OSR275 - GB - Instruction Manual PDF

ITALY, 36015 Schio (VI)
www.gamitaly.com
[email protected]
Tel+39 0445 576205
We Temper…You create Fax +39 0445 500026
INSTRUCTION MANUAL
One Shot
Dosing machine
mod. OSR275
Before using the machine, read carefully this manual.

www.gamitaly.com
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INTRODUCTION
This manual provides all the information for use and maintenance of the machine.
Smooth functioning and duration depend on the attention dedicated during use and
maintenance.
Before leaving the factory, this specific model has been subject to rigorous testing to
ensure maximum reliability, but even then, it is necessary to verify that the machine has
not suffered structural damage during transport, which could affect its operation and
security.
This manual is an integral part of the machine and should remain with the same until its
demolition.
In case of loss or damage Gami Srl should be asked for a replacement copy.
The technical information contained in this manual is property of Gami Srl and must be
regarded as confidential.
All reproduction, even partial, of graphic design, text and illustrations is prohibited by
law.
Some details of the illustrations in this manual may be different from your machine,
some elements have been removed for clarity of images.
This manual should be kept in an accessible place for all the dedicated staff and
machine maintenance.
Any dispute shall be settled by the Court of VICENZA (ITALIA)
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Index:
1. INFORMATION pag. 4
1.1 Introduction 4-5

1.2 Manufacturer contact data 5
1.3 Plates 5
1.4 Expected applications 5
1.5 Technical data and overall dimensions 6
1.6 Environmental employment conditions 7
1.7 Lighting 7
1.8 Vibrations 7
1.9 Stockage 7
1.10 Demolishing the machine 7-8
1.11 Products use conditions 8
1.12 Warranty conditions 9-10
1.13 Professionals authorized to use the machine 10-11
2. SAFETY pag. 12
2.1 Safety information 12

2.2 Safety provisions 13-15
2.3 Safety labels and symbols 16
2.4 Safety dispositions and protections 16-17
2.5 Working, command and safety areas 17
2.6 Safety measures provided by the customer 18
2.7 Individual protection equipment 18-19
2.8 Residual risks 19-21
2.9 Compliance with standards 21
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3. SHIPPING AND HANDLING pag. 22
3.1 General outline 22-23

3.2 Dimensions and weights 23
4. INSTALLATION pag. 24
4.1 Machine positioning 24

4.2 Floor levelling 24
4.3 Electrical connection to the main panel 25
4.4 Commissioning 25-26
5. OPERATION pag. 27
5.1 Pages description 27-46

5.2 Possible anomalies and blocks 47
6. MAINTENANCE SECTION pag. 48
6.1 Notes 48
6.2 General safety norms 48-49
6.3 Cleaning 49-50
6.4 Mechanical pieces maintenance 50
6.5 Electrical system maintenance 50-51
6.6 Residual risks for maintenance technicians 51
6.7 Cleaning the machine 51
6.8 Gears, hoppers and moulding plate cleaning and
joints replacement 52-55
6.9 Repairs 56
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SECTION 1) INFORMATION
1.1 INTRODUCTION
This manual is intended for operators and specialized staff, to allow correct operation
with the machine.
Inside the operator can find instructions and guidelines for:
• Proper installation of the machine;

• A functional description of the machine and all its parts;
• Making adjustments in the phase of commissioning and start-up;
• A proper maintenance;
• Pay attention to the most basic rules of safety and accident prevention.
The operator will therefore be able to know the issues with the machine and its
operation.
To improve understanding of this manual we indicate below the terms used therein:
• DANGER ZONE: area inside or in the vicinity of the machine in which the presence
of an exposed person determines a risk for the safety and health of the person
itself.
• EXPOSED PERSON: person within or partially within a danger zone.
• OPERATOR: person in charge of the installation, operation, routine maintenance
and cleaning of the machine.
• QUALIFIED TECHNICIAN: Specialized person trained and qualified to perform the
extraordinary maintenance or repairs which require specific knowledge of the
machine operations, safety devices and their intervention modes.
WARNING: Accident prevention rules for the operator.
WARNING: There is a possibility of damage to the machine and / or its components.
PRECAUTION: Additional information about the current operation.
NOTE: Provides useful information.
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It is imperative for the operator and the technician to read and understand the
contents of the manual, which must be preserved intact and is an integral part of the
machine itself.
IMPORTANT
Before using the machine, read the instructions in the manual and follow the indications
carefully.
Keep this manual and all publications enclosed in an accessible place known by all
users (operators and maintenance personnel).
1.2 MANUFACTURER CONTACT DATA

GAMI S.r.l.
Via Lago di Lavarone 14
36015 - Schio - Vicenza (Italy)
Tel: +39 0445 570265
Fax: +39 0445 500026
1.3 PLATES
During all interactions with the manufacturer the data on the plate of the machine
must be communicated.
1.4 EXPECTED APPLICATIONS

The one-shot OSR275 dosing machine is designed and built for dosing chocolate and
cream or just chocolate and / or cream in the dedicated moulds and respecting hourly
production as defined in the technical data sheet.
The one-shot OSR275 dosing machine is mainly composed of a machine body made of
aluminium in which are accommodated the metering gears; the hoppers, which
contain the products, are mounted above.
The machine is equipped with two servo-motors used to move the metering wheels and
one servo-motor which permits movement of the dispensing head in the vertical
direction.
The machine is designed for continuous operation without long intermediate stops.
Uses different from the ones depicted here are to be considered «inappropriate».
WARNING
The machine must be used for the treatment of the product specified in this manual
and in the prescribed time terms. The use of the machine for other processing or to
obtain quantities of the product outside of the specifications is considered "improper
use" and therefore the manufacturer declines all responsibilities for any damage
caused to property and / or persons, and considers any type of warranty on the
machine itself obsolete.
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1.5 TECHNICAL DATA AND OVERALL DIMENSIONS
- Dimensions: 1170x720x1380h mm
- Weight: 182 Kg. / Power: 2,4 kW / Voltage: 230 V - 50/60 Hz
Chocolate Filling
hopper hopper
1380 mm
720 mm
mm.
1170 mm
mm.
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1.6 ENVIRONMENTAL EMPLOYMENT CONDITIONS

To ensure proper functioning, the machine must be positioned inside a building, with an
ambient operating temperature of at least 19°.
The work environment must be clean, properly illuminated and free of explosive
atmosphere.
1.7 LIGHTING
During normal operation, illumination must permit easy identification of the control
panel.
During routine maintenance it’s necessary that the light is enough to allow the
execution of necessary safety operations.
Regarding how to provide adequate lighting, it’s the user’s responsibility to comply with
the legislation.
1.8 VIBRATIONS
In conditions of use consistent with the indications indicated in this manual, vibrations
are not likely to cause danger.
If the presence of vibrations is noticed, the operator must stop the machine
immediately and report the problem to the manufacturer.
1.9 STOCKAGE
Detach mobile protections and remove any foreign body from the machine, then
clean the surface. Cover with a protective lubricant (using a brush) all the mechanical
parts, including fasteners. This lubricant must be removed before re installation with an
alkaline degreasing agent (sodium hydroxide).
Lubricate mechanical parts.
Cover the surface with a protective lubricant.
Regroup parts and fix them on pallets in reference to the packing list, following the
instructions on handling.
Place bags of hygroscopic salt of silica gel on the pallets.
Store everything in a place protected from the weather with temperatures between
0°C and 40°C protect parts with nylon to avoid dust accumulation.
1.10 DEMOLISHING THE MACHINE

NOTE: As in each country are present different demolishing modes, you must comply
with the requirements imposed by law and by the competent authorities of the
countries themselves.
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WARNING
The demolition of the machine must be performed by qualified personnel, both
mechanics and electricians.
Before starting to disassemble you must create a large enough tidy space around the
machine, so to allow all movements without additional risks created by environment.
You need to:

- Disconnect the machine from the electrical network.
- Disconnect the supply pipes
- Disassemble the electrical panel.
- Disassemble the machine in its main parts.
WARNING
During this operation pay due attention to remove the heavy parts that can produce
lower limb injuries. Caution is advised when removing screws or bolts: before loosening
a screw make sure that the freed piece won’t be a danger to the operators engaged
in the demolition, and consider arranging appropriate support.
- Separate parts of the machine according to their nature (for example, plastic,
metal, electrical, etc...) and send them to recycling centres.
WARNING
The engine contains oil that might harm the environment: it must be properly
recovered and sent to the authorized collection centers.
1.11 PRODUCTS USE CONDITIONS

The chocolate forming the shell of the product must be liquid. Regarding filling, given
the enormous variety, we prefer using a viscosity range. That must be between 2000
and 6000 centipoise (cp), where a poise equals 1 g/(cm· s), or 0.1 Pa· s. Products
outside this range must be tested and probably slightly modified. You must also
consider that you can’t have solid pieces in the shell or filling, as those would block the
nozzles.
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1.12 WARRANTY CONDITIONS
WARRANTY
− 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 are not covered by this guarantee.
− 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 by 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
center 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 labor 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
SOFTWARE / FIRMWARE WARRANTY AND SERVICING
− Programs 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
programs including installation). By the end of this period the customer must have
tested that the entire program 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.
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EXCLUSION OF OTHER WARRANTIES
− 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.
1.13 PROFESSIONALS AUTHORIZED TO USE THE MACHINE

The machine must only be used by authorized and trained personnel; the same caution
also applies to maintenance performing staff. Do not let foreign personnel approach
the machine during operations or maintenance.
After receiving all the necessary instructions, the machine can only be manned by the
following professionals:
Safety officer
The safety officer is responsible for protection and risks prevention, as specified by the
European Directive 89/391 EEC (Safety).
The safety officer shall ensure that all persons who use the machine have received all
the concerning instructions contained in this manual.
Operator
Operator trained and qualified to operate the machine (duty cycle, settings, etc.). Can
perform only operations specifically described in this manual. Use of the machine by
inexperienced personnel must be avoided.
Maintenance mechanic
Specialized technician able to man the machine as the operator, to make it work with
disabled protections, intervene on adjustments, regulations and maintain and repair
electrical installations.
He is not permitted to work on electrical systems under tension. The maintenance
mechanic needs general experience in mechanics and specific experience about the
mechanics of this machine model.
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Maintenance electrician
Specialized technician able to man the machine as the operator, to make it work with
disabled protections, intervene on adjustments, regulations and maintain and repair
electrical installations.
The Maintenance electrician needs general experience in electrical panels and
specific experience about the electrical panel and electrical components of this
machine model.
Manufacturer
For all other operations not expressly provided in this manual or assigned to any
professional other than those listed above, you must contact Gami Srl.
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SECTION 2) SAFETY
2.1 Safety information
The security agent has the obligation to inform workers about the risks associated with
the use of the machine.
There also is the obligation for the employer to implement information, training and user
training as required by applicable law.
Non-compliance of regulations or of basic safety precautions could result in an

accident during operation, maintenance and fixing of the machine.
An accident can often be avoided by recognizing potentially hazardous situations
before they occur.
The operator must be aware of the potential risks and have the necessary training, skills
and tools to perform these tasks properly.
Gami Srl cannot be held liable in any case of accident or damage resulting from the
use of the machine by unproperly trained personal, or personal that has misused the
machine, or from the total or partial inobservance of standards and safety procedures
contained in the manual.
Safety instructions and warnings are given in this manual and on the product itself.
If you do not pay attention to these messages of danger, the operator can suffer
accidents with serious consequences for himself and for others.
Gami Srl cannot anticipate every possible circumstance that may cause a potential
hazard.
Warnings in this publication and on the product are not exhaustive.
In case you used tools, procedures, working methods or techniques which are not
explicitly recommended by Gami Srl you must ensure that there is no danger to you
and others.
Gami Srl disclaims all liability for the use of non-original parts.
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2.2 SAFETY PROVISIONS
WARNING
The following indications may not fully protect from all hazards that may incur during
the use of the machine; they should be integrated by common sense and by the
experience of the workers
Each section lists additional safety requirements specific to different tasks.
WARNING
It is forbidden to use the machine for staff which is not authorized and formed.
Operators engaged in activities permitted on the machine must be informed of the use
of personal protective equipment such as shoes, gloves, etc... that allows them to
cancel all risks arising from its activities.
Never clean or lubricate moving parts while they are moving.
Never detach safety protections or devices.
If you make a treatment or procedure that is not expected, following a procedure

different from that indicated in the manual, consult Gami Srl before proceeding.
Except for the operator, no people or animal should be present in the machine’s area
of operation.
In the event that a user installs on the machine tools that are not provided by Gami Srl,
it should be checked that the safety conditions required by Directive 2006/42 EC, are
maintained and, however, Gami Srl assumes no responsibility for any problems resulting
from the use of this tool.
The machine must not be operated in a corrosive or explosive environment. Keep the
machine clean of other materials such as debris, oil, tools and other objects that may
damage the operation and cause injury.
Greasy, wet or dirty floor can cause accidents.

Dry and clean immediately the floor from spots of any liquid or grease that might have
formed during interventions on the machine.
Avoid the use of toxic or flammable solvents for cleaning.
Avoid prolonged contact with and inhalation of vapors.
Do not use solvents near fire or heat sources; ensure adequate ventilation.
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Prolonged overloads or failures can cause overheating of the electric motors and
electrical equipment with the development of noxious fumes; immediately turn off the
power supply and do not approach the machine until you have scattered the smoke
with adequate ventilation.
In case of fire, never use water jets on the machine, but use CO2 extinguishers.
The operator, the eventual technical support and maintenance technicians must use
appropriate protective equipment when working the machine.
They will also have to use hearing protection if the sound pressure level at workstations
exceeds 85 dB (A).
Wear appropriate work clothing.
In the case of long hair use special nets against the risk of entanglement.
Responsibilities for the various activities in the use of the machine must be clearly
established, as described in the "professionals allowed to use the machine" chapter.
The manual must always be at hand for future reference to ensure correct operation of
the cycle whenever you have doubts.
If this manual is lost or damaged, you should ask Gami Srl for a replacement copy.
Structural damage, modification, alteration or improper repair can change the
protection capacity of the machine, thus eliminating this certification.
Change interventions must only be performed by Gami Srl technicians.
During maintenance a sign reading " MAINTENANCE DO NOT TURN ON" must be placed
on the machine, possibly on the control console,
If during the execution of a particular technical intervention, maintenance, inspection

or repair responsible staff must disable, open or remove (totally or partially) safety
devices, then it will be his duty to restore at the end of the operations the functionality
of the involved safety components.
Do not climb on the machine.
Do not touch the electrical cables, switches, buttons, etc... with wet hands.
The red emergency stop button allows the machine to stop according to norm UNI-EN
60204.
During recovery operations of the original working conditions, working staff must verify
that at the end of the intervention the normal security functions of the machine are
again guaranteed, especially safety devices affected by the operation.
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Staff must also ensure that, at the end of the intervention does no foreign bodies remain
inside the machine, in particular, machine parts, tools or equipment used in
intervention, which could result in damage to the machine or malfunction.
Personnel responsible for maintenance, inspection and repair, shall, before starting
work, turn off the main switch of the machine and implement all necessary safety
measures, especially those to be carried out manually.
Substitution, disconnection or partial removal of guards, safety devices and protective

structures are strictly prohibited.
The same rule applies for warning alerts provided on the machine.
Protections and safety devices must always be kept in perfect working order; if broken,
they must be repaired or replaced immediately.
Whether to allow the implementation of a particular technical intervention on a

specialized electric-electronic device of the machine, personnel must operate with
electrical cabinets or control panels open and exceptionally with the general switch in
the ON position, they should be careful and work with extreme caution.
During these operations, in fact, the presence of high voltage inside electrical-
electronic devices is a danger to the lives of staff.
Before resuming work, it is always necessary to be careful and make sure that there is
no staff in the working area of the machine.
Parts subject to wear based on their own work must be checked and replaced when
they show signs of significant wear.
The manufacturer has designed and built the machine to last for a reasonable period
taking into account the normal use of the client; anyway, you need to periodically
check all these components carefully.
If you find "mechanical cracking" and permanent structural or cyclical deformations,

consult the manufacturer or expert technicians who will take appropriate action.
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2.3 SAFETY LABELS AND SYMBOLS

On the device are applied plaques with symbols and / or safety messages.
WARNING
Make sure all safety messages are readable. Wipe them with a soft cloth, soap and
water. Do not use solvents, gasoline or naphtha. Replace damaged plates asking them
to Gami Srl. If a plate is located on a part which is replaced, make sure that the on the
new part a new plate is applied.
2.4 SAFETY DISPOSITIONS AND PROTECTIONS
WARNING
The following components are particularly important for safety. In case of damage or
wear they must be replaced with parts supplied or approved by the manufacturer.
During machine utilization all protections must be properly assembled.
Magnetothermal circuit breaker
In the case of an electrical short-circuit the magnetothermal circuit breaker intervenes.

You can reactivate the machine following the instructions:
• Set the main switch to 0

• Open the panel, reactivate the breaker
Restart the machine according to the starting procedure, taking care to check any
abnormal situations that can arise for errors or inadvertent manumissions during
maintenance.
Thermal circuit breakers
Located inside the control cabinet, these devices prevent the engine from excessive
heating up. When one of those protections activate they must be unlocked as per
following instructions:
• Set the main switch to 0. Open the electrical panel; each thermal has a button
which sticks out from the breaker itself when the protection intervenes.
• To unlock it, you need to press the reset button located at its sides. If it doesn’t
remain pressed, you must wait a few minutes for the protection to cool down,
and then press the button again.
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Protections
Fixed panels are stably positioned with locks and knobs, if the knobs are removed the
protections cannot stay attached to the machine, and must be grounded.
All panels are rounded for safety of the operators.
WARNING
Never start the machine if the movable guards are removed or not properly secured.
Never leave cloths, keys or tools for maintenance inside the machine. Before closing
the lid and starting the machine, check carefully and if necessary remove foreign
elements that are inside.
Attention!
Do not remove or manipulate protections’ micro switches. Maximum danger.
Safety Micro and protection grids
The removal of the protection transparent cover causes the block of the motor and the
temporary non-operation of the machine by a safety micro allocated in the carter. To
reset push the blue button RESET.
The protection grids have been mounted mechanically entrance of hoppers to avoid
injury.
2.5 WORKING, COMMAND AND SAFETY AREAS

The only area of activity is in front of the control panel because the operator must turn
on / off the machine and set the adjustments.
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2.6 SAFETY MEASURES PROVIDED BY THE CUSTOMER
Here are the security measures that the customer must provide.
Facilities for proper installation:
• Proper floor;
• Normal and emergency lighting;
• Adequate ventilation;
• Routes of emergency evacuation;
• Lines connecting the power supply;
• Suitable means for the collection and subsequent disposal of hazardous or
special wastes (oils and fats, broken or waste materials, etc.)
• prohibition of unauthorized entry;
• Systems and equipment for protection against fire;
• Training of operators and maintenance personnel, proper basic and tasks-
related training;
• Instructions to operators and maintenance personnel: manual reading and
understanding, diagrams, signs, reproductions of parts of the instruction manual
with local papers for special situations;
• Preparation of a maintenance diary.
2.7 INDIVIDUAL PROTECTION EQUIPMENT

Operators and maintenance personnel must use personal protective equipment that
allows them to avoid all possible risks arising from the implementation of the various
activities in accordance with the requirements of the installation plant.
WARNING
The clothes of those who work or performs maintenance of the machine must be in
compliance with the essential safety requirements set by EU Directives 2006/42 and laws
applicable in the country where the machine is installed.
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WARNING
During management and maintenance operations personnel should wear appropriate
clothing to prevent the occurrence of accidents.
To prevent risks of mechanical type, such as trapping, it is forbidden to wear details
such as bracelets, watches, rings and necklaces during the work cycle.
2.8 RESIDUAL RISKS
Accurate risks analysis the carried by the manufacturer and archived in the data sheet,
has eliminated most risk conditions of the machine. The manufacturer recommends
that you follow the instructions, procedures and recommendations contained in this
manual, including the use of protective devices provided, both integrated into the
machine and individual.
WARNING
As a precautionary measure for safety reasons it’s necessary to periodically check the
correct operation of safety devices. It is strictly forbidden to make any kind
of mechanical or electrical change, in order not to create additional hazards and
risks resulting therefrom, which are not covered.
The residual risks present on the machine are:
Electrical hazards during maintenance due to the need to operate under tension
According to DPR 547/55 only electrically qualified personnel is allowed to work under
tension, and only in presence of double insulation to ground.
WARNING
Before making the connection, make sure the AC tension at the point of installation is
not higher than that stated on the circuit breakers.
Otherwise, the user is required to provide at his own expense the appropriate limitation
devices.
Risks of improper use in the presence of explosive o inflammable substances

It should be noted that the machine is not equipped of AD Class for norm IEC 64/2. It
should therefore not be used in an environment containing substances in the form of
liquid which can evaporate at ambient temperature and flammable gas or dust.
Risks connected to use in a high humidity environment

Comply with the limits specified in this manual Section 1.7, environmental employment
conditions.
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Risks during working cycle

Risks of cutting, tearing and crushing following access to the moving parts of the
machine, due to the removal of fixed guards or to bypass of safety devices during
automatic operation, installation and adjustment.
WARNING
Personal exposure to moving parts of the machine may create situations of serious
danger.
It is strictly forbidden to start the machine until the fixed guards are not properly
installed.
It is strictly forbidden to alter or bypass safety protections by mean of personal tools.
Risk of cutting, tearing and crushing during maintenance, cleaning and change of
equipment type.
WARNING
During the operations of replacement equipment, the operator must use appropriate
protective gloves.
You must disconnect and lock all energy sources before accessing the machine to
follow the maintenance procedures described in the manual.
Risks during machine’s handling

It is recommended to tie the machine or its components in appropriate places, lift with
appropriate means and at the minimum allowed height, proceed at a slow pace and
make sure the people who help in the manoeuvres at a safe distance of the moving
object. Before starting the movement ensure that the transition zone is clear and there
are no objects near the machine trail. It is important that the support and transport
vehicle is operated by a qualified person for this operation to avoid sudden movements
or movements likely to cause danger to people who are aiding handling operations.
Risk of failures in the signalling, safety, protection and emergency stop circuits.
In case of circuit failure, the safety and signalling circuits, safety devices and
emergency stop may lose their effectiveness, for this it is necessary to carry out periodic
inspections of their condition.
Prohibition signs on the machine

Following risks identification, the manufacturer has installed on the machine a number
of signs, labels and / or warnings in compliance with rules relating to graphical symbols
for use on hazardous materials.
The user is obliged to immediately replace the signs and / or warning that should
become unreadable due to wear or damage.
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WARNING
It is absolutely forbidden to remove labels and / or safety warning from the machine.
The manufacturer declines all responsibility for the safety of the machine in case of non-
compliance with this prohibition.
Risk of injury and damage to the machine

Always wear gloves and safety goggles during disassembly, maintenance and cleaning
by air compressor.
Assign settings and periodic servicing to qualified personnel.
Danger of death (electrocution)

If it is necessary to operate with the electrical cabinet open and voltage activated,
work only with the help of specialized personnel. Protect from the risks surrounding area
with danger warning.
Risk of machine block

Before using a megohmmeter to verify the insulation of electrical components, verify
that all the electronical devices have been disconnect, to avoid damages to the
components.
Risk of fire propagation

In case of fire, never use water jets near the machine. Disconnect the machine from
power lines and use CO2 fire extinguishers.
Fire, poisoning, pollution risks

Clean the areas of intervention during maintenance. NEVER use flammable or toxic
solvents. Always use safety glasses and gloves. Do not release in the environment rags
or paper used to clean but put everything in their special containers.
2.9 COMPLIANCE WITH STANDARDS

To the machine described in this manual apply the following guidelines:
• 2006/42 CE Machine directive
• 2014/30 CE Electromagnetic compatibility - EMC
• 2014/35 CE Low tension
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SECTION 3) SHIPPING AND HANDLING

3.1 GENERAL OUTLINE
WARNING
Make sure that the following instructions are known by all personnel involved in the
transportation and installation of the machine.
It’s the customer's responsibility to check the resistance of the floor is suitable for the
weight of the machine.
If the floor of the workshop isn’t strong enough or not flat enough, you will have to
perform a specific concrete foundation; this to avoid the deformation of the structure
of the machine and free it from all other vibrations from adjacent machines.
WARNING
When the machine has been lifted higher than 50 mm the workers must maintain a safe
distance from the perimeter of at least 2 meters.
Rupture of the lifting system or uncontrolled movement are, in fact, a serious threat to
the personnel safety.
During the manipulation of components whose dimensions do not allow for adequate
visibility is better to employ several operators to provide necessary indications.
Before moving packaging, verify that the elevation system and related equipment
(ropes, cables, brackets, etc...) Are adequate for the load.
Check the stability of the packaging before lifting.
The cables must be long enough to lift the machine without stressing the safety cases.
Any stress may affect the accuracy of the machine.
The staff not involved in the operation should not stop in the handling area.
Before moving the machine, always check the weight and general instructions on the
packaging.
When you make a move with a forklift, lift the load of 200 mm from the ground and slew
backwards. During the lifting of loads, considered the height of the environment in
which you work.
Travel backward while descending ramps; driving downwards with the load in the front
decreases the stability of the forklift. Before starting the movement that the transition
zone is clear and there are no objects near the machine movement area.
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Ropes and chains must be protected against sharp angles with protections (cloth or
wood).
Before moving the machine, you must perform some preliminary preparation tasks:
• Check that the device isn’t attached to the ground;

• Remove loose parts;
• Block all moving parts to prevent damage during transportation;
• Use only lifting equipment that is appropriate for the stated weight.
3.2 DIMENSIONS AND WEIGHTS

Handling and transportation are the responsibility of the customer.
Tests were performed by technicians Gami Srl.
Machine’s weight is Kg. 182
Dimensions are 1170x720x1380h mm
WARNING
To lift and move the machine properly in safe conditions, use a forklift, or pallet jack or
lift with ropes, as indicated below.
WARNING
To lift the machine, use proper ropes (weight: 182 kg.)
WARNING
When using forklifts, avoid accelerating or braking too fast.
WARNING
Never place the device on top of other packages, but put it directly on the floor of the
transport vehicle, tying it with straps or similar.
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SECTION 4) INSTALLATION
4.1 MACHINE POSITIONING
WARNING
Before positioning the machine, it is necessary to make a thorough visual inspection to
identify any potential damage occurred during transportation.
If one or more components are damaged, it is essential to stop the installation and
report the problem to the manufacturer, to find together a course of action.
The machine can operate according to the technical parameters provided, if it is
properly placed on the floor of the workshop in a stable manner during operation.
If the floor of the workshop is insufficiently strong or not flat enough, you have to
perform a specific concrete foundation; this to avoid the deformation of the structure
of the machine and to free it from all other vibrations from adjacent machines.
During the cleaning operation personnel must be equipped with the required personal
protective equipment.
WARNING
Electrical connections must be performed by qualified and trained personnel.
Do not leave electricity cables in contact with pointed or sharp parts.
Always leave a free space of at least 1200 mm around the machine, to permit
maintenance.
4.2 FLOOR LEVELLING
Check that the machine is perfectly level.

Otherwise, turn the adjustable feet.
Once the adjustment is complete block the feet with the nuts.
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4.3 ELECTRICAL CONNECTION TO THE MAIN PANEL
WARNING
Connection to the power supply must be carried out by qualified personnel, who must
comply with the legal requirements for safety and prevention of accidents in the
workplace. During connection of the machine, the personal protective equipment
must be used.
Connection to the power supply must be in compliance with safety regulations in force
in the country where the machine is used.
Installed capacity and the supply voltage of the machine are as follows:
2,4 kW, 230 V/50 Hz monophase
WARNING
Carry out electrical connections according to the diagram provided.
Before turning on the machine, check the correspondence between the value of the
supply voltage and the data on the specifical plate applied on the cabinet.
4.4 COMMISSIONING
Check that all sections of the machine are mounted and aligned perfectly.
Make sure that all electrical equipment is properly secured.
Check that there are no special mechanical defects, foreign bodies in the working
area of the machine, and that limit switches and cases are not badly positioned.
Check safety systems: security guards, emergency control devices.
Ensure that the work area, there are no obstructions (cables, pipes, etc...) These may be
of hindrance and danger to personnel.
Check the operation of the main control panel and the correspondence between the
action of command and movement.
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WARNING
Connections of the electrical system should be performed by personnel qualified for
installation and maintenance of the machine and provided with the necessary
personal protective equipment.
The installation and adjustment of the device must be made while the machine is
stopped and disabled energy sources are disabled.
Before performing any manual movement required for adjustments and settings of the
machine and equipment, make sure the working area is clear of people and tools and
there is no anomalies in order to avoid damage to personnel and damage to the
machine.
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SECTION 5) OPERATION
5.1 PAGES DESCRIPTION
1. Touch screen control panel

2. Emergency button
3. Blu reset button
4. USB port
Main Page
The “knife” allows to see all pages

and to modify some parts of them
(the parts you can’t modify are the
gray ones). In order to do it, you
need to insert a password by
pressing the button with the “key”.
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Password
Choose the user “Operator”. The

default password is “A”. Press the
opened padlock to enter.
Press “Change password” to set your
personal password.
To set your password
Write your personal password in “New

password” and confirm it in “Confirm
Password”. Please be informed that if
you forget it, there’s no way to
recover it but we should reinstall the
software. So, we are not responsible
for your forgetfulness.
Password
After setting your personal password,

you can enable the “password
request to change the recipes data”
by setting ON, or you can disable the
“password request to change the
recipes data” by setting OFF.
Remember to press the closed
padlock in order to log out, otherwise
all users will be able to modify your
data.
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Temperature controls
1: Turns on/off hopper heating

2: Turns on/off dosing head heating
3: Shows actual dosing head
temperature
4: Shows and controls dosing head
set temperature
5: Percentage of hoppers
temperature regulation
1 Alarms notification
1: Shows actual active alarms

2: Reset active alarms
Manual movement controls

1 1
1: Discharges/aspires product
2: Raises/lowers dosing head
2 2 3: Moves belt forward/backwards
3 3
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CONFIGURATION PAGES
Configuration Pages
Configuration Pages
Configuration Pages
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Configuration Pages
Configuration Pages
Configuration Pages
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Configuration Pages
Configuration Pages
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RECIPES
Recipes
1) To enter in the section PRALINE

2) To enter in the section CHOCOLATE
BAR
3) To enter in the section TABLET
4) Press “Save/Restore” to enter in the
recipes save/restore section
1) Praline type selection
Choose the type of praline
2) Bar type selection
Choose the type of bar
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3) Tablet type selection
Choose the type of tablet
4) How to save the recipes
Press “Machine – Usb” to transfer

the recipes from the machine to
your usb. Press “Usb – Machine” to
transfer the recipes from your usb
to the machine.
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RECIPES SETTING AND EXAMPLE OF RECIPES
1 Recipes settings
2 2
3 3 1: Choose saved recipe
3 2: Create new/delete recipe
3 3: Set dosing distances
4: Save your changes to the
recipes
5: Sends current recipe in
production
4
5
Recipes settings:
ONLY FOR FULL PRODUCT and if you want

to use both hoppers
Set the number of pistons specified into

the dosing plate.
Set “NO” if you want to use both hoppers
Recipes settings:

to use only the left hopper (chocolate)
Halve the number of pistons specified into

the dosing plate
Set “NO” to use only the left hopper

(chocolate)
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Recipes settings:

to use only the right hopper (filling)
Halve the number of pistons specified into

the dosing plate
Set “YES” to use only the right hopper

(filling)
Recipes settings: Example 1
Customize your recipe regulating

the desired settings
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ATTENTION:
For some recipes you need a different molding plates.
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VIBRATING DEVICE
Control of vibrating device
To arrive at this page you need to

enter your password by pressing the
key button and then the knife
button. Go to page 4 of the
configuration pages (the page you
see in the picture beside) and press
on the “Vibrator device” and
“Vibrator conveyor” rows to
activate the vibrating device (the
rows from red become green).
You can control the vibrating

device when the “Vibrator device”
row and the “Vibrator conveyor”
row in the image above are green.
This is the page you see. Press the
button “Vibrating device” to go to
the page below. A page with the
details of the vibrating device will
appear (see next picture)
When the “Vibrator device” row

and the “Vibrator conveyor” row in
the top image are green and so the
vibrator device is activated, it is
possible to increase or decrease its
speed by setting ON in the image
beside and by pressing the plus and
the minus signs.
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5.2 POSSIBLE ANOMALIES AND BLOCKS
The machine doesn’t dose:

The machine doesn’t dose because the gears do not pump. The cause may be:
• Chocolate has solidified;
• The servomotors didn’t perform the reset cycle when the machine was last turned
on;
• The dosing head’s position sensors don’t read properly its position, or they are
broken;
• The plate isn’t properly attached;
• Sugar encrustings have formed on the gears;
(In this case clean the gears).
The plate doesn’t dose correctly:

• Check the product level in the hopper;
• Check if the dosing spouts are blocked;
(In this case clean the gears).
The product exits from the gears’ covers:

• Change the joints
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SECTION 6) MAINTENANCE
6.1 NOTES
This section describes the inspections and routine maintenances necessary to ensure
the proper functioning of the machine.
Any other action that may be necessary to eliminate defects or failures must be
expressly authorized by the manufacturer.
In such cases, please always provide the identification data (model, serial number,
identification of electrical appliances, etc..).
For major repairs, it’s better to contact the manufacturer that with his own specialized
personnel, equipped with all the technological experiences of the original construction
in the factory, is always available and willing to intervene in due time.
For maintenance or replacement of commercial components installed on the machine

follow the instructions provided by the manufacturers and reported on their specific
manuals or catalogs.
6.2 GENERAL SAFETY NORMS
Maintenance work must be performed by technicians specialized and trained in

specific areas, that for this machine are:
• Maintenance mechanic
• Maintenance electrician
It is specifical duty of the security officer to guarantee the professionalism and

competence of these technicians. Before starting maintenance, the safety officer must:
• Make sure the working area is free from people and materials.
• Make sure the necessary tools are in proximity and in good conditions.
• Make sure the lighting is enough and, when necessary, provide the technicians
with portable lights.
• Make sure maintenance personnel is equipped with personal protection devices
(gloves, glasses, boots, etc.).
• Make sure maintenance personnel has read thoroughly this instruction manual.
Before starting maintenance, the technician must unplug the machine.
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WARNING
The switch must be set to "0" position and must be secured with a padlock to prevent
accidental activation. The key of the lock shall be kept by the Maintenance
technician.
At the end of maintenance and before resuming service, maintenance technician

must ENTIRELY analyze cycle of work, systems security and protections’ integrity.
Work on engines or other electrical components should be performed only by the
maintenance electrician, trained and authorized by the Safety officer.
WARNING
After maintenance, the safety officer must ensure the security of the machine and its
protection devices.
Always use tools in perfect condition and especially designed for the operation to be
performed; the use of equipment that is not dedicated, or not in good condition can
cause serious damage.
Never work, unless expressly requested to eliminate a failure, on the adjustment and
positioning micro limit switches: their misuse can cause serious damage to the machine.
Mark the pieces together during disassembly to later ensure their correct assembly.
Before installing a unit, always spread a thin layer of oil over internal parts and contact
surfaces.
Always be sure of the presence of ground connections and compliance with
standards.
Before starting the machine always make sure tools or materials has not been left in the
working area of the machine.
6.3 CLEANING
Before starting control and maintenance operations, it is necessary to carefully remove

all the dirt on the machine by vacuum cleaning and suitable solvents, avoiding use of
compressed air jets, which could create storage areas for dirt, or damage to persons in
the cleaning area.
Clean any dirt with a soft, dry cloth that does not leave lint, or with a very soft brush.
If the dirt is encrusted and difficult to remove with a cloth or dry brush, use a suitable
liquid solvent. Use personal protection equipment.
Buy only solvents suitable for manual use.
Check the characteristics declared by the manufacturer.
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WARNING
Stay far from open flames when using cleaning solvents, and ensure good ventilation.
Avoid exposing personnel to solvent vapors.
Failure to follow these instructions can cause personal injury.
6.4 MECHANICAL PIECES MAINTENANCE
Perform removal and handling of heavy elements (over 30 kg) with the help of hoists or
cranes.
If no detailed drawings are available, mark each point and take note of its location to
avoid errors during reassembly.
Always use tools of right dimensions.
Replace the screws and bolts that present signs of wear immediately.
For screwing and unscrewing operations do not apply tubes or extensions to the keys to
increase power. If you are using torque wrenches and special tools, verify that the
calibration is appropriate for the component.
Particular attention should be paid when using pneumatic and hydraulic tools.
Before disassembling particular oxidized units, pulverize with appropriate lubricants
(Svitol, etc..).
Before the replacement procedure, spread a thin layer of oil on all contact surfaces.
Be especially careful when installing self-locking devices used by the manufacturer
(washers, spring washers, etc..), Always replace worn components.
In particular, nuts and lock nuts with locking ring plastic must be replaced at each
disassembly because worn equipment loses its function.
WARNING
Always use personal protective equipments such as gloves, safety shoes and so on.
6.5 ELECTRICAL SYSTEM MAINTENANCE
Before working on electrical components, disconnect power to the machine.

Always carefully check the insulation coatings, terminals and resistance of cases.
Immediately replace ruined seals and joints.
If necessary Check and restore labels and cable identification bands.
Make sure indications of danger and explanatory plaques are perfectly legible and
attached.
Do not use compressed air for cleaning. Use only vacuum cleaners.
Replacement of broken control components must be done with pieces complying with
norm EN 60204-1 (colors, sizes, protections, etc.).
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Electrical cables, especially when exposed to heat, moisture and low temperatures,
lose with time their insulating ability.
Check their integrity with the assistance of technical experts.
All electrical components composed by mechanical moving parts during the work
cycle (buttons, switches, relays, etc.) are guaranteed by the manufacturer for a
number of cycles, high but still limited.
Frequently inspect their condition and seek expert technicians for the eventual periodic
replacement.
6.6 RESIDUAL RISKS FOR MAINTENANCE TECHNICIANS
Maintenance technicians may be exposed to the following residual risks:
• Possible contact with cutting or pointed edges.

• Possible falling of significantly weighting units.
• Possible contact with moving pieces during manual maintenance.
• Possible contact with patr under tension.
WARNING
Operators must be properly informed of these potential risks and educated on
precautions to avoid them.
For the maintenance of commercial components, it will be necessary to refer to the

manuals provided by the manufacturer.
6.7 CLEANING THE MACHINE
Keep electronic control tools on the panel clean.

When used normally, with continuity, the machine can be full of chocolate and does
not require periodic internal cleaning.
WARNING
Do not leave the machine stopped and dirty with milk chocolate for long periods, but
“rinse” it with dark chocolate.
With dark chocolate, and when unused for long periods of time (a year or more)
request the intervention of our technicians to remove and clean the chocolate inside.
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6.8 GEARS, HOPPERS AND MOULDING PLATE CLEANING AND JOINTS

REPLACEMENT
Gears:
Gears (dosing pistons) do not require specifical maintenance.
Being housed inside the aluminum block that forms the head of the machine, they
remain heated and protected by the product itself.
It is advisable to wash the gear only when the characteristics of the product make it
necessary during a change of output (for example moving from a grease-based
product to an alcohol-based one, or from a sweet product to one with no sugar). To
clean the gears, follow the operations as shown in the pictures:
1. Loose the knobs blocking the cover

2. Take out the covers
3. Exit the gears using the dedicated key
4. Clean the gears with warm water and dry thoroughly
5. Assemble the gears with all the connection joints, and put them back in their
housing
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HOPPERS:
1. Disassemble the locking poles

2. Detach the hopper’s heating power cables
3. Remove the hoppers
4. Clean with warm water and dry thoroughly
JOINTS:
The plastic joints fitted between the gears should be washed following the same
method.
JOINTS REPLACEMENT:
Joints wear out over time, so they must be replaced periodically to ensure the
accuracy of the machine during the dosing phase.
The period of "life" for which they are designed depends on the hours of operation of
the machine and also on the type of product distributed (whether a product is very
sweet, as the "basis" and joints wear out more quickly report a very fat).
As a guideline, if the machine is running two shifts per day throughout the year, you
should replace the seals every 12/24 months.
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HOW TO CLEAN THE MOLDING PLATE:
1. Remove the molding plate as in the picture
2. Remove the 10 screws
3. Use 2 of the ten screws to disassemble the first part of the molding plate (see the
arrows)
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4. Do the same thing to disassemble the second part of the molding plate (see the
arrows)
HOW TO ASSEMBLE THE MOLDING PLATE:
WARNING
DO NOT REVERSE THE DIRECTION OF THE PLATE DURING THE ASSEMBLY AFTER
THE CLEANING OPERATIONS.
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6.9 REPAIRS
For any damage to the machine, you should directly contact our technicians using the
following numbers:
Tel: +39 0445 576205

Fax: +39 0445 500026
E-mail: [email protected]
WARNING
Unauthorized repairs, made in a way that can cause damage to the machine, relieve
the manufacturer of civil and criminal liability.
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ITALY, 36015 Schio (VI)

Before using the machine, read carefully this manual.

Any dispute shall be settled by the Court of VICENZA (ITALIA)

1.1 Introduction 4-5

2.1 Safety information 12

3. SHIPPING AND HANDLING pag. 22

3.1 General outline 22-23

4.1 Machine positioning 24

5.1 Pages description 27-46

6. MAINTENANCE SECTION pag. 48

• Proper installation of the machine;

WARNING: Accident prevention rules for the operator.

WARNING: There is a possibility of damage to the machine and / or its components.

PRECAUTION: Additional information about the current operation.

NOTE: Provides useful information.

1.2 MANUFACTURER CONTACT DATA

1.4 EXPECTED APPLICATIONS

1.5 TECHNICAL DATA AND OVERALL DIMENSIONS

- Weight: 182 Kg. / Power: 2,4 kW / Voltage: 230 V - 50/60 Hz

1.6 ENVIRONMENTAL EMPLOYMENT CONDITIONS

1.10 DEMOLISHING THE MACHINE

You need to:

1.11 PRODUCTS USE CONDITIONS

1.12 WARRANTY CONDITIONS

SOFTWARE / FIRMWARE WARRANTY AND SERVICING

− Programs developed by the Manufacturer are guaranteed for 90 (ninety) days

EXCLUSION OF OTHER WARRANTIES

− The Manufacturer shall not acknowledge any other Guarantee, whether

EXCLUSION OF LIABILITY FOR INDIRECT DAMAGE

1.13 PROFESSIONALS AUTHORIZED TO USE THE MACHINE

Non-compliance of regulations or of basic safety precautions could result in an

Warnings in this publication and on the product are not exhaustive.

2.2 SAFETY PROVISIONS

Each section lists additional safety requirements specific to different tasks.

Never clean or lubricate moving parts while they are moving.

Never detach safety protections or devices.

If you make a treatment or procedure that is not expected, following a procedure

Greasy, wet or dirty floor can cause accidents.

Avoid prolonged contact with and inhalation of vapors.

Wear appropriate work clothing.

If during the execution of a particular technical intervention, maintenance, inspection

Do not climb on the machine.

Substitution, disconnection or partial removal of guards, safety devices and protective

Whether to allow the implementation of a particular technical intervention on a

If you find "mechanical cracking" and permanent structural or cyclical deformations,

2.3 SAFETY LABELS AND SYMBOLS

2.4 SAFETY DISPOSITIONS AND PROTECTIONS

Magnetothermal circuit breaker

In the case of an electrical short-circuit the magnetothermal circuit breaker intervenes.

• Set the main switch to 0

Thermal circuit breakers

Safety Micro and protection grids

2.5 WORKING, COMMAND AND SAFETY AREAS

2.6 SAFETY MEASURES PROVIDED BY THE CUSTOMER

Facilities for proper installation:

2.7 INDIVIDUAL PROTECTION EQUIPMENT

2.8 RESIDUAL RISKS

The residual risks present on the machine are:

Risks of improper use in the presence of explosive o inflammable substances