Stoelting O431 Operators Manual
Model O431
SERVICE MANUAL
Manual No. 513641 Rev.1
This manual provides basic information about the machine. Instructions and suggestions are
given covering its operation and care.
The illustrations and specifi cations are not binding in detail. We reserve the right to make
changes to the machine without notice, and without incurring any obligation to modify or provide new parts for machines built prior to date of change.
DO NOT ATTEMPT to operate the machine until instructions and safety precautions in this
manual are read completely and are thoroughly understood. If problems develop or questions
arise in connection with installation, operation, or servicing of the machine, contact Stoelting.
stoeltingfoodservice.com
Stoelting Foodservice Equipment
502 Highway 67
Kiel, WI 53042-1600
U.S.A.
Main Tel: 800.558.5807
Fax: 920.894.7029
Customer Service: 888.429.5920
Fax: 800.545.0662
Email: foodservice@stoelting.com
© 2014 PW Stoelting, LLC
A Few Words About Safety
Safety Information
Read and understand the entire manual before
operating or maintaining Stoelting equipment.
This manual provides the operator with information
for the safe operation and maintenance of Stoelting
equipment. As with any machine, there are hazards
associated with their operation. For this reason safety
is emphasized throughout the manual. To highlight
specifi c safety information, the following safety defi ni-
tions are provided to assist the reader.
The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and
their explanations, deserve your careful attention
and understanding. The safety warnings do not by
themselves eliminate any danger. The instructions
or warnings they give are not substitutes for proper
accident prevention measures.
If you need to replace a part, use genuine Stoelting
parts with the correct part number or an equivalent
part. We strongly recommend that you do not use
replacement parts of inferior quality.
Safety Alert Symbol:
This symbol Indicates danger, warning or caution.
Attention is required in order to avoid serious personal injury. The message that follows the symbol
contains important information about safety.
Signal Word:
Signal words are distinctive words used throughout
this manual that alert the reader to the existence and
relative degree of a hazard.
WARNING
The signal word “WARNING” indicates a potentially
hazardous situation, which, if not avoided, may result
in death or serious injury and equipment/property
damage.
CAUTION
The signal word “CAUTION” indicates a potentially
hazardous situation, which, if not avoided, may result
in minor or moderate injury and equipment/property
damage.
CAUTION
The signal word “CAUTION” not preceded by the
safety alert symbol indicates a potentially hazardous
situation, which, if not avoided, may result in equipment/property damage.
NOTE (or NOTICE)
The signal word “NOTICE” indicates information or
procedures that relate directly or indirectly to the
safety of personnel or equipment/property.
TABLE OF
CONTENTS
Section Description Page
1 Description and Specifi cations
1.1 Description .................................................................................................. 1
1.2 Specifi cations ............................................................................................. 2
1.3 Modes of Normal Operation .......................................................................3
A. Initial Status..........................................................................................................3
B. Serve Mode ..........................................................................................................3
C. Standby Mode ......................................................................................................3
D. Sleep 1 Mode .......................................................................................................4
E. Sleep 2 Mode .......................................................................................................4
F. IntelliTec Restart ...................................................................................................4
G. Sleep 3 Mode ....................................................................................................... 4
H. Clean Mode .......................................................................................................... 5
1.4 Mix Level Indicators .................................................................................... 5
1.5 Storage Refrigeration .................................................................................5
1.6 Operation During Sensor Failure ................................................................ 5
A. Serve and Standby Mode..................................................................................... 5
B. Cabinet Refrigeration ...........................................................................................5
1.7 Motor Profi le Cutout Compensation ........................................................... 5
2 Installation Instructions
2.1 Safety Precautions .....................................................................................7
2.2 Shipment and Transit ..................................................................................7
2.3 Machine Installation .................................................................................... 7
2.4 Installing Permanent Wiring ........................................................................ 7
2.5 Mix Pump .................................................................................................... 8
A. Mix Pump Hose Installation.................................................................................. 8
B. Mix Pickup Hose Installation ................................................................................8
C. Mix Low Level Indicator Adjustment ..................................................................... 10
3 Initial Set-Up and Operation
3.1 Operator’s Safety Precautions ................................................................... 11
3.2 Operating Controls and Indicators .............................................................. 11
3.3 Disassembly of Machine Parts ................................................................... 13
A. Disassembly of Front Door ................................................................................... 13
B. Disassembly of Auger ..........................................................................................13
3.4 Cleaning Disassembled Parts ....................................................................14
3.5 Sanitizing Machine Parts ............................................................................14
3.6 Cleaning the Machine ................................................................................. 14
3.7 Assembling Machine ..................................................................................14
3.8 Sanitizing .................................................................................................... 15
Section Description Page
3.9 Initial Freeze Down and Operation .............................................................16
A. Adding Mix ........................................................................................................... 16
B. Preparing the IntelliTec Control ............................................................................ 16
C. Initial Freeze Down ..............................................................................................16
D. Adjusting the IntelliTec Control ............................................................................. 16
E. Serving Product....................................................................................................17
3.10 Normal Freeze Down and Operation .......................................................... 17
3.11 Mix Information ...........................................................................................17
3.12 Operation of Mix Pump ............................................................................... 18
3.13 Mix Pump Cleaning ....................................................................................18
3.14 Disassembly and Inspection of Removable Parts ...................................... 19
4 Maintenance and Adjustments
4.1 Machine Adjustment ................................................................................... 21
4.2 Product Consistency Adjustment ................................................................ 21
4.3 Locking the Control Panel ..........................................................................21
4.4 Obtaining Readings and Modifying Settings (Service Personnel Only) ...... 21
4.5 Readings (Service Personnel Only) ...........................................................22
4.6 Adjustments (Service Personnel Only) ....................................................... 23
4.7 Other Settings (Service Personnel Only) .................................................... 23
4.8 Overrun Adjustment .................................................................................... 24
4.9 Mix Pump Hose Reposition ........................................................................ 25
4.10 Mix Pump Hose Replacement ....................................................................25
4.11 Cab Temperature Adjustment ..................................................................... 26
4.12 Drive Belt Tension Adjustment .................................................................... 26
4.13 Condenser Cleaning (Air-Cooled Machines) ..............................................27
4.14 Preventative Maintenance .......................................................................... 27
4.15 Extended Storage ....................................................................................... 27
5 Refrigeration System
5.1 Refrigeration System .................................................................................. 29
5.2 Refrigerant Recovery and Evacuation ........................................................ 29
A. Refrigerant Recovery ...........................................................................................30
B. Evacuating the Refrigeration System ...................................................................30
5.3 Refrigerant Charging .................................................................................. 30
5.4 Compressor ................................................................................................ 31
5.5 Condenser .................................................................................................. 32
5.6 Evaporator .................................................................................................. 32
Section Description Page
5.7 Valves ......................................................................................................... 32
A. Thermostatic Expansion Valve (TXV) ..................................................................32
B. Check Valve ......................................................................................................... 33
C. High Pressure Cutout ........................................................................................... 33
D. Hot Gas Bypass ...................................................................................................34
E. Water Valve (Water Cooled Models Only) ............................................................ 35
5.8 Solenoid ...................................................................................................... 36
5.9 Filter Drier ................................................................................................... 37
5.10 Cab Unit ...................................................................................................... 37
6 Electrical and Mechanical Control Systems
6.1 IntelliTec Controller ..................................................................................... 39
6.2 Contactors .................................................................................................. 39
6.3 Drive Motor ................................................................................................. 40
6.4 Capacitors ..................................................................................................41
6.5 Gearbox ...................................................................................................... 41
6.6 Condenser Fan Motor (Air-Cooled Only) .................................................... 42
6.7 Cab Condenser Fan Motor .........................................................................42
6.8 Switches ..................................................................................................... 43
A. Spigot Switch ....................................................................................................... 43
B. Pump Pressure Switch .........................................................................................44
C. Cab Door Magnetic Reed Switch .........................................................................44
6.9 Temperature Control Sensor ......................................................................45
7 Troubleshooting
7.1 Error Codes ............................................................................................... 47
7.2 Troubleshooting - Error Codes .................................................................. 47
7.3 Troubleshooting - Machine .........................................................................50
7.4 Troubleshooting - Mix Pump ....................................................................... 51
8 Replacement Parts
8.1 Brushes, Decals and Lubrication ................................................................ 53
8.2 Spigot Extension ......................................................................................... 53
8.3 Auger Shaft and Front Door .......................................................................54
8.4 Cab Tubing Assembly ................................................................................. 55
8.5 Spigot Cam Assembly ................................................................................ 56
8.6 Stainless Steel Panels ................................................................................ 56
8.7 Rear ............................................................................................................ 57
8.8 Right ........................................................................................................... 58
8.9 Left .............................................................................................................. 59
8.10 Front Panel and Header Panel ...................................................................60
8.11 Cab Interior ................................................................................................. 61
8.12 Pump Parts ................................................................................................. 62
8.13 Part Kits ...................................................................................................... 64
8.14 Refrigeration Diagram and Wiring Diagram ................................................ 65
SECTION 1
DESCRIPTION AND SPECIFICATIONS
1.1 DESCRIPTION
The Stoelting O431 fl oor model machine is pressure fed.
The machine is equipped with fully automatic controls to
provide a uniform product. The machine is designed to
operate with almost any type of commercial soft-serve or
non-dairy mixes available, including ice milk, ice cream,
yogurt, and frozen dietary desserts.
This manual is designed to assist qualifi ed service per-
sonnel and operators in the installation, operation and
maintenance of the Stoelting O431 pressure machine.
Figure 1-1 Model O431
1
Model O431
Dimensions Machine with crate
width 19-1/8’’ (48,6 cm) 27’’ (68,6 cm)
height 67-7/8’’ (172,4 cm) 78’’ (198,1 cm)
depth 37-3/4’’ (95,9 cm) 48’’ (121,9 cm)
Weight 500 lbs (226,7 kg) 650 lbs (294,8 kg)
Electrical 1 Phase, 208-240 VAC, 60Hz
Air Cooled Water Cooled
running amps
connection type
International Option 1 Phase, 220-240 VAC, 50Hz or 3 Phase, 380-415 VAC, 50Hz
Compressor 15,000 Btu/hr Scroll™ Compressor
Drive Motor Two - 3/4 hp
Air Flow Air cooled units require 3” (7,6 cm) air space on both sides and back.
Plumbing Fittings Water cooled units require 1/2” N.P.T. water and drain fi ttings.
Hopper Volume Two - 5.5 gallons (20,82 liters)
Freezing Cylinder
Volume
17A 15A
NEMA L6-30P NEMA L6-30P
Two - 1 gallon (3,79 liters)
O431
Refrigerant R-404A
Charge
Suction Pressure
(at 72°F)
Discharge Pressure 195-215 psig
(W/C) 26 oz
(A/C) 36 oz
19-21 psig
Menu Display Value
Basic CutOut * amps
Cut In T 21 °F
Cycles 20 count
Stir On 15 seconds
Stir Off 300 seconds
Advanced On Time 28 seconds
Off Time 450 seconds
Stb Time 120 minutes
Sl1DrvOn 120 seconds
Sl1DrOff 180 seconds
Sl2CutIn 32 °F
Sl2CtOut 28 °F
DftOffTm 600 seconds
Storage Refriger ** 3 Cabinet
(Left CabCutIn 37 °F
control CabCtOut 33 °F
only) Cab Off 13 minutes
Cab On 130 seconds
* CutOut value needs to be adjusted to product
requirements.
** The Refriger setting on the right control board
must be set to None.
2
1.3 MODES OF NORMAL OPERATION
Following are details of the operational modes on the O431.
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 6
for details on each setting.
A. INITIAL STATUS
When the Main Freezer Power and Freezing Cylinder
switches are 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 blink.
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. 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
over-freezing of product, especially during frequent, small
volume draws. If 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 product has not 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
3
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 fl ow 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 fi rst “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
Figure 1-6 Sleep 2 Mode
pressed. When this 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 fi rst “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 41°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.
4
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 cabinet is equipped with a capacitive sensor to monitor mix level. When the mix level drops below the sensor
limit, the lower line of the display will read “Low Mix” and
the display will fl ash. To clear the “Low Mix” error, add
mix to the cabinet’s mix container.
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 (DftOffTm) 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 STORAGE REFRIGERATION
The IntelliTec control is programmed to handle refrigeration
of the cabinet independently from the freezing cylinder.
The control maintains cabinet temperature between two
preset values (CabCutIn and CabCtOut). The cabinet
will operate automatically unless one of the following
conditions are met:
If the Main Power switch is in the OFF position
the Cab Off light on the front of the machine will
fl ash.
If the cabinet door is opened during a refrigeration
cycle, the evaporator fan will continue to run but
the refrigeration cycle will be interrupted to prevent
the evaporator coils from icing up.
If there is a High Pressure Cutout Error (E9) all
the refrigeration stops.
NOTE
If the temperature in the cabinet stays above 50°F
for more than two hours, the machine will go into
Sleep Mode and a clean message will be shown
on the display.
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 cabinet 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)
B. CABINET REFRIGERATION
In the event of a temperature sensor failure in the cabinet, the cabinet refrigeration cycle is managed by preset
times (Cab On and Cab Off). This refrigeration cycle is
independent of the freezing cylinder refrigeration and the
cycle restarts if the cabinet door is opened.
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
specifi c temperature and consistency irrespective of the
supply voltage. A motor profi le 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 profi le. This feature is
automatic and does not need any confi guring.
5
IntelliTec Control Setting Specifi cations
Basic Menu DISPLAY Value MODE DEFINITION
CutOut * Serve Amp draw setting for cut out
Cut In T 21°F Serve Temperature setting for cut in
Cycles 20 Serve Freezing cycles before going into Standby Mode
Stir On 15 sec Serve Stir-only on time
Stir Off 300 sec Serve Stir-only off time
Advanced Menu DISPLAY Value MODE DEFINITION
On Time 28 sec Standby Freezing cycle “on” time (runs on timers only)
Off Time 450 sec Standby Freezing cycle “off” time
Stb Time 120 sec Standby Total time in mode
Sl1DrvOn 120 sec Sleep 1 Drive motor “on” timer
Sl1DrOff 180 sec Sleep 1 Drive motor “off” timer
Sl2CutIn 32°F Sleep 2 Cut in temperature
Sl2CtOut 28°F Sleep 2 Cut out temperature
DftOffTm 600 sec No Sensor Default “off” time. Used in case of sensor failure
Storage Menu DISPLAY Value MODE DEFINITION
Refriger Cabinet All Set to None, 1 Hopper, 2 Hopper, or Cabinet
CabCutIn 37°F All Refrigerated cab cut in temperature
CabCtOut 33°F All Refrigerated cab cut out temperature
Cab Off 13 min No Sensor Default “off” time. Used in case of sensor failure
Cab On 130 sec No Sensor Default “on” time. Used in case of sensor failure
* The CutOut value needs to be adjusted to product requirements. Refer to the 2187295 - Specifi cation Sheet for O431
Control located in the plastic pouch behind the header panel.
Table 1-1 IntelliTec Control Settings
6
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
2.2 SHIPMENT AND TRANSIT
The machine has been assembled, operated and inspected
at the factory. Upon arrival at the fi nal destination, the
entire machine must be checked for any damage which
may have occurred during transit.
With the method of packaging used, the machine should
arrive in excellent condition. THE CARRIER IS RESPONSIBLE FOR ALL DAMAGE IN TRANSIT, WHETHER
VISIBLE OR CONCEALED. Do not pay the freight bill
until the machine has been checked for damage. Have
the carrier note any visible damage on the freight bill. If
concealed damage and/or shortage is found later, advise
the carrier within 10 days and request inspection. The
customer must place a claim for damages and/or shortages in shipment with the carrier. Stoelting cannot make
any claims against the carrier.
2.3 MACHINE INSTALLATION
B. Install the four casters. Turn the threaded end
into the machine until no threads are showing. To
level, turn out casters no more than 1/4” maximum,
then tighten all jam nuts.
C. The machine must be placed in a solid level
position.
NOTE
Accurate leveling is necessary for correct drainage
of freezing cylinder and to insure correct overrun.
D. Machines with air cooled condensers require a
minimum of 3” (7,5cm) clearance at the sides and
6” at the back for proper circulation. (Fig. 2-1)
Figure 2-1 Space and Ventilation Requirements
E. Machines that have a water cooled condenser
require 1/2” NPT supply and drain fi ttings.
F. In air-cooled machines, use a voltmeter to measure
incoming voltage. If the supply voltage is 215 or
less, remove the right side panel and move the
voltage selector toggle switch to the 208V position.
NOTE
Supply voltage must be checked to make sure the
fan motor operates properly.
WARNING
Installation must be completed by a qualifi ed
electrician/refrigeration specialist.
Incorrect installation may cause personal injury,
severe damage to the machine and will void factory warranty.
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.
2.4 INSTALLING PERMANENT WIRING
If permanent wiring is required by local codes, the following procedure must be performed:
A. Refer to the nameplate on the side panel of the
machine for specifi c electrical requirements. Make
sure the power source in the building matches
the nameplate requirements.
B. Remove the back panel and the junction box
cover located at the back of the machine.
C. Remove the installed cord and install permanent
wiring according to local code.
7
6” (15cm)
Figure 2-2 Mix Hose Installation
2.5 MIX PUMP
A. MIX PUMP HOSE INSTALLATION
Follow the steps below to install the mix pump hose in
the cabinet part of the machine.
1. Turn the mix pump on. The switch is located on
the header panel.
2. Feed one end of the mix pump hose into the
entering or pickup hose side (left) of black cover
(Fig 2-2).
NOTE
Feed the tube into the clamp so the natural curve of
the tube is towards the outside of the black cover.
This prevents the hose from looping around the
black cover twice.
3. Gently push the hose into the black cover until it
begins to feed.
4. Allow the hose to feed itself through the pump
until about 6” (15cm) remains on the entering
side.
5. Turn the pump off.
6. Connect the mix pump hose to the elbow fi tting
(located on the left side of the mix line manifold)
using a small hose clamp. Be careful not to twist
the mix hose.
7. Turn the pump on.
8. Allow the remaining 6” (15cm) of tubing to feed
through pump until the hose adapter prevents
further feeding.
9. Turn the pump off.
CAUTION
Risk of Product Damage
Air/Mix Tee must remain below the black cover
clamp. If the Tee is above the pump, mix may drain
into the air compressor resulting in pump damage.
10. Connect the free end of the mix pump hose to
the 3-way Tee (Fig. 2-3). When all connections
are complete, the 3-way Tee must be lower than
the black pump housing.
B. MIX PICKUP HOSE INSTALLATION
The O431 machine may be connected to the standard
mix containers or up to three prepacked mix bags. Follow the instructions below that match your confi guration.
Standard Connection:
1. Connect a 2” (5cm) length of 3/8” (9,5mm) ID
plastic food grade tubing to the mix pickup
assembly. Secure with hose clamps. Place the
assembly through the hole in the cover and install
the retaining clip.
8
Figure 2-3 Mix Pump Connections for Standard Mix Container
2. Connect the free end of the tubing to the mix check
valve. Observe the direction of the check valve
fl ow arrow. Secure with a hose clamp. Connect a
24” (61cm) length of 3/8” (9,5mm) ID plastic food
grade tubing to the free end of the check valve
and secure with a hose clamp.
3. Connect the elbow fi tting to the free end of the
tubing. Connect the opposite end of the elbow
to 1/4” ID tan tubing on the left side of the pump
head. Secure with hose clamps (Fig. 2-3).
When Using Bag Connection System (BCS) with Three
Bags (optional kit #2183987):
The position of the three bags in the mix container is
important. The bag that is connected nearest the outlet
of the manifold will drain last and should be placed at
the back of the mix container. The mix low level indicator
relies on proper bag placement.
1. Connect 3/8” (9,5mm) ID plastic food grade tubing
to a bag adapter. Secure with hose clamps.
2. Slide the hose clip over free end of 3/8” (9,5mm)
ID plastic food grade tubing. Attach the free end
of the tubing to a manifold adapter. Secure with
a large hose clamp or equivalent.
3. Push the manifold adapter with spring and valve
into the left port (nearest the manifold outlet) of
the mix inlet manifold and secure with a retaining
clip. (Fig. 2-5).
Mix Outlet
Drains
Last
Figure 2-4 BCS Mix Inlet Manifold
9
4. Repeat steps 1 to 3 for the middle port and for
the right port of the mix inlet manifold.
5. Place three mix bags into the mix container.
6. Connect the bag adapter attached to the left side
of the manifold (closest to the mix outlet) to the
mix bag in the back of the mix container.
7. Connect the bag adapter attached to the middle
of the manifold to the mix bag in the middle of
the mix container.
8. Connect the bag adapter attached to the right
side of the manifold (farthest from the mix outlet)
to the mix bag in the front of the mix container.
When Using Bag Connection System (BCS) with One
or Two Bags (optional kit #2183987):
When connecting one or two bags, the manifold adapters must be installed closest to the manifold outlet and
the manifold plug(s) must be placed farthest from the
manifold outlet.
1. Connect 3/8” (9,5mm) ID plastic food grade tubing
to a bag adapter. Secure
with hose clamps.
2. Slide the hose clip
over the free end of
the tubing. Attach the
free end of the tubing
to a manifold adapter.
Secure with a large hose
clamp.
3. Push the manifold
adapter with spring and
valve into the left port
(nearest the manifold
outlet) of the mix inlet
manifold and secure
with retaining clip. (See
Figure 2-5).
4. If using two mix bags,
repeat steps 1 to 3 for
the middle port.
5. Install a manifold plug
into each empty inlet and
secure with a retaining
clip.
6. Place the mix bag(s) into
the mix container.
7. Connect the bag adapter
attached to the left side
of the manifold (closest
to the mix outlet) to the
mix bag in the back of
the mix container.
Manifold
Adapter
C. MIX LOW LEVEL INDICATOR ADJUSTMENT
The sensitivity of the “Mix Low” indication that displays on
the control panel can be adjusted to operator preference.
If more advanced notice of low mix is required, loosen the
black adjustment knobs located on the sensor brackets
at the back of the machine cabinet and slide the bracket
upwards. If the “Mix Low” message appears while there
is still suffi cient mix in the container, slide the bracket
downward. Be sure to tighten the adjustment knobs after
properly positioning the sensor.
Mix Inlet
Retaining
Clip
Manifold
Plug
Bag Adapter
Manifold
Figure 2-5 Bag Connection System (Optional)
10
SECTION 3
INITIAL SET-UP AND OPERATION
3.1 OPERATOR’S SAFETY PRECAUTIONS
SAFE OPERATION IS NO ACCIDENT; observe these
rules:
A. Know the machine. Read and understand the
Operating Instructions.
B. Notice all warning labels on the machine.
C. Wear proper clothing. Avoid loose fi tting 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 power 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. For the information regarding error codes
displayed on the control panel, refer to the troubleshooting
section of this manual.
A. MAIN FREEZER POWER SWITCH
The Main Freezer Power switch is a two position rocker
switch that supplies power to the IntelliTec control, freezing cylinder circuits lower cabinet refrigeration system.
When the switch is placed in the ON position, the cabinet
refrigeration system will run until the preset temperature
is reached; then it will cycle ON and OFF to maintain that
temperature. Power to the freezing cylinders can then be
controlled with the Freezing Cylinder OFF/ON switch.
B. FREEZING CYLINDER OFF/ON SWITCH
The Freezing Cylinder OFF/ON switch is a two position
toggle switch used to supply power to each freezing cylinder control circuit. When the switch is in the OFF position,
the freezing cylinder’s refrigeration system and auger will
not operate. When the switch is in the ON position, the
machine will be operational.
Main Freezer
Power Off/On
Pump Power
Off/On
Freezing
Cylinder Off/On
Dispense
Rate Adjustor
Cab Off
Indicator Light
Figure 3-1 Machine Controls
Pump Power
Off/On
Freezing
Cylinder Off/On
IntelliT ec Control
(See Figure 3-2)
11
C. SPIGOT SWITCH
The spigot switch is mounted to the spigot cam assembly
behind the header panel. When the spigot is opened to
dispense product, the spigot switch opens and the “Serve
Mode” begins.
D. DISPENSE RATE ADJUSTOR
The dispense rate adjustor is located under the header
panel, to the immediate right of each spigot handle. Turning
the knob counterclockwise will decrease the dispense rate.
E. CAB OFF INDICATOR LIGHT
A fl ashing light indicates the Main Freezer Power Switch
is in the OFF position; no refrigeration is being supplied
to the cab. Place the Main Freezer Power switch in the
ON position for cab refrigeration.
F. PUMP SWITCH
The pump motor switch is the toggle switch located in
the upper left-hand side of the refrigerated cab. When
the switch is placed in the OFF position, the pump will
not run. When the switch is placed in the ON position,
the pump will run until the preset pressure is reached. It
then cycles on and off as product is drawn to maintain
that pressure.
G. PUSH TO FREEZE BUTTON
The PUSH TO FREEZE button is a snap switch used to
initiate “Serve Mode”.
NOTE
After the PUSH TO FREEZE button is pressed,
the drive motor starts. After a 3-second delay, the
compressor will start.
H. LEDS
The membrane switch (touchpad) features two lights: a
green LED and an amber LED. The green LED is lit during “Serve Mode”. During freeze down, it is not lit. When
product consistency approaches 75% in the freezing
cylinder, the green LED fl ashes. The amber LED is on
during all other modes. Both LEDs alternatively fl ash if
an error occurs or if the freezing cylinder is off.
I. CLEAN BUTTON
The CLEAN button is a snap switch. When the button is
pressed, the freezing cycle stops and the drive motor will
start. A CLEAN message will display on the LCD screen
along with a 5-minute countdown timer. To exit the CLEAN
mode, turn the Freezing Cylinder OFF/ON switch to the
OFF position or press the CLEAN button again. If the
machine is left in CLEAN for more than 20 minutes, an
error code (E4) will be displayed on the display panel.
Place the Freezing Cylinder OFF/ON switch in the OFF
position and back in the ON position to clear this error.
J. DRIVE MOTOR OVERLOAD
The internal drive motor overload will trip if the drive
motor is overloaded. It will reset after approximately 1012 minutes. If the drive motor continues to trip, refer to
Troubleshooting in Section 5.
K. MIX LOW LIGHT INDICATOR
A MIX LOW message will appear on the LCD display to
alert the operator of a low mix condition. The message
will display when there is approximately one gallon of
mix left in the mix container or when one bag of the Bag
Connection System (BCS) is empty. When the MIX LOW
message is displayed, refi ll the container or replace a
bag immediately.
L. MENU 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 (Fig. 3-2).
Selection Button (SEL) The SEL button is used in
combination with the up arrow button to enter into
the settings of the IntelliTec control. This button is
also used to navigate through the control settings
menu.
Set Button (SET) The SET button is used to save
a change made to the product consistency setting.
It is also used to save changes when modifying
control settings.
Left Arrow Button () If the left arrow button is
pressed for 5 seconds, the display will remain lit.
To turn the light off, press the left arrow button for
5 seconds. The left arrow button is used primarily
to navigate through the control settings.
Up Arrow Button () After pressing the SET
button, the up arrow button will change the value
of the product consistency setting. This button
is used primarily to navigate through the control
settings.
Push to Freeze
Green LED
Amber LED
Clean Button
SEL Button
SET Button
12
Left Arrow Button
Up Arrow Button
Figure 3-2 IntelliTec Control
3.3 DISASSEMBLY OF MACHINE PARTS
WARNING
Moving machinery can grab, mangle and dismember. Place the Main Freezer Power Off/On switch in
the OFF position before disassembling for cleaning
or servicing.
Before using the machine for the fi rst time, complete
machine disassembly, cleaning and sanitizing procedures need to be followed. Routine cleaning intervals
and procedures must comply with the local and state
health codes. Inspection for worn or broken parts should
be made at every disassembly of the machine. 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 fl ights on a regular basis (Fig.
3-3) and replace as needed. Frequency of cleaning must
comply with the local health regulations.
Figure 3-4 Removing O-Ring
6. Remove all o-rings from parts by fi rst wiping off
the lubrication using a clean towel. Then squeeze
the o-ring upward to form a loop (Fig. 3-4). Roll
the o-ring out of the groove.
CAUTION
Do not use any type of sharp object to remove the
o-rings.
Wear Line
Figure 3-3 Auger Flight Wear
To disassemble the machine, refer to the following steps:
A. DISASSEMBLY OF FRONT DOOR
1. Turn the Main Freezer Power Off/On switch to
the OFF position.
2. Remove the knobs on the front door.
3. Remove the front door by pulling it off the studs.
4. Remove the air bleed valve by unscrewing the
knob while holding the valve stem from behind.
Remove the compression spring and push the
air bleed valve through the rear of the front door.
5. Remove the spigots through the bottom of the
front door.
B. DISASSEMBLY OF AUGER
1. Remove the front auger support and bushing.
2. Remove the auger assembly from the machine.
Pull the auger out of the machine barrel slowly.
As the auger is being pulled out, carefully remove
each of the plastic fl ights with springs.
3. Keep the rear of the auger tipped up once it is
clear of the freezing cylinder to prevent the rear
seal assembly from dropping.
4. Wipe the hex drive anti-seize off of the hex end
of the auger with a paper towel. Remove the rear
seal assembly (Fig. 3-5).
5. Unscrew the springs from the auger fl ights.
Remove O-Ring
From Inside Insert
13
Figure 3-5 Rear Seal Assembly
3.4 CLEANING DISASSEMBLED PARTS
Disassembled machine 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.
3.5 SANITIZING MACHINE 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.
3.7 ASSEMBLING MACHINE
To assemble the machine parts, refer to the following steps:
NOTICE
Petrol-Gel sanitary lubricant or equivalent must be
used when lubrication of machine parts is specifi ed.
NOTICE
The United States Department of Agriculture and
the Food and Drug Administration require that lubricants used on food processing equipment be certifi ed 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 fi lm of sanitary
lubricant to exposed surfaces of the o-rings.
B. Lubricate the rear seal area on the auger shaft
with a thin layer of sanitary lubricant. Install the
rear seal o-ring. Lubricate the outside of the rear
seal o-ring with sanitary lubricant.
C. Install the stainless steel rear seal adapter into
the rear seal dry (without lubricant). Lubricate the
inside surface of the rear seal adapter, including
the adapter o-ring, and install it onto the auger
shaft. DO NOT lubricate the outside of the rear
seal adapter (Fig. 3-6).
Petrol-Gel
Place O-Ring
Inside Insert
3.6 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
fi nish. 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.
Spline
Lubricant
Figure 3-6 Rear Seal Assembly
D. Lubricate the hex drive end of the auger with
a small amount of hex drive anti seize. A small
container of anti seize is shipped with the machine.
E. Screw the springs onto the studs in the plastic
fl ights. The springs must be screwed into the
fl ights completely to provide proper compression.
F. Install the two plastic fl ights onto the rear of the
auger and insert it part way into the freezing
cylinder.
G. Install the remaining plastic fl ights, push the auger
into the freezing cylinder and rotate slowly until
the auger engages the drive shaft.
14
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 of 90°F to 110°F (32°C 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.
CAUTION
Figure 3-7 Front Door
H. Apply a thin layer of sanitary lubricant to the inside
and outside of the auger support bushing. Install
the bushing onto the auger support and install the
auger support into the front of the auger. Rotate
the auger support so that one leg of the support
points straight up.
H. Assemble the air bleed valve o-ring onto the air
bleed valve. Position the o-ring into the groove
close to the wide part. Apply a thin fi lm of sanitary
lubricant to the o-ring.
I. Insert the air bleed valve into the back of the front
door. Install the compression spring onto the air
bleed valve then screw the knob on fi nger tight.
J. Apply a thin layer of sanitary lubricant to the
o-rings on the spigot body and install the spigot
body through the bottom of the front door.
K. Apply a thin fi lm of sanitary lubricant to the door
seal o-ring and fi t it into the groove on the rear
of the front door.
M. Place the front door assembly on the mounting
studs and the push front door against the machine
carefully.
N. Secure the front door to the machine by placing
the knobs on the studs and tightening until fi nger
tight. Do not overtighten. Proper o-ring seal can
be observed through the transparent front door.
3.8 SANITIZING
Sanitizing must be done after the machine is clean and
just before the machine is fi lled with mix. Sanitizing the
night before is not effective. However, you should always
clean the machine and parts after using it.
NOTE
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 certifi ed for this use.
Risk of Product Damage
Avoid prolonged contact of sanitizer with machine
parts. Sanitizer may cause corrosion of stainless
steel parts if there is prolonged contact.
A. Prepare 2 gallons of sanitizing solution following
the manufacturer’s instructions. Pour it into a
clean container and place the container into the
cabinet. Put the mix pick-up tube in the sanitizer.
B. Place the mix pump switch in the ON position
and open the air bleed valve on the front door
by pushing the valve in and holding (see Figure
3-8).
Air Bleed
Valve
Figure 3-8 Air Bleed Valve
C. Let sanitizing solution fi ll the freezing cylinder to
the air bleed valve. Close the valve by pulling it
out to lock it into place.
D. Place the Main Power OFF/ON and Freezing
Cylinder OFF/ON switches in the ON position.
Press the CLEAN button.
E. Check for leaks when the freezing cylinder is fi rst
pressurized with sanitizing solution.
1. Check for leaks at the front door seals.
2. Check the drain tray located in the front panel
for leaks coming from the rear of the rear auger
seal.
3. Check the inside of the cab unit for leaks at
the hose connections.
15
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