Stoelting E111I Operators Manual

Model E111I / F111I

SERVICE MANUAL

Manual No. 513663 Nov. 2010

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

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

1.3 Modes of Normal Operation ........................................................................3

1.4 Mix Level Indicators....................................................................................5

1.5 Hopper Refrigeration ...................................................................................5

1.7 Motor Profile Cutout Compensation ............................................................5

2 Installation Instructions

2.1 Safety Precautions.....................................................................................7

2.2 Shipment and Transit .................................................................................8

2.3 Machine Installation....................................................................................8

3 Initial Set-Up and Operation

3.1 Operator’s Safety Precautions....................................................................9

3.2 Operating Controls and Indicators...............................................................9

3.3 Important Information Regarding Cleaning and Sanitizing............................11

3.4 Disassembly of Parts .................................................................................12

3.5 Cleaning Disassembled Parts.....................................................................13

3.6 Sanitizing Parts..........................................................................................13

3.7 Cleaning the Machine.................................................................................13

3.8 Assembling the Machine ............................................................................14

3.9 Sanitizing ...................................................................................................15

3.10 Initial Freeze Down and Operation ..............................................................15

3.11 Normal Freeze Down and Operation ...........................................................16

3.12 Mix Information...........................................................................................17

4 Maintenance and Adjustments

4.1 Machine Adjustment...................................................................................19

4.2 Product Consistency Adjustment ...............................................................19

4.3 Locking the Control Panel...........................................................................19

4.4 Obtaining Readings and Modifying Settings................................................19

4.5 Readings ....................................................................................................21

4.6 Adjustments...............................................................................................22

4.7 Other Settings............................................................................................22

4.8 Drive Belt Tension Adjustment....................................................................23

4.9 Condenser Cleaning ...................................................................................24

4.10 Preventative Maintenance ...........................................................................24

4.11 Extended Storage.......................................................................................24

Section Description Page

5 Refrigeration System

5.1 Refrigeration System ..................................................................................25

5.2 Refrigerant Recovery and Evacuation ..........................................................25

5.3 Refrigerant Charging ...................................................................................26

5.4 Compressor................................................................................................27

5.5 Condenser ..................................................................................................28

5.6 Evaporator ..................................................................................................28

5.7 Valves ........................................................................................................28

A. Thermostatic Expansion Valve (TXV)..................................................................28

B. Check Valve.........................................................................................................29

C. High Pressure Cutout ......................................................................................... 29

D. Hot Gas Bypass.................................................................................................. 30

E. Evaporator Pressure Regulator (EPR) ............................................................... 3 1

F. Water Valve (Water Cooled Models Only) ...........................................................31

5.8 Solenoid .....................................................................................................32

5.9 Filter Drier ..................................................................................................33

5.10 Capillary Tube ............................................................................................33

6 Electrical and Mechanical Control Systems

6.1 IntelliTec Controller .....................................................................................35

6.2 Contactors..................................................................................................35

6.3 Drive Motor .................................................................................................36

6.4 Capacitors ..................................................................................................37

6.5 Gearbox .....................................................................................................37

6.6 Condenser Fan Motor (Air Cooled Models Only) .........................................38

6.7 Spigot Switch.............................................................................................38

6.8 Temperature Control Sensor .......................................................................39

7 Troubleshooting

7.1 Error Codes ................................................................................................41

7.2 Troubleshooting ..........................................................................................41

7.3 Troubleshooting - Machine..........................................................................44

8 Replacement Parts

8.1 Auger & Front Door Parts...........................................................................45

8.2 Hopper Cover & Trays.................................................................................46

8.3 Spigot Cam Assembly................................................................................46

8.4 Left Side.....................................................................................................47

8.5 Machine Front ............................................................................................48

8.6 Machine Back ............................................................................................49

8.7 Decals & Miscellaneous.............................................................................51

8.8 Panels........................................................................................................51

8.9 Wiring Diagram...........................................................................................52

SECTION 1

DESCRIPTION AND SPECIFICATIONS

1.1 DESCRIPTION

The Stoelting E111 & F111 counter machines are gravity fed. The machines are equipped with fully automatic controls to provide a uniform product. The machines are designed to operate with almost any type of commercial soft serve or non-dairy mix 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 E111 & F111 gravity machines.

Figure 1-1 Model E111 & F111

Figure 1-2 Specifications

1.2 SPECIFICATIONS

Dimensions Machine with crate Machine with crate

width 15'' ( 38, 1 cm ) 19-1/ 2' ' ( 4 9, 5 cm) 15'' ( 38,1 cm) 19-1/2'' ( 49,5 cm)

h eight 35-3/4'' (90,8 cm ) 43'' ( 109, 2 cm ) 35-3/ 4' ' ( 90,8 cm) 43'' (109,2 cm )

depth 28-3/4'' ( 73, 0 cm ) 33-1/ 2' ' ( 8 5, 1 cm) 28-3/ 4' ' ( 7 3, 0 cm) 33-1/ 2' ' (85,1 cm )

Weight

Electrical

ru nn ing amps

connection type

International Option

Compressor

Dri ve Motor

Air Flow

Plum bing Fit t ings

Hopper Vol ume

Freezing Cyl i nde r

Volume

Model E111I Model F111I

220 lbs ( 99,7 kg) 265 lbs ( 120,2 kg) 230 lbs ( 104,3 kg) 27 5 lbs (124, 7 kg)

1 Phase, 115 VA C, 60Hz 1 Phase, 208- 2 40 VA C, 60Hz

approximately 12A approximat ely 10A

NEM A5- 20P power cor d pr o vided NEMA6-15P pow e r cord provided

1 Phas e, 2 20- 2 40 VAC, 50Hz 1 Phase, 220-240 VAC, 50Hz

3,550 Bt u/hr

3/4 hp

Air cooled unit s requir e 3" ( 7,6 cm) air spa ce on both sides

N/A

Water c ooled u nits r equire 3/ 8" N .P.T .

3 gallon (11,35 l it er s )

0.65 gallon (2. 6 quart ) , 2,46 liters 0.85 ga l lon ( 3.4 qu ar t ) , 3,22 liters

5,450 Bt u/hr

wat er and drain f ittings.

E111I / F111I

Refrigerant

Charge

Suction Pressure

(at 7 2°F )

Discharge Pressure

Hot Gas Bypass

Pressure

EPR Valve

E111I - 28 oz F111I - 30 oz

Freez ing Cyl inder Only 19-22 psig

Freez ing Cyl inder & Hopper 22- 25 ps ig

14 psig (on ly hopper running)

R-404A

Hopper O nly 14 psig

225-235 psig

59-61 psig

Menu Display E111I F111I

Basic

Advanced

Storage

CutOut * amps * amps

Cut In T 18 °F 21 °F

Cycl es 20 count 20 count Stir On 15 seconds 15 seconds

Stir Off 300 seconds 300 seconds On Time 15 seconds 15 seconds Off Time 450 seconds 450 seconds

Stb T ime 120 min utes 120 minutes

Sl1DrvOn 120 secon ds 120 seconds

Sl1DrOff 180 seconds 180 secon ds Sl2CutI n 33 °F 33 °F

Sl2CtO ut 30.5 ° F 30.5 °F DftOffTm 540 seconds 600 seconds

Ref r iger 1 Hopper 1 Hopper

HprCutIn 34 °F 34 °F

HprCtOut 32 °F 32 °F

HprOffst 8 °F 8 °F

Hpr Off 13 minu tes 13 minu tes Hpr O n 60 seconds 60 secon ds

* CutOut value needs to be adjusted to product requirements.

1.3 MODES OF NORMAL OPERATION

Following are details of the operational modes of the IntelliTec control.

NOTE:

The preset amounts, times, and temperatures listed below are references to actual settings on the IntelliTec control. Refer to Table 1-1 on page 7 for details on each setting.

A. Initial status

When the Main Freezer Power is placed in the ON position, the machine will start in the “Sleep 1 Mode". The display will read "Sleep 1 Mode". The control will eventually move into the “Sleep 2” mode if the PUSH TO FREEZE button is not pressed. When the PUSH TO FREEZE button is pressed the control will move to the “Serve Mode”.

B. Serve Mode

When the PUSH TO FREEZE button is pressed or a spigot handle is pulled, the “Serve Mode” begins. The drive motor starts, and after a 3 second delay, the compressor starts. The display reads “FREEZING” on the top line and a bar on the bottom line increases with product consistency. A toroid on the IntelliTec control senses increasing drive motor amperage as the product comes to consistency in the freezing cylinder. When the control senses the product is at 75% of consistency, the display will read "SERVE", the amber LED will go out, and the green LED will flash. At this time, product can be served from the machine. The drive motor and compressor will continue to run until the toroid reads a preset value (CutOut amps). When the toroid reads the CutOut amps on the drive motor, the compressor turns off and the green LED will remain lit. After a 3 second delay, the drive motor turns off. The product in the freezing cylinder is now at serving temperature and consistency and the green LED will remain lit.

After product is at consistency, the IntelliTec control continuously monitors refrigerant temperature through a thermistor mounted on the side of the freezing cylinder. When the temperature increases to a preset amount (Cut In T), a 3-second drive motor pre-stir analyzes product consistency. The pre-stir check is also performed each time the spigot handle is opened. This check prevents overfreezing of product, especially during frequent, small volume draws. If the product requires a freezing cycle, the control will start the cycle.

During the “Serve Mode”, a stir cycle starts. This cycle is independent of the freezing cycle and is based on preset times (Stir On and Stir Off). The stir cycle prevents product separation. If a freezing cycle is initiated, the timer is reset.

In addition to the "Serve Mode" freezing cycle, there is a freezing cycle based on a preset time (DftOffTime). If this time is attained without a freezing cycle, the control will automatically start a freezing cycle. If a freezing cycle is initiated, the timer is reset

Figure 1-3 Serve Mode

The machine will remain in “Serve Mode” until the cycle count setting is attained. The cycle count is the number of active freezing cycles and is based on a preset value (Cycles). Once the cycle count has been reached without user interruption, the control will move into the "Standby Mode".

If the PUSH TO FREEZE button is pressed or a spigot handle is pulled, the cycle count is reset and the control will move to the beginning of the "Serve Mode". Refer to Figure 1-3 for a graphical representation of the "Serve Mode".

C. Standby Mode

If no product has been drawn from the spigot and the preset number of active freezing cycles is met, the control moves into the “Standby Mode”. In "Standby Mode", the freezing cycle is based on preset timers (On Time and Off Time), and prevents ice crystals from building up in the product. Because the product remains partially frozen, it can quickly return to servable consistency when the PUSH TO FREEZE button is pressed.

During “Standby Mode”, the stir cycle runs. This cycle is based on preset, timed intervals (Stir On and Stir Off) and prevents product separation.

Figure 1-4 Standby Mode

The "Standby Mode" maintains product quality during slow times, while minimizing reactivation time. This mode lasts for a preset time (Stb Time). Once this time has been reached without user interruption, the control moves into the "Sleep 1 Mode". Refer to Figure 1-4 for a graphical representation of the "Standby Mode".

If a spigot is opened or the PUSH TO FREEZE button is pressed, the control will move to “Serve Mode”. Product in the front of the freezing cylinders may or may not be at consistency. The state of the product is dependant on a number of variables but will come to consistency quickly.

D. Sleep 1 Mode

After the “Standby Mode” time has expired without user interruption, the control will move into the “Sleep 1 Mode”. During the "Sleep 1 Mode", the stir cycle is handled by preset timers (Sl1DrvOn and Sl1DrOff), and allows product to melt to a liquid state by using agitation cycles without any flow of refrigerant. Although the product temperature never increases above 41°F, the product thaws rapidly which minimizes product breakdown. The control will stay in the “Sleep 1 Mode” until sensing a preset temperature (Sl2CutIn). When this temperature has been reached without user interruption, the control will move to the "Sleep 2 Mode". Refer to Figure 1-5 for a graphical representation of the "Sleep 1 Mode".

Figure 1-5 Sleep 1 Mode

If a spigot is opened or the PUSH TO FREEZE button is pressed, the control will move to “Serve Mode”. If the spigot is opened in "Sleep 1 Mode", the product will not be at consistency. The operator must wait until the first "Serve Mode" freezing cycle has completed to serve product.

E. Sleep 2 Mode

The “Sleep 2 Mode” maintains the freezing cylinder temperature between two preset values (Sl2CutIn and Sl2CtOut). During the “Sleep 2 Mode”, the stir cycle runs. This cycle is based on preset, timed intervals (Stir On and Stir Off) and prevents product separation. The "Sleep 2 Mode" is often referred to by customers as the “night mode” and the machine will stay in this mode until a spigot is opened or the PUSH TO FREEZE button is pressed. When this

Figure 1-6 Sleep 2 Mode

occurs, the control will move to “Serve Mode”. If the spigot is opened at this time, the product will be liquid. The operator must wait until the first "Serve Mode" freezing cycle has completed to serve product. Refer to Figure 1-6 for a graphical representation of the "Sleep 2 Mode".

F. IntelliTec Restart

If a hard error occurs (refer the hard error list below), the IntelliTec control will wait 5 minutes then attempt to clear the error by restarting itself. The control will count each restart attempt. The restart count will reset if the PUSH TO FREEZE button is pressed, the spigot is pulled, or the Freezing Cylinder OFF/ON switch is placed in the OFF position.

The following are considered hard errors: ERROR CODE MALFUNCTION

2 High Torque 3 Run Time 4 Clean 7 Drive Motor 9 High Pressure Cutout

When a restart occurs, the second line of the display will read "Restart" and the backlight will blink. This will occur regardless of the system mode.

G. Sleep 3 Mode

If a high torque, run time, or drive motor error condition occurs on the third restart attempt, the control will move to the "Sleep 3 Mode".

In "Sleep 3 Mode" freezing cylinder refrigeration will run for 4 seconds every 10 minutes. This ensures the product temperature never increases above 40°F. The stir cycle and the auger do not run during "Sleep 3 Mode".

The control will exit "Sleep 3 Mode" if the PUSH TO FREEZE button is pressed, the spigot is pulled, or the Freezing Cylinder OFF/ON switch is placed in the OFF position.

H. Clean Mode

When the CLEAN button is pressed, freezing cylinder refrigeration stops, the drive motor starts and will run for 20 minutes, and a 5 minute countdown timer is displayed. After the time has elapsed, an optional audible alarm will sound if this accessory has been installed. The audible alarm is a reminder for the operator to end the "Clean Mode" when cleaning is completed.

If the machine is kept in "Clean Mode" for more than 20 minutes, the auger drive motor stops and an error code (E4) is displayed on the display panel. The error code prevents damage to the machine that could occur during an extended clean mode (Refer to Section 8 - Troubleshooting for details). To clear this error, place the Freezing Cylinder Off/On switch in the OFF position and back in the ON position. If the machine is still being cleaned, pushing the CLEAN button will reset the timer and restart the "Clean Mode".

1.4 MIX LEVEL INDICATORS

The hoppers are equipped with a sensor that monitors mix level. When the mix level drops below the sensor probe, the lower line of the display will read "Low Mix" and the display will flash. To clear the "Low Mix" error, add mix to the hopper.

A. Serve and Standby Mode

In the event of a temperature sensor failure on a freezing cylinder, the IntelliTec control will function in two modes, "Serve Mode" and "Standby Mode". When the product is at consistency in "Serve Mode", the IntelliTec control uses a timer instead of the sensor and will not start another freezing cycle until a preset value (DftOffTme) is met.

The control will monitor product after it is at consistency, activating the stir cycle and counting the number of cycles. When the cycle count is reached, the control will move to "Standby Mode".

The "Standby Mode" is the same as in normal operation with the exception of when the preset time (Stb Time) is met, the control moves back into the "Serve Mode". Refer to Figure 1-7 for details.

1.5 HOPPER REFRIGERATION

The IntelliTec control is programmed to handle refrigeration of the hopper independently from the freezing cylinder. The control maintains hopper temperature between two preset values (HprCutIn and HprCtOut).

The hopper refrigeration cycle starts when the temperature of either hopper reaches the HprCutIn value and stops when hopper reaches the HprCutOut value.

In addition to this refrigeration cycle, hopper refrigeration may start when the freezing cycle starts. This reduces compressor cycles which preserves compressor life. Hopper refrigeration will start if the hopper temperature is above a preset value (HprOffst + HprCtOut). This value is always between HprCutIn and HprCtOut. Refrigeration of the hopper will continue until the HprCtOut is reached or until the freezing cycle is completed in the freezing cylinder.

The refrigeration cycle will run for a maximum of 4 minutes. After 4 minutes, the refrigeration cycle will stop for a minimum of 3 minutes. At the expiration of 3 minutes, the control will check product temperature. If product temperature is at or above HprCutIn, another refrigeration cycle will start.

1.6 OPERATION DURING SENSOR FAILURE

The IntelliTec control is designed to allow the machine to continue to function if a temperature sensor failure occurs. If a sensor fails, the display will show the error and the control will run the machine on timers for the freezing cycle or hopper refrigeration. This allows the operator to continue to serve product from the machine until proper servicing can be completed.

Figure 1-7 Serve Mode (Sensor Failure)

In the event a hopper temperature sensor fails, the control will use the temperature of the other hopper to control the refrigeration cycle.

If both temperature sensors fail, the refrigeration cycle is managed by preset times (Hpr On and Hpr Off). This refrigeration cycle is independent of the freezing cycle.

1.7 MOTOR PROFILE CUTOUT COMPENSATION

The IntelliTec control is programmed to automatically function at a range of supply voltages. This feature provides the advantage of having product maintained at a specific temperature and consistency irrespective of the supply voltage. A motor profile curve is programmed on the IntelliTec control and provides a relationship between the supply voltage and drive motor cutout amperage. Depending on the supply voltage, the control varies cutout amperage according to the motor profile. This feature is automatic and does not need any configuring.

IntelliTec Control Setting Specificat ions

Basic Menu

Adva nced Menu

DISPLAY E111 F111 MODE DEFINITION

CutOut * * S erve A m p draw s et ting for cut out

Cut In T 18°F 21°F S erve Temperature s et ting for cut i n

Cycles 20 20 Serve Freezing cycles before going into Standby M ode

St i r On 15 sec 15 sec Serve Stir-only on time

St i r Off 300 s ec 300 sec S erve S tir-only off tim e

DISPLAY E111 F111 MODE DEFINITION

On Time 15 sec 15 sec St andby Freez ing cycle "on” time (runs on timers only)

Off Time 450 s ec 450 sec S t andby Freez ing cycle “off” time St b Time 120 min 120 min Standby Total t i m e i n mode Sl1DrvOn 120 sec 120 sec S l eep 1 Drive mot or “on” ti m er

Sl1DrOff 180 sec 180 s ec Sleep 1 Drive mot or “off” timer

Sl 2Cut In 33°F 33° F Sleep 2 Cut in t em perat ure

Sl2Ct Out 30. 5°F 30.5°F Sleep 2 Cut out tem perat ure

DftOffTm 540 sec 600 s ec No Sens or Default “off” time. Used i n c ase of sens or failure

Stor age M enu

* The CutOut value needs to be adj us ted to produc t requirement s . Refer to the 2183150 - S pec i f i cati on S heet for E111 IntelliTec Control or t he 1183229 - S pec i fic at i on S heet for F111 I ntelliTec Control l ocated in the plas t i c pouch behi nd t he l eft

si de panel.

DISPLAY MODE DEFINITION

Refriger All S et t o None, 1 Hopper, 2 Hopper, or Cabinet

HprCutIn All Refrigerated c ab cut in temperat ure

HprCtOut All Refrigerated c ab cut out t em perature

Hpr Off No Sensor Default “off” time. Used i n cas e of sensor failure

Hpr On No S ensor Default “on” ti m e. Us ed i n c ase of sens or failure

E111 & F111

1 Hopper

34°F

32°F 13 min 60 sec

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

ATTENTION: Customer Service

502 Hwy. 67

Kiel, Wisconsin 53042

Figure 2-1 Warning Label Locations

2.2 SHIPMENT AND TRANSIT

The machine has been assembled, operated and inspected at the factory. Upon arrival at the final destination, the complete 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 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. If the machine is equipped with an air cooled

condenser, correct ventilation is required. The right side of the machine is the air intake and left side discharge. Both sides must have 3" clearance the top requires 10" of clearance.

CAUTION

D. Place the OFF-ON switch in the OFF position. E. Connect the power cord to the proper power

supply. Check the nameplate on your machine for 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 (Fig. 2-3). 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.

208/230V

115V

20 Amp

Figure 2-3 Electrical Plug

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 .

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

other miscellaneous parts on the machine.

15 Amp

Failure to provide adequate ventilation will void warranty.

Figure 2-2 Space and Ventilation Requirements

SECTION 3

INITIAL SETUP 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. 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.

Main Power OFF-ON

Dispense Rate Adjustor

IntelliT ec Control

(See Figure 3-2)

Figure 3-1 E11 1 & F1 1 1 Controls

B. Main Freezer Power OFF-ON Switch

The Main Freezer Power 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, power will not be supplied to the control

board or refrigeration system. When the switch is

in the ON position, the machine will operate in the

freezing mode or cleaning mode. The machine will

be in the sleep mode until a switch is activated.

C. PUSH TO FREEZE Button

The PUSH TO FREEZE button is used to initiate

the serve mode. To start the machine, place the

Main Freezer Power OFF-ON switch in the ON

position and press the PUSH TO FREEZE button.

NOTE

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

D. LEDs

The membrane switch features two lights; a green

LED and an amber LED. The green LED is lit during

serve mode. During freeze down, the green LED is

not lit. When product consistency approaches

75% in the freezing cylinder, the green LED flashes.

The amber LED is lit during all other modes. In the

event of an error or when the freezing cylinder is off,

both LEDs will alternatively flash.

NOTE

If the machine shuts off, and alternating green and amber lights are flashing, the machine is in an error condition. If the LCD displays 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. CLEAN Button

The CLEAN button will stop all refrigeration and

start auger rotation. A CLEAN message will display

on the LCD screen and a 5 minute timer begins. To

exit the CLEAN mode, press the CLEAN button

again. If the machine is left in CLEAN for more than

20 minutes, it will go into an error to prevent

damage to the freezing cylinder. When this error

occurs, refrigeration will start to prevent mix

spoilage. To reset, place the Main Freezer Power

OFF-ON switch in the OFF position and back in the

ON position.

F. Mix Low Light Indicator

The MIX LOW message will appear on the LCD

display to alert the operator to a low mix condition.

The message will 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. Dispense Rate Adjustor

The dispense rate adjuster limits the opening of the spigot. To adjust product dispense rate, turn the adjusting knob clockwise for slower flow and counterclockwise for faster flow. It takes at least five complete turns of the adjusting knob to make a noticeable difference in the dispense rate.

H. Front Door Safety Switch

The front door safety switch prevents the auger 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.

I. Manu Navigation Buttons

The Menu Navigation Buttons allow the user to display information regarding the machine's status of operation as well as adjust product consistency.

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.

Set Button (SET) Pressing this button will save a change made to the product consistency setting. Refer to Section 3-15 for consistency adjustment procedures.

Left Arrow Button (⇐) 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 (⇐) button for five seconds. The backlight function can be reset to normal operation in the same manner.

Up Arrow Button (⇑) Pressing this button will change the value of the product consistency. Refer to Section 3-15 for consistency adjustment procedures.

Push to Freeze

Green Light

Amber Light

Clean Switch

SEL Button

SET Button

Left Arrow Button

Up Arrow Button

Figure 3-2 IntelliT ec Control

3.3 IMPORTANT INFORMATION REGARDING CLEANING AND SANITIZING

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

The following information 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 ice-cream/ 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 buildup.

MILKSTONE – Is a white/gray film that forms on equipment and utensils that are exposed to 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 vs. SANITIZING It is important to distinguish between cleaning and sanitiz-

ing. Although these terms may sound synonymous, they are not. BOTH are required for adequate food safety and proper machine maintenance.

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 SANITIZER 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 freezing cylinder 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 most 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. Individual parts are also soaked in a deliming solution for an extended period of time (more about delimers in Additional Information).

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.

• 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. Carefully follow safety instructions provided with delimer products.

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

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.

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.

Two main factors 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.

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. Check the wear line on the auger flights on a regular basis (Fig. 3-3) and replace as needed. Frequency of cleaning must comply with the local health regulations.

Wear Line

Figure 3-3 Auger Flight Wear

To disassemble the machine, refer to the following steps: A. Remove hopper cover and drain tray. B. Remove the mix inlet regulator from the hopper by

pulling straight up.

C. Remove the front door by turning the circular knobs

and then pulling the front door off the studs.

D. Remove the rosette cap from the front door. Push

the spigot body through the bottom of the front door and remove.

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

3-4).

3.4 DISASSEMBLY OF PARTS

WARNING

Hazardous Moving Parts

Revolving auger shaft can grab and cause injury. Place the Main Freezer Power OFF-ON switch in the OFF position before disassembling for cleaning or servicing.

Figure 3-4 Removing Auger Support

Figure 3-5 Removing Auger Shaft and Flights

F. Remove the auger assembly from the machine

(Fig. 3-5). Pull the auger out of the machine barrel slowly. As the auger is being pulled out, carefully remove each of the plastic flights with springs.

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

is clear of the machine to avoid dropping rear seal.

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. 3-6). When a loop is formed, roll out of the o-ring groove.

3.5 CLEANING DISASSEMBLED PARTS

Disassembled parts require complete cleaning, sanitizing and air drying before assembling. Local and state health codes will dictate the procedure required. Some state health codes require a four sink process (pre-wash, wash, rinse, sanitize, air dry), while others require a three sink process (without the pre-wash step). The following procedures are a general guideline only. Consult your local and state health codes for the procedures required in your location.

A. Disassemble all parts. (Refer to Section 3.4 for the

disassembly of machine parts.)

B. Place all front door and auger parts in clean 90° to

110°F (32°C to 43°C) water and wash thoroughly (four sink procedure only).

C. Place all parts in 90° to 110°F (32°C to 43°C) mild

detergent water and wash thoroughly.

D. Rinse all parts with clean 90° to 110°F (32°C to

43°C) water.

E. Sanitize all machine parts following procedures

outlined below.

3.6 SANITIZING PARTS

A. Use a sanitizer, mixed according to manufacturer’s

instructions, to provide a 100 parts per million strength solution. Mix sanitizer in quantities of no less than 2 gallons of 90° to 110°F (32°C to 43°C) water. Any sanitizer must be used only in accordance with the manufacturer’s instructions.

B. Place all parts in the sanitizing solution for 5

minutes, then remove and let air dry completely before assembling in machine.

CAUTION

Do not use any type of sharp object to remove the orings.

Figure 3-6 Removing O-Ring

3.7 CLEANING THE MACHINE

The exterior should be kept clean at all times to preserve the luster of the stainless steel. A high grade of stainless steel has been used on the machine to ease cleanup. To remove spilled or dried mix, wash the exterior with 90° to 110°F (32°C to 43°C) soapy water and wipe dry.

Do not use highly abrasive materials, as they will mar the finish. A mild alkaline cleaner is recommended. Use a soft cloth or sponge to apply the cleaner. For best results, wipe with the grain of the steel.

A. Clean the rear seal surface from inside of the

freezing cylinder.

B. Using sanitizing solution and the large barrel brush

provided, sanitize the freezing cylinder by dipping the brush in the sanitizing solution and brushing the inside of the freezing cylinder.

C. Remove the drip tray by pulling from the front panel.

Clean and replace the drip tray.

3.8 ASSEMBLING 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.

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. Assemble all o-rings onto parts dry, without

lubrication. 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 machine.

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

Springs must be screwed into the flights completely to provide proper compression (Fig. 3-7).

Figure 3-8 Front Door Parts

F. Install the remaining plastic flights, push the auger

into the machine 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.

H. Install the spigot body with o-ring into the front door

from bottom (Fig. 3-8). Push straight up until the

spigot is in place. I. Install the front door on the machine. J. Install the circular knobs on the machine studs. K. Look for the proper seal between the freezing

cylinder, o-ring, and front door.

Figure 3-7 Auger Springs

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

and insert part way into machine barrel.

CAUTION

Overtightening or uneven tensioning of circular knobs may cause damage to front door and cause leaking. Hand tighten circular knobs evenly .

3.9 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 AGRICULTURE AND THE FOOD AND DRUG ADMINISTRATION REQUIRE THAT 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.

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. Push the mix inlet regulator into hopper with air

inlet (long) tube toward the front of the machine (Fig. 3-9).

Figure 3-9 Mix Inlet Regulator

C. Place the Main Freezer Power OFF-ON toggle

switch in the ON position and press the CLEAN switch. Check for leaks.

Figure 3-10 Sanitizing Hopper

D. Clean sides of hopper, mix inlet regulator and

underside of hopper cover using a sanitized soft

bristle brush dipped in the sanitizing solution. (Fig.

3-10). E. After five minutes, place a bucket under the spigot

and open spigot to drain sanitizing solution. When

solution has drained, press the CLEAN button to

stop the auger. Allow the machine barrel to drain

completely.

3.10 INITIAL FREEZE DOWN AND OPERATION

Every Stoelting soft serve machine needs to be set on site. The following adjustment will provide optimal product con-

sistency while prolonging product life.

NOTE

The machine is designed for correct operation in ambient temperatures between 50°F and 1 10°F . T emperatures out of that range may cause refrigeration problems and product quality issues.

A. ADDING MIX

1. Sanitize the machine immediately before use.

2. Make sure the Main Freezer Power OFF-ON

switch is in the OFF position.

3. Fill the hopper with at least 2.5 gallons of mix.

4. Place a container under the spigot and open the

spigot to allow the mix to flush out about 8 ounces

(0.23 liters) of sanitizing solution and liquid mix.

Close the spigot.

B. PREPARING THE INTELLITEC CONTROL

5. On the IntelliTec control, press and hold the SEL

button for 8 seconds. While still holding the SEL

button, press the up arrow (⇑) button. The LCD will

read “DISPLAY”.

6. Press the left arrow (⇐) button once. The display

will read “BASIC”.

7. Press the up arrow (⇑) button once. The display will

read “CutOut amps”.

8. Press the SET button. A cursor will start blinking under the far right digit.

9. Change the value to 8.0. Press the left arrow (⇐) button to move the cursor. Press the up arrow (⇑) button to increase the digit. When a digit reaches 9, pressing the up arrow (⇑) button again will change the value to 0.

10. After entering 8.0, press SET to save this value. The LCD will read “CutOut Set -- OK”.

11. Press the SEL button. The LCD will read “CutOut amps 8.0”.

12. Press the SEL button twice. The LCD will read “DISPLAY”.

13. Press the up arrow (⇑) button to navigate to the “°F” and “amps” readings.

C. INITIAL FREEZE DOWN

14. Place the Main Freezer Power OFF-ON switch in the ON position.

15. Press the PUSH TO FREEZE button.

NOTE

After the drive motor starts, there is a 3-second delay before the compressor starts.

16. As the product freezes, the “amps” value on the display will increase. When it reaches 2.8A, open the spigot, take a 6-8 ounce sample and measure the temperature. For most soft serve mixes, the desired temperature is between 19.0°F and 19.5°F.

17. Draw samples at every increase of 0.2A until reaching the desired consistency and temperature.

NOTE

Show the sample to the customer and make sure it meets their required consistency and temperature.

18. Record the “amps” value.

19. Place the Main Freezer Power OFF-ON switch in the OFF position.

D. ADJUSTING THE INTELLITEC CONTROL

20. Press the SEL button. The display will read “DISPLAY”.

21. Press the left arrow (⇐) button once. The display will read “BASIC”.

22. Press the up arrow (⇑) button once. The display will read “CutOut amps”.

23. Change the value to the recorded value by pressing the SET button. A cursor will start blinking under the far right digit.

24. Press the left arrow (⇐) button to move the cursor. Press the up arrow (⇑) button to increase the digit. When a digit reaches 9, pressing the up arrow (⇑) button again will change the value to 0.

25. Press the SET button to save the value. The LCD will read “CutOut Set -- OK”.

26. Press the SEL button. The LCD will read “CutOut amps” along with the programmed value from the previous step.

27. Press the SEL button three times. The LCD will read “EXITMENU”.

28. Press the up arrow (⇑) button to exit the menu.

29. Adjustment to the control is completed.

E. SERVING PRODUCT

30. Place the Main Freezer Power OFF-ON switch in the ON position.

31. Press the PUSH TO FREEZE button.

32. When the product is at 75% consistency, the display will read “SERVE”.

33. For normal dispensing, move the spigot handle fully open.

34. The machine dispenses product at a reasonable draw rate. If the machine is overdrawn, the result is a soft product or a product that will not dispense at all. If this occurs, allow the machine to run for approximately 30 seconds before dispensing more product. A dispense rate adjustor is located under the header panel, to the immediate right of the spigot handle. Turning the knob counterclockwise will decrease the dispense rate.

35. Do not operate the machine when the MIX LOW message is displayed. Refill the mix container immediately.

NOTE

The machine has a standby and sleep mode. After a preset number of freezing cycles, it will enter the standby mode (followed by sleep mode) and remain there until someone draws product or presses the PUSH TO FREEZE button. In the sleep mode, the machine will keep the product below 41°F (4.4°C). Sleep modes do not take the place of cleaning and sanitizing. Federal, State, and local regulatory agencies determine frequency of cleaning and sanitizing.

3.11 NORMAL FREEZE DOWN AND

OPERATION

The following section contains the recommended operating procedures for the safe operation of the machine.

A. Sanitize immediately before use. B. Make sure the Main Freezer Power OFF-ON

switch is in the OFF position.

C. Fill the hopper with at least 2.5 gallons of mix. D. Place a container under the spigot and open the

spigot to allow the mix to flush out about 8 ounces (0.23 liters) of sanitizing solution and liquid mix.

E. Place the Main Freezer Power OFF-ON switch in

the ON position.

F. Press the PUSH TO FREEZE button.

NOTE

After the drive motor starts, there is a 3-second delay before the compressor starts.

G. When the product is at 75% consistency, the

display will read “SERVE”. Open the spigot to dispense product.

H. The machine dispenses product at a reasonable

draw rate. If the machine is overdrawn, the result is a soft product or a product that will not dispense at all. If this occurs, allow the machine to run for approximately 30 seconds before dispensing more product. A dispense rate adjustor is located under the header panel, to the immediate right of the spigot handle. Turning the knob counterclockwise will decrease the dispense rate.

I. Do not operate the machine when the MIX LOW

message is displayed. Refill the mix container immediately.

NOTE

Figure 3-11 During Freezing Cycle

3.12 MIX INFORMATION

Mix can vary considerably from one manufacturer to another. Differences in the amount of butterfat content and 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. Mixes should provide a satisfactory product in the 17°F to 24°F range. Diet and lowcarb mixes typically freeze to proper consistency at higher temperatures.

When checking the temperature, stir the thermometer in the frozen product to get an accurate reading.

Old mix, or mix that has been stored at too high a temperature, can result in a finished product that is unsatisfactory.

SECTION 4

MAINTENANCE AND ADJUSTMENTS

4.1 MACHINE ADJUSTMENT

This section is intended to provide maintenance personnel with a general understanding of the machine adjustments. It is recommended that any adjustments in this section be made by a qualified person.

4.2 PRODUCT CONSISTENCY ADJUSTMENT

The operator can adjust product consistency by modifying the Fine Adjustment setting on the membrane switch. This is the only adjustment that can be made by the operator without using a pass code key sequence. Product consistency fine adjustment allows a 0.4 amp maximum adjustment to the drive motor amp draw cutout. Increasing this setting will increase the drive motor amperage cutout and increase product consistency. Follow the instructions below to make fine adjustments to product consistency.

A. Place the Main Freezer Power switch in the ON

position.

B. Press the SET button on the Control Panel once.

Fine Adj will appear on the LCD screen.

C. Press the up arrow button (⇑) until the desired

consistency setting is displayed. The higher the number, the firmer the product consistency. The control may be set from 1 to 9. The value increases by 1 each time the up arrow button is pressed. After the value reaches 9, numbering restarts at 0. The 0 setting cannot be set.

D. Press the SET button once to save the setting and

return to the current mode display.

4.3 LOCKING THE CONTROL PANEL

The IntelliTec control has a tamper proof mode to prevent unauthorized use. When set, all buttons on the control panel are disabled. Follow the instructions below to lock the control panel

A. Press and hold the PUSH TO FREEZE button for

at least 5 seconds.

B. While still holding the PUSH TO FREEZE button,

press the CLEAN button once.

C. Release both buttons. An asterisk (*) will appear

on the bottom line of the display, indicating that the control is in the lock out mode.

NOTE:

Repeat steps A, B, and C to unlock the control p anel.

4.4 OBTAINING READINGS AND

MODIFYING SETTINGS (SERVICE PERSONNEL ONLY)

Readings and settings on the IntelliTec control are accessed through the IntelliTec Control Menu Settings (Refer to Figure 4-2). Locating machine readings and system function settings are completed using the up arrow (⇑) and left arrow ( IntelliTec Menu Settings sheet is located in the information pouch behind the header panel.

IntelliTec Control Readings

To obtain machine readings, locate the value on the machine's menu settings sheet and follow the steps below.

A. Press and hold SEL button for 8 seconds. While

B. Release both buttons. C. Press the up arrow button (⇑) to navigate to the

D. Press the up arrow (⇑) and left arrow (

E. When all readings have been obtained, press the

⇐⇐

⇐) buttons on the membrane switch. A printed

⇐⇐

still holding the SEL button, press the up arrow button (⇑). The LCD Screen will read DISPLAY.

correct reading under DISPLAY or press the left arrow ( menu.

to navigate through the rest of the readings as needed.

up arrow button (⇑) from ExitMenu to return to the current mode display.

⇐⇐

⇐) button to navigate to the ERRCODES

⇐⇐

⇐) buttons

⇐⇐

Figure 4-1 Membrane Switch

Figure 4-2 IntelliT ec Control Menu Settings

Modifying Control Settings

To change the value of a system function, locate the function on the IntelliTec Settings Menu and follow the steps below.

IMPORTANT:

Before making changes to any settings, record the original values. If the setting changes do not achieve desired results, revert settings to their original values.

A. Press and hold SEL button for 8 seconds. While

still holding the SEL button, press the up arrow

button (⇑). The LCD Screen will read DISPLAY. B. Release both buttons. C. Press the left arrow button (

menu (Basic, Advanced, or Storage). D. Press the up arrow button (⇑) to navigate to the

value that needs to be changed. E. Press SET button to enter edit mode. F. Press the up arrow button (⇑) to change setting. G. Press SET button to save the setting and exit the

edit mode. H. Press the up arrow (⇑) and left arrow (

to navigate through the rest of the settings as

needed. I. When all changes have been completed, press

the up arrow button (⇑) from ExitMenu to return to

the current mode display.

⇐⇐

⇐) to get to the correct

⇐⇐

⇐) buttons

⇐⇐

4.5 READINGS (SERVICE PERSONNEL ONLY)

The IntelliTec control continuously monitors and records temperatures, voltages, amps, and error code details. Each of these readings are beneficial to service personnel when troubleshooting.

DISPLAY READINGS

Following are the readings available under the DISPLAY menu:

Hopper (°F)

The temperature of the hopper is constantly

monitored by the IntelliTec control.

Cycles (count)

This reading counts down the number of cycles in

the current "Serve Mode". The starting value is

dependant upon the Cycles setting on the IntelliTec

control.

°F and amps

The suction line temperature on the freezing cylinder

and the drive motor amps are available on the same

screen to assist with setup and troubleshooting.

Aux. Temp (°F)

This reading provides the ambient temperature around the IntelliTec control.

Supply V (VAC)

A calculated input voltage is recorded.

ERROR CODE READINGS

The following details are recorded under the ERRCODES menu for each of the last 25 error codes received:

Err1 (hours)

A numerical count of the last 25 error codes is recorded. When the 26th error has occurred the earliest error code is erased. A timer also begins when an error occurs. The timer records the number of hours since the error occurred. If power to the machine is interrupted, the timer will stop until power has been restored.

°F and amps

The suction gas temperature on the freezing cylinder and the drive motor amps are recorded at the time of the error.

Aux. Temp (°F)

Ambient temperature of the IntelliTec control is recorded at the time of the error.

Str (°F)

The storage temperature is recorded at the time of the error.

VAC and Mode

A calculated input voltage and mode at which the error occurred are recorded. Following are descriptions of each mode:

Mode Description 0 Start of freezing cycle 1 Compressor and drive motor on 2 Stir Cycle 3 Compressor off 4 "Standby Mode" 5 "Sleep 1 Mode" 6 "Sleep 2 Mode" 7 "Clean Mode" 8 Startup 9 Storage only refrigeration 10 Freezing cycle is shut down 11 Door safety switch triggered 1 2 High pressure cutout

Up Time (hours)

This value is a record of the total time the machine

has been in service. If power is interrupted, the

timer will stop until power is restored. This timer

does not reset.

RUN STATISTICS

In addition to dynamic readings and recorded

error code details, the IntelliTec control records

rolling averages of run statistics. Following are

the readings available under the RUNSTATS

menu:

On Times (sec)

The control records the time of each freezing

cycle and provides a rolling average.

Off Times (sec)

The control records the time between freezing

cycles and provides a rolling average.

Brl. Min (°F)

The lowest average barrel temperature is

recorded.

Brl. Max (°F)

The highest average barrel temperature is

recorded.

Stor Min (°F)

The lowest average hopper temperature is recorded.

Stor Max (°F)

The highest average hopper temperature is

recorded.

Power On (hrs)

This value is a record of the time the machine has

been in service. If power is interrupted, the timer

will reset.

4.6 ADJUSTMENTS (SERVICE PERSONNEL ONLY)

The following adjustments directly affect product consistency and length of time in "Serve Mode". The default settings have been created using a 5% milkfat soft serve mix and provide optimal product consistency while prolonging product life.

CutOut (amps)

It is recommended to change the CutOut value at

initial startup and when changing mix types.

Adjustments to this setting directly affect the

length of the freezing cycle which changes product

consistency. To properly set the CutOut value,

refer to Section 3.

Cut In T (°F)

After the consistency value has been determined, the Cut In T value can be adjusted. The Cut In T is the temperature of the refrigerant gas in the evaporator. Changing this setting changes the temperature at which the freezing cycle starts. This value along with the CutOut value determines the range of temperatures (or "temperature window") of the product. Decreasing the temperature decreases the temperature window and, under normal use, increases the amount of freezing cycles. This creates a greater chance of product breakdown by stirring the product often. Increasing the Cut In T increases the temperature window which decreases freezing cycles and increases the chance of heat shock within the product.

Cycles (count)

This setting determines the number of freezing cycles during "Serve Mode". Increasing the value will increase the total time in "Serve Mode". Factory default is 16 cycles. This results in "Serve Mode" lasting about 2 to 2-1/2 hours without the PUSH TO FREEZE button being pressed or a spigot handle being pulled. If the PUSH TO FREEZE button is pressed or the spigot handle is pulled at any time during "Serve Mode", the Cycles count will reset.

4.7 OTHER SETTINGS (SERVICE PERSONNEL ONLY)

Changing any setting on the IntelliTec control will alter machine operation and affect the product temperature, consistency, or life. Refer to the IntelliTec Control System Settings sheet located in the information pouch behind the header panel of the machine. If any of the following settings on the IntelliTec control differ from the System Settings sheet, it is recommended to revert those settings to factory defaults.

Stir On (sec)

Adjustments to this setting affect the amount of time the auger rotates in the stir cycle. The stir cycle occurs in "Serve Mode", "Standby Mode", and "Sleep 2 Mode".

Stir Off (sec)

Adjustments to this setting affect the time between stir cycles. The stir cycle occurs in "Serve Mode", "Standby Mode", and "Sleep 2 Mode".

On Time (sec)

Increasing this value will increase the length of the freezing cycle during "Standby Mode" and result in a decrease of average product temperature in the barrel.

Off Time (sec)

Increasing this value will increase the time between

freezing cycles in "Standby Mode" and result in an

increase of product temperature in the barrel.

Stb Time (sec)

This setting determines the total amount of time in

"Standby Mode".

Sl1DrvOn (sec)

Adjustments to this setting affect the amount of

time the auger rotates in the stir cycle. This stir

cycle only occurs in "Sleep 1 Mode".

Sl1DrOff (sec)

Adjustments to this setting affect the time between

stir cycles. The stir cycle only occurs in "Sleep 1

Mode".

Sl2CutIn (°F)

Changing this setting affects the temperature at

which the freezing cycle starts in "Sleep 2 Mode".

Sl2CtOut (°F)

Changing this setting affects the temperature at

which the freezing cycle stops in "Sleep 2 Mode".

DftOffTm (sec)

In "Serve Mode", this value determines the

maximum time without a freezing cycle. If this

value is met, a freezing cycle will start. In the event

of a freezing cylinder temperature sensor failure,

this value affects the amount of time between

freezing cycles during "Serve Mode".

Refriger

This setting changes how the control handles the

storage refrigeration cycle. The setting for the

E111 & F111 is 1 Hopper.

HprCutIn (°F)

This setting determines the temperature at which

the hopper refrigeration cycle starts. This setting

is only available on the left control.

HprCtOut (°F)

This setting determines the temperature at which

the hopper refrigeration cycle stops. This setting

is only available on the left control..

Hpr Off (min)

If the temperature sensor in the hopper fails, this

setting determines the time between hopper

refrigeration cycles. This setting is only available

on the left control..

Hpr On (sec)

If the temperature sensor in the hopper fails, this

setting determines the length of the hopper

refrigeration cycle. This setting is only available

on the left control..

4.8 DRIVE BELT TENSION ADJUSTMENT

To check belt tension, refer to Figure 4-3 and follow the steps below:

WARNING

Hazardous voltage

The Main Freezer Power switch must be placed in the OFF position when disassembling for servicing. The machine must be disconnected from electrical supply before removing any access panel. Failure to disconnect power before servicing could result in death or serious injury .

A. Remove the back panel. B. Use a Burroughs Belt Tension Gauge to set the

tension for the drive belt. Set the belt tension to the following:

E111: 30-40 lbs. F111: 15-25 lbs.

C. If an adjustment is necessary, loosen the four

motor plate retaining nuts, adjust belt tension then retighten the four nuts.

D. Using a straightedge, check that the drive motor

pulley is aligned with the speed reducer pulley. Align the pulley if necessary.

NOTE

Belt life will be increased if new drive belts are tightened after two or three weeks of operation.

Belt T ension

Adjustment Nut

Figure 4-3 Belt T ension Adjustment

4.9 CONDENSER CLEANING

The air-cooled condenser is a copper tube and aluminum fin type. Condensing is totally dependent upon airflow. A plugged condenser filter, condenser, or restrictions in the louvered panel will restrict airflow. This will lower the capacity of the system and damage the compressor. The condenser must be kept clean of dirt and grease. The machine must have a minimum of 3” (7.5 cm) of ventilation on the right and left sides of the unit for free flow of air. Make sure the machine is not pulling over 100° F (37° C) air from other equipment in the area.

The water-cooled condenser is a tube and shell type. The condenser needs a cool, clean supply of water to properly cool the machine, inlet and discharge lines must be 3/8” I.D. minimum.

The condenser and condenser filter require periodic cleaning. To clean, refer to the following procedures.

1. Remove the right side panel and the rear panel.

2. To remove the condenser filter, grasp the top and

pull off. Visually inspect for dirt. If the filter is dirty,

shake or brush excess dirt off the filter and wash in

warm, soapy water. Once the filter is clean rinse

thoroughly in warm, clear water and shake dry,

taking care not to damage the filter in any way.

3. Visually inspect the condenser for dirt by shining

a light through the coil from the back (inside) of the

condenser.

4. If the condenser is dirty, place a wet towel over the

outside of the condenser.

5. Using compressed air or a CO2 tank, blow out the

dirt from the inside of the condenser. Most of the

dirt will cling to the wet towel.

NOTE

If the condenser is not kept clean, refrigeration efficiency will be lost.

4.11 EXTENDED STORAGE

Refer to the following steps for storage of the machine over any long period of shutdown time:

A. Clean thoroughly with warm detergent all parts

that come in contact with mix. Rinse in clear water and dry all parts. Do not sanitize.

NOTE

Do not let cleaning solution stand in machine barrel or mix pump during the shutdown period.

B. Remove, disassemble, and clean the front door,

and auger shaft. Leave disassembled during the shutdown period.

C. Place the auger flights and auger support bushing

in a plastic bag with a moist paper towel. This will prevent them from becoming brittle if exposed to dry air over an extended period of time (over 30 days).

D. For water-cooled machines that are left in unheated

buildings, or buildings subject to freezing, the water must be shut off and disconnected. Disconnect the water inlet fitting. The fitting is located at the rear of the machine. Run the compressor for 2 - 3 minutes to open water valve (the front door must be attached for the compressor to run). Blow out all water through water inlet. Drain the water supply line coming to the machine. Disconnect the water outlet fitting.

E. Place the Main Freezer Power OFF/ON switch in

the OFF position.

F. Disconnect the machine from the source of

electrical supply.

4.10 PREVENTATIVE MAINTENANCE

It is recommended that a preventative maintenance schedule be followed to keep the machine clean and operating properly. The following steps are suggested as a preventative maintenance guide.

The United States Department of Agriculture and the Food and Drug Administration require that lubricants used in food zones be certified for this use. Use lubricants only in accordance with the manufacturer’s instructions.

A. Daily checks

Check for any unusual noise or condition and repair

immediately. B. Monthly checks

Check the condenser filter for dirt. (Refer to section

4.9).

C. Quarterly Checks

Check drive belts for wear and tighten belts if

necessary. (Refer to section 4.8)

SECTION 5

REFRIGERATION SYSTEM

5.1 REFRIGERATION SYSTEM

The E111 & F111 refrigeration systems have two functions:

Medium-Temperature - Maintaining product

temperature in the hopper.

Low-Temperature - Producing and maintaining

high quality soft serve in the freezing cylinder. The system is designed for efficient use with R404A

refrigerant. The proper charge is indicated on the information plate.

5.2 REFRIGERANT RECOVERY AND EVACUATION

Refer to the following procedures to properly recover and evacuate the refrigeration system. Do not purge refrigerant into the atmosphere.

NOTE

For qualified service personnel only . Anybody working with refrigerants must be certified as a Technician TYPE I as required by 40 CFR 82 Subpart F and hold all State and/or local refrigerant handling certifications. In addition, all handling, storage, and disposal of refrigerants must be in accordance with Environmental Protection Agency (EP A) guidelines and standards and all State and local guidelines and standards.

WARNING

Hazardous voltage

!

#&  

 $#

## 

#% 

 



  

"

## 

  



## 

 

 

%'% 

 



 

Figure 5-1 Water Cooled Refrigeration System

A. REFRIGERANT RECOVERY

1. Disconnect the machine from electrical supply

before removing any panels for servicing.

2. Remove all panels.

3. Connect the recovery unit to the suction and

discharge service valves of the compressor.

4. Locate the compressor contactor behind the

header panel and disconnect the brown wire #65.

5. Wrap electrical tape around wire to insulate it.

6. Remove the belt from the pulley to allow the drive

motor to spin freely.

7. Connect power to the machine.

8. Turn the Main Power OFF/ON switch and Freezing

Cylinder OFF/ON switch to the ON position.

9. Press the Push To Freeze button on the IntelliTec

control. This will energize the solenoid valves.

CAUTION

The solenoid valves must be energized to allow all refrigerant to be recovered and to prevent injury when brazing.

NOTE

If evacuation is not completed after 20 minutes, press the Push T o Freeze button again. This will keep the solenoid valves open.

11. If the system will not maintain a standing vacuum test with the vacuum pump off (gauge increases towards atmosphere), find the leak, fix it, and evacuate again.

5.3 REFRIGERANT CHARGING

Refer to the following procedures to properly charge the refrigeration system. Stoelting recommends liquid refrigerant charging.

NOTE

A. Ensure the electrical supply has been removed

before continuing.

10. Operate the recovery unit per manufacturer’s instructions

NOTE

If recovery is not completed after 20 minutes, press the Push T o Freeze button again. This will keep the solenoid valves open.

B. EVACUATING THE REFRIGERATION SYSTEM

1. Close any open ports in the refrigeration system.

2. Connect a vacuum gauge to one of the Schrader valves next to an evaporator.

3. Connect the evacuation unit to the suction and discharge service valves of the compressor.

4. Locate the compressor contactor behind the header panel and disconnect the brown wire #65.

5. Wrap electrical tape around wire to insulate it.

6. Remove belts from the pulleys to allow drive motors to spin freely.

7. Connect power to the machine.

8. Turn the Main Power OFF/ON switch and Freezing Cylinder OFF/ON switches to the ON position.

9. Press the Push To Freeze button on both IntelliTec controls. This will energize the solenoid valves

10. Evacuate the system until the gauge reads 300µ Hg for 5 continuous minutes.

WARNING

Hazardous voltage

B. If the system has been opened or if there was a

leak, refer to Section 5.2 - Refrigerant Recovery and Evacuation to evacuate the system prior to charging.

C. Refer to machine’s information plate for total

charge requirements.

NOTE

The refrigeration systems of the E111 & F111 are critically charged. Be sure to charge the system to the weight listed on the machine’s information plate.

D. For liquid refrigerant charging, connect refrigerant

cylinder to the discharge Schrader valve of the compressor.

E. Energize all five solenoid valves. There are three

liquid line solenoids and two suction line solenoids.

F. Add the proper amount of refrigerant according to

the machine’s information plate.

5.4 COMPRESSOR

The E111 & F111 have hermetic reciprocating compressors (Refer to Figure 5-2).

Details of the compressors’ starting components are in Section 6.

Figure 5-2 Compressor

A. WINDING TEST

To test the compressor motor windings for possible problems, perform the following steps:

A. Disconnect the machine from electrical supply

before removing any panels for servicing.

B. Remove the left side panel. C. Remove the protective cover from the compressor

terminals. Disconnect the three terminals; C (common), R (run), and S (start).

D. Connect an ohmmeter to the C and R terminals on

the compressor. Resistance through the run winding should be as follows:

E111: 3.05Ω ±10% F111: 3.09Ω ±10%

E. Connect an ohmmeter to the C and S terminals on

the compressor. Resistance through the start winding should be as follows:

E111: 10.45Ω ±10% F111: 3.82Ω ±10%

F. To check if windings are shorted to ground, connect

one ohmmeter lead to a bare metal part on the compressor (such as any copper line leading to or from the compressor) and check terminals C, R, and S.

NOTE

The compressor is equipped with an internal overload protector. If the compressor is warm and ohmmeter readings indicate an open winding, allow up to one hour for overload to reset.

B. COMPRESSOR REMOVAL

A. Disconnect the machine from electrical supply

before removing any panels for servicing.

WARNING

Hazardous voltage

B. Disconnect the electrical plug from the compressor. C. Recover refrigerant charge per the instructions in

Section 5.2.

D. Leave the suction and discharge ports open to

prevent pressure buildup during compressor removal.

E. Remove six inches of insulating tubing on the

suction line going to the compressor and unsweat the suction and discharge line from the compressor.

F. Remove the four nuts and washers from the base

of the compressor. G. Remove the compressor. H. Remove the four rubber compressor mounts from

the compressor. I. Crimp and braze all open ports of the old

compressor.

NOTE

A compressor returned to Stoelting with any open ports will void the warranty . ALW AYS crimp and braze ports on a compressor that has been removed.

C. COMPRESSOR INSTALLATION

A. Disconnect the machine from electrical supply

before removing any panels for servicing. B. Install the four rubber mounts on the compressor. C. Install the compressor into the machine, fitting the

base over the four bolt holes. D. Install the four washers and nuts onto the bolts and

tighten securely. E. Remove all tubing plugs from the replacement

compressor.

NOTE

The compressor plugs protect the compressor from moisture in the air. Do not remove the plugs until you are ready to install. The compressor must not be opened to the atmosphere for more than 10 minutes.

F. Leave the suction and discharge ports open to

prevent pressure buildup. Braze the suction and

discharge line to the compressor. G. Connect the wires to the compressor terminals. H. Replace the drier per the instructions in Section

5.9.

I. Evacuate the system per the instructions in Section

5.2

J. Recharge the system per the instructions in

Section 5.3. K. Replace the insulating tubing on the suction line.

Figure 5-3 TXV

5.5 CONDENSER

The F111 is available with a water-cooled or an air-cooled condenser. The E111 is available with an air-cooled condenser. The capacity of these machines is directly related to keeping the condenser clean and free of debris.

The water-cooled condenser is a tube and shell type. This condenser requires cool, clean water to function properly. Inlet and discharge lines must be 3/8” ID minimum.

The air-cooled condenser is a copper tube and aluminum fin type. The machine must have a minimum of 3” of clearance on the sides for proper air flow.

CONDENSER TESTING

The condenser can be checked for leaks using the bubble test or using a leak detector.

5.6 EVAPORATOR

The E111 & F111 have a freezing cylinder evaporator and a hopper evaporator.

EVAPORATOR TESTING

The evaporator can be checked for leaks using the bubble test or using a leak detector.

NOTE

Foam insulation in the evaporator will set off electronic leak detectors if disturbed.

5.7 VALVES

A. THERMOSTATIC EXPANSION VALVE (TXV)

The Thermostatic Expansion Valve (TXV) is used to meter the refrigerant to the evaporator. It does so by maintaining a low, constant superheat in the evaporator. The selfregulating TXV is preset by the manufacturer and adjustment is not recommended. Figure 5-3.

TXV TESTING & ADJUSTMENT

When testing a TXV, disconnect the hopper liquid line solenoid.

NOTE

The bulb has an indent which must be positioned against the tubing. Good contact between the bulb and the suction line is necessary for proper operation of the valve. The bulb must also be well insulated.

A. Connect a gauge to the Schrader valve on the

suction line next to the evaporator.

B. Connect a thermocouple to the suction line next to

the evaporator.

C. Immediately before the refrigeration cycle ends,

the gauge should read between 19-22 psig and superheat should be 10-16°F.

D. If the pressure reading is higher than expected and

the superheat is low, check to see if there is an overcharge of refrigerant.

E. If the pressure reading is lower than expected and

the superheat is high, check to see if there is a low refrigerant charge or if there is a restriction in the system.

NOTE

The TXV is the LAST component to adjust in the refrigeration system.

F. The TXV can be adjusted after the steps above are

completed. When adjusting, do not turn the valve over 1/4 turn (90°). Turn the valve stem clockwise to increase the superheat or counterclockwise to decrease the superheat.

TXV REMOVAL

A. Disconnect the machine from the electrical supply

before removing any panels for servicing. B. Remove the side panel. C. Remove bulb from suction line exiting from the

evaporator. D. Recover refrigerant charge per instructions in

Section 5.2. E. Leave the suction and discharge ports open to

prevent pressure buildup during TXV removal. F. Remove any insulation from the TXV and

immediate surrounding lines. G. Apply a heat sink (wet cloth) to the valve dome. H. Unsweat the TXV and remove.

TXV REPLACEMENT

To replace the TXV, perform the following procedures: A. Position the TXV with a heat sink into the system. B. With the suction and discharge ports open, braze

the TXV into the system using appropriate brazing

material. C. Remove the heat sink from the TXV. D. Install bulb on suction line exiting the evaporator

using existing clamp. The bulb has an indent

which must be placed against the tubing.

NOTE

Good contact between the bulb and the suction line is necessary for proper operation of the valve. The bulb must also be well insulated.

E. Tighten clamp to 20 in/lb using a torque wrench. F. Replace insulation to the TXV and surrounding

lines. G. Replace the drier per the instructions in Section

5.9.

H. Evacuate the system per the instructions in Section

5.2.

I. Recharge the system per the instructions in

Section 5.3.

B. CHECK VALVE

The refrigeration system has 2 magnetic check valves (Refer to Figure 5-4). Each valve is positioned in the suction line and prevents backflow of refrigerant into an evaporator. If there is reversed flow, the product in the freezing cylinder softens and liquid refrigerant can flood into the compressor on startup.

If a check valve needs to be replaced, use a heat sink (wet cloth) when installing the new valve to prevent damage.

Figure 5-4 Check Valve

C. HIGH PRESSURE CUTOUT

The high pressure cutout stops the compressor if the discharge pressure reaches 445 psig.

Figure 5-5 High Pressure Cutout

HIGH PRESSURE CUTOUT TEST

A. Connect a gauge to the Schrader valve on the

discharge line.

B. Disconnect cooling:

Air-Cooled - Disconnect evaporator fan Water-Cooled - Shut off water supply

C. High pressure cutout should trip when pressure

reaches 445 psig ±9.

HIGH PRESSURE CUTOUT REMOVAL

A. Remove the front panel. B. Recover refrigerant charge per instructions in

Section 5.2. C. Leave the suction and discharge ports open to

prevent pressure buildup during removal. D. Unsweat high pressure cutout from discharge line. E. Disconnect the wires from high pressure cutout.

HIGH PRESSURE CUTOUT REPLACEMENT

A. With the suction and discharge ports open, braze

the high pressure cutout to the discharge line. C. Replace the drier per the instructions in Section

5.9.

D. Braze the high pressure cutout to the discharge

line. E. Evacuate the system per the instructions in Section

5.2.

F. Recharge the system per the instructions in Section

5.3.

G. Connect the wires to the high pressure cutout.

D. HOT GAS BYPASS

The hot gas bypass valve is installed in parallel to the compressor and helps to regulate the compressor temperature (Refer to Figure 5-6). When the hopper evaporator is the only part of the system requiring refrigerant, the bypass valve will allow discharge gas to bypass into the suction line to prevent liquid refrigerant from entering the compressor.

Figure 5-6 Hot Gas Bypass

HOT GAS BYPASS ADJUSTMENT

NOTE

Before adjusting the hot gas bypass, check the EPR valve and adjust if necessary .

A. Turn the Main Power OFF/ON switch to the OFF

position.

WARNING

Hazardous voltage

B. Connect a gauge to the Schrader valve on the

suction line next to the compressor.

C. Turn the Main Power OFF/ON switch to the ON

position.

D. After the hopper refrigeration starts, wait until the

gauge stops moving. E. Unscrew the seal cap from the top of the valve. F. Using a 5/16” Allen wrench, adjust the valve

counterclockwise to decrease pressure and

clockwise to increase pressure.

NOTE

Each 360° turn will change the pressure about 6 psig.

G. Adjust the hot gas bypass valve to 14 psig ±1. H. Wait 2 minutes to ensure pressure remains stable. I. Hand-tighten seal cap to valve.

HOT GAS BYPASS REMOVAL

A. Remove the side and rear panels. B. Recover refrigerant charge per instructions in

Section 5.2. C. Remove insulation around hot gas bypass and

tubing. D. Leave the suction and discharge ports open to

prevent pressure buildup during hot gas bypass

removal. E. Apply a heat sink (wet cloth) to the hot gas bypass. F. Unsweat the hot gas bypass and remove.

HOT GAS BYPASS REPLACEMENT

To replace the hot gas bypass, perform the following procedures:

A. Apply a heat sink (wet cloth) to the hot gas bypass. B. With an open port, braze the hot gas bypass into

the system using appropriate brazing material.

C. Remove the heat sink from the hot gas bypass. D. Replace the filter drier. Refer to Section 5.8 for

details.

E. Evacuate and recharge system per instructions in

Section 5.2.

E. EVAPORATOR PRESSURE REGULATOR (EPR)

There is one EPR in the refrigeration system (Refer to Figure 5-7). It is located on the suction line of the hopper and regulates evaporator refrigerant pressure.

Figure 5-7 EPR Valve

EPR TEST AND ADJUSTMENT

A. Place the Main Power OFF/ON switch in the OFF

position.

B. Connect a gauge to the access fitting on the

suction line between the hopper evaporator and the EPR.

C. Place the Main Power OFF/ON switch to the ON

position.

D. After the hopper refrigeration starts, the gauge

should read 60 psig ±1. If it does not, then adjustment is needed.

E. Remove the plastic cap and loosen the locknut on

the EPR. Using a small screwdriver, turn the adjustment screw counterclockwise 1/2 turn, then adjust as necessary. Turn the valve stem clockwise for higher pressure or counterclockwise for lower pressure.

F. Allow the system to stabilize for 2-3 minutes to

ensure pressure remains stable.

EPR REMOVAL

A. Remove the side panel. B. Recover refrigerant charge per instructions in

Section 5.2.

C. Leave the suction and discharge ports open to

prevent pressure buildup during EPR removal.

D. Unsweat the EPR and remove.

EPR REPLACEMENT

To replace the EPR, perform the following procedures: A. Apply a heat sink (wet cloth) to the EPR. B. With an open port, braze the EPR into the system

using appropriate brazing material.

C. Remove the heat sink from the hot gas bypass. D. Replace the filter drier. Refer to Section 5.8 for

details. E. Evacuate and recharge system per instructions in

Section 5.2.

F. WATER VALVE (WATER COOLED MODELS ONLY)

The water valve monitors refrigerant pressure and opens on an increase of pressure. The opening point pressure is the refrigerant pressure required to lift the valve disc off the valve seat. (Figure 5-8)

Figure 5-8 Water Valve

WATER VALVE ADJUSTMENT

A. Remove the back panel. B. Connect a gauge to the access fitting on the

discharge line of the compressor. C. Connect the machine to the electrical supply, start

the refrigeration cycle, and read the pressure. D. The proper gauge reading should be 175-180 psig.

The exit water temperature should be 95-107°F. E. If the water temperature and high side pressure are

too low, the opening point pressure should be

increased to slow the water flow. Turn the

adjustment screw counterclockwise. F. If the water temperature and high side pressure are

too high, the opening point pressure should be

decreased to increase the flow of water. Turn the

adjustment screw clockwise.

WATER VALVE REMOVAL

The water valve is connected to the refrigeration system by capillary tube brazed to the discharge line.

A. Turn off and disconnect the water supply. Blow out

the water lines with compressed air or CO2. B. Recover refrigerant charge per instructions in

Section 5.2. C. Leave the suction and discharge ports open to

prevent pressure buildup during water valve removal. D. Unsweat the capillary tube from the discharge line.

E. Remove the clamps from the water lines at the

valve.

F. Remove the two screws holding the water valve to

the frame and remove the valve.

WATER VALVE REPLACEMENT

To replace the water valve, perform the following procedures:

A. Position the water valve and attach to the frame

using the two screws.

B. Install the water lines onto the valve with hose

clamps.

C. Leave the suction and discharge ports open to

prevent pressure buildup during water valve installation.

D. Braze the capillary tube into the system using

appropriate brazing material.

E. Connect the water supply line and turn on the water

supply.

F. Check for leaks in the water lines. If there are no

leaks, turn off the water supply.

G. Replace the filter drier. Refer to Section 5.8 for

details.

H. Evacuate and recharge system per instructions in

Section 5.2.

I. Turn on the water and check for leaks in the water

lines with the refrigeration system running.

J. Adjust the valve as necessary.

5.8 SOLENOID

Solenoid valves are installed on the liquid and suction line of the freezing cylinder evaporator and on the liquid line of the hopper evaporator (Refer to Figures 5-9 and 5-10). A solenoid valve has a magnetic coil that, when energized, lifts a plunger and allows refrigerant to flow. The solenoids are activated by the IntelliTec control and determine which evaporator receives refrigeration.

Figure 5-9 Liquid Line Solenoid Valve

Figure 5-10 Suction Line Solenoid

The suction line solenoid prevents refrigerant flow in the evaporator when the suction pressure drops due to the operation of the other evaporators in the system.

ACTIVATING THE SOLENOID VALVES

A. Turn the Main Power OFF/ON switch to the OFF

position. B. Locate the compressor contactor behind the right

panel and disconnect the gray wire #47. C. Wrap electrical tape around wire to insulate it. D. Remove the belt from the pulley to allow drive motor

to spin freely. E. Connect power to the machine. F. Turn the Main Power OFF/ON switch to the ON

position. G. Press the Push To Freeze button on the IntelliTec

control. This will energize the solenoid valves.

SOLENOID TESTING

When activated, a solenoid coil produces a magnetic field. This field can be detected by placing the tip of a metal screwdriver close to the retaining screw on the solenoid coil. The retaining screw will like as a magnet and pull on the screwdriver tip. Additionally, the solenoid will make a clicking sound when activated.

SOLENOID MAGNETIC COIL REMOVAL

A. Remove the side panel. B. Disconnect the electrical wires. C. Remove the retaining screw from the top of the

solenoid and pull the magnetic coil off.

SOLENOID MAGNETIC COIL INSTALLATION

To replace the magnetic coil, perform the following procedures:

A. Connect the two electrical wires to the magnetic

coil. B. Push the coil on to the solenoid valve stem. C. Make sure there isn’t any foam insulation between

the valve coil and valve body. Trim any excess

insulation. D. Install the retaining screw onto top of coil.

SOLENOID VALVE REMOVAL

A. Recover refrigerant charge per instructions in

Section 5.2.

B. Remove insulation around valve and attached

refrigeration lines.

C. Apply heat sinks (wet cloth) to the insulated

refrigerant lines near the valve.

CAUTION

When replacing the solenoid, a heat sink (wet cloth) must be used to prevent damage to the valve.

D. Leave a port open to prevent pressure buildup

during solenoid removal.

E. Identify and disconnect the two wires from the

solenoid coil.

F. Remove the retainer holding the coil to the solenoid

body and remove the coil.

G. Unsweat the solenoid and remove.

SOLENOID VALVE REPLACEMENT

To replace the solenoid, perform the following procedures: A. Position the new solenoid with the arrow pointing

toward the direction of flow. B. Apply a heat sink (wet cloth) to the solenoid valve. C. With the suction and discharge ports open, braze

the solenoid into the system using appropriate

brazing material. D. Remove the heat sink from the valve. E. Replace insulation around valve. F. Replace the filter drier. Refer to Section 5.8 for

details. G. Evacuate and recharge system per instructions in

Section 5.2.

5.9 FILTER DRIER

The filter drier must be replaced every time the refrigeration system is opened for service. A new filter drier improves operation of the entire refrigeration system by stopping the circulation of moisture and by removing harmful contaminants (Refer to Figure 5-11).

FILTER DRIER REMOVAL

WARNING

Hazardous voltage

A. Recover refrigerant charge per instructions in

Section 5.2.

B. Cut the refrigeration line as close to the filter drier

as possible and remove drier.

FILTER DRIER REPLACEMENT

A. Position the filter drier so the arrow is pointing

towards the evaporators (pointing away from the

condenser). B. Apply a heat sink (wet cloth) to the filter drier. C. With the suction and discharge ports open, braze

the filter drier into the system using appropriate

brazing material. D. Evacuate the system per instructions in Section

5.2.

E. Recharge the system per instructions in Section

5.3.

5.10 CAPILLARY TUBE

The capillary tube meters refrigerant flow in the hopper evaporator (Refer to Figure 5-12). The rate of flow is dependent on the length and ID of the capillary tube as well as the refrigerant charge.

Figure 5-11 Filter Drier

Figure 5-12 Capillary Tube

CAPILLARY TUBE REMOVAL

A. Recover refrigerant charge per instructions in

Section 5.2.

B. Leave a port open to prevent pressure buildup

during capillary tube removal.

C. Remove foam insulation from the capillary tube at

the evaporator inlet.

D. Unsweat the capillary tube and remove.

CAPILLARY TUBE REPLACEMENT

A. Position the capillary tube in the refrigeration

system. B. Apply a heat sink (wet cloth) to the capillary tube. C. With the suction and discharge ports open, braze

the capillary tube into the system using appropriate

brazing material. D.. Replace foam insulation to the capillary tube at the

evaporator inlet. E. Evacuate the system per instructions in Section

5.2.

F. Recharge the system per instructions in Section

5.3.

SECTION 6

ELECTRICAL AND MECHANICAL CONTROL SYSTEMS

NOTE

The wiring diagram is available in Section 8.

6.1 INTELLITEC CONTROLLER

Understanding the modes of operation and individual control settings will make servicing the control straight forward.

A. COMPONENTS OF CONTROLLER

The IntelliTec control consists of three main components; the control board (Figure 6-1), the membrane switch (Figure 6-2), and the display panel module (Figure 6-3). The membrane switch is connected to the display panel module via a 9-pin ribbon cable. The display panel module is connected to the IntelliTec control board through a telephone cord. The IntelliTec control board is connected to the machine through an 8-pin connector, a 7-pin connector, and a 6-pin connector.

Figure 6-2 Membrane Switch

6.2 CONTACTORS

The contactors are mounted behind the right side panel. There is a contactor for the compressor and a contactor for the drive motor.

The IntelliTec control sends electronic signals to trigger the contactors. The signals to the contactors are staggered, so the drive motor will always start and stop three seconds before the compressor. By staggering the starting and stopping of the drive motor, maximum starting torque is available and voltage spikes are reduced.

Figure 6-1 IntelliT ec Control Board

Figure 6-3 Display Panel Module

A. CONTACTOR TESTS

The following tests will show if a contactor is working properly.

1. Remove the header panel and visually check the

IntelliTec control board.

2. Check for a signal going to contactor. When the

spigot is opened or the Push To Freeze button is

pressed, the DRV LED on the control board will

light up. After three seconds, the CMP LED will

light up (Refer to Figure 6-4). If the LEDs do not

light up, refer to Section 7 Troubleshooting.

NOTE

In addition to the LEDs lighting, there will be an audible click from the contactors and the motor and compressor will start.

Tension

Adjustment

Nut

CMP LED

DRV LED

Figure 6-4 IntelliT ec LEDs

3. Check to ensure contactor is receiving signal.

Read voltage across the coils of the contactor

during a freezing cycle. Voltage should be about

115V. If there is no voltage reading, refer to

Section 7 Troubleshooting.

6.3 DRIVE MOTOR

The drive motor is used to rotate the auger assembly. An internal, normally closed, centrifugal switch starts the drive motor. The motor has an internal thermal overload.

A. DRIVE MOTOR REMOVAL

1. Disconnect machine from electrical supply before

removing any panels for servicing.

WARNING

Hazardous voltage

Figure 6-5 Motor Removal

2. Remove the back panel.

3. Remove the electrical cover plate from the back of the motor.

4. Identify (mark) wires and remove them from the motor.

5. Loosen the belt tension adjustment nut and remove the belt. (Refer to Figure 6-5)

6. Remove the motor mounting bolts and remove the motor.

7. Loosen the two allen head screws from the pulley.

8. Remove the pulley and key from the motor shaft.

B. DRIVE MOTOR INSTALLATION

1. Place the drive motor in position and install the four mounting bolts.

2. Place the pulley and key on the motor shaft.

NOTE

Do not tighten the pulley screws until after the belt tension has been properly adjusted.

3. Install the belt and tighten the tension bolt.

4. Use a Burroughs Belt Tension Gauge to set the tension for the drive belt. Set the belt tension to the following:

E111: 30-40 lbs. F111: 15-25 lbs.

5. Using a straightedge, align the drive motor pulley with the gearbox pulley. Tighten the two allen head screws.

6. Install wiring according to wiring diagram (located behind header panel). Install electrical cover plate.

7. Install back and side panels.

6.4 CAPACITORS

The compressor start and run contactors are mounted behind the right side panel. The start and run capacitors for the drive motors are mounted directly onto the motor body.

Start

Capacitor

Run

Capacitor

Figure 6-6 Compressor Capacitors

A. CAPACITOR TEST

1. Disconnect machine from electrical supply before removing any panels for servicing.

WARNING

Hazardous voltage

2. Place the Main Power OFF/ON switch in the OFF position.

3. Remove a lead from one of the capacitor terminals.

4. Using insulated pliers, create a short across the capacitor terminals with a 20KΩ 5W resistor to discharge the capacitor.

NOTE

Create the short even if there is a bleeder resistor across the terminals. There may be an open in the bleeder resistor preventing it from working properly.

5. Disconnect the bleeder resistor from the circuit.

6. Measure the capacitance across the terminals. The results should be as follows:

Rating

Part MFD VAC

Drive M otor (#522858) Run 231078 50 MFD 370 VAC Drive M otor (#522858) Start 231095 500 MF D 125 VAC Compressor (#282043) St art 2306 31 270-324 MF D 110 VAC Compressor (#282046) St art 2306 34 175-216 MF D 330 VAC Compressor (#282043) Run 2310 26 15 MFD 370 VAC Compressor (#282046) Run 2310 27 25 MFD 370 VAC Compressor (#282051) Run 2310 72 15 MFD 440 VAC Compressor (#282051) St art 2310 99 64-77 M F D 250 V A C

6. Check the resistance across the capacitor terminals. The reading should be close to 0 and will rise slowly (as the meter charges the capacitor).

7. If the resistance stops increasing, there may be an internal short in the capacitor.

8. Short the capacitor if the test needs to be repeated.

B. CAPACITOR REPLACEMENT

1. Disconnect machine from electrical supply before removing any panels for servicing.

2. Place the Main Power OFF/ON switch in the OFF position.

3. Remove leads from the capacitor terminals.

4. Using insulated pliers, create a short across the capacitor terminals with a 20KΩ 5W resistor to discharge the capacitor.

NOTE

Create the short even if there is a bleeder resistor across the terminals. There may be an open in the bleeder resistor preventing it from working properly.

5. Pull the capacitor out of its holder and replace.

6. Connect the leads to the terminals.

6.5 GEARBOX

A. GEARBOX INSPECTION

Inspect the gearbox and listen for unusual noise. A grinding sound generally indicates a bad gear.

B. GEARBOX REMOVAL

1. Disconnect machine from electrical supply before removing any panels for servicing.

2. Remove the back panel and a side panel.

3. Remove the belts.

4. Remove the pulley by loosening the set screws.

5. Remove the bolts holding the gearbox to the barrel.

6. Remove the bolts holding the gearbox to the mounting bracket and remove the gear box through the rear of the machine.

C. GEARBOX INSTALLATION

1. Place the gear box in position from the rear of the machine. Fasten the bolts through the gear box to the rear of the barrel.

2. Fasten the gearbox to the mounting bracket using the two bolts.

3. Mount the pulley on the gear box shaft and align with the motor pulley, then tighten the allen head screws.

4. Install the belt.

5. Use a Burroughs Belt Tension Gauge to set the tension for the drive belt. Set the belt tension to the following:

E111: 30-40 lbs. F111: 15-25 lbs.

6. If an adjustment is necessary, loosen the four motor plate retaining nuts, adjust belt tension then retighten the four nuts.

6.6 CONDENSER FAN MOTOR (AIR-

COOLED ONLY)

A. FAN MOTOR REPLACEMENT

1. Disconnect machine from electrical supply before removing any panels for servicing.

WARNING

Hazardous voltage

2. Remove a side panels.

3. Trace and disconnect the wires on the compressor contactor.

4. Loosen set screw on fan blade.

5. Remove the bolts from the fan motor mounting plate and remove the motor.

B. FAN MOTOR INSTALLATION

1. Attach motor to the mounting plate with the three bolts.

2. Place fan blade on motor shaft and tighten set screw.

3. Wire the fan motor according to the wiring diagram located in the header panel.

6.7 SPIGOT SWITCH

The spigot switch is a normally closed, held open switch. When a spigot is pulled, the spigot switch sends a signal to the IntelliTec control to start the auger drive and refrigeration system. This signal moves the control to “Serve Mode”, or if it already is in “Serve Mode”, it resets the cycle count. After serving product, the IntelliTec continues a freezing cycle until the product reaches consistency.

SPIGOT SWITCH TEST - ADJUSTMENT

NOTE

Adjustments to the spigot switch should be done after the product is at consistency in “Serve Mode” or when the machine is empty .

1. Open the spigot slowly and listen for a click when the spigot switch closes.

2. The clicking sound should be within the first 1/2” of the spigot glide movement (Refer to Figure 6-7). If the switch does not close, an adjustment may be necessary.

SPIGOT SWITCH TESTING - ELECTRICAL

1. Disconnect the switch from the circuit by unplugging the connectors.

2. Check resistance readings across the common (COM) and normally closed (NC) terminals. When the spigot is closed, the resistance should show an open. When the spigot is opened, the switch will close and the resistance should be 0 ohms.

SPIGOT SWITCH ADJUSTMENT

1. Place the Main Power OFF/ON switch and both Freezing Cylinder OFF/ON switches in the OFF position.

2. Remove the header panel.

3. Loosen the bolts on the spigot switch.

4. Using a pencil, mark the spigot glide 1/4” from the spigot housing.

5. Adjust the switch to activate when the plastic glide reaches the mark.

6. Fully tighten the retaining bolts and remove mark from spigot glide.

COM

Spigot Glide

Figure 6-7 Spigot Cam Assembly

11. Replace the dispense rate adjuster knob and tighten.

12. Replace the header panel and secure with the two Phillips head screws.

6.8 TEMPERATURE CONTROL SENSOR

The temperature control sensor is a thermistor used to sense the temperature of the suction line. As the suction line temperature increases, the internal resistance of the thermistor will decrease. Refer to Figure 6-9 for the relationship between sensor resistance and temperature. The IntelliTec control board monitors this value. In “Serve Mode”, when the temperature of the sensor equals the Cut In T value on the control, a freezing cycle will start.

Figure 6-8 Spigot Switch Replacement

SPIGOT SWITCH REPLACEMENT

1. Disconnect machine from electrical supply before removing any panels for servicing.

WARNING

Hazardous voltage

2. Remove the header panel.

3. Remove the dispense rate adjuster knob located below the header panel. (Refer to Figure 6-8)

4. Remove the two Phillips head screws that attach the spigot cam assembly to the panel. Remove the assembly.

5. Disconnect the connector from the switch and remove the switch.

6. Install the replacement switch onto the handle assembly. Do not fully tighten the retaining screws at this time.

7. Using a pencil, mark the spigot glide 1/4” from the spigot housing. Adjust the switch to activate when the spigot handle moves the glide to the mark.

8. Fully tighten the retaining screws.

9. Attach the connector to the spigot switch.

10. Position the spigot handle assembly in the electrical box and fasten securely with the two Phillips head screws.

°F Resistance °F Resistance

-22 176950 40 26100

-20 165200 42 24725

-18 154300 44 23400

-16 144200 46 22175

-14 134825 48 21000

-12 126125 50 19900

-10 118050 52 18875

-8 110550 54 17900

-6 103550 56 17000

-4 97075 58 16125

-2 91025 60 15325 0 85400 62 14550 2 80150 64 13825 4 75275 66 13150 6 70725 68 12500 8 66475 70 11875

10 62500 72 11300 12 58800 74 10750 14 55325 76 10250 16 52100 78 9750 18 49075 80 9300 20 46250 82 8850 22 43600 84 8450 24 41125 86 8050 26 38800 88 7675 28 36625 90 7325 30 34575 92 7000 32 32675 94 6675 34 30875 96 6375 36 29175 98 6100 38 27600 100 5825

Figure 6-9 Resistance Related to Temperature

SECTION 7

TROUBLESHOOTING

7.1 ERROR CODES

When the machine experiences a problem, one of the following error codes will be displayed on the control panel. Each error code directs you to the system location of the malfunction.

ERROR CODE MALFUNCTION

1 Soft 2 High Torque 3 Run Time 4 Clean 5 Freezing Cylinder Sensor 6 Hopper Sensor (single hopper machines) 7 Drive Motor 8 Cab Sensor 9 High Pressure Cutout 1 0 Auxiliary Sensor 11 Low Temperature 12 Left Hopper Sensor 13 Right Hopper Sensor

To return the machine to normal operation, any error causing condition must be corrected and the Main Freezer Power Off-On switch must be placed in the Off position and back in the On position before the machine will return to normal operation.

7.2 TROUBLESHOOTING - ERROR CODES

Error Code 1 - Soft Error

The Soft Error (E1) is an internal control board error that is logged for future analysis. The refrigeration is never stopped and the machine will continue to operate normally.

Error Code 2 - High Torque

If the control panel displays a High Torque Error (E2), the controller has sensed that the drive motor is running at 125% of the preset CutOut amp setting for 10 or more seconds. Very low and/ or fluctuating supply voltages typically cause this error. The error can also be caused by faulty motor or starting components which could produce a high amp draw.

Error Code 3 - Run Time

The Run Time Error (E3) occurs when the compressor runs continuously for 20 minutes without the product reaching consistency in “Serve Mode” or if the product does not reach proper temperature in “Sleep 2 Mode”. This error is generally caused by very low mix levels in the hopper or from product breakdown. Another common cause results

from a restriction preventing mix from entering the freezing cylinder. Check the mix in the hopper. If the level mix is low, add mix. If there is a possibility that the mix is broken down, clean and sanitize the machine and replace the mix with fresh product.

Ice crystals in the hopper can clog the mix inlet regulator and prevent mix from entering the freezing cylinder. Thoroughly thaw mix per manufacturer's recommendations. To check for ice crystals, pour a small amount of product in the mix container through a clean and sanitized sieve or strainer. If ice crystals are in the mix, check the temperature where the mix is stored. If the hopper temperature is below 34°F (1°C), adjust the temperature from the left control touchpad, under the Storage Menu (Refer to Section 4.7).

The Run Time Error may also occur if airflow within the machine has reduced or stopped. Check the sides and top of the machine for anything that would restrict airflow. Check the condenser filter and clean if necessary. Check the evaporator for frost that could restrict airflow.

The compressor will run continuously if a solenoid valve fails to open. This could be due to loose wiring, magnetic coil failure, a stuck valve or a faulty control board.

After the cause of the problem is found and remedied place the Main Freezer Power Off-On switch in the Off position and back in the On position.

Error Code 4 - Clean

If the machine is left in the Clean Mode for more than 20 minutes, the control panel will display a Clean Error (Error 04). This condition does not reflect a problem with the machine itself. The Clean Error has been programmed into the controller as a safeguard to protect the machine from potential damage caused by the machine being accidentally left in “Clean Mode”. The control will attempt to restart itself after 5 minutes. The display will then flash and read Restart. To clear the Clean Error, turn the Main Freezer Power OffOn switch Off and back On. After restarting the machine, a refrigeration cycle will begin. This protects the product in case the clean button was pressed by mistake.

Error Code 5 - Freezing Cylinder Sensor

The Freezing Cylinder Sensor Error (E5) indicates a failure of the barrel sensor or an extreme out of range condition (< -34°F or > 99°F). If the control panel displays an E5, place the Main Freezer Power Off-On switch Off and back On. If the control panel still displays the error code, refer to the machine's wiring diagram and the Temperature Sensor Chart (Figure 7-1). Check each lead of the sensor to ground for continuity. If continuity is found, replace the sensor. To check the resistance of the sensor, place a thermocouple on the suction line at the exit of the freezing cylinder. Compare temperature and sensor resistance with the table as reference. If measured value does not coincide with a value on the table (± 400 ohms), replace the sensor.

NOTE

When the machine encounters a Freezing Cylinder Sensor Error, the machine will continue to run using preset timers. This mode will allow the operator to continue serving product until the machine can be serviced.

°F Resistance °F Resistance

-22 176950 40 26100

-20 165200 42 24725

-18 154300 44 23400

-16 144200 46 22175

-14 134825 48 21000

-12 126125 50 19900

-10 118050 52 18875

-8 110550 54 17900

-6 103550 56 17000

-4 97075 58 16125

-2 91025 60 15325 0 85400 62 14550 2 80150 64 13825 4 75275 66 13150 6 70725 68 12500 8 66475 70 11875

Error Code 6 - Hopper Sensor (single hopper machines)

The Hopper Sensor Error (E6) indicates a failure of the hopper sensor or an extreme out of range condition (< -34°F or > 99°F). If the control panel displays an E6, turn the Main Freezer Power OffOn switch Off and back On. If the control panel still displays the error condition code, refer to the machine's wiring diagram and the Temperature Sensor Chart (Figure 7-1). Check each lead of the sensor to ground for continuity. If continuity is found, replace the sensor. To check the resistance of the sensor, place a thermocouple on the suction line at the exit of the hopper evaporator. Compare temperature and sensor resistance with the table as reference. If measured value does not coincide with a value on the table (± 400 ohms), replace the sensor

Error Code 7 - Drive Motor

If the control panel displays a Drive Motor Error (E7), the control does not sense current coming from the drive motor. Turn the Main Freezer Power Off-On switch Off and back On. If the error returns, use the machine's wiring diagram and check connections at the IntelliTec control and at the motor. An E7 may also be the result of a faulty drive motor contactor.

Error Code 8 - Cab Sensor

A Cab Sensor Error (E8) will not occur on the E111 or the F111.

Error Code 9 - High Pressure Cutout

High Pressure Cutout Errors (E9) are usually caused by a dirty or inefficient condenser. If the control panel displays an E9, place the Main Freezer Power Off-On switch in the Off position. Press the High Pressure Cutout Reset switch (water-cooled only) and place the Main Freezer Power Off-On switch back in the On position.

In air cooled condenser models, check the air filter to make sure it is clean. Replace or clean the filter as required. Check for proper air clearance around the machine. Refer to the Section 2 - Installation Instructions for clearances. Check the condenser for blockage, and be sure condenser fan is functioning.

On water cooled condenser models, check for proper water flow through the condenser coil.

After the cause of the error is determined and corrected, turn the Main Freezer Power Off-On switch Off and back On.

Figure 7-1 Resistance Related to Temperature

Error Code 10 - Auxiliary Sensor

An Auxiliary Temperature Sensor Error (R10) occurs if the temperature sensor on the control board fails. Turn the Main Freezer Power Off-On switch Off and back On.

Error Code 11 - Low Temperature

The Low Temperature Error (E11) occurs when the temperature of the gas refrigerant at the barrel sensor falls below -20°F. Although the machine will not shut down, the active freezing cycle will immediately end. This error usually occurs when the machine continues to run in a low mix condition or if the machine runs out of mix. The product towards the front of the barrel tends to freeze solid.

Error Code 12 - Left Hopper Sensor

The Left Hopper Sensor Error (E12) will not occur on the E111 or the F111.

Error Code 13 - Right Hopper Sensor

The Right Hopper Sensor Error (E13) will not occur on the E111 or the F111.

COMMO TIMEOUT Error

A COMMO TIMEOUT Error indicates a communication interruption between the display and the control board. This error can be caused by a poor connection or a faulty phone cable. Disconnect and reconnect the telephone cable at the control board. If the error does not clear, disconnect and reconnect the telephone cable at the display panel module. If the error still appears, the cable may be faulty or the display panel module may be faulty.

Alternating Flashing Control Panel Lights

The display panel lights will flash in an alternating sequence under any error codes. Clear the error and place the Main Freezer Power Off-On switch in the Off position and back in the On position.

7.3 TROUBLESHOOTING - MACHINE

PROBLEM

Machine does not run.

Machine w il l not shut off.

Product is too firm.

Product is too soft.

Product does not dispense .

Drive belt slipping or squeali ng.

Rear auger seal leaks.

Front door leaks.

P OS SIBLE CAU SE REMEDY

1. P ower t o m achine is off. 1. S uppl y power to machine.

2. B l own fus e or t ripped circ ui t. 2. Replace or reset.

3. Freeze-up (auge r wi l l no t tu rn). 3. Turn Main Freezer P o wer OF F for 15 m i n utes , then restart.

4. High press ure c ut -out tripped. 4. Wait until aut om atic reset for machine t o s tart.

5. F ront door not i n pl ace. 5. A ss embl e front door in pl ace.

1. Drive belt failure. 1. Replace drive belt.

2. Cons i stency temperature sett i ng i s too

firm.

3. Refrigeration problem. 3. Check system. (See Section 5)

1. Cut Out s et ting is too hi gh. 1. A dj ust the CutOut am ps (See S ecti on 3-10).

1. No vent spac e for free flow of c ool i ng

air.

2. A i r t emperature ent ering condenser is

above 100°F.

3. Condens er i s dirty. 3. Clean. (See Secti on 3)

4. CutOut setting is too low. 4. Adjust the CutOut amps (See Section 3-10).

5. Stabilizers in mix are broken down. 5. Remove mix, c lean, sanitize and freeze down

6. A uger i s assembl ed incorrect l y. 6. Remove m i x , c lean, reassemble, sani tiz e and

7. Product break down. 7. Drain, clean and sanitize machine. Fill with

8. Refrigeration problem. 8. Check system. (See Section 5)

1. No mi x in hopper. 1. Fill hopper with mi x .

2. Capac i ty of machine i s bei ng

exceeded.

3. Drive motor overload t ri pped. 3. W ai t for autom atic reset. (If conditi on

4. Drive belt failure. 4. Replace drive belt.

5. F reez e-up (A uger will not turn). 5. Turn Main Freezer Power OFF for 15 minutes,

1. Worn drive bel t . 1. Replace drive belt.

2. F reez e-up (A uger will not turn). 2. Turn Main Freezer Power OFF for 15 minutes,

3. Not tensi oned properly 3. A dj ust bel t tens i on

1. Outs ide surface of rear auger seal is

lubricated.

2. Rear s eal m i ssi ng or dam aged. 2. Chec k or replac e.

3. S eal o-ri ng m iss i ng, dam aged or

installed incorrectly.

4. Worn or scratched auger shaft. 4. Replac e auger shaft.

1. F ront door knobs are loose. 1. Tighten knobs.

2. S pi got parts are not lubri cated. 2. See S ecti on 3.

3. Chipped or worn s pi got o-rings. 3. Replace o-rings .

4. O-ri ngs or spigot i ns talled wrong. 4. Remove spigot and chec k o-ring.

5. Inner s pigot hole in front door ni c ked or

scratched.

2. Turn Consistency Adjustment knob counterclockwise.

1. A m i ni m um of 3" of vent spac e required. (S ee Section 2)

2. Change locati on or direct hot air away from machine.

with fresh mix.

freeze down.

fresh mi x.

2. Slow up on the draw rate.

co ntinu es, call dist ri butor for s e rvice . )

then restart.

1. Clean l ubricant from outside of rear seal , lubricate inside of seal and rei ns tall .

3. Chec k. or replace.

5. Replace front door.

REPLACEMENT PARTS

8.1 AUGER & FRONT DOOR PARTS

SECTION 8

666786

381804

3159696

624598-5

482019

3170644

2177698

625133

694255

149003

624678-5

E11 1 - 4157952 F11 1 - 4157968

Quantity

Part Description E111 F111

149003 Bushing - Front Auger Support 1 381804 Auger Flight 3 4

482019 Knob - Front Door (Black) 2 2 624598-5 O-Ring - Spigot Body - Black (5 Pack) 2 2 624678-5 O-Ring - Rear Seal - Black (5 Pack) 1 1

625133 O-Ring - Front Door - Red 1 1

666786 Seal - Rear Auger - Black 1 1

694255 Spring - Auger Flight 3 4

2177698 Door w/Pins 1 1 3159696 Spigot Body 1 1

3170644 Support - Front Auger 1 1 4157952 Auger Shaft 1 4157968 Auger Shaft 1

8.2 HOPPER COVER & TRAYS

744606

314452

744284

2149238

744283-SV

232734

Quantity

Part Description E111 F111

232734 Cap - Rosette 1 1

314452 Cover - Hopper 1 1 624677-5 O-Ring - Mix Inlet - Black (5 Pack) 2 2

744283-SV Tray - Drip 1 1

744284 Insert - Drip Tray 1 1

744606 Tray - Drain (Black Plastic) 1 1

2149238 Mix Inlet Assembly - 3/16" Hole - Standard Length (3A) 1 1

624677-5

8.3 SPIGOT CAM ASSEMBLY

570961

428045

Part Description E111 F111

428045 Knob - Spigot Handle (Black) 1 1

570961 Pin - Cotterless Clevis (Spigot Handle) 1 1

696044 Spring - Torsion (Spigot Handle) 1 1

718773 Switch - Spigot 1 1

2158082 Glide - Spigot Socket 1 1 2158260 Handle - Spigot (Metal Only) 1 1

718773

2158082

696044

2158260

Quantity

8.4 LEFT SIDE

2183248 2183422

762978

272065 763423 763589

762329

762455

458003

763482

430165 430172

Part Description E111 F111

114068 Hook - Condenser Filter Fastening 4 4

231078 Capacitor - Run (#522858 Motor) 1 1

231095 Capacitor - Start (#522858 Motor) 1 1

231108-SV Cap Tube & Drier Assembly 1

272065 Valve Coil - Solenoid (#763423 Valve) 1

368140 Filter - Air 1 1

430165 Cord - Power 1

430172 Cord - Power 1

458003 Sight Glass 1 1

521236 Insulation - Molded (TXV Valve) 1 1

521237 Insulation - Molded (TXV Bulb) 1 1

718794 Switch - High Pressure Reset 1

762275 Valve - Magna Check (Suction Line) 1 1

762329 Valve - Magna Check (EPR) 1 1

762455 Valve - Expansion (R404A) 1 1

762978 Valve - EPR 1 1

763017 Valve - Hot Gas Bypass 1 1

763128 Valve Coil - Solenoid (Sporlan) (#763433) 1

763422 Valve - Solenoid (1/4") (Sporlan) (Liquid Line) 1

763423 Valve - Solenoid (1/2") (Suction Side) 1

763433 Valve - Solenoid (Sporlan) (Liquid Line) 1

763482 Valve Coil - Solenoid (#763422) (Sporlan) (Liquid Line) 1

763589 Valve - Solenoid (Sporlan) (Suction Side) 1

2171962 Sensor Probe Kit 1 1

2183248 Evaporator Assembly 1 2183422 Evaporator Assembly 1

231078

231095

763128 763422 763433

Quantity

8.5 MACHINE FRONT

284071

744142

718532

521686-115

521686-230

332541

482004

162077

719025-SV

522291

282043-SV

282046

342004

232091

3158185

Part Description E111 F111

162077 Blade - Fan (Air-Cooled Condenser) 1 1

215061 Plug - Bumper (Drip Tray) 2 2

229116 Cable - Phone (Control Board To Display Board) 1 1

232091 Cap - Protective (Gray) - #490716 Leg 4 4

266076 Clip - Drip Tray 2 2

282043-SV Compressor - R404A (No Capacitors) (60 Hz) 1

282046 Compressor - 60 Hz - R404A (No Capacitors) 1

282051 Compressor - 50 Hz - R404A (No Capacitors) (Ser. #30855 Plus) -

282053 Compressor - R404A (50 Hz) -

284071 Condenser (Air-Cooled) 1 1

332541 Board - Display Module 1 1

342004 Drier (Main) 1 1

396174 Gasket - Front Evaporator 1 1

482004 Knob (Spigot Adjustment) 1 1

490716 Leg 4 4

521686-115 Board - Program - IntelliTec (115V) 1 521686-230 Board - Program - IntelliTec (208V / 230V) 1

522291 Moto r - F a n (50/ 6 0 H z ) 1 1

718532 Switch - Toggle (Main Power On-Off) 1 1

719025-SV Switch - Membrane Strip (Touchpad & Ribbon) 1 1

744142 Transformer 1 1

1170836-SV Switch Assembly - Limit (Door Interlock) 1 1

3158185 Handle - Lifting (Metal) 1 1

490716

Quantity

8.6 MACHINE BACK

618151 618534

231026 231027

295017 295019

230631 230634

614233

152293 152307

598245

522858-SV

598072

Quantity

Part Description E111 F111

152293 Belt - Gripnotch (AX37) (Each) (60 Hz) 1

152307 Belt - Gripnotch (AX38) (Each) (60 Hz) 1

152323 Belt - Gripnotch (AX39) (Each) (50 Hz) -

230631 Capacitor - Start (#282043 Compressor) 1

230634 Capacitor - Start (#282046 Compressor) 1

231026 Capacitor - Run (#282043 Compressor) 1

231027 Capacitor - Run (#282046 Compressor) 1

231072 Capacitor - Run (#282051 Compressor) -

231099 Capacitor - Start (#282051 Compressor) -

246048 Spacer - Speed Reducer 1

284104 Condenser (Water-Cooled) 1

295017 Contactor (45CG20AG) 2

295019 Contactor (45CG20AF) 2

522858-SV Motor - Drive (115V / 208V / 230V, 60 Hz) 1 1 522859-SV Motor - Drive (220V / 240V, 50 Hz) - -

598072 Pulley - Drive Motor (60 Hz) 1 1

598100 Pulley - Drive Motor (50 Hz) - -

598245 Pulley - Speed Reducer (50/60 Hz) 1 1

614233 Speed Reducer 1 1

618151 Relay (#282046 Compressor) 1

618502 Relay - Overload (#282043 Compressor) 1

618534 Relay (#282043 Compressor) 1

763181 Valve - Water 1

8.7 DECALS & MISCELLANEOUS

Part Description E111 F111

208135 Brush - 4" X 8" X 16" (Barrel) 1 1

208380 Brush - 1/4" X 3" X 14" 1 1

208401 Brush - 1" X 3" X 10" 1 1

208467 Brush - 3/8" X 1" X 5" 1 1

236040 Card - Cleaning Instruction 1 1

324105 Decal - Caution Electrical Shock 1 1

324106 Decal - Caution Electrical Wiring Materials 1 1

324107 Decal - Caution Hazardous Moving Parts 1 1

324141 Decal - Caution Rotating Blades 1 1

324200 Decal - High Pressure Cut-Out 1

324208 Decal - Attention Refrigerant Leak Check 1 1

324509 Decal - Cleaning Instructions 1 1

324566 Decal - Wired According To 1 1

324584 Decal - Adequate Ventilation 3" 2 2

324594 Decal - Attention Heat Sensitive 1 1

324686 Decal - Danger Automatic Start 1

324803 Decal - Domed Stoelting Logo (Large) (Header Panel) 1 1

324804 Decal - Domed Stoelting Swirl (Header Panel) 1 1

324825 Decal - Main Freezer Power 1 1

396240 Gasket - Freezer Base 1 1

508048 Lubricant - Spline (2 oz Squeeze Tube) 1 1

508135 Petrol Gel - 4 oz Tube 1 1 513532-5 Manual - Owner’s (IntelliTec Models) 1 1

1183437 O-Ring & Bearing Kit 1 1 2177917 Brush Kit 1 1

Quantity

8.8 PANELS

Part Description E111 F111

647653 Screw - Panel (Front Lower, Rear & Header Panel) - -

649000-39 Screw (Side Panel) - -

2183249 Panel - Top 1

2183423 Panel - Top 1 2183420-SV Panel - Front Lower w/Insulation 1 1 2183428-SV Panel - Rear w/Insulation 1 1 2183432-SV Panel - Side w/Insulation 2 2

Quantity

8.9 WIRING DIAGRAMS

DOMESTIC WARRANTY

(Including Mexico)

SOFT SERVE / SHAKE EQUIPMENT

1. Scope: PW Stoelting, L.L.C. (“Stoelting”) warrants to the first user (the “Buyer”) that the freezing cylinders,

hoppers, compressors, drive motors, speed reducers, and augers of Stoelting soft serve / shake equipment will be free from defects in materials and workmanship under normal use and proper maintenance appearing within five (5) years, and that all other components of such equipment manufactured by Stoelting will be free from defects in material and workmanship under normal use and proper maintenance appearing within twelve (12) months after the date that such equipment is originally installed.

2. Disclaimer of Other Warranties: THIS WARRANTY IS EXCLUSIVE; AND STOELTING HEREBY DISCLAIMS ANY

IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.

3. Remedies: Stoelting’s sole obligations, and Buyer’s sole remedies, for any breach of this warranty shall be the

repair or (at Stoelting’s option) replacement of the affected component at Stoelting’s plant in Kiel, Wisconsin, or (again, at Stoelting’s option) refund of the purchase price of the affected equipment, and, during the first twelve (12) months of the warranty period, deinstallation/reinstallation of the affected component from/into the equipment. Those obligations/remedies are subject to the conditions that Buyer (a) signs and returns to Stoelting, upon installation, the Start-Up and Training Checklist for the affected equipment, (b) gives Stoelting prompt written notice of any claimed breach of warranty within the applicable warranty period, and (c) delivers the affected equipment to Stoelting or its designated service location, in its original packaging/crating, also within that period. Buyer shall bear the cost and risk of shipping to and from Stoelting’s plant or designated service location.

4. Exclusions and Limitations: This warranty does not extend to parts, sometimes called “wear parts”, which are generally expected

to deteriorate and to require replacement as equipment is used, including as examples but not intended to be limited to o-rings, auger flights, auger seals, auger support bushings, and drive belts. All such parts are sold

AS IS.

Further, Stoelting shall not be responsible to provide any remedy under this warranty with respect to

any component that fails by reason of negligence, abnormal use, misuse or abuse, use with parts or equipment not manufactured or supplied by Stoelting, or damage in transit.

THE REMEDIES SET FORTH IN THIS WARRANTY SHALL BE THE SOLE LIABILITY

STOELTING AND THE EXCLUSIVE REMEDY OF BUYER WITH RESPECT TO EQUIPMENT SUPPLIED BY STOELTING; AND IN NO EVENT SHALL STOELTING BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER FOR BREACH OF WARRANTY OR OTHER CONTRACT BREACH, NEGLIGENCE OR OTHER TORT, OR ON ANY STRICT LIABILITY THEORY.

SFWARR-013

Revision 04

Page 1 of 1

Stoelting E111I Operators Manual

Specifications and Main Features

Frequently Asked Questions

User Manual