Stoelting E111 Service Manual

Model E111 & F111

SERVICE MANUAL

Manual No. 513531-2 Dec. 2005

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: [phone]
Fax: [phone]

Customer Service: 888.429.5920
Fax: [phone]
Email: [e-mail]

© 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

SECTION 1 INTRODUCTION

1.1 Description .....................................................................................1

1.2 Specifications .................................................................................1

SECTION 2 INSTALLATION INSTRUCTIONS

2.1 Safety Precautions .........................................................................3

2.2 Shipment and Transit .....................................................................4

2.3 Freezer Installation .........................................................................4

2.4 Floor Stand Installation ...................................................................5

2.5 Installing Permanent Wiring............................................................5

SECTION 3 INITIAL SET-UP AND OPERATION

3.1 Operator’s Safety Precautions........................................................7

3.2 Operating Controls and Indicators ..................................................7

3.3 Sanitizing ........................................................................................8

3.4 Freeze Down and Operation...........................................................9

3.5 Mix Information...............................................................................10

3.6 Removing Mix Inlet Regulator.........................................................10

3.7 Cleaning the Freezer ......................................................................11

3.8 Disassembly of Freezer Parts.........................................................11

3.9 Cleaning the Freezer Parts.............................................................12

3.10 Sanitize Freezer & Freezer Parts....................................................12

3.11 Assembly of Freezer.......................................................................12

3.12 Routine Cleaning ............................................................................13

3.13 Preventive Maintenance .................................................................14

3.14 Extended Storage...........................................................................16

SECTION 4 REFRIGERATION SYSTEM

4.1 Refrigeration System ......................................................................17

4.2 Evaporators ....................................................................................18

4.3 Compressor Winding Test..............................................................18

4.4 Condensers ....................................................................................19

4.5 T.X.V. .............................................................................................20

4.6 T.X.V. Adjustment ..........................................................................20

4.7 T.X.V. Removal ..............................................................................20

4.8 T.X.V. Installation ...........................................................................21

4.9 Hopper............................................................................................22

4.10 E.P.R. Valve Adjustment ................................................................22

4.11 E.P.R. Removal ..............................................................................23

4.12 E.P.R. Valve Installation .................................................................23

4.13 Capillary Tubes...............................................................................24

4.14 Capillary Tube Removal .................................................................24

4.15 Capillary Tube Installation...............................................................24

4.16 Solenoid Valve................................................................................25

4.17 Solenoid Magnetic Coil Removal ....................................................25

4.18 Solenoid Magnetic Coil Installation .................................................26

4.19 Solenoid Valve Removal.................................................................26

4.20 Solenoid Valve Installation..............................................................26

4.21 Refrigerant Charge (All Models) .....................................................26

SECTION 5 CONTROLS

5.1 Control System Type 4 ...................................................................27

5.2 Power Board...................................................................................27

5.3 Program Module.............................................................................27

5.4 Contactors ......................................................................................34

5.5 Spigot Switch..................................................................................34

5.6 Spigot Switch Removal...................................................................34

5.7 Spigot Switch Installation................................................................35

5.8 Front Door Interlock Switch ............................................................35

5.9 Front Door Interlock Removal.........................................................35

5.10 Front Door Interlock Switch Assembly ............................................36

5.11 Touch Pad Switch Module ..............................................................36

5.12 Touch Pad Switch Module Removal ...............................................36

5.13 Touch Pad Switch Module Assembly..............................................36

5.14 Sensor ............................................................................................37

5.15 Sensor Removal.............................................................................37

5.16 Sensor Installation ..........................................................................37

5.17 Preparation for Major Component Removal ...................................38

5.18 Condenser Fan Motor and Lubrication ...........................................38

5.19 Condenser Fan Motor Removal......................................................38

5.20 Condenser Fan Motor Installation...................................................39

5.21 Drive Motor.....................................................................................39

5.22 Drive Motor Removal......................................................................39

5.23 Drive Motor Installation ...................................................................40

5.24 Speed Reducer...............................................................................40

5.25 Speed Reducer Removal................................................................40

5.26 Speed Reducer Installation.............................................................41

5.27 Compressor....................................................................................41

5.28 Compressor Removal.....................................................................41

5.29 Compressor Installation..................................................................42

5.30 Final Assembly of Freezer ..............................................................43

SECTION 6 TROUBLESHOOTING

6.1 Dispensing, Servability, and Overrun..............................................46

6.2 Barrel and Hopper Mix Temperature Maintenance .........................47

6.3 Electro-Mechanical .........................................................................48

6.4 Control Displayed Error Conditions.................................................54

SECTION 7 REPLACEMENT PARTS

7.1 How To Order Parts........................................................................57

LIST OF ILLUSTRATIONS

FIGURE TITLE PAGE

1 Model Endura/Futura 111 Freezer..........................................................1

2 Specifications .........................................................................................1

3 Warning Label Locations ........................................................................3

4 Leveling the Freezer ...............................................................................4

5 Space and Ventilation Requirements......................................................4

6 Electrical Plug.........................................................................................4

7 Installing Tray and Cover........................................................................4

8 Floor Stand.............................................................................................5

9 Power Cord Connection..........................................................................5

10 Controls ..................................................................................................7

11 Mix Inlet Regulator..................................................................................9

12 Clean Control..........................................................................................9

13 Sanitizing Hopper ...................................................................................9

14 Draining Solution ....................................................................................9

15 Dispensing Product ................................................................................10

16 Removing Mix Inlet Regulator.................................................................10

17 Draining Mix ...........................................................................................10

18 Auger Flight Wear and Front Auger Support Bushing Wear ...................11

19 Removing Front Door .............................................................................11

20 Front Door Disassembly .........................................................................11

21 Removing Auger Support .......................................................................11

22 Auger Shaft Removal .............................................................................12

23 Removing “O” Ring.................................................................................12

24 Cleaning Freezer Barrel..........................................................................12

25 Exploded View of Auger .........................................................................13

26 Exploded View of Front Door..................................................................13

27 Mix Inlet Regulator..................................................................................13

28 Refrigeration System ..............................................................................17

29 Compressor Terminal Cover ..................................................................18

30 Compressor Connections .......................................................................18

31 Ohmmeter and Connections...................................................................18

32 Electrical Box..........................................................................................19

33 Condenser and Filter ..............................................................................19

34 Condenser Inspection.............................................................................20

35 T.X.V. (Thermostatic Expansion Valve)..................................................20

36 Bulb Removal .........................................................................................21

37 T.X.V. Removal ......................................................................................21

38 Bulb Installation ......................................................................................22

39 Filter Drier...............................................................................................22

40 E.P.R. Schrader Access Fitting ..............................................................22

41 E.P.R. Valve Adjustment ........................................................................23

42 E.P.R. Valve and Lines...........................................................................23

43 Filter Drier...............................................................................................24

44 Capillary Tube and Drive Assembly ........................................................24

45 Filter Drier...............................................................................................24

46 Pressure Gauges ...................................................................................25

47 Power Cord ............................................................................................25

48 Solenoid Replacement............................................................................25

49 Solenoid Coil Removal ...........................................................................26

50 Power Board...........................................................................................28

51 Program Module.....................................................................................29

52 Membrane Switch Panel Display Board..................................................30

53 Spigot Switch Replacement....................................................................35

54 Interlock Switch Removal .......................................................................35

55 Interlock Switch Assembly......................................................................36

56 Switch Module Removal .........................................................................36

57 Cover Plate Removal..............................................................................37

58 Foam Insulation Removal .......................................................................37

59 Ty-raps Removal ....................................................................................37

60 Fan Motor Connections ..........................................................................38

61 Fan Bracket Removal .............................................................................39

62 Drive Belt Removal.................................................................................39

63 Drive Motor Wire Removal .....................................................................40

64 Motor Pulley Adjustment.........................................................................40

65 Belt Tension Adjustment.........................................................................40

66 Speed Reducer Removal........................................................................41

67 Speed Reducer Adjustment....................................................................41

68 Belt Tension Adjustment.........................................................................41

69 Compressor Cover Removal ..................................................................42

70 Compressor Connections .......................................................................42

71 Compressor Oil Test Kit .........................................................................42

72 Filter Drier...............................................................................................43

SECTION 1

DESCRIPTION AND SPECIFICATIONS

1.1 DESCRIPTION

The Stoelting Endura/Futura 11 1/1 12 counter freezers are
gravity fed. The freezers are equipped with fully automatic
controls to provide a uniform product. The freezers are
designed to operate with almost any type of commercial
soft serve or non-dairy mixer available, including ice milk,
ice cream, yogurt, and frozen dietary desserts. This
manual is designed to assist qualified service personnel
and operators in the installation, operation and mainte­nance of the Stoelting Model Endura 1 1 1/112 and Futura
1 1 1/1 12 gravity freezers.

1.2 SPECIFICATIONS

Model Endura/Futura
Front View

Figure 1. Model Endura/Futura 111/112 Freezer

Model Endura/Futura
Side Views

Figure 2. Specifications

1

MODEL ENDURA/FUTURA 1 1 1/112
COUNTER MODEL
GRA VITY FREEZER

DIMENSIONS:

Freezer: 15" (38 cm) wide x 28.6" (72 cm) deep x 35.6" (90 cm) high
Crated: 19.5" (50 cm) wide x 33" (84 cm) deep x 40" (102 cm) high

WEIGHT:

Freezer: 230 lbs. (140 kg) Crated: 275 lbs. (125 kg)

ELECTRICAL:

Description Endura 11 1-37G Futura 11 1-38G
Voltage AC 1 PH 115V 1 PH 208/230
T ot al Run Amp s 12.00 10.00
Drive Motor 3/4 HP 3/4 HP

Use 20 amp HACR circuit breaker.
Automatic safeguard circuit built into electronic control-protects major

freezer components under abnormal operating conditions.

COOLING:

Air cooled requires minimum 3" (7.6 cm) air clearance on right and left hand side.
No clearance needed in the rear.

HOPPER:

3 Gallons (1 1.5 liters) refrigerated and insulated.

2

SECTION 2

THERMISTOR. HEAT SINK MUST BE
USED WHEN BRAZING ON EVAPORATOR

UNDER THIS COVER. TEMPERATURE
MUST NOT EXCEED 220°F NEAR

HEAT SENSITIVE THERMISTOR LOCATED

OUTLET. CHECK RESISTANCE BEFORE
SEE SERVICE MANUAL.

REMOVAL OF THERMISTOR.

INSTALLATION INSTRUCTIONS

2.1 SAFETY PRECAUTIONS
Do not attempt to operate the freezer 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 freezer. 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 freezer. 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.

ATTENTION: Customer Service

502 Hwy. 67

Kiel, Wisconsin 53042

Figure 3. Warning Label Locations

3

2.2 SHIPMENT AND TRANSIT

The freezer has been assembled, operated and inspected
at the factory. Upon arrival at the final destination, the
complete freezer must be checked for any damage which
may have occurred during transit.

With the method of packaging used, the freezer 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 freezer 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 FREEZER INSTALLATION

Installation of the freezer involves moving the freezer close
to its permanent location, removing all crating, setting in
place, assembling parts, and cleaning.

A. Uncrate the freezer.
B. Accurate leveling is necessary for correct drainage of

freezer barrel and to insure correct overrun. Place a
spirit level on top of the freezer at each corner to
check for level condition. If adjustment is necessary,
level the freezer by turning the bottom part of each leg
in or out. Then separate freezer base gasket and
install with seam to the back and angle to the top. (Fig.

4).

Figure 5. Space and Ventilation Requirements

E. Connect the power cord. The plug is designed for 208

or 230 volt/20 amp duty. Check the nameplate on your
freezer for proper supply. The unit must be connected
to a properly grounded receptacle. The electrical cord
furnished as part of the freezer has a three prong
grounding type plug (Fig. 6). 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.

115V

20 Amp

208/230V

20 Amp

Figure 4 - Leveling

C. The freezer is equipped with an air cooled condenser

and requires correct ventilation. The right side of the
freezer is the air intake and left side discharge. Both
sides must have 3" clearance the top requires 10" of
clearance. (Fig. 5).

CAUTION
FAILURE T O PROVIDE ADEQUA TE VENTILA TION
WILL VOID W ARRANTY!

D. Place the OFF-ON switch in the OFF position. (Fig.10).

Figure 6. Electrical Plug

CAUTION

DO NOT ALTER OR DEFORM PLUG IN ANY WAY!

F. Install the drip tray, drain tray, hopper cover and other

miscellaneous parts on the freezer. (Fig. 7).

Figure 7. Installing Tray and Cover

4

2.4 FLOOR ST AND INST ALLA TION

2.5 INSTALLING PERMANENT WIRING

To install the E or F111/112 onto the floor stand, follow the
steps outlined below:

A. Uncrate the floor stand and place in an upright posi-

tion.

NOTE

Detailed instructions are included with each floor
stand.

B. Place a spirit level across the top of the stand to check

for level condition, side to side and front to back. If
adjustment is necessary , level the st and by turning
the bottom part of each leg in or out, then tighten the
lock nut.

WARNING
DO NOT INSTALL CASTERS ON THIS FLOOR
ST AND. THE ST AND IS UNST ABLE WITH CAST ­ERS AND COULD TIP CAUSING SERIOUS IN­JURY.

C. Place supports under freezer , then remove the 4 legs

and replace with the rubber stud/plate mounts pro­vided. Mounts must be fully tightened to the freezer.

D. Place the freezer base gasket on the floor stand with

the connected seam to the back and angle side up.
Center the gasket side to side and 1-3/4 inches from
the rear of the floor stand.

If permanent wiring is required by local codes, the follow­ing procedure must be performed.

WARNING
DISCONNECT FREEZER FROM THE SOURCE
OF ELECTRICAL SUPPL Y BEFORE SERVICING.

A. Remove the back panel.
B. Disconnect the wires from the terminal

block. Disconnect the green ground wire from the
grounding stud. (Fig. 9).

E. Place the freezer on the floor stand with the front of

the freezer to the door end. All 4 stud/plate mounts
must engage the holes in the floor stand. Secure the
mounts with the nuts and washers provided. (Fig. 8).

Figure 9. Power Cord Connection

C. Remove the power cord.
D. Install permanent wiring according to local code.
E. Replace the back panel.

Figure 8 - Floor Stand

5

6

SECTION 3

INITIAL SETUP AND OPERATION

3.1 OPERATOR'S SAFETY PRECAUTIONS

SAFE OPERA TION IS NO ACCIDENT; Observe these
rules:

A. Know the freezer . Read and underst and the

Operating Instructions.
B. Notice all warning labels on the freezer.
C. Wear proper clothing. Avoid loose fitting gar-

ments, and remove watches, rings or jewelry which

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 freezer until the main electrical power has been

disconnected.

High Pressure Cutout

Switch Located Back

of Freezer

(Some Models)

G. Do not operate under unsafe operating condi-

tions. Never operate the freezer if unusual or exces-

sive noise or vibration occurs.

3.2 OPERATING CONTROLS AND INDICATORS

Before operating the freezer, it is required that the
operator know the function of each operating control.
Refer to Figure 10 for the location of the operating
controls on the freezer. For the information regarding
flashing indicator lights, refer to the troubleshooting
section.

WARNING
THE OFF-ON SWITCH MUST BE PLACED IN THE OFF
POSITION WHEN DISASSEMBLING FOR CLEANING
OR SERVICING. THE FREEZER MUST BE DISCON­NECTED FROM ELECTRICAL SUPPLY BEFORE RE­MOVING ANY ACCESS PANEL.

OFF-ON

POWER SWITCH

ÊÊ

Ê

ÊÊ

SPIGOT SWITCH

ÊÊ

Ê

ÊÊ

Figure 10. Controls

7

HOLD READY

SWITCH

ÈÈ

È

ÈÈ

ÇÇ

Ç

ÇÇ

ÅÅ

Å

ÅÅ

ÅÅ

Å

ÅÅ

ÅÅ

Å

ÅÅ

CONSISTENCY/TEMPERATURE
ADJUSTMENT

PUSH TO FREEZE

CLEAN

MIX LOW

A. SPIGOT SWITCH

The SPIGOT switch will automatically actuate the
auger drive and refrigeration systems when the spigot
is opened to dispense product. When the spigot is
closed, the drive motor and compressor will remain
"on" until the product in the barrel reaches the proper
consistency, or temperature.

B. OFF-ON SWITCH

The OFF-ON switch is a two position toggle switch
used to supply power to the control circuit. When the
switch is in the OFF position, nothing will run. When
the switch is in the ON position the freezer will be in
the idle mode until a switch is activated.

C. PUSH TO FREEZE SWITCH

The PUSH TO FREEZE switch is a "snap" switch used
to start the freezing cycle. During initial freeze down,
the OFF-ON switch is placed in the ON position. Then
the PUSH TO FREEZE switch is pressed until the
drive motor and compressor come "ON".

NOTE

After the gearmotor starts, there is a 3 second de­lay before the compressor starts.

During the normal operation, the red PUSH TO FREEZE
switch light will illuminate after the freezer has been
idle for the preset cycles. Before drawing product,
press the PUSH TO FREEZE switch if it is illuminated.
Wait until the green light is illuminated before dispens­ing.

NOTE

If the freezer shuts off and the PUSH TO FREEZE
light flashes, you have an error condition. Turn the
OFF-ON swtich to the OFF position, correct the
problem and turn the freezer back on. (See Trouble­shooting.)

D. GREEN LIGHT

The green light is used to indicate that the product has
reached the proper consistency or temperature and is
ready to be dispensed.

NOTE

If the PUSH TO FREEZE red light is illuminated,
push the PUSH TO FREEZE switch and wait until
the green light illuminates before dispensing.

F. DRIVE MOTOR OVERLOAD

The internal DRIVE MOTOR OVERLOAD will trip if the
drive motor is overloaded. It will reset after approxi­mately 10-12 minutes. If the drive motor continues to
trip, refer to Troubleshooting (Sec. 4).

G. RED MIX LOW LENS

The red MIX LOW light is designed to alert the operator
to a low mix condition. The lens will illuminate with
approximately one gallon of mix in the hopper. When
the MIX LOW lens is lit, refill hopper immediately.

NOTE

Failure to refill hopper immediately may result in
operational problems.

H. HOLD READY SWITCH

The HOLD READY switch is a push button switch.
When pushed in and held for 5 seconds, the hold ready
mode will be activated. The product will remain ready
to serve and the freezer will not go to idle. To return to
normal operation push and hold for 5 seconds.

3.3 SANITIZING

Sanitizing must be done after the freezer is cleaned and
just before the hopper is filled with mix. Sanitizing the night
before is not effective. However, you should always clean
the freezer and parts after using it.

WARNING

THE UNITED ST ATES 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 freezer, refer to local sanitary regula­tions for applicable codes and recommended sanitizing
products and procedures. The frequency of sanitizing
must comply with local health regulations. 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 120°F 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.

E. CLEAN SWITCH

The CLEAN switch is a "snap" switch. When the
switch is pushed the refrigeration system will be OFF
and the auger will rotate for cleaning. When the switch
is pushed again, the auger will stop and the CLEAN
light will flash indicating the freezer is in the CLEAN
mode. To exit the CLEAN mode turn the OFF-ON
switch to the OFF position. If the freezer is left in
CLEAN for more than 30 minutes or is pushed three
times in ten seconds, it will go in error. To reset place
the CLEAN-OFF-ON switch in the ON position and
allow the error light to flash a minimum of 10 minutes.
Then turn to off, wait 5 seconds and turn on.

NOTE

Stoelting, Inc. has found that STERA-SHEEN
GREEN LABEL SANITIZER AND CLEANER does
an effective job of properly sanitizing and cleaning a
soft serve freezer. We therefore include a sample
with each new freezer. Other products may be as
effective. For further information refer to cleaning and
sanitizing information Section 3.13.

CAUTION
PROLONGED CONTACT OF SANITIZER WITH
FREEZER MA Y CAUSE CORROSION OF ST AIN­LESS STEEL P ARTS.

8

In general, sanitizing may be conducted as follows:
A. Push the mix inlet regulator into hopper with air

inlet (long) tube toward the front of the freezer
(Fig.11).

Figure 11. Mix Inlet Regulator

B. Prepare 2 gallons (7.5 liters) of sanitizing solution

following manufacturer's instructions. Pour into hop­per with mix inlet regulator in place.

C. Place the OFF-ON toggle switch in the ON position

while pressing the CLEAN switch. Check for leaks.
(Fig. 12.)

E. After five minutes, place a bucket under the spigot and

open spigot to drain sanitizing solution. When solution
has drained, press the CLEAN snap switch to stop the
auger. Allow the freezer barrel to drain completely
(Fig. 14).

Figure 14. Draining Solution

3.4 FREEZE DOWN AND OPERATION

This section covers the recommended operating proce­dures to be followed for the safe operation of the freezer.

Figure 12. Clean Control

D. Clean sides of hopper, mix inlet regulator and under

side of hopper cover using a sanitized soft bristle brush
dipped in the sanitizing solution. (Fig. 13).

A. Sanitize just prior to use.
B. Place the OFF-ON switch in the OFF position.
C. With spigot open, pour approximately 1 gallon (3.8

liters) of mix into the hopper. Allow the mix to flush out
about 8 ounces (0.23 liters) of sanitizing solution and
liquid mix. Close the spigot.

D. Fill hopper with approximately 3 gallons (11.4 liters) of

pre-chilled (40°F or 4°C) mix.

CAUTION
DO NOT OVERFILL THE HOPPER. MIX LEVEL
MUST NOT BE HIGHER THAN THE AIR INLET
TUBE ON THE MIX INLET REGULA TOR.

E. The freezer barrel will automatically fill until it is about

1/2 full. If freezer barrel does not fill, check for obstruc­tion in the mix inlet regulator. If freezer barrel fills over
1/2 full, indicated by low overrun, check for leaks at the
mix inlet regulator "O" Ring or check if the mix inlet
regulator was installed correctly or that the freezer is
level.

F. Place the OFF-ON switch in the ON position, then

press the PUSH TO FREEZE switch until the freezer
starts.

Figure 13. Sanitizing Hopper

NOTE

After the gearmotor starts, there is a 3 second de­lay before the compessor starts.

9

G. After about 6 to 10 minutes the freezer will shut OFF

and the green lens will illuminate. The product is ready
to serve. Freeze down time may be longer for some
frozen diet dessert mixes. High ambient temperatures
may extend freeze down time.

H. For normal dispensing, move the spigot handle fully

open 60° (Fig. 15).

Figure 15. Dispensing Product

Mix does not improve with age. Old mix, or mix that has
been stored at too high temperature, can result in a
finished product that is less than satisfactory from the
appearance and taste standpoint. 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).

Some products tend to foam more than others. If excess
foam should occur, skim off with a sanitized utensil and
discard. Periodically, stir the mix in the hopper with a
sanitized utensil.

3.6 REMOVING MIX FROM FREEZER

To remove the mix from the freezer, refer to the following
steps:

A. Remove the mix inlet regulator from the hopper by

pulling straight up (Fig. 16).

CAUTION
REFRIGERATION IS AUTOMATICALLY ACTI­V A TED WHEN THE SPIGOT IS OPENED. CLOSE
THE SPIGOT COMPLETELY AFTER DISPENS­ING.

I. The freezer is designed to dispense the product at a

reasonable draw rate. If the freezer is overdrawn, the
result is a soft product or a product that will not
dispense at all. If this should occur, allow the freezer
to run for approximately 30 seconds before dispensing
additional product. After a while the operator will sense
or feel when the freezer is beginning to fall behind, and
will slow down on the rate of draw so as not to exceed
the capacity.

J. Do not operate the freezer when the MIX LOW light is

on or with less than 1-3/4 inches (4.4 cm) of mix in the
hopper. Refill the hopper immediately.

3.5 MIX INFORMATION

Mix can vary considerably from one manufacturer to
another. Differences in the amount of butter-fat content and
quantity and quality of other ingredients have a direct
bearing on the finished frozen product. A change in freezer
performance that cannot be explained by a technical
problem may be related to the mix.

Figure 16. Removing Mix Inlet Regulator

B. Place the OFF-ON rocker switch in the ON position

and push the CLEAN switch to rotate the auger. Allow
the mix to agitate in freezer barrel until the mix has
become a liquid, about 5 minutes.

C. Drain the liquid mix by opening the spigot. A bucket or

container should be placed under the spigot to catch
the liquid mix. (Fig. 17).

D. Place the OFF-ON switch in the OFF position.

Proper product serving temperature varies from one
manufacturer's mix to another. Soft serve mixes should
provide a satisfactory product in the 18° to 20°F (-7° to

-6°C) range, shake mixes 24° to 28°F (-4° to -2°C).
When checking the temperature, stir the thermometer in

the frozen product to read the true temperature.

Figure 17. Draining Mix

10

3.7 CLEANING THE FREEZER

To disassemble the freezer, refer to the following steps:

NOTE

The frequency of cleaning the freezer and freezer
parts must comply with local health regulations.

After the mix has been removed from the freezer, the
freezer must be cleaned. To clean the freezer, refer to the
following steps:

A. Close the spigot and fill the hopper with 2 gallons (7.5

liters) of cold tap water.

B. Place the OFF-ON switch in the ON position while

pushing the CLEAN switch to rotate the auger.

C. Allow the water to agitate for approximately 5 minutes.

NOTE

If freezer is left in CLEAN for more than 30 minutes,
it will go to error.

D. Open the spigot to drain the water. Remember to place

a bucket or container under the spigot to catch the
water. When the water has drained, turn the OFF-ON
switch to the OFF position. Allow the freezer barrel to
drain completely.

E. Repeat Steps A through D using a mild detergent

solution.

3.8 DISASSEMBLY OF FREEZER PARTS

A. Remove hopper cover and drain tray (Fig. 19).
B. Remove the mix inlet regulator from the hopper by

pulling straight up.

C. Remove the front door by turning off the circular knobs

and then pulling the front door off the studs.

Hopper Cover

ËË

Ë

ËË

Drain Tray

D. Remove the rosette and adapter, then remove the

spigot body from the front door by pulling the clevis pin
out of the spigot handle. Push the spigot body through
the bottom of the front door (Fig. 20). Remove spigot
body and spring.

ÆÆ

Æ

ÆÆ

Figure 19. Removing Front Door

CAUTION
PLACE THE OFF-ON TOGGLE SWITCH IN THE
OFF POSITION BEFORE DISASSEMBLING FOR
CLEANING OR SERVICING.

Inspection for worn or broken parts should be made at
every disassembly of the freezer for cleaning or other
purposes. All worn or broken parts should be replaced to
ensure safety to both the operator and the customer and
to maintain good freezer performance and a quality prod­uct. Two normal wear areas are the auger flights and front
auger support (Fig.18). Frequency of cleaning must com­ply with the local health regulations.

Figure 20. Front Door Disassembly

E. Remove the front auger support and bushing (Fig. 21).

Figure 18. Auger Flight Wear and Front Auger

Support Bushing Wear

Figure 21. Removing Auger Support

11

F. Remove the auger assembly from the freezer (Fig. 22).

Pull the auger out of the freezer barrel slowly. As the
auger is being pulled out, carefully remove each of the
plastic flights with springs.

Figure 22. Auger Shaft Removal

G. Keep the rear of the auger shaft tipped up once it is

clear of the freezer to avoid dropping rear seal.

3.9 CLEANING THE FREEZER PARTS

Place all loose parts in a pan or container and take to the
wash sink for cleaning. To clean freezer parts refer to the
following steps:

A. Place all parts in warm mild detergent water and clean

with brushes provided. Rinse all parts with clean hot
water.

CAUTION
DO NOT DAMAGE PARTS BY DROPPING OR
ROUGH HANDLING.

B. Wash the hopper and freezer barrel with warm deter-

gent water and brushes provided. (Fig. 24).

H. Remove the rear seal.
I. Wipe socket lubricant from the drive end (rear) of the

auger with a cloth or paper towel.

J. Remove all "O" Rings from parts by first wiping off the

lubricant using a clean paper towel. Then squeeze the
"O" Ring upward with a dry cloth (Fig. 23). When a loop
is formed, roll out of the "O" Ring groove.

WARNING
DO NOT USE ANY TYPE OF SHARP OBJECT TO
REMOVE THE "O" RINGS.

Figure 24. Cleaning Freezer Barrel

C. Clean the drip tray and insert with a soap solution.

Rinse with clean hot water.

3.10 SANITIZE FREEZER AND FREEZER PARTS

A. Use a sanitizing solution of 100 parts per million to

sanitize the parts before assembly.

B. Place all parts in the sanitizing solution, then remove

and let air dry.

C. Using this sanitizing solution and the large barrel

brush provided, sanitize the rear of the barrel by
dipping the brush in the sanitizing solution and
brushing.

3.11 ASSEMBLY OF FREEZER

To assemble the freezer parts, refer to the following steps:

NOTE

Petro-Gel sanitary lubricant or equivalent must be
used when lubrication of parts is specified.

Figure 23. Removing "O" Ring

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.

12

A. Assemble all "O" Rings onto parts dry, without lubri-

cation. Then apply a thin film of sanitary lubrication to
exposed surfaces of the "O" Rings. Apply a thin film of
sanitary lubricant to metal part of rear seal. Also apply
a thin film of sanitary lubricant inside and outside of the
front auger support bushing.

B. Assemble the rear seal onto the auger with the large

end to the rear. Be sure the "O" Ring is in place before
installing the rear seal.

C. Lubricate the auger drive (rear) with a small amount of

white socket lubricant. A small container of socket
lubricant is shipped with the freezer.

D. Screw the springs onto the studs in plastic flights.

Springs must be screwed into the flights com­pletely to provide proper compression (Fig. 25).

Figure 26. Exploded View of Front Door

NOTE

The spigot handle can only be installed one way .

I. Install the front door on the freezer. Shoulder on the

rear of the door must be inside of freezer barrel.

J. Install the circular knobs on the freezer studs.

Figure 25. Exploded View of Auger (E111 Shown)

CAUTION
DO NOT PLACE THE MIX INLET REGULATOR
INTO THE HOPPER BEFORE INST ALLING THE
AUGER.

E. Install the two plastic flights onto rear of the auger and

insert part way into freezer barrel.

F. Install the remaining plastic flights, push the auger into

the freezer barrel and rotate slowly until the auger
engages the drive shaft.

G. Install the bushing and auger support into the front of

the auger with one leg of the support pointing straight
up.

CAUTION
FINGER TIGHTEN THE CIRCULAR KNOBS
EVENL Y . DO NOT OVERTIGHTEN KNOBS.

Look for the proper seal between the freezer barrel, "O"
Ring, and front door.

K. Install the mix inlet regulator into the freezer with the

air tube to the front of the freezer (Fig. 27).

L. Install hopper cover and drain tray.

NOTE

Apply a small amount of Petro-Gel to the surface of
the cam on the spigot handle prior to assembly of
handle to the spigot body .

H. Install the spigot body with "O" Rings and spring into

the front door from bottom (Fig. 26). Push straight up
until the spigot is in place. Place the spigot handle on
top of the spigot and insert clevis pin, then install the
adapter and rosette.

Figure 27. Mix Inlet Regulator

3.12 ROUTINE CLEANING

To remove spilled or dried mix from the freezer exterior,
simply wash in the direction of the finish with warm soapy
water and wipe dry. Do not use highly abrasive materials
as they will mar the finish.

13

3.13 PREVENTIVE MAINTENANCE

It is recommended that a maintenance schedule be fol­lowed to keep the freezer clean and operating properly.

A. Cleaning and Sanitizing Information

CLEANING vs. SANITIZING

It is important to distinguish between cleaning and
sanitizing. Although these terms may sound
synonymous, they are not. BOTH are required for
adequate food safety and proper machine
maintenance.

Soft serve freezers require special consideration
when it comes to food safety and proper cleaning
and sanitizing.

The following information has been compiled by
Purdy Products Company, makers of Stera-Sheen
Green Label Cleaner/Sanitizer and specifically
covers issues for cleaning and sanitizing frozen
dessert machines. This information is meant to
supplement a comprehensive food safety program.

Soil Materials Associated with Frozen Dessert
Machines

MILKFAT/BUTTERFAT – As components of ice­cream/frozen custard mix, these soils will
accumulate on the interior surfaces of the machine
and its parts. Fats are difficult to remove and help
attribute to milkstone build-up.

MILKSTONE – Is a white/gray film that forms on
equipment and utensils that come in contact with
dairy products. These films will accumulate slowly
on surfaces because of ineffective cleaning, use of
hard water, or both. Milkstone is usually a porous

deposit, which will harbor microbial
contaminants and eventually defy sanitizing
efforts.

Once milkstone has formed, it is very difficult to
remove. Without using the correct product and
procedure, it is nearly impossible to remove a thick
layer of milkstone.
(NOTE: general-purpose cleaners DO NOT remove
milkstone.) This can lead to high bacteria counts

and a food safety dilemma.

IT IS BEST TO CONTROL MILKSTONE ON A
DAILY BASIS BEFORE IT CAN BECOME A
SIGNIFICANT FOOD SAFETY PROBLEM.

In addition to food safety, milkstone can cause
premature wear to machine parts which can add to
costs for replacement parts or possibly more
expensive repairs if worn machine parts are not
replaced once they have become excessively worn.

Important Differences Between Cleaning and
Sanitizing

CLEANING

· Is the removal of soil materials from a surface.

· Is a prerequisite for effective sanitizing.

NOTE

An UNCLEAN surface will harbor

bacteria that can defy sanitizing efforts.

Bacteria can develop and resist sanitizing efforts
within a layer of soil material (milkstone). Thorough

cleaning procedures that involve milkstone
removal are critical for operators of frozen
dessert machines.

SANITIZING

· Kills bacteria.

· Can be effective on clean surfaces only.

NOTE

Using a SANTITIZER on an unclean surface will not

guarantee a clean and safe frozen dessert machine.

Proper Daily Maintenance:
The Only Way to Assure Food Safety and
Product Quality

Proper daily maintenance can involve a wide variety
of products and procedures. Overall, the products
and procedures fall into three separate categories.

(Please note that this is a brief overview intended for
informational purposes only.)

1. CLEANING – This involves draining mix from the
freezer barrel and rinsing the machine with
water. Next, a cleaner is run through the
machine. Then, the machine is disassembled
and removable parts are taken to the sink for

cleaning.

2. MILKSTONE REMOVAL – Since almost all
cleaners do not have the ability to remove
milkstone, the use of a delimer becomes
necessary. Although this procedure may not be
needed on a daily basis, it will usually follow the
cleaning procedure. It requires letting a delimer
solution soak in the machine for an extended
period of time. Individual parts are also soaked
in a deliming solution for an extended period of
time (more about delimers in Additional
Information).

14

3. SANITIZING – After the machine has been
cleaned and contains no milkstone, the
machine is reassembled. Then a FDA-approved
sanitizing solution is run through the machine to
kill bacteria. The machine is then ready for food
preparation.

As a recommended cleaner and sanitizer for your
frozen dessert machine, STERA-SHEEN has proven
to be one of the best daily maintenance products for:

· CLEANING – Thorough removal of all solids

including butterfat and milk fat.

· MILKSTONE REMOVAL – Complete removal of

milkstone.

THE USE OF CHLORINE TEST STRIPS

“Test strips” are used to determine concentrations of
active chlorine in sanitizing solutions. To use the
strips, tear off a small portion and submerge it into
the sanitizing solution. Then, compare the color
change to the color key on the side of the test strip
dispenser to determine the approximate chlorine
concentration.

The ideal concentration of chlorine needs to be 100
ppm (as stated by the FDA).

NOTE

Follow the directions on the container for proper
concentration.

· SANITIZING – FDA-approved no rinse sanitizer

for food contact surfaces.

Additional Information

THE USE OF DELIMERS

A delimer is a strong acid that has the ability to
dissolve milkstone. This type of chemical may
become necessary once high levels of milkstone
have developed. While these products are very
effective for removing HIGH levels of milkstone, they
are not ideal for two reasons:

1. PRODUCT SAFETY – Strong acids are

dangerous chemicals and handling them
requires safety

2. MACHINE DAMAGE – Strong acids will attack

metal and rubber causing premature wear of
parts. The use of a delimer needs to be closely
monitored to avoid damage to machine surfaces
and parts.

With proper daily use of STERA-SHEEN or it’s
equivalent, there is no need for the use of a
DELIMER.

DO NOT USE BLEACH

· BLEACH HAS ABSOLUTELY NO CLEANING

PROPERTIES.

· BLEACH IS CORROSIVE. It can and will

damage components of the machine causing
premature wear and metal corrosion.

There are two main factors that contribute to falling
chlorine concentrations in a sanitizing solution.

1. PRODUCT USE – As the chlorine in the
solution is being used, chlorine concentrations
fall.

2. TIME – As time passes, small amounts of
chlorine “evaporate” from the solution. (That is
why you can smell it.)

Sanitizing solutions should not be allowed to fall
below 100 ppm chlorine. New solutions should be
mixed once old solutions become ineffective

WARNING
NEVER ATTEMPT TO REPAIR OR PERFORM
MAINTENANCE ON FREEZER UNTIL THE MAIN
ELECTRICAL POWER HAS BEEN DISCON­NECTED.

B. DAILY

1. The exterior should be kept clean at all times to
preserve the lustre of the stainless steel. A mild
alkaline cleaner is recommended. Use a soft
cloth or sponge to apply the cleaner.

CAUTION
DO NOT USE ACID CLEANERS, STRONG CAUS­TIC COMPOUNDS OR ABRASIVE MA TERIALS TO
CLEAN ANY P ART OF THE FREEZER EXTERIOR
OR PLASTIC P ARTS.

GENERAL PURPOSE CLEANERS

General purpose cleaners do not have the ability to
remove milkstone. Milkstone will become a problem
if not remedied with additional products and
procedures.

C. WEEKLY

1. Check "O" Rings and rear seal for excessive
wear and replace if necessary.

2. Remove the drip tray by gently lifting up to
disengage from the support and pulling out.
Clean behind the drip tray and front of the
freezer with a soap solution.

15