Stoelting CF101 Service Manual
Model CF101
SERVICE MANUAL
Manual No. 513644 Mar. 2009
This manual provides basic information about the machine. Instructions and suggestions are
given covering its operation and care.
The illustrations and specifi cations are not binding in detail. We reserve the right to make
changes to the machine without notice, and without incurring any obligation to modify or provide new parts for machines built prior to date of change.
DO NOT ATTEMPT to operate the machine until instructions and safety precautions in this
manual are read completely and are thoroughly understood. If problems develop or questions
arise in connection with installation, operation, or servicing of the machine, contact Stoelting.
stoeltingfoodservice.com
Stoelting Foodservice Equipment
502 Highway 67
Kiel, WI 53042-1600
U.S.A.
Main Tel: 800.558.5807
Fax: 920.894.7029
Customer Service: 888.429.5920
Fax: 800.545.0662
Email: foodservice@stoelting.com
© 2014 PW Stoelting, LLC
A Few Words About Safety
Safety Information
Read and understand the entire manual before
operating or maintaining Stoelting equipment.
This manual provides the operator with information
for the safe operation and maintenance of Stoelting
equipment. As with any machine, there are hazards
associated with their operation. For this reason safety
is emphasized throughout the manual. To highlight
specifi c safety information, the following safety defi ni-
tions are provided to assist the reader.
The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and
their explanations, deserve your careful attention
and understanding. The safety warnings do not by
themselves eliminate any danger. The instructions
or warnings they give are not substitutes for proper
accident prevention measures.
If you need to replace a part, use genuine Stoelting
parts with the correct part number or an equivalent
part. We strongly recommend that you do not use
replacement parts of inferior quality.
Safety Alert Symbol:
This symbol Indicates danger, warning or caution.
Attention is required in order to avoid serious personal injury. The message that follows the symbol
contains important information about safety.
Signal Word:
Signal words are distinctive words used throughout
this manual that alert the reader to the existence and
relative degree of a hazard.
WARNING
The signal word “WARNING” indicates a potentially
hazardous situation, which, if not avoided, may result
in death or serious injury and equipment/property
damage.
CAUTION
The signal word “CAUTION” indicates a potentially
hazardous situation, which, if not avoided, may result
in minor or moderate injury and equipment/property
damage.
CAUTION
The signal word “CAUTION” not preceded by the
safety alert symbol indicates a potentially hazardous
situation, which, if not avoided, may result in equipment/property damage.
NOTE (or NOTICE)
The signal word “NOTICE” indicates information or
procedures that relate directly or indirectly to the
safety of personnel or equipment/property.
TABLE OF
CONTENTS
Section Description Page
1 Description and Specifications
1.1 Description.................................................................................................1
1.2 Specifications............................................................................................. 2
2 Installation Instructions
2.1 Safety Precautions.....................................................................................3
2.2 Shipment and Transit.................................................................................3
2.3 Machine Installation ...................................................................................3
3 Initial Set-Up and Operation
3.1 Operator’s Safety Precautions ...................................................................5
3.2 Operating Controls and Indicators .............................................................5
3.3 Sanitizing ...................................................................................................6
3.4 Freeze Down and Operation ......................................................................7
3.5 Mix Information ..........................................................................................8
3.6 Removing Mix from Machine .....................................................................8
3.7 Cleaning the Machine ................................................................................8
3.8 Disassembly of Machine Parts...................................................................8
3.9 Cleaning the Machine Parts.......................................................................9
3.10 Assembly of Machine.................................................................................9
3.11 Routine Cleaning .......................................................................................10
3.12 Cleaning and Sanitizing Information...........................................................10
4 Maintenance and Adjustments
4.1 Machine Adjustment ..................................................................................13
4.2 Obtaining Readings and Modifying Settings (Service Personnel Only) ......13
4.3 Readings (Service Personnel Only) ...........................................................13
4.4 Settings (Service Personnel Only) .............................................................14
4.5 Drive Belt Tension Adjustment...................................................................15
4.6 Preventative Maintenance..........................................................................15
4.7 Extended Storage ......................................................................................16
Section Description Page
5 Refrigeration System
5.1 Refrigeration System .................................................................................17
5.2 Refrigerant Recovery and Evacuation........................................................17
5.3 Refrigerant Charging..................................................................................18
5.4 Compressor...............................................................................................19
5.5 Condenser .................................................................................................20
5.6 Evaporator .................................................................................................20
5.7 Valves........................................................................................................20
A. Thermostatic Expansion Valve (TXV)..................................................................20
B. Check Valve ........................................................................................................21
C. High Pressure Cutout ..........................................................................................22
D. Hot Gas Bypass ...................................................................................................22
E. Evaporator Pressure Regulator (EPR) ................................................................23
5.8 Solenoid.....................................................................................................23
5.9 Filter Drier..................................................................................................25
5.10 Capillary Tube............................................................................................25
5.11 Receiver ....................................................................................................25
6 Electrical and Mechanical Control Systems
6.1 IntelliTec Controller....................................................................................27
6.2 Contactors .................................................................................................27
6.3 Drive Motor ................................................................................................28
6.4 Capacitors .................................................................................................29
6.5 Gearbox.....................................................................................................29
6.6 Condenser Fan Motor................................................................................30
6.7 Potential Relay...........................................................................................30
6.8 Temperature Control Sensor .....................................................................30
7 Troubleshooting
7.1 Error Codes ...............................................................................................31
7.2 Troubleshooting Error Codes.....................................................................31
7.3 Troubleshooting Tables .............................................................................33
8 Replacement Parts
8.1 Decals and Lubrication ..............................................................................35
8.2 Panels and Panel Screws ..........................................................................35
8.3 Beater Shaft and Faceplate Parts ..............................................................36
8.4 Hopper Parts and Trays.............................................................................37
8.5 Electrical Panel ..........................................................................................38
8.6 Front ..........................................................................................................39
8.7 Rear...........................................................................................................40
8.8 Left Side ....................................................................................................41
8.9 Wiring Diagram..........................................................................................42
SECTION 1
DESCRIPTION AND SPECIFICATIONS
1.1 DESCRIPTION
The CF101 is a counter top continuous flow custard
machine. It is equipped with fully automatic controls to
provide a uniform product and features Quick-Freeze
technology. This manual is designed to assist qualified
service personnel and operators in the installation, operation and maintenance of the CF101 frozen custard machine.
Figure 1-1 Model CF101
Figure 1-2 MachineSpecifications
1
1.2 SPECIFICATIONS
z
Dimensions
width
height
depth
Weight
Electrical
conn ection type
Compressor
Drive M ot or
Air Fl ow
Hopper Volum e
Freezing Cyl i nder
Volume
Superheat out of
CF101
Machi ne with cr at e
19-1/ 2' ' ( 49, 5 c m ) 38-3/ 4'' (9 8, 4 cm )
37-3/ 4' ' ( 95, 9 c m ) 28-3/ 4'' (7 3, 0 cm )
28'' (71,1 cm) 43'' (109,2 cm)
310 lbs (140 , 6 kg) 380 lbs ( 172,3 kg)
1 Phase, 208-240 VA C, 60Hz
NEM A6-20P power cord provided
14,000 Bt u/ hr
1-1/2 h p
Air cooled units r equire 6" ( 15, 2 cm ) air space at l e f t and r ight sides and 10"
(25, 4) air spa ce above t he m achine.
5.4 gallon (30,28 l iters)
0.8 gallon ( 3. 2 quart), 3,03 l it ers
CF101
Refrigerant
Charge
Evaporator
R-404A
No Receiver 64 oz
With Receiver 80 o
8°F
Suction Pr essur e
(at 72° F)
Discharge Pr essur e
Hot Gas Bypass
Pressure
EPR Valve
Menu Display Value
Product 1
Product 2
Standby
Storage
Freezin g Cyl inder On ly 19- 20 psig
Freezin g Cyl inder & H opper 23 ps ig
Hopper O nly 14 ps ig
235-305 p sig
14 psig (on ly hopper ru nnin g)
46-48 psig
Cut In T 3 °F
Cut Out T -20 °F
Cut In T 3 °F
Cut Out T -13 °F
On T ime 180 seconds
Of f Time 30 secon ds
Cut In T
Cut Out T
On T ime 60 seconds
Of f Time 900 secon d s
HprCutIn 27.5 °F
HprCtOut 26.5 °F
Hpr O n 100 secon d s
Hpr Off 6 minutes
35 °F w/Receiver
25 °F w / o R eceiver
25 °F w/Receiver
15 °F w / o R eceiver
2
SECTION 2
INSTALLATION INSTRUCTIONS
2.1 SAFETY PRECAUTIONS
Do not attempt to operate the machine until the safety
precautions and operating instructions in this manual are
read completely and are thoroughly understood.
Take notice of all warning labels on the machine. The
labels have been put there to help maintain a safe working
environment. The labels have been designed to withstand
washing and cleaning. All labels must remain legible for
the life of the machine. Labels should be checked periodically to be sure they can be recognized as warning labels.
If danger, warning or caution labels are needed, indicate
the part number, type of label, location of label, and
quantity required along with your address and mail to:
STOELTING, INC.
A TTENTION: Customer Service
502 Hwy . 67
Kiel, Wisconsin 53042
Figure 2-2 Space and Ventilation Requirements
CAUTION
Failure to provide adequate ventilation will void warranty .
2.2 SHIPMENT AND TRANSIT
The machine has been assembled, operated and inspected at the factory. Upon arrival at the final destination,
the entire machine must be checked for any damage
which may have occurred during transit.
With the method of packaging used, the machine should
arrive in excellent condition. THE CARRIER IS RESPONSIBLE FOR ALL DAMAGE IN TRANSIT, WHETHER
VISIBLE OR CONCEALED. Do not pay the freight bill until
the machine has been checked for damage. Have the
carrier note any visible damage on the freight bill. If
concealed damage and/or shortage is found later, advise
the carrier within 10 days and request inspection. The
customer must place claim for damages and/or shortages
in shipment with the carrier. Stoelting, Inc. cannot make
any claims against the carrier.
2.3 MACHINE INSTALLATION
Installation of the machine involves moving the machine
close to its permanent location, removing all crating,
setting in place, assembling parts, and cleaning.
A. Uncrate the machine.
B. Accurate leveling is necessary for correct drainage
of the freezing cylinder and to insure correct
overrun. Place a bubble level on top of the machine
at each corner to check for level condition. If
adjustment is necessary, level the machine by
turning the bottom part of each leg in or out. Then
separate machine base gasket and install with
seam to the back and angle to the top.
C. Correct ventilation is required. The CF101 requires
a minimum of 6" (15,2 cm) air space at left and
right sides and 10" (25,4) air space above the
machine.
D. Place the Main Freezer Power Off/On switch in
the Off position.
E. Connect the power cord to the proper power
supply. The plug is designed for 208-240 Volt/20
amp duty. Check the nameplate on your machine
for the proper supply. The unit must be connected
to a properly grounded receptacle. The electrical
cord furnished as part of the machine has a three
prong grounding type plug. The use of an extension
cord is not recommended, if necessary use one
with a size 12 gauge or heavier with ground wire.
Do not use an adapter to get around grounding
requirement.
WARNING
Do not alter or deform electrical plug in any way.
Altering the plug to fit into an outlet of different configuration may cause fire, risk of electrical shock,
product damage and will void warranty .
3
4
SECTION 3
INITIAL SET-UP AND OPERATION
3.1 OPERATOR’S SAFETY PRECAUTIONS
SAFE OPERATION IS NO ACCIDENT; observe these
rules:
A. Know the machine. Read and understand the
Operating Instructions.
B. Notice all warning labels on the machine.
C. Wear proper clothing. Avoid loose fitting garments,
and remove watches, rings or jewelry that could
cause a serious accident.
D. Maintain a clean work area. Avoid accidents by
cleaning up the area and keeping it clean.
E. Stay alert at all times. Know which switch, push
button or control you are about to use and what
effect it is going to have.
F. Disconnect electrical cord for maintenance. Never
attempt to repair or perform maintenance on the
machine until the main electrical power has been
disconnected.
G. Do not operate under unsafe operating conditions.
Never operate the machine if unusual or excessive
noise or vibration occurs.
3.2 OPERATING CONTROLS AND INDICATORS
Before operating the machine, it is required that the
operator know the function of each operating control.
Refer to Figure 3-1 for the location of the operating
controls on the machine.
WARNING
High voltage will shock, burn or cause death. The
Off/On switch must be placed in the OFF position
prior to disassembling for cleaning or servicing. Do
not operate machine with cabinet panels removed.
A. Main Freezer Power Off/On Switch
The Main Freezer Power Off/On switch is a twoposition toggle switch used to supply power to the
control circuit. When the switch is in the Off
position, power will not be supplied to the control
board or refrigeration system. When the switch is
put in the On position, the machine will be in
standby mode. The display will read Standby and
the amber LED will light.
Main Freezer
Power Off/On
Product
Selector
Switch
IntelliT ec Control
(See Figure 3-2)
Figure 3-1 CF101 Controls
5
B. Product Selector Switch
The product selector switch changes the
refrigeration profile to allow two different products
to be made. Before the machine is in ready mode,
this switch can be moved to the desired profile.
C. PUSH TO FREEZE Button
The PUSH TO FREEZE button is used to initiate
the run mode. To start the machine, place the
Main Freezer Power Off/On switch in the On
position and press the PUSH TO FREEZE button.
D. LEDs
The membrane switch features two lights; a green
LED and an amber LED. The green LED will flash
when the freezing cylinder is near ready mode
and stay lit during ready mode. The amber LED is
lit during standby, purge and clean modes.
NOTE
If the machine enters an error condition, alternating
green and amber lights will flash. The LCD will display an error. Turn the Main Freezer Power Off/On
switch to the OFF position, correct the problem (Refer to Troubleshooting in Section 4) and turn the
machine back on.
E. PURGE/CLEAN Button
PURGE Mode - When the PURGE/CLEAN button
is pressed, the beater shaft will rotate. A PURGE
message will display on the screen along with a 5
minute timer. Hopper refrigeration will continue to
run. When the timer gets to 0:00 and no other
buttons are pressed, the machine will go into
standby mode.
CLEAN Mode - During PURGE mode, if the
PURGE/CLEAN button is pressed and held for 3
seconds, the CLEAN mode will begin. The beater
shaft will continue to rotate and hopper refrigeration
will stop.
F. Mix Low Light Indicator
The MIX LOW message will appear on the LCD
display when there is approximately one gallon of
mix left in the hopper. When the MIX LOW
message is displayed, refill hopper immediately.
NOTE
Failure to refill hopper immediately may result in
operational problems.
G. Menu Navigation Buttons
The Menu Navigation Buttons are primarily used
for machine calibration.
Selection Button (SEL) The SEL button is not
functional in the normal operation mode. This
button is only used by service technicians for
machine calibration.
Push to Freeze
Green LED
Amber LED
Purge/Clean
Button
SEL Button
SET Button
Left Arrow Button
Up Arrow Button
Figure 3-2 IntelliT ec Control
Set Button (SET) The SET button is not functional
in the normal operation mode. This button is only
used by service technicians for machine
calibration.
Left Arrow Button (Õ) Pressing any button on
the control panel will automatically illuminate the
display. The backlight will turn off several seconds
after use. To keep the display constantly lit, press
and hold the left (Õ) button for five seconds. The
backlight function can be reset to normal operation
in the same manner.
Up Arrow Button (×) The × button is not
functional in the normal operation mode. This
button is only used by service technicians for
machine calibration.
H. Front Door Safety Switch
The front door safety switch prevents the beater
shaft from turning when the front door is removed.
The switch is open when the door is not in place
and closed when the door is properly installed.
3.3 SANITIZING
Sanitizing must be done after the machine is cleaned and
just before the hopper is filled with mix. Sanitizing the night
before is not effective. However, you should always clean
the machine and parts after each use.
THE UNITED STATES DEPARTMENT OF AGRICUL TURE AND THE FOOD AND DRUG ADMINISTRA TION REQUIRE THA T ALL CLEANING AND
SANITIZING SOLUTIONS USED WITH FOOD
PROCESSING EQUIPMENT BE CERTIFIED FOR
THIS USE.
When sanitizing the machine, refer to local sanitary regulations for applicable codes and recommended sanitizing
products and procedures. The frequency of sanitizing
must comply with local health regulations.
6
Mix sanitizer according to manufacturer’s instructions to
provide a 100 parts per million strength solution. Mix
sanitizer in quantities of no less than 2 gallons (7.5 liters)
of 90° to 110°F (32° to 43°C) water. Allow sanitizer to
contact the surfaces to be sanitized for 5 minutes. Any
sanitizer must be used only in accordance with the
manufacturer’s instructions.
In general, sanitizing may be conducted as follows:
A. Prepare Stera-Sheen Green Label Sanitizer or
equivalent according to manufacturer’s
instructions to provide a 100ppm strength solution.
Mix the sanitizer in quantities of no less than 2
gallons of 90° to 110°F (32° to 43°C) water. Any
sanitizer must be used only in accordance with
the manufacturer’s instructions.
B. Place the tapered end of the flow valve into the
hopper drain hole with the arm pointing towards
the left. Connect the flow control rod to the flow
valve and the flow valve arm (Fig. 3-3).
I. When the sanitizer has drained from the hopper,
press and hold the PURGE/CLEAN button for 3
seconds to stop the beater shaft. Allow the freezing
cylinder to drain completely.
J. Shut off the flow control valve by turning the flow
control knob counterclockwise to the 12:00
position.
3.4 FREEZE DOWN AND OPERATION
This section covers the recommended operating procedures to be followed for the safe operation of the machine.
A. Sanitize just prior to use.
NOTE
Make sure the flow control assembly is in place before adding mix and that the flow control knob is set
to the 12:00 position.
B. Fill hopper with approximately 3 gallons (11.4
liters) of pre-chilled (40°F or 4°C) mix.
E. Place the Main Freezer Power Off/On switch in
the On position. The display will read STANDBY
MODE.
F. Press the PUSH TO FREEZE button. The display
will read CUSTARD and a bar on the second line
will start to fill. For PRODUCT 2, move the product
selector switch to the PRODUCT 2 position.
NOTE
The product selector switch can be changed until
the READY message is displayed on the second
line.
Figure 3-3 Flow Control Assembly
C. Make sure the flow control valve is shut by turning
the control knob counterclockwise to the 12:00
position.
D. Place a bucket under the slide.
E. Pour the sanitizer into the hopper.
NOTE
A small amount of sanitizer may drain into the bucket
with the flow control shut.
F. Place the Main Freezer Power Off/On switch in
the On position and press the PURGE/CLEAN
button. The display will read PURGE.
G. Press and hold the PURGE/CLEAN button for 3
seconds. The display will read CLEAN and a 20
minute timer will start.
G. Turn the flow control knob fully open (clockwise).
H. Clean sides of hopper, flow valve and underside
of hopper cover using a sanitized soft bristle brush
dipped in the sanitizing solution.
G. When the display reads CUSTARD READY, the
freezing cylinder is at the correct temperature
(Fig. 3-4).
H. Open the front gate.
I. Turn the flow control knob clockwise to the 6:00
Figure 3-4 Custard Mode
7
position. A small amount of mix and remaining
sanitizer will drain from the machine.
J. Turn the flow control knob between the 1:00-2:00
position for vanilla or between the 5:00-6:00 for
chocolate. After a few minutes, a ribbon of product
starts to form.
K. Adjust the flow control knob until the product flow
fills the faceplate outlet and is at the desired
texture (Fig. 3-5). The flow control knob setting
will be different for each type of product.
NOTE
Adjustments take up to 1 minute before a noticeable difference is seen in the product.
NOTE
A high-pitched noise from the freezing cylinder is
an indication that there is not enough mix entering
the freezing cyliner. Slowly turn the flow control knob
clockwise to increase the flow. It can take up to 1
minute for the adjustment to stop the noise.
Figure 3-5 Proper Flow
3.5 MIX INFORMATION
Mix can vary considerably from one manufacturer to
another. Differences in the amount of butterfat content
and the quantity and quality of other ingredients have a
direct bearing on the finished frozen product. A change in
machine performance that cannot be explained by a
technical problem may be related to the mix.
Proper product serving temperature varies from one
manufacturer’s mix to another. When checking the temperature, stir the thermometer in the frozen product to read
the true temperature.
Old mix or mix that has been stored at elevated temperatures will produce poor-quality product with a bad taste and
unacceptable appearance. To retard bacteria growth in
dairy based mixes, the best storage temperature range is
between 36° to 40°F (2.2° to 4.4°C).
3.6 REMOVING MIX FROM MACHINE
To remove the mix from the machine, refer to the following
steps. Make sure the gate on the faceplate is open.
A. Press the PURGE/CLEAN button. The display
will read PURGE.
B. Press and hold the PURGE/CLEAN button for 3
seconds. The display will read CLEAN and a 20
minute timer will start.
C. Open the flow control valve fully by turning the flow
control knob clockwise until the pointer is near the
12:00 position.
D. After the hopper and freezing cylinder have
drained, place the Main Freezer Power Off/On
switch in the OFF position.
3.7 CLEANING THE MACHINE
NOTE
The frequency of cleaning the machine and machine
parts must comply with local health regulations.
After the mix has been removed from the machine, the
machine must be cleaned. To clean the machine, refer to
the following steps:
A. Place a container under the slide of the faceplate.
Fill the hopper with 2 gallons (7.5 liters) of tap
water.
B. Place the Main Freezer Power Off/On switch in
the On position. Press the PURGE/CLEAN button.
The display will read PURGE.
C. Press and hold the PURGE/CLEAN button for 3
seconds. The display will read CLEAN and a 20
minute timer will start.
D. When the water has drained, place the switch in
the OFF position. Allow the freezing cylinder to
drain completely.
E. Prepare detergent water by mixing 2 oz. of
Palmolive detergent or equivalent in 2 gallons of
90° to 110°F (32° to 43°C) water. Repeat steps A
through D using the detergent solution.
3.8 DISASSEMBLY OF MACHINE PARTS
Inspection for worn or broken parts should be made each
time the machine is disassembled. All worn or broken
parts should be replaced to ensure safety to both the
operator and the customer and to maintain good machine
performance and a quality product. Frequency of cleaning
must comply with local health regulations.
8
To disassemble the machine, refer to the following steps:
CAUTION
Hazardous Moving Parts
A revolving beater shaft shaft can grab and cause
injury . Place the Main Freezer Power Off/On switch
in the OFF position before disassembling for cleaning or servicing.
A. Remove the flow control rod and flow control
valve from the hopper by pulling straight up.
C. Remove the slide from the faceplate and remove
the faceplate.
D. Remove the beater shaft wearguard.
F. Remove the beater shaft assembly from the
machine. Pull the beater shaft out of the freezing
cylinder slowly. As it is being pulled out, carefully
remove each of the blades and springs.
G. Remove the seal from the back of the beater
shaft.
I. Wipe socket lubricant from the drive end (rear) of
the beater shaft with a cloth or paper towel.
NOTE
The United States Department of Agriculture and
the Food and Drug Administration require that lubricants used on food processing equipment be certified for this use. Use lubricants only in accordance
with the manufacturer’s instructions.
A. Coat the rear seal with a generous amount of
Petrol Gel.
B. Install the rear seal onto the beater shaft.
C. Lubricate the drive (rear) end of the beater shaft
with a small amount of white socket lubricant. A
small container of socket lubricant is shipped with
the machine.
D. Install two of the springs and blades onto the rear
of the beater shaft and insert the shaft part way
into freezing cylinder. Rotate the shaft so another
spring and blade can be placed onto it.
3.9 CLEANING THE MACHINE PARTS
Place all loose parts in a pan or container and take to the
wash sink for cleaning. To clean the parts refer to the
following steps:
A. Prepare detergent water by mixing 2 oz. of
Palmolive detergent or equivalent in 2 gallons of
90° to 110°F (32° to 43°C) water.
B. Place all parts in detergent solution and clean with
the provided brushes.
C. Wash the hopper and freezing cylinder with the
detergent water and brushes provided.
D. Wash the inside of the freezing cylinder with the
detergent water.
E. Rinse all parts with clean 90° to 110°F (32° to
43°C) water.
NOTE
If the machine is not going to be immediately operated, store the faceplate in a clean and sanitized
container in a cooler.
3.10 ASSEMBLY OF MACHINE
To assemble the machine parts, refer to the following
steps:
NOTE
Petrol Gel sanitary lubricant or equivalent must be
used when lubrication of parts is specified.
Figure 3-6 Installing Blades
E. Install the remaining blades, push the beater shaft
into the freezing cylinder and rotate it slowly until
the shaft engages the drive coupling.(Fig. 3-6).
Figure 3-7 Install Front Wear Bushing
F. Lubricate the inside and outside of the wearguard
and install it onto the beater shaft (Fig. 3-7).
9
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