing the monitor will display SET MINUTES (MINUTES), then press

(SX=Enter) to display the value of real time and through (Increment) and

(DX=Decrement) set the exact value

Go ahead as described above, i.e., press and then (SX=Enter) in order to set all
values:

SET HOURS (HOUR)

SET MINUTES (MINUTES)
SET SECONDS (SECONDS)
SET DAY OF WEEK (DAY OF THE WEEK)
SET DAYS (DAY OF THE MONTH)
SET MONTH (MONTH)

Last, set LEFT SIDE STOP in order to return to STOP.

8
FUNCTIONS

The machine has 2 sections, LEFT (sx) and RIGHT SIDES (dx) which work separately.

STOP:

When both sides are in Stop, real time is on display.

In this function the machine is OFF and its led is ON.
One can access any function from Stop position. In order to change a function, IT IS ALWAYS
NECESSARY to first return to STOP.

LEFT SIDE STOP BUTTON IS ALSO USED TO RESET ANY ALARM

PRODUCTION:

The product is cooled down till HOT reaches the value programmed in steps 1 and 2 (P01 and P02).
On reaching the desired consistency (HOT), the beater keeps on running 3 more seconds and then it
stops; on the contrary, the compressor is ON and tank solenoid valve is energized instead of the
cylinder one, in order to bring the tank mix to the storage temperature (when cold is necessary inside
the tank).
After reaching HOT, the beater starts every 10 minutes in order to check ice-cream consistency: if it
is lower (HOT – HOT HYSTERESIS), the compressor starts together with cylinder solenoid valve
in order to cool ice-cream down to the programmed consistency.

It is possible to change ice cream consistency (PAYING ATTENTION NOT TO EXCEED BATER
MOTOR RATING INPUT) as follows:

When the machine is in distribution mode, press Programming push-button followed by

(SX=Enter). The display will indicate HOT value to be reached.

To modify HOT value, press INCREMENT push-button if you want to increase the value

or DECREMENT (DX=Decrement) if you want to decrease it.

Press Programming push-button in order to stor new HOT value and continue to dispense
ice cream.

9
When cooling the cylinder, ice cream consistency value is displayed, namely 0 to 12, thence on 2
figures, only, whereas in Programming mode, this value can be set 50 to 120 (that means 5÷12 in
Production).

PUMP MOTORS

In this machine the pump for each side is controlled by relevant Beater Motor.
In PRODUCITON and CLEANING TTA1 and TTA2 depending on side selected.
In PASTEURIZATION and STORAGE TTA3 and TTA4 depending on side selected
(REVERSAL). In this case, pumps are in “freewheel” operating mode.

NOTE1:

If the level indicator switches ON, the machine will allow about 10 more portions only (that can be
programmed); after that, it will automatically pass from Distribution to Storage.
No return to Distribution is allowed while filling the tank with mix.

Tank mixer motor (MMV) in Production

MMV is activated in Production mode only if EVFV is energized in place of EVRF, and viceversa.

TEMPERATURE CHECK
When setting the machine to STOP from Production mode, TEV tank temperature is checked
and if it is at 10°C or higher, a Pasteurization cycle will have to be executed. So pressing the
Production key, the machine will automatically pass to Pasteurization. In practice, if one
starts a manual pasteurization program and the temperature raises beyond +10°C, it is no
longer allowed to enter in production, as long as a pasteurization cycle is completed.
After the machine weekly wash, it is necessary to press the production key within 60
minutes after the front lid closure (AL09 IMS). In this case, the test on TEV = 10°C is
cancelled for a time of 60’ and Production key is accepted. After 60 minutes, the
machine will not accept the production key and it always sets to Pasteurization function.

10
PASTEURIZATION:

SX DX

No Pasteurization process will ever start if the mix inside the tank is below the mean level.
In case of malfunction of the tank level sensor, the mean level led will be blinking and, as a
consequence, no Pasteurization process will start. Now, the machine will automatically set (after
about 20”) to STORAGE (pasteurization process will not be carried out) In order to force
Pasteurization even if mean level led blinks, it is necessary to press Pasteurization push-button

, release it and then keep it 5 seconds down. By this, you will “skip” tank level check
block.
The product either in tank or in cylinder is heated up to 65°C (programable), kept at this temperature
for 30 minutes (fixed), and then cooled down to reach the storage temperature.

As to the description of functions in Heating, Pauese and Cooling, please refer to DISPLAY.

Delta TGV-TEC
In Pasteurization Heating, the difference TGV-TEV is checked: if it is >= 30°C (this value can be
programmed in steps DELTA1 and DELTA2 depending on side involved), the machine sets to
STOP with AL20 BELT1 for sx-side and AL50 BELT2 for dx-side. Alarm may be caused by tank
mixing Motor non-functioning.

Heating
During Heating cycle, the compressor heats cylinder and tank, at intervals.
Typical heating time for cylinder and tanks are as follows: 15” CYLINDER and 30” TANK.
Times are changed depending on the difference between TEC and TEV.

If TEC > TEV:

- if the difference is 1°C, EVRV ON 32” / EVRC ON 15”
- if the difference is 2°C, EVRV ON 34” / EVRC ON 15”
- if the difference is 3°C, a EVRV ON 38” / EVRC ON 15”
- if the difference is >= 4°C, EVRV ON 46” / EVRC ON 15”

If TEV > TEC:

- if the difference is 1°C, EVRC ON 16” / EVRV ON 30”
- if the difference is 2°C, EVRC ON 17” / EVRV ON 30”
- if the difference is 3°C, EVRC ON 19” / EVRV ON 30”
- if the difference is >=4°C, EVRC ON 23” / EVRV ON 30”

If the tank reaches the Pasteurization temperature before the cylinder does, beater times in the
cylinder are on a cyclic basis, namely, 15” ON and 20” OFF.

11
Pause
During the 30 minutes pause in Pasteurization, the beater motor runs 15 seconds and stops 2
minutes, till pause time is over.
If the cylinder needs be heated during pastuerization pause, the beater motor will run 15 seconds and
then it stops 30 seconds.

If you want to skip the 30 minutes pause after the temperature of 65°C has been reached, press
Pasteurization push-button and hold it 3 seconds down; by this you will pass to Cooling and have
skipped the 30 minutes pause.

By pressing Pasteurization push-button once, pause time left (minutes) will be displayed. 5” later, the
temperature will automatically be displayed again.

Cooling
Cooling is cyclic: 15” ON cylinder and 30” ON tank.
The beater runs only when the cylinder needs be cooled. When it however reaches the temperature of
+20°C, the beater runs continuously. When reaching the Storage temperature, the beater stops and
restars only when the cylinder needs be cooled again.

On cycle end, the machine sets to Storage. PE (Pasto End) in both left and right digits will be
displayed, according to whether relevant Pasteurization program has been successfully executed.

Caution: if TES (Safety Thermostat) trips, the machine will set to Storage but on Pasto end,
PE will not be displayed, because Pasteurization was not successfully completed.

Automatic Pasteurization
At the time set in steps START PASTO1 and START PASTO2 the machine will automatically
switch over to Pasteurization and the program will be fully carried out. This will happen if machine
was left in the functions Production, Storage and Pasteurization.
When the Pasteurization cycle has been completed, PE (Pasto End) will be displayed on relevant
section side.

Tank Mixer Motor (MMV) in Pasteurization

MMV is activated all the Pastuerization cycle long. When program is over, it will only start if EVFV
or EVRV is energized.

12
TOPPING:

optional

It is a function independent from the other ones and can be thus enabled from any function.

When pressing relevant push-button, its led will switch on.

Resistances will be activated if:
- water in topping container is enough to cover topping level,
- in Programming, SET TOPPING step is not = 0
- the temperature TET is lower than SET TOPPING

When pressing relevant push-button, topping resistances will be activated and these will bring water
temperature to the value set in Programming (55°C, as a rule) and keep it as such, under
thermostatic control.
When Topping led is on, tank topping level sensor is covered with water.
If water does not reach the level sensor, heating will automatically cut out and Topping led will start
blinking.

Notes:
- By pressing left side STOP, topping will switch off.
- Set Topping=0 in Programming disables Topping controls.

BEATING:

The beater runs (and ice cream mix pump, too). After 3 minutes, the machine automatically returns
to STOP in order to avoid a severe wear of both cylinder and beater.

The temperature displayed is TEC (TEC1 sx, TEC2 dx). If you press Beating push-button once, you
will have the display of TGV (TGV1 sx, TGV2 dx) 5” long, then display is back on TEC

13
WATER INLET / DRY
FILLING:

Water inlet

This function is enabled from STOP position.

This push-button shall be held some 4” down in order to start the function. This will avoid an
unintentional inlet start while cleaning the keyboard. Once the function has been accepted, relevant
led will switch on and Water Solenoid valve will be activated 60” fixed. By pressing the same push-
button again, water inlet stops and its led switches off, as well.
Water inlet will NOT stop when reaching medium levels: they are not taken into account.

Dry Filling (DF)

This funciton is enabled from STOP and PRODUCTION (if step DRY FILLING is > 0 and mean
level is not covered):

By pressing STOP push-button from STOP position, STOP and

DF leds will blink or, by pressing PRODUCTION push-button
from PRODUCTION mode, STOP and PRODUCTION leds will
blink, as to confirm that a DF program can be executed.
On display you can see the number of litres set. Ex.: 2.50:

By pressing Programming and Enter you can change

(SX=enter)

The number of litres through Increment and Decrement push- (Increment)

buttons:

(DX=Decrement)

Press then Progrmming to confirm:

You now have 15 seconds to activate Dry Filling.

By pressing Water Inlet push-button, now,

the number of litres displayed will be let in (the monitor will display
the number of litres also if the function yuou selcted is Production.
Practically, the number of litres has the display priority).

14
During water inlet, the monitor displays litres and decilitres
countdown.
When litres decrement is over, the tank beater starts running
(ANTICLOCKWISE) on 3 seconds delay for 11 minutes, if mean
level is not covered, and 16 minutes if it is covered.
The monitor displays “dF” on side relevant to DF during the first 3
minutes in which all functions are inhibited (DF BLOC TIME
programable).
For example on left side:

During the execution of Dry Filling cycle from Production, the machine automatically sets to STOP.
When Dry Filling cycle is over, the function Production will start again.

WASH

On every access to the function Production, “Wash-N Days” will be displayed, this means that there
are still N days to the machine cleaning.
The message will be displayed about 5 sec., after that, routine display is reset.
If, for instance, we enter in Production and the message “Wash-3 Days” will be displayed, it means
that there are 3 days to next cleaning.
When the number of days is >0 and <5 , then whenever production is selected, the number of days to
wash will be displayed.
The wash day, the message on display will be “Wash Today”: the function of production is
inhibited, machine does not accept Production mode and automatically sets to Storage.

NOTE 1: Wash day decrements every day between 23.58 and 23.59h.

15
MIX LEVEL

Low mix level in the tank is warned by relevant led switching on.
When low mix level is intermittently on, it means MEAN level is not covered and the access to
Pasteurization is not allowed (the machine automatically sets to Storage).
When low mix level is such that its led is fixed on, it mean LOW mix is on and in Production one can
just dispense the number of cones set in step CONES (1=Sx, 2=Dx).

CONE-COUNTER

To display the number of cones dispensed, press as already explained in paragraph CLOCK
SETTING.
You can have access to relevant step CONES1 or CONES2 and check how many portions have been
dispensed from relevant side.

SET HOURS (HOUR)

SET MINUTES (MINUTES)
SET SECONDS (SECONDS)
SET DAY OF WEEK (DAY OF THE WEEK)
SET DAYS (DAY OF THE MONTH)
SET MONTH (MONTH)
CONES1 00000 (NUMBER OF CONES ON SX-SIDE)
CONES2 00000 (NUMBER OF CONES ON DX-SIDE)

To reset the number of cones to 0, press (SX=Enter) and hold it 3” down, while the writing
CONES is scrolling.
Cones taken out from central piston will be reckoned both on the LEFT and on the RIGHT side.

16
ALARMS

The machine is provided with a self-"CHECK" device warning about any possible troubles.
The "CHECK" led blinks when an alarm is active and it remains ON, to remind us that an alarm has
been activated.
Press STOP to read the last alarm occurred.
When the "CHECK" led is ON (or blinking), check from the table below which alalrm is active. Press
STOP to read last alarm for just once.
The machine can be used in ice cream production even if an alarm is active; if it is a critical one, the
machine will not allow you to select ice cream production program; in this case, press STOP and do
not use the machine till its repair.
Alarms available on the machine are reported in the table below:

ALARMS DESCRIPTION
Left side and
MUTUAL
AL01 (RT1) Thermal relay left side has tripped.
This may be caused by Thermal Relay relevant to beater motor 1, Thermal
Relay compressor motor 1, Thermal Protection mixing motor 1.

AL03 (TES1) Cylinder/Tank safety thermostat left side has tripped and machine sets to
Storage.
This alarm is active when TEC>20°C and TEV>20°C
It is not read in Distribution mode.

AL05 (TEV1) Tank sensor TEV1 faulty.

AL06 (TEC1) Cylinder sensor faulty.

The alarm might also be caused by an insufficient feeding to cylinder. If this
is the case, TEC temperature drops to the minimum value (full scale) of the
CPU and the sensor alarm is displayed.
Check whether the pump runs properly.
When the temperature in the cylinder falls back within the sensor range, the
alarm resets.
MACHINE SETS TO STOP.

AL07 (TGV1) Tank evaporator sensor faulty.

AL09 (IMS) Safety magnet switch open.

Check whether the front lid is closed or check the safety magnet switch.
Alarm has delayed by 4” since contact opening in order to avoid wrong
warnings.
AL11 (PR1) High pressure switch, left side, has tripped.
Check cooling water flow. Machine remains in the function in which it is (it
does not set to STOP).

17
AL17 (TET) TET sensor alarm.
TET is the sensor indicating the topping tank temperature.
In case of trouble, the message AL17 will be on display and check led will
blink.

AL20 (BELT1) In Pasteurization Heating, if DELTA T trips , i.e., the difference TGV1-
TEV1 gets >= 30°C (programable in step DELTA1), machine must be set
to STOP.
This alarm might also be caused by non-functioning of the tank mixing
Motor.
AL23 (COMM) No communication between CPU1 and CPU2. Check connection serial
cable.

More available alarms for the right side, besides the mutual ones described before:

ALARMS DESCRIPTION
Right side

AL31 (RT2) Thermal relay right side has tripped.

This may be caused by Thermal Relay relevant to beater motor 2, Thermal
Relay compressor motor 2 Thermal Protection mixing motor 2.

AL33 (TES2) Tank/cylinder right side safety thermostat has tripped; machine set to
Storage. On Pasto end, PE (Pasto End) will NOT be displayed.
This alarm is active when TEC2>20°C and TEV2>20°C
Alarm not read in Distribution mode.
AL35 (TEV2) Tank sensor TEV2 faulty

AL36 (TEC2) Right cylinder sensor faulty.

The alarm might also be caused by an insufficient feeding to cylinder. If this
is the case, TEC temperature drops to the minimum value (full scale) of the
CPU and the sensor alarm is displayed.
Check whether the pump runs properly.
When the temperature in the cylinder falls back within the sensor range, the
alarm resets.
MACHINE SETS TO STOP.

AL37 (TGV2) Right tank evaporator sensor faulty.

AL41 (PR2) High pressure switch right side has tripped.

Check cooling water flow. Machine remains in the function in which it is (it
does not set to STOP).
AL50 (BELT2) In Pasteurization Heating, if DELTA T trips, i.e., the difference TGV2-
TEV2 gets = 30°C (programable in step DELTA2), machine must be set to
STOP.
This alarm might also be caused by non-functioning of the tank mixing
Motor.

18
ALARMS TABLES

The table herebelow shows for each alarm when the machine keeps function in which it was when an
alarm activates or sets to another function, automatically.

The machine keeps in the function of…

ALARMS with Production Pasteurization Beating Storage Topping

machine in STOP

AL01 ( RT1 ) NO NO NO NO YES

AL31 ( RT2 ) ⇒ STOP ⇒ STOP ⇒ STOP ⇒ STOP

AL03 ( TES1 ) YES NO YES YES YES

AL33 ( TES2 ) ⇒ CONS

AL05 ( TEV1 ) NO NO YES NO YES

AL35 ( TEV2 ) ⇒ STOP ⇒ STOP ⇒ STOP

AL06 ( TEC1 ) YES NO YES NO YES

AL36 ( TEC2 ) ⇒ STOP ⇒ STOP

AL07 ( TGV1 ) YES YES YES YES YES

AL37 ( TGV2 )

AL09 ( IMS ) NO NO NO NO NO
⇒ STOP ⇒ STOP ⇒ STOP ⇒ STOP ⇒ STOP
It keeps the
AL11 ( PR1 ) function in NO NO NO YES
AL41 ( PR2 ) programs after ⇒ STOP ⇒ STOP ⇒ STOP
3 trippings or
after 2’ open
contact it sets to
STOP

AL17 ( TET ) YES YES YES YES YES

AL20 ( BELT1 ) YES YES YES YES YES

AL50 ( BELT2 )

AL23 ( COMM ) YES YES YES YES YES

19
The table herebelow shows for each alarm whether the machine accepts a function inspite of the
active alarm:

Access to the function ...allowed

ALARMS with Production Past eurization Beating Storage Topping

machine in STOP

AL01 ( RT1 ) NO NO NO NO YES

AL31 ( RT2 )

AL03 ( TES1 ) YES NO YES YES YES

AL33 ( TES2 ) ⇒ CONS

AL05 ( TEV1 ) NO NO YES NO YES

AL35 ( TEV2 )

AL06 ( TEC1 ) YES NO YES NO YES

AL36 ( TEC2 )

AL07 ( TGV1 ) YES YES YES YES YES

AL37 ( TGV2 )

AL09 ( IMS ) NO NO NO NO NO

AL11 ( PR1 ) NO NO NO NO YES

AL41 ( PR2 )

AL17 ( TET ) YES YES YES YES YES

AL20 ( BELT1 ) YES YES YES YES YES

AL50 ( BELT2 )

AL23 ( COMM ) YES NO YES YES YES

20
BLACKOUT

In the event of black-out, if the machine was in Beating mode, on power return, it sets to STOP.

While Heating in Pateurization or in Pause during Pasteurization program, on power return, the
machine is again in the function where it was before power failure.

If the machine was in:

Soft ice production, Cooling in Pasteurization or Storage

on power return, the machine checks the temperature and how long the power failure lasted; if a
blackout lasts more than what indicated in the table, the machine will repeat the pasteurization
completely , while CHECK led is ON and AL15 appearing in the “events list“.
Otherwise, if blackout time is shorter than the one shown in the table below, the machine will return
to the function where it was before it took place.

Temperature TEV Time

68°C ÷ 50°C 30 minutes

49°C ÷ 15°C 10 minutes
14°C ÷ 10°C 20 minutes
9°C ÷ 4°C 2 hours

21
AUTOSETUP AND MACHINE MODEL

(Increment)

If necessary, autosetup has to be done after Carpigiani service’ authorization, only.

CAUTION: Every time a new machine model is inserted, sensor offset values are zeroed. It
is consequently advisable to always carry out a Download Memory before an autosetup.

The procedure sets all programable values according to the ones indicated in the column of relevant
model.

To do that, unplug the machine, press (Increment), then plug it again.

Keep (Increment) down until the machine model is displayed:

Mod _ _

Using (Increment) and (DX=Decrement), buttons, select the Machine Model

Number taken from Programming table in Mod. line.
Press then:

LEFT SIDE to confirm.

If you do not confirm through push-button the Machine Model will not be stored.
The machine is now programmed with the values indicated in relevant column.
Available models :

Mod Features

1 400V / 50 Hz / 3
2
3

22
EVENTS LIST

The machine is provided with a bib storage space that helps us store most of the events (function you
select, alarms, ...).

To read the events stored in the memory you must have the machine in STOP, then press
and keep pushing it 5 seconds.

On the display you’ll get the last event followed by the MONTH-DAY, HOUR and MINUTES.

To scroll all events backward (starting from the most recent one), press (Increment) each
time you desire to read the previous event.
If you do not press any button for 30 sec. or you press STOP, the machine will go to STOP.
The events list helps us understand when and how many times a certain alarm has occurred.
Moreover, we can have a report informing us about the pasteurization cycle and check:

START PASTO: PASTEURIZATION STARTING MM-DD-HH-mm

HEATING END: HEATING END MM-DD-HH-mm
PAUSE END: PAUSE END MM-DD-HH-mm
PASTO END: PASTEURIZATION END MM-DD-HH-mm

MM-DD-HH-mm means Month - Day – Time (hour) - Minutes.

Events list is available in English, only.

NB: The highest number of storable events is 800.

One more event will cancel the last one (the eighthundredth).

23
PROGRAMMING for the technician

Technicians can changes some parameters.

In order to have access to Program mode, it is necessary to have the machine in STOP,

then press (SX=Enter) sequentially.

The monitor now displays the first programming step, i.e., P01 HOT.

Press (SX=Enter) to read the step value that can be changed using (Increment) and

(DX=Decrement) push-buttons.

To have access to the next step, press Programming push-button ,

• So, by pressing you have access to the next program step.

• By pressing (SX=Enter) you get the value programmed at this step.

Use push-button (Increment) and (DX=Decrement) to modify this value.

In order to leave the Programming mode, press STOP or do not press any push-button 10”.

24
PROGRAMMING TABLE
Version Flash Eprom: Kamd04.bin Display: Kam04
Description AES 503 KA AES 503 KA Checking
Step Min Max 400/50/3 400/50/3 value
Mod 1 Mod 2
P01 HOT 1 050 120 100 100
P02 HOT 2 050 120 100 100
P03 HOT HYSTERES 002 020 008 008
P04 TRIMMER HOT 000 199 78 78
P05 SET HOPCYL12 02 06 04 04
P06 TEV1 ADJUST TEV1-9 TEV1+9
P07 TEC1 ADJUST TEC1-9 TEC1+9
P08 TGV1 ADJUST TGV1-9 TGV1+9
P09 TEV2 ADJUST TEV2-9 TEV2+9
P10 TEC2 ADJUST TEC2-9 TEC2+9
P11 TGV2 ADJUST TGV2-9 TGV2+9
P12 TET ADJUST TET-9 TET+9
P13 PAST HOPCYL1 055 085 065 065
P14 PAST HOPCYL2 055 085 065 065
P15 DELTA TGVTEV 10 60 30 30
P16 DF BLOC TIME 0 15 3 3
P17 DRY FILLING 0.00 disab 9.95 0.00 0.05
P18 CORR DF COST 000 010 000 000
P19 CORR DF PROP 0.00 0.20 0.00 0.00
P20 TGV1 SET DFR -34 0 -15 -15
P21 TGV2 SET DFR -34 0 -15 -15
P22 DEFR HYSTER 002 020 005 005
P23 SET TOPPING 000 disab. 085 075 075
P24 CONES 1 000 099 000 000
P25 CONES 2 000 099 000 000
P26 HOT GAS 1 00.0 25.0 01.0 01.0
P27 HOT GAS 2 00.0 25.0 01.0 01.0
P28 AGITA TIME 001 020 003 003
P29 CYCLIC TIMER 001 099 010 010
P30 START PASTO1 000 010 2 2
P31 START PASTO2 000 010 3 3
P32 DAYS WASH 000 060 0
P33 AL 01 RT1 YES NO YES YES
P34 AL 31 RT2 YES NO YES YES
P35 AL 11 PRESS 1 YES NO YES YES
P36 AL 41 PRESS 2 YES NO YES YES
P37 AL 03 TES 1 YES NO YES YES
P38 AL 33 TES 2 YES NO YES YES

25
PROGRAMMING TABLE NOTES

Step NOTE

P01 HOT 1
When increasing this number, one gets harder ice cream and also an increase in input value
of beater motor 1 or LEFT SIDE.
P02 HOT 2
When increasing this number, one gets harder ice cream and also an increase in input value
of beater motor 2 or RIGHT SIDE.
P03 HOT HYSTERES (hysteresis)
A lower value makes HOT more sensitive during icecream distribution.When machine is in
Ice cream Production and MIR being energized, after that the compressor cuts out due to
HOT operating, the compressor starts again if consistency valuedisplayed is lower than
HOT minus the value set in this step.
To LEFT AND RIGHT SIDES applicable.

P04 TRIMMER HOT

The number programmed in this step refers to ice cream consistency. When increasing it, ice
cream consistency decreases and, as a consequence, when decreasing it, ice cream
consistency increases.
Consistency is meant on cut-out, i.e., when the compressor stops as the consistency has
reached the value set in step HOT.
For example (values are approxiamte): HOT = 100; TRIMMER HOT = 82; MA input on
compressor cut-out (HOT) = 3A
When TRIMMER HOT is changed between 82 and 90:
HOT = 100; TRIMMER HOT = 70; MA input on compressor cut-out (HOT) = 2.2 A
(softer ice cream).
The number can also be automatically set after Autosetup.
Caution: to change this number, it is necessary to check the beater motor current that must
not exceed 110% rating value.

P05 SET HOPCYL12

LEFT and RIGHT tank and cylinder storage set. It is thus one for tank 1, cylinder 1, tank 2
and cylinder 2.

P06 TEV1 ADJUST

Tank temperature TEV1 setting.
With a precise thermometer and probe inside the tank, the reading on the display must agree with
the value read on the thermometer, otherwise value read on display must be adjusted through

(Increment) e (DX=Decrement) buttons, so that both readings will agree.

26
P07 TEC1 ADJUST
Cylinder temperature TEC1 setting.

P08 TGV1 ADJUST

Setting of tank evaporator temperature TGV (for tank 1 defrosting).
This temperature must be adjusted as TEV but the probe of a precise thermometer shall be
put into the probe-holder which you find into the tank evaporator.

P09 TEV2 ADJUST

Tank temperature TEV2 setting.

P10 TEC2 ADJUST

Cylinder temperature TEC2 setting.

P11 TGV2 ADJUST

Setting of tank evaporator temperature TGV2 (for tank 2 defrosting).

P12 TET ADJUST

Topping temperature setting.

P13 PAST HOPCYL1

Pasteurization temperature for LEFT cylinder and tank.

P14 PAST HOPCYL2

Pasteurization temperature for RIGHT cylinder and tank.
P15 DELTA TGVTEV
In Heating relevant to Pasteurization mode, the difference TGV1-TEV1 (if left side) or
TGV2-TEV2 (if right side) is checked and when >= 30°C (this value can be set in this step)
makes the machine got to STOP: on display AL20 BELT if involving left side and AL50
BELT if involving right side.
This alarm may happen when tank Mixer Motor fails to work.

P16 DF BLOC TIME

Machine lock time (in minutes) after the execution of a Dry Filling: it secures homogeneity
of mix in the tank.

P17 DRY FILLING

Water quantity inlet in D/F.
If set to 0, D/F is disabled.

P18 CORR DF COST

Steady D/F correction.
Output is decreased by n x 40 cc fixed, where n is the value set in this step.

P19 CORR DF PROP

Proportional D/F correction. Output is decreased by n cc every 40 cc where n is the value
set in this step

27
P20 TGV1 SET DEFR
When temperature TGV1 reaches a value equal to or lower than the one programmed in
this step, solenoid valve for tank-1 cooling switches off and hot gas solenoid valve switches
on in order to defrost the tank 1.

P21 TGV2 SET DEFR

When temperature TGV2 reaches a value equal to or lower than the one programmed in
this step, solenoid valve for tank-2 cooling switches off and hot gas solenoid valve switches
on in order to defrost the tank 2.

P22 DEFR HYSTER

When temperature TGV1 reaches a value equal to or lower than the one programmed in
TGV1 SET DRF, solenoid valve for tank-1 cooling switches off and hot gas solenoid valve
switches on in order to defrost the tank 1 till the temperature of TGV1increases by the
value set in this step.
When temperature TGV2 reaches a value equal to or lower than the one programmed in
TGV2 SET DRF, solenoid valve for tank-2 cooling switches off and hot gas solenoid valve
switches on in order to defrost the tank 2 till the temperature of TGV2 increases by the
value set in this step.

P23 SET TOPPING

Topping temperature by which topping is controlled by thermostat.
If step is set at 0, topping option and its alarms (AL16 - AL17)will be disabled.

P24 CONES 1
It’s the number of cones the machine can dispense in Production after low level sensor led
LEFT SIDE switches on.
The machine will then automatically set to storage mode.

P25 CONES 2
It’s the number of cones the machine can dispense in Production after low level sensor led
RIGHT SIDE switches on.
The machine will then automatically set to storage mode.

P26 HOT GAS1

Hot gas activation every time solenoid valve for LEFT cylinder cooling turns off.

P27 HOT GAS2

Hot gas activation every time solenoid valve for RIGHT cylinder cooling turns off..

P28 AGITA TIME

It is the time in which the beater keeps on running after that the compressor stops owing to
HOT.

P29 CYCLIC TIMER

Cyclic timer in Ice cream Production.
Every 10 minutes (programmed in this step) the beater starts in order to check ice cream
consistency.

28
P30 START PASTO1
Left side automatic Pasteurization starting time.

P31 START PASTO2

Right side automatic Pasteurization starting time

P32 DAYS WASH

It indicates the number of days to the machine cleaning.
Machine must be cleaned or its controls will all be locked (machine does not accept
Production and automatically sets to Storage).
If set to 0, wash control will be disabled.

P33 AL 01 RT1
Enabling (YES) or disabling (NO) alarm RTA1, RTC1, PTMMV1.

P34 AL 31 RT2
Enabling (YES) or disabling (NO) alarm RTA2, RTC2, PTMMV2.

P35 AL 11 PRESS1
Enabling (YES) or disabling (NO) alarm high pressure switch, left side.

P36 AL 41 PRESS2
Enabling (YES) or disabling (NO) alarm high pressure switch, right side
P37 AL 03 TES1
Enabling (YES) or disabling (NO) alarm safety thermostat tank/cylinder LEFT SIDE.

P38 AL 33 TES2
Enabling (YES) or disabling (NO) alarm safety thermostat tank/cylinder RIGHT SIDE.

• If an alarm is enabled, the machine will be protected by the same alarm.

• When an alarm is disabled, the machine will not display the alarm

29
CPU BOARD REGULATIONS

• JUMPERS
CPU is provided with 3 jumpers J1, J2 and J3 (see CPU layout).

J1: Current transformer (T/A) selection

J1 must be selected depending on current transformer.
In case of a red current transformer 1:1000 the jumper must be inserted into the internal position A.
In case of a black current transformer 1:120 (USA) the jumper must be inserted into the external
position B (see CPU board layout).

J2
It must be inserted near to keyboard flat cable connector.
It is for internal use in CARPIGIANI.

J3: Temperature range selection

By self-pasteurizing machines, this jumper must be inserted in the “-34” scale (internal position).

• SERIAL PORT JP15

To make a CPU software upgrade, you must use the special serial cable, delivered by Carpigiani, that
connects the CPU (JP15, see CPU board layout) to the RS232 port of any Personal Computer (PC).
The software Upgrade can be done by downloading the new software from the computer to the CPU
using the Dloader Program delivered by Carpigiani.

• SOFTWARE UPGRADE

Connect your PC (RS 232) to the CPU (JP15) and run the DLOADER program.
The new software you want to download to the processor must be resident in the same directory as
DLOADER program.
Disconnect the machine from the mains (from AESMD19 onwards this is a necessary action).

Press STOP on LEFT side and keep it down.

Turn the machine on.
When you hear a beep and the display is fully off, the processor is ready to accept the new software
version from the computer.
A software upgrade, if the version changes, sets all sensors offsets to zero.

Events will go missing.

Clock does not stop, consequently, it does not need resetting.

30
• TRIMMER R78

Trimmer R78 is used to adjust the sensitivity of the level sensors.

By turning the trimmer to a clockwise direction, level sensor will be less sensitive and level led will
switch off.
By turning the trimmer to a counter clockwise direction you get a more sensitive level sensor and
level led will switch on.

Attention:
If you excessively turn the trimmer R78 anticlockwise, ALARM RTA will warn that you are too far
from proper regulations and must turn back clockwise, so as to eliminate the ALARM (press STOP
for display resetting).

MIN - A: levels are ON and ALARM RTA is ON.

NEVER SET THE TRIMMER TO THIS POSITION.

A - B: levels are on and ALARM RTA is OFF.

NEVER SET THE TRIMMER TO THIS POSITION.

B - C: trimmer setting area. 0 - 950 ohm

TRIMMER MUST BE SET TO 950 OHM, i.e., with red notch in C.

How to set the trimmer in relation to mix conductivity.

31
1) The trimmer must be turned clockwise to switch the level led off, as with scarcely conductive
mixes.
2) Highly conductive mixes (R<950 ohm) may bring about foam trouble:
foam can be conductive even if the mix is below the minimum line: in such a case, the trimmer shall
be turned anticlockwise, so that, being the sensor covered with just foam, the level led switches on
(never turn, however, up to reach A-B areas).

• HOT CONTROL

P1 automatic control push-button

Ice cream consistency to the max. value to be adjusted as follows:

1- Fill cylinder and tank with mix.

2- Press Ice cream Production push-button.

3- Press automatic control button P1 (see CPU layout) once (the beeper will beep intermittently).

4- Check the current of the beater motor with a clamp tester.

5- When the current read on the tester is equal to the value corresponding in the following table,
press on the automatic control button in order to conclude HOT setting procedure and store the
adjustment value “TRIMMER HOT” at program step P05.

AES 503KA TRIMMER HOT DISPLAY

400/50/3 P05

MA current in HOT
( rated Amps ) 2.9A 78 100
(1.1kW)

6- Press STOP.

32
CARD layout

33
DIP SWITCH SCHEDA ATL 573700178

Card code: 573 700 178 µP: ST6ka2.hex

The 4 coloured DIP are all in OFF.

TABLE °C-OHM

The table herebelow shows the relation between the temperature read by a PTC sensor and the
resistance in OHM as read by a tester.
It is useful to check sensor readings.

TEMPERATURE °C OHM
-50 503,5
-45 528,9
-40 555,2
-35 582,5
-30 610,6
-25 639,6
-20 669,6
-15 700,5
-10 732,2
-5 764,9
0 798,5
5 832,9
10 868,3
15 904,6
20 941,8
25 980
30 1019
35 1058,9
40 1099,7
45 1141,5
50 1184,1
55 1227,6
60 1272,1
65 1317,5
70 1363,7
75 1410,9
80 1459
85 1508
90 1557,9
95 1608,7
100 1660,4
105 1713
110 1766,5
115 1820,9

34
 INDEX

GENERAL NOTE: ............................................................................................................................ 2

SOFTWARE VERSION............................................................................................................. 2
DISPLAY .................................................................................................................................... 3
AVAILABLE CONTROLS........................................................................................................ 5
ENABLING PROGRAMMING KEYS ..................................................................................... 6
SENSORS LOCATION.............................................................................................................. 7
CLOCK SETTING ..................................................................................................................... 8
FUNCTIONS............................................................................................................................... 9
STOP:.......................................................................................................................................... 9
PRODUCTION:.......................................................................................................................... 9
PASTEURIZATION:................................................................................................................ 11
TOPPING: ................................................................................................................................ 13
BEATING: ................................................................................................................................ 13
WATER INLET / DRY FILLING: .......................................................................................... 14
WASH ....................................................................................................................................... 15
MIX LEVEL ............................................................................................................................. 16
CONE-COUNTER.................................................................................................................... 16
ALARMS .................................................................................................................................. 17
ALARMS TABLES .................................................................................................................. 19
AUTOSETUP AND MACHINE MODEL............................................................................... 22
EVENTS LIST .......................................................................................................................... 23
PROGRAMMING FOR THE TECHNICIAN........................................................................ 24
PROGRAMMING TABLE ...................................................................................................... 25
PROGRAMMING TABLE NOTES ........................................................................................ 26
CPU BOARD REGULATIONS ............................................................................................... 30
• JUMPERS ............................................................................................................................ 30
• SERIAL PORT JP15 ............................................................................................................. 30
• SOFTWARE UPGRADE ....................................................................................................... 30
• TRIMMER R78..................................................................................................................... 31
• HOT CONTROL ................................................................................................................... 32
CARD LAYOUT....................................................................................................................... 33
DIP SWITCH SCHEDA ATL 573700178................................................................................ 34
TABLE °C-OHM...................................................................................................................... 34

35