Stoelting O431 Operators Manual

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Model O431
SERVICE MANUAL
Manual No. 513641 Rev.1
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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.
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
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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.
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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
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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
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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
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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
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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 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.
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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
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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.
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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 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.
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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
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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.
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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.
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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 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
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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)
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Page 19
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
Page 20
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
Page 21
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
Page 22
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 certi­ 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 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
ights. The springs must be screwed into the 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
Page 23
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
Page 24
F. Using a sanitized soft bristle brush (or equivalent)
dipped in sanitizing solution, clean the mix container.
G. After fi ve minutes, open the spigot to expel
sanitizing solution. Drain all of the solution from the machine.
H. When the solution has drained, press the CLEAN
button to stop the auger and place the Main Power OFF/ON and Freezing Cylinder OFF/ON switches in the OFF position. Allow the freezing cylinder to drain completely.
The machine is now sanitized and ready for adding mix.
3.9 INITIAL FREEZE DOWN AND OPERATION
Every Stoelting soft serve machine needs to be set on site.
The following adjustment will provide optimal product consistency while prolonging product life.
NOTE
The machine is designed for correct operation in ambient temperatures between 50°F and 110°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 Freezing Cylinder OFF/ON switch is in the OFF position.
3. Fill the mix container in the cab with at least 2.5 gallons of mix.
4. Attach the mix inlet probe to the container and place the container in the refrigerated cab.
5. The mix pump switch is located inside the cab unit. Place it in the ON position.
6. Place a container under the spigot and open the spigot to allow the mix to fl ush out about 8 ounces (0.23 liters) of sanitizing solution and liquid mix. Close the spigot.
7. Open the air bleed valve on the front door by pressing and holding. Hold the valve open until the mix level in the freezing cylinder is 1/2” from the air bleed valve.
B. PREPARING THE INTELLITEC CONTROL
8. 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”.
9. Press the left arrow () button once. The display will read “BASIC”.
10. Press the up arrow () button once. The display will read “CutOut amps”.
11. Press the SET button. A cursor will start blinking under the far right digit.
12. 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.
13. After entering 8.0, press SET to save this value. The LCD will read “CutOut Set -- OK”.
14. Press the SEL button. The LCD will read “CutOut amps 8.0”.
15. Press the SEL button twice. The LCD will read “DISPLAY”.
16. Press the up arrow () button to navigate to the “°F” and “amps” readings.
C. INITIAL FREEZE DOWN
17. Place the Freezing Cylinder OFF/ON switch in the ON position.
18. Press the PUSH TO FREEZE button.
NOTE
After the drive motor starts, there is a 3-second delay before the compressor starts.
19. 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.
20. 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.
21. Record the “amps” value.
22. Place the Freezing Cylinder OFF/ON switch in the OFF position.
D. ADJUSTING THE INTELLITEC CONTROL
23. Press the SEL button. The display will read “DISPLAY”.
24. Press the left arrow () button once. The display will read “BASIC”.
25. Press the up arrow () button once. The display will read “CutOut amps”.
26. Change the value to the recorded value by pressing the SET button. A cursor will start blinking under the far right digit.
27. 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.
16
Page 25
28. Press the SET button to save the value. The LCD will read “CutOut Set -- OK”.
29. Press the SEL button. The LCD will read “CutOut amps” along with the programmed value from the previous step.
30. Press the SEL button three times. The LCD will read “EXITMENU”.
31. Press the up arrow () button to exit the menu.
32. Adjustment to the control is completed.
E. SERVING PRODUCT
33. Place the Freezing Cylinder OFF/ON switch in the ON position.
34. Press the PUSH TO FREEZE button.
35. When the product is at 75% consistency, the display will read “SERVE”.
36. For normal dispensing, move the spigot handle fully open.
37. 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.
38. Do not operate the machine when the MIX LOW message is displayed. Refi ll 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 (5°C). Sleep modes do not take the place of cleaning and sanitizing. Federal, State, and local regulatory agencies determine frequency of cleaning and sanitizing.
E. Place the mix pump switch in the ON position.
F. Place a container under the spigot and open the
spigot to allow the mix to fl ush out about 8 ounces (0.23 liters) of sanitizing solution and liquid mix.
G. Open the air bleed valve on the front door by
pressing and holding. Hold the valve open until the mix level in the freezing cylinder is 1/2” from the air bleed valve.
H. Place the Freezing Cylinder OFF/ON switch in
the ON position.
I. Press the PUSH TO FREEZE button.
NOTE
After the drive motor starts, there is a 3-second delay before the compressor starts.
J. When the product is at 75% consistency, the
display will read “SERVE”. Open the spigot to dispense product.
K. 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.
M. Do not operate the machine when the MIX LOW
message is displayed. Refi ll 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 (5°C). Sleep modes do not take the place of cleaning and sanitizing. Federal, State, and local regulatory agencies determine frequency of cleaning and sanitizing.
3.10 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 Freezing Cylinder Off/On switch
is in the OFF position.
C. Fill the storage container in the cab with at least
2.5 gallons of mix.
D. Attach the mix inlet probe to the container and
place the container in the refrigerated cab.
3.11 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 fi nished 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 20°F to 24°F range. Diet and low-carb mixes typically freeze to proper consistency at higher temperatures.
17
Page 26
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 fi nished product that is unsatisfactory. To retard bacteria growth in dairy based mixes, the best storage temperature range is between 33° to 38°F (0.5° to 3.3° C).
3.12 OPERATION OF MIX PUMP
The mix pump switches are located inside the refrigerated cabinet. When a pump switch is placed in the ON posi­tion, the mix pump motor will start pumping mix into the freezing cylinder. When the set pressure is reached, the mix pump will shut off automatically. When the switch is placed in the OFF position, the mix pump will not operate.
NOTE
The mix pump motor is equipped with an internal overload that will “trip”, disabling the pump when the motor is overloaded. Consult the trouble shoot­ing section for corrective information. The internal overload will automatically reset after cooling. If the condition continues, contact a qualifi ed service person.
A. Mix Operation: The peristaltic mix pump contains
one continuous mix pump hose. When looking at the face of the peristaltic mix pump, the left side of the hose is the mix intake or pickup. The right side of the hose is the mix discharge. Mix is drawn up the pickup side of the hose and transferred through the discharge side to the machine (Fig. 3-9).
Air/mix to
Air Line
Freezing Cylinder
3-way
Tee
B. Air Operation: The air compressor operates
whenever the peristaltic mix pump is running. Air enters through a check valve on the piston downstroke. The air is discharged through a second check valve, on the piston upstroke. The air and mix join at the tee and then travel to the machine.
C. The overrun adjustment is preset at the factory.
If an adjustment becomes necessary, refer to Section 4.
3.13 MIX PUMP CLEANING
NOTICE
Any cleaning procedure must always be followed by sanitizing before fi lling machine with mix. (Refer to section 3.3)
The mix pump is approved for CIP (clean in place). It is thoroughly cleaned when the detergent solution is pumped through the machine. We recommend completely disas­sembling the pump and disconnecting tubing every 14 days for inspection of parts to confi rm the CIP has been properly performed. If any residue is detected, clean or replace those parts as outlined below.
A. Place the Main Power OFF/ON and Freezing
Cylinder OFF/ON switches in the ON position and press the CLEAN button. Allow the auger to agitate for 5 to 10 minutes.
B. Remove the suction tube from the mix container.
Open the spigot to remove the mix remaining in the freezing cylinder.
C. Pump 2 gallons (7.5 liters) of potable water through
machine until the water coming out of the spigot is clear.
D. Pump 2 gallons (7.5 liters) of 90° to 110°F (32°C
to 43°C) detergent solution through the machine. The use of soft water is recommended, along with dishwashing detergents such as “Joy”, “Dawn”, or equivalent.
E. Place the mix pump switch in the OFF position.
Open the spigot to relieve the remaining pressure.
F. Press the CLEAN button to stop the auger and
place the Main Power OFF/ON and Freezing Cylinder OFF/ON switches in the OFF position.
Mix
Intake
Figure 3-9 Mix Pump Hose Routing
Mix
Discharge
18
Page 27
3.14 DISASSEMBLY AND INSPECTION OF
REMOVABLE PARTS
Inspection of removable parts should be made whenever maintenance is performed or when the pump requires disassembly.
NOTE
If the mix line or air line is diffi cult to remove, soften the tubing with a rag soaked in hot water. Hose connections may be sprayed with Haynes Sanitary Lubricant for ease of removal.
WARNING
Hazardous Moving Parts
Revolving pump head can grab, mangle, and cause serious crushing injury. The Main Power Off/ On switch must be placed in the OFF position for cleaning and power must be disconnected when disassembling or servicing.
CAUTION
System Under Pressure
Never disconnect hoses from the machine or the pump without fi rst opening the spigot to relieve pressure.
C. Completely disassemble the hose assembly and
the check valve (Fig. 3-10). Place hoses, tee, check valve assembly, and pickup hose adapter in 90° to 110°F (32°C to 43°C) mild detergent water and wash thoroughly. Use soft bristle brushes to clean inside of fi ttings. Rinse all parts in clean 90° to 110°F (32°C to 43°C) water.
D. Carefully inspect each part for wear or damage.
Replace worn or damaged parts.
E. Wash the feed tube and the air tube in the cabinet
with 90° to 110°F detergent water and brushes provided. Rinse with clean, 90° to 110°F water.
F. Prepare two gallons (7.5 liters) of sanitizing
solution using a USDA certifi ed grade sanitizing solution. Sanitize all removed parts. Allow them to air dry.
G. Check the Hose Service Record decal to determine
if a hose reposition or a hose replacement is required.
H. Reassemble both hose assemblies per the
diagram located on the inside of the cab door. Reconnect the assemblies to the pump hose and the discharge hose, using the clamps. (Refer to Section 2.5 Mix Pump).
I. Sanitize assembled machine as per instructions
outlined in Section 3.9.
A. Loosen the clamp and remove the air hose from
the pump compressor.
B. Loosen the clamp and disconnect the mix pump
hose. Remove the pickup hose, the mix check valve and the pickup hose adapter (and bag adapter if applicable) as an assembly from the mix container.
Figure 3-10 Mix Pump Removable Parts
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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 qualifi ed 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. Increasing this setting will increase the drive motor amperage cutout and increase product consistency. Follow the instructions below to make fi ne 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 fi rmer 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.
Figure 4-1 Touchpad
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 panel.
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. Locating machine readings and system function settings are done using the up arrow () and left arrow () but­tons on the membrane switch. A printed 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 the 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 up arrow button () to navigate to the
correct reading under DISPLAY or press the left arrow () button to navigate to the ERRCODES menu.
D. Press the up arrow () and left arrow () buttons
to navigate through the rest of the readings as needed.
E. When all readings have been obtained, press
the up arrow button () from ExitMenu to return to the current mode display.
Modifying Control Settings
To change the value of a system function, locate the function on the IntelliTec Settings Menu and follow the steps below.
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IMPORTANT:
Before making changes to any settings, record the original values. If the setting changes do not achieve desired results, return settings to their original values.
A. Press and hold the 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 () to get to the correct
menu (Basic, Advanced, or Storage).
D. Press the up arrow button () to navigate to the
value that needs to be changed.
E. Press the SET button to enter the edit mode. F. Press the up arrow button () to change the
setting.
G. Press the SET button to save the setting and exit
the edit mode.
H. Press the up arrow () and the left arrow ()
buttons 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.
4.5 READINGS (SERVICE PERSONNEL
ONLY)
The IntelliTec control continuously monitors and records temperatures, voltages, amps, and error code details. Each reading is benefi cial to service personnel when troubleshooting.
DISPLAY READINGS
Following are the readings available under the DISPLAY menu:
Cabinet
The temperature of the cab 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
Suction line temperature on the freezing cylinder
and 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 board.
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 timer 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 board
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
12 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.
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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 cabinet temperature is
recorded.
Stor Max (°F)
The highest average cabinet 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 set the CutOut value at
initial startup and when changing mix types. Adjustments to this setting directly affect the length of the freezing cycle and indirectly change product consistency. To properly set the CutOut value, during startup navigate to the “°F” and “amps” values under the Display menu (Refer to Section
4.4), start the machine and freeze the product to the desired consistency. Monitor consistency by taking a 6 ounce sample at each change of the “amps” display. When the desired consistency has been reached, record the temperature and amps, and change the CutOut value to the recorded amps value
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 at the front of the freezing cylinder. 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 20 cycles, which results in “Serve Mode” lasting about 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 return 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.
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Page 32
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 O411 is Cabinet.
CabCutIn (°F)
If the Refriger value is set to Cabinet, this
setting determines the temperature at which the refrigeration cycle starts. If None, 1 Hopper, or 2 Hopper is selected for the Refriger setting, CabCutIn will not be shown on the IntelliTec menu.
CabCtOut (°F)
If the Refriger value is set to Cabinet, this
setting determines the temperature at which the refrigeration cycle stops. If None, 1 Hopper, or 2 Hopper is selected for the Refriger setting, CabCtOut will not be shown on the IntelliTec menu.
Cab Off
If the Refriger value is set to Cabinet and the
temperature sensor in the cabinet fails, this setting determines the time between refrigeration cycles. If None, 1 Hopper, or 2 Hopper is selected for the Refriger setting, Cab Off will not be shown on the IntelliTec menu.
Cab On
If the Refriger value is set to Cabinet and the
temperature sensor in the cabinet fails, this setting determines the length of the refrigeration cycle. If None, 1 Hopper, or 2 Hopper is selected for the Refriger setting, Cab On will not be shown on the IntelliTec menu.
4.8 OVERRUN ADJUSTMENT
The product, when served, is a combination of air and mix. Overrun is a measure of the amount of air blended into the mix.
Overrun can be expressed in terms of the amount of weight loss for a given volume. For example, if a pint of liquid mix weighs 18 ounces and a pint of frozen product with air added weighs 12 ounces, the overrun is said to be 50 percent: 18 oz. - 12 oz. = 6 oz., (6/12) x 100 = 50%
The overrun can be checked by placing a one pint con­tainer on an ice cream scale and zeroing out the scale. Then fi ll a one pint container with frozen product. The container should be fi lled over the top and leveled with a straightedge. The product should not contain any air pockets. When weighed on an ice cream scale, one pint of product should weigh 12 to 13 ounces.
The mix pump has been preset at the factory to produce a product with approximately 40% overrun. Because of differences in mix formulation, temperatures and baro­metric pressure, this fi gure may vary. It will be necessary for approximately 2 gallons of mix to be pumped through the machine before overrun changes in the product are noticeable.
Overrun is controlled by the length of the air compressor piston stroke within the piston cylinder. Lengthening the stroke within the cylinder will increase overrun. Conversely, shortening the stroke will decrease overrun. To perform an overrun adjustment, refer to the following procedure:
WARNING
Hazardous Voltage
The Main Freezer Power switch must be placed in the OFF position when disassembling for servicing. The freezer must be disconnected from electrical supply before removing any access panel. Failure to disconnect power before servicing could result in death or serious injury.
24
Page 33
A. Turn the mix pump switch to the OFF position.
Disconnect power sources/circuit breakers.
B. Remove the back panel from the machine.
C. On the air compressor side of the pump, locate
the long/slender piston rocking arm. The rocking arm downward travel is limited by a stationery cam. On the face of the cam there is an overrun setting indicator plate numbered 3 through 8 and an adjustment knob (Fig. 4-2).
Figure 4-2 Overrun Adjustment
D. The overrun setting is indicated by a pin.
E. To adjust overrun, loosen the allen-head screw
(located within the center of the adjustment knob) with the 5/32” allen wrench provided. Rotate the adjustment knob counterclockwise to a higher number for higher overrun, or clockwise to a lower number for lower overrun. Each number multiplied by 10 represents the overrun percentage (i.e. setting 4 = 40% overrun).
F. Tighten the allen screw, then place the wrench
back in its clip. Replace the lower back panel and secure with the four screws. Turn the mix pump power switch to the ON position.
4.9 MIX PUMP HOSE REPOSITION
Mix pump hose must be repositioned every 800 gallons of mix pumped or every 2 weeks. Failure to reposition the hose will result in reduced mix pump liquid capacity, dispense stoppage, popping, and possible mix pump hose leakage. Follow the steps below to reposition the hose:
A. Run cleaning solution through pump.
B. Turn the pump off and relieve any pressure by
opening the spigot.
C. Grasp the pickup hose end of the mix pump hose
with one hand and turn the pump on. Pull down on the pickup hose end until 12 to 14 inches of tubing has fed through the pump then turn the pump off (Fig. 4-3).
Pickup
End
Figure 4-3 Pump Hose Reposition
D. Loosen the small clamp at the pick-up hose
adapter and disconnect the mix pump hose.
E. Cut 7-1/2 inches off the end of the mix pump
hose.
F. Reconnect the mix pump hose to the adapter.
G. Continue normal operation. Mix hose will
automatically reposition itself with the adapter near the black cover.
Each hose is long enough for 3 repositions before replacement is required.
12” to 14”
NOTE
4.10 MIX PUMP HOSE REPLACEMENT
Mix pump hose must be replaced when tubing cannot be further repositioned (every four to eight weeks). Failure to comply will result in hose failure and possible pump damage. Follow the steps below to replace the hose:
A. Run cleaning solution through pump.
B. Turn the pump off and relieve any pressure by
opening the spigot.
C. Disconnect the mix pump hose at each end.
D. Grasp the discharge hose end with one hand and
turn the pump on. Pull down on the hose until all of the remaining hose is removed from the pump. Turn pump off.
E. Rotate pump roller assembly so one roller is at
the 6:00 position.
F. Use a brush that fi ts in the opening and clean the
pump roller assembly, fi rst with detergent water and then clear water.
25
Page 34
G. Connect the new mix pump hose to the pickup
hose adapter using the small clamp.
H. Feed one end of the mix pump hose into the
pickup hose side (left) of the black cover.
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.
C. Press the left arrow button () three (3) times to
navigate to the Storage menu.
D. Press the up arrow button () once to navigate
to the CabCutIn value. Record this value.
IMPORTANT:
Before making changes to any settings, record the original values. If the setting changes do not achieve desired results, return settings to their original values.
I. Gently push the hose into the black cover until it
begins to feed.
J. Allow the hose to feed itself through the pump
until about 6” (15cm) remains on the entering side.
K. Turn pump off.
L. 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.
M. Turn the pump on.
N. Allow the remaining 6” (15cm) of tubing to feed
through the pump until the hose adapter prevents further feeding.
O. 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, the mix may drain into the air compressor, resulting in pump damage.
P. Connect the free end of the mix pump hose to the
3-way Tee. When all connections are complete, the 3-way Tee must be lower than the black pump housing.
Q. The pump is now ready to sanitize.
E. Press SET button to enter edit mode. F. Press the up arrow button () to increase the
number to the value required. The value increases by 1 each time the up arrow button () is pressed. After the value reaches 9, numbering restarts at
0.
G. Press SET button to save the setting and exit the
edit mode.
H. Press the up arrow button () once to navigate
to the CabCtOut value. Record this value.
I. Press SET button to enter edit mode. J. Press the up arrow button () to increase the
number to the value required. The value increases by 1 each time the up arrow button () is pressed. After the value reaches 9, numbering restarts at
0.
K. Press SET button to save the setting and exit the
edit mode.
L. Press the up arrow () and left arrow () buttons
to navigate to ExitMenu.
M. Press the up arrow button () from ExitMenu to
return to the Mode Screen.
N. Locate the Specifi cation Sheet for SU412 Control
behind the header panel and record the new values on this sheet.
4.12 DRIVE BELT TENSION ADJUSTMENT
A. Remove a side panel and the back panel.
B. Press fi rmly on one belt.
4.11 CAB TEMPERATURE ADJUSTMENT
Cab temperature is monitored and controlled by two set­tings on the IntelliTec control: CabCutIn and CabCtOut. The cut in value determines the temperature at which the refrigeration cycle starts. The cut out setting determines when the cycle stops. To change the CabCutIn or CabC­tOut, follow the steps below:
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.
WARNING
Hazardous Voltage
The Main Freezer Power switch must be placed in the OFF position when disassembling for servicing. The freezer must be disconnected from electrical supply before removing any access panel. Failure to disconnect power before servicing could result in death or serious injury.
26
Page 35
C. When the tension is properly adjusted, the belt
will depress the approximate width of the belt with the pressure of a fi nger.
D. If an adjustment is necessary, loosen the four
motor plate retaining nuts, adjust belt tension then retighten the four nuts.
NOTE
Belt life will be increased if new drive belts are tightened after two or three weeks of operation.
4.13 CONDENSER CLEANING (AIR-COOLED
MACHINES)
The condenser requires periodic cleaning. To clean the condenser, refer to the following steps:
A. Lift the condenser fi lter off of the machine cover
panel. Visually inspect the condenser fi lter for dirt (Fig. 4-4).
The United States Department of Agriculture and the Food and Drug Administration require that lubricants used in food zones be certifi ed 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
1. Check drive belts for wear and tighten belts if necessary. (Refer to section 4.12)
2. Check the condenser fi lter for dirt. (Refer to section 4.13).
4.15 EXTENDED STORAGE
Refer to the following steps for winterizing the machine or for storing the machine over any long period.
A. Clean all of the parts that come in contact with
mix thoroughly with warm detergent . Rinse in clear water and dry all parts. Do not sanitize.
NOTE
Do not let cleaning solution stand in freezing cylin­der or mix pump during the shutdown period.
Figure 4-4 Removing Condenser Filter
B. If the condenser fi lter is dirty, vacuum or brush
it clean. Rinse it with clean water and allow it to dry before replacing it on the machine.
NOTE
If the condenser is not kept clean, refrigeration ef­ ciency will be lost.
4.14 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.
B. Remove, disassemble, and clean the front door,
auger shaft, and mix pump. Leave disassembled during the shutdown period.
C. Place the plastic auger fl ights in a plastic bag with
a moist paper towel. This will prevent the fl ights from becoming brittle if exposed to dry air over an extended period (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 fi ttings at the water inlet and the water outlet lines of the machine. The fi ttings are located at the rear of the machine. Run the compressor for 2 - 3 minutes to open the water valve. Blow out all the water, fi rst through the water inlet, then through the water outlet lines with air or carbon dioxide. Drain the water supply line coming to the machine.
E. Place the Pump OFF/ON switch and the Main
Freezer Power OFF/ON switch in the OFF position.
F. Disconnect the machine from the source of the
electrical supply in the building.
27
Page 36
28
Page 37
SECTION 5
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REFRIGERATION SYSTEM
5.1 REFRIGERATION SYSTEM
The O431 refrigeration system has two functions:
Medium-Temperature - Maintaining product
temperature in the cab unit.
Low-Temperature - Producing and maintaining
high quality soft serve in the freezing cylinders.
The system is designed for effi cient 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 qualifi ed service personnel only. Anybody work- ing with refrigerants must be certifi ed as a T echni- cian TYPE I as required by 40 CFR 82 Subpart F and hold all State and/or local refrigerant handling certifi cations. 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
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.
Figure 5-1 Water Cooled Refrigeration System
29
Page 38
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 red wire #90.
5. Wrap electrical tape around wire to insulate it.
6. Remove the belts from the pulleys to allow the 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.
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 To 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), fi nd the leak, fi x 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
For qualifi ed service personnel only. Anybody work- ing with refrigerants must be certifi ed as a T echni- cian TYPE I as required by 40 CFR 82 Subpart F and hold all State and/or local refrigerant handling certifi cations. 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.
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 red wire #90.
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
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.
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 system of the O431 is 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 fi ve 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.
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5.4 COMPRESSOR
The O431 has a scroll type compressor (Refer to Figure 5-2). This compressor type uses two spiral shaped scrolls to compress gas. One scroll rotates around an identical stationary scroll. Gas is drawn into the compression chamber by the rotating scroll and is compressed as it moves towards the center of the chamber. Operation of this compressor is continuous because, during each rotation, several gas ‘pockets’ are compressed simultaneously.
Details of the compressor’s starting components are in Section 6.
Figure 5-2 Scroll Type 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. Pull the compressor connector plug off the
compressor. The compressor has three terminals; C (common), R (run), and S (start). (Refer to Figure 5-3)
D. Connect an ohmmeter to the C and R terminals.
Resistance through the run winding should be
1.01 ±10%.
E. Connect ohmmeter to terminals C and S.
Resistance through the start winding should be
2.28 ±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.
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 through the side of the
machine.
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. ALWAYS crimp and braze ports on a compressor that has been re­moved.
C
S
R
Figure 5-3 Compressor Connection
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.
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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.
C. Install the compressor into the machine, fi tting
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.
5.6 EVAPORATOR
The O431 has two freezing cylinder evaporators and a cab 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 self-regulating TXV is preset by the manufacturer and adjustment is not recommended. Figure 5-4.
F. Leave the suction and discharge ports open to
prevent pressure buildup. Braze the suction and discharge line to the compressor.
G. Connect the electrical plug to the compressor.
The plug is keyed and will only install one way. (Refer to Figure 5-3)
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.
5.5 CONDENSER
The O431 is available with a water-cooled or an air-cooled condenser. The capacity of the machine 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 fi n type. The machine must have a minimum of 3” of clearance on the sides and 6” clearance at the back for proper air fl ow.
CONDENSER TESTING
The condenser can be checked for leaks using the bubble test or using a leak detector.
Figure 5-4 TXV
TXV TESTING & ADJUSTMENT
When testing a TXV, run only the evaporator that the TXV meters. If checking the left side TXV, place the right side freezing cylinder and cab switches to the OFF position. If checking the right side TXV, place the left side freezing cylinder and cab switches in the OFF position. If checking the cab TXV, place the both freezing cylinder switches in the OFF position.
NOTE
The bulb has an indent that 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 19-21 psig.
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D. If the pressure reading is higher than expected,
check to see if there is an overcharge of refrigerant.
E. If the pressure reading is lower than expected,
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. Remove the side panel.
B. Remove bulb from suction line exiting from the
evaporator.
C. Recover refrigerant charge per instructions in
Section 5.2.
D. Leave the suction and discharge ports open to
prevent pressure buildup during TXV removal.
E. Remove any insulation from the TXV and
immediate surrounding lines.
F. Apply a heat sink (wet cloth) to the valve dome
(Figure 5-5).
G. 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 that 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 O431 has 3 magnetic check valves (Refer to Figure 5-6). Each valve is positioned in the suction line and prevents backfl ow of refrigerant into the evaporator. If there is reversed fl ow, the product in the freezing cylinder softens and liquid refrigerant can fl ood into the compres- sor 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 5-6 Check Valve
C. HIGH PRESSURE CUTOUT
The high pressure cutout stops the compressor if the discharge pressure reaches 445 psig.
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.
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Page 42
HIGH PRESSURE CUTOUT REMOVAL
A. Remove the panels.
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 the high pressure cutout from the
discharge line.
E. Disconnect the wires from the 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 5-9). When the cab 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.
HOT GAS BYPASS ADJUSTMENT
NOTE
Before adjusting the hot gas bypass, check the EPR valve and adjust if necessary.
Figure 5-9 Hot Gas Bypass
NOTE
The cab door remains open for this test. The rela­tively warm ambient air will keep the cab refrigera­tion running.
D. Turn the Main Power OFF/ON switch to the ON
position.
E. Wait 5 minutes to allow the gauge to stop moving.
F. Unscrew the seal cap from the top of the valve.
G Using a 5/16” Allen wrench, adjust the valve
counterclockwise to decrease pressure and clockwise to increase pressure. (Refer to Figure 5-10)
NOTE
Each 360° turn will change the pressure about 6 psig.
A. Turn the Main Power OFF/ON switch and both
Freezing Cylinder OFF/ON switches in the OFF position.
B. Connect a gauge to the Schrader valve on the
suction line next to the compressor.
C. Open the cab door and place a piece of tape on
the cab door interlock switch.
Figure 5-10 Hot Gas Bypass Adjustment
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Page 43
H. Adjust the hot gas bypass valve to 18 psig ±1.
I. Wait 2 minutes to ensure pressure remains stable.
J. 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 fi lter drier. Refer to Section 5.8 for
details.
E. Evacuate and recharge system per instructions
in Section 5.2.
E. WATER VAL VE (W ATER COOLED MODELS ONLY)
Figure 5-12 Water Valve
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 5-12)
WATER VALVE ADJUSTMENT
A. Remove the back panel.
B. Connect a gauge to the compressor discharge
Schrader valve.
C. Connect the machine to the electrical supply, start
the refrigeration cycle, and read the pressure.
D. The proper gauge reading should be 225-235 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 fl ow. 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 fl ow 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 fi lter 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.
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Page 44
5.8 SOLENOID
Solenoid valves are installed on the liquid and suction lines of each freezing cylinder evaporator and on the liquid line of the cab evaporator (Refer to Figure 5-13). A solenoid valve has a magnetic coil that, when energized, lifts a plunger and allows refrigerant to fl ow. The solenoids are activated by the IntelliTec control and determine which evaporator receives refrigeration.
The suction line solenoid prevents refrigerant fl ow in the evaporator when the suction pressure drops due to the operation of the other evaporators in the system.
Figure 5-13 Solenoid Valve
ACTIVATING THE SOLENOID VALVES
A. Turn the Main Power OFF/ON switch and both
Freezing Cylinder OFF/ON switches to the OFF position.
B. Locate the compressor contactor behind the
header panel and disconnect the red wire #90.
C. Wrap electrical tape around wire to insulate it.
D. Remove belts from the pulley to allow drive motor
to spin freely.
E. Connect power to the machine.
F. Turn the Main Power OFF/ON switch and Freezing
Cylinder OFF/ON switches to the ON position.
G. Press the Push To Freeze buttons on the IntelliTec
control. This will energize the solenoid valves.
SOLENOID TESTING
When activated, a solenoid coil produces a magnetic fi eld. This fi eld 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 is not 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 fl ow.
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 fi lter drier. Refer to Section 5.8 for
details.
G. Evacuate and recharge system per instructions
in Section 5.2.
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Page 45
5.9 FILTER DRIER
The fi lter drier must be replaced every time the refrigeration system is opened for service. A new fi lter drier improves operation of the entire refrigeration system by stopping the circulation of moisture and by removing harmful con­taminants (Refer to Figure 5-14).
Figure 5-14 Filter Drier
FILTER DRIER REMOVAL
A. Recover refrigerant charge per instructions in
Section 5.2.
B. Cut the refrigeration line as close to the fi lter drier
as possible and remove drier.
FILTER DRIER REPLACEMENT
A. Position the fi lter drier so the arrow is pointing
towards the evaporators (pointing away from the condenser).
B. Apply a heat sink (wet cloth) to the fi lter drier.
C. With the suction and discharge ports open, braze
the fi lter 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 CAB UNIT
The IntelliTec control is programmed to handle refrigeration of the cabinet independently from the barrel. The control maintains cabinet temperature between two preset values (CabCutIn and CabCtOut). 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.
The refrigeration will run for a maximum of 4 minutes. After this time is reached, the refrigeration cycle will stop for a minimum of 3 minutes. At the expiration of 3 minutes, the control will check cabinet temperature. If product tempera­ture is at or above CabCutIn, a refrigeration cycle will start.
To adjust temperature, refer to Section 4-4 Obtaining Readings and Modifying Settings.
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Page 46
38
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SECTION 6
ELECTRICAL AND MECHANICAL CONTROL SYSTEMS
NOTE
The wiring diagram is available in Section 8.
6.1 INTELLITEC CONTROLLER
The IntelliTec control is Stoelting’s most advanced con­troller. It combines all of the best features of previous controllers with advanced sensing and troubleshooting capabilities.
Understanding the modes of operation and individual con­trol settings will make servicing the control straightforward.
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.
The left side membrane switch (touchpad) controls the left side of the freezer and the right side membrane switch controls the right side. The IntelliTec control boards are mounted in the same respect; the left control board runs the left side and the right control board runs the right side.
Figure 6-2 Membrane Switch
6.2 CONTACTORS
The compressor and drive motor contactors are mounted inside the electrical box behind the header panel. There is a contactor for compressor and a contactor for each 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 IntelliTec Control Board
Figure 6-3 Display Panel Module
39
Page 48
A. CONTACTOR TESTS
The following tests will show if a contactor is working properly.
1. Open 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.
CMP LED
DRV LED
Figure 6-4 IntelliTec LEDs
11. Place the Main Power OFF/ON and Freezing Cylinder OFF/ON switches in the OFF position.
12. Install the belt and tighten the tension bolt.
13. Use a Burroughs Belt Tension Gauge to set the tension for the drive belt. Set the belt tension to 40-50 lbs.
14. Using a straightedge, align the drive motor pulley with the gearbox pulley. Tighten the two allen head screws.
B. DRIVE MOTOR REMOVAL
1. Disconnect machine from electrical supply before removing any panels for servicing.
2. Remove the back panel and side panel.
3. Remove the electrical cover plate from the back of the motor.
4. Identify (mark) wires and remove them from the motor.
5. Remove the speed reducer support from the side of the machine. (Refer to Figure 6-5)
6. Loosen the belt tension adjustment nut and remove the belt. (Refer to Figure 6-5)
7. Remove the motor mounting bolts.
8. Loosen the two allen head screws from the pulley.
9. Remove the pulley and key from the motor shaft.
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 motors are used to rotate the auger assemblies. An internal, normally closed, centrifugal switch starts the drive motor. The motors have an internal thermal overload.
A. DRIVE MOTOR TEST
1. Make sure the Main Freezer Power and the Freezing Cylinder OFF/ON switches are in the OFF position.
2. Remove the back panel and a side panel.
3. Loosen the belt tension adjustment nut and remove the belt.
9. Start the drive motor.
10. Put a clamp ammeter on the motor wire at T1 of the motor contactor. The ammeter should read
2.1 amps ±0.5.
NOTE
The motor amps are based on 230VAC supply voltage.
Speed Reducer Support
Tension
Adjustment
Nut
Figure 6-5 Motor Removal
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Page 49
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 40-50 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 the speed reducer support.
8. Install the back and side panels.
6.4 CAPACITORS
The compressor start and run contactors are mounted behind the side panels. 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.
3. Remove a lead from one of the capacitor terminals.
4. Using insulated pliers, discharge the capacitor by connecting a 20KΩ 5W resistor across the terminals.
NOTE
Discharge the capacitor 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. Check the capacitance across the terminals. Refer to the table below for the correct readings.
Rating
Capacitor Part MFD VAC
Compressors - Start 230638 88-106 MFD 330 VAC
Compressor - Run 230653 40 MFD 370 VAC
Motor - Start 231095 500 MFD 125 VAC
Motor - Run 231078 50 MFD 370 VAC
Fan Motor 230654 5 MFD 400 VAC
B. CAPACITOR REPLACEMENT
1. Disconnect machine from electrical supply before removing any panels for servicing.
2. Place the Main Power OFF/ON switch and both Freezing Cylinder OFF/ON switches in the OFF position.
3. Remove leads from the capacitor terminals.
4. Using insulated pliers, discharge the capacitor by connecting a 20KΩ 5W resistor across the terminals.
NOTE
Discharge the capacitor 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.
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.
2. Place the Main Power OFF/ON switch and both Freezing Cylinder OFF/ON switches in the OFF position.
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 the machine from electrical supply before removing any panels for servicing.
2. Remove the back panel and side panel.
3. Remove protective shield from side of machine.
4. Remove the belts.
5. Remove the pulley by loosening the set screws.
41
Page 50
6. Remove the three bolts holding the gearbox to the barrel.
4. Remove the two bolts holding the gearbox to the mounting bracket and remove the gearbox through the rear of the machine.
C. GEARBOX INSTALLATION
1. Place the gearbox in position from the rear of the machine. Fasten the three bolts through the gearbox to the rear of the barrel.
2. Fasten the gearbox to the mounting bracket using the two bolts.
3. Mount the pulley on the gearbox 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 40-50 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)
The fan motor requires the buck-boost transformer to be connected if supply voltage is lower than 215.
A. CHECK VOLTAGE
1. With the machine connected to power and the Right Side & Cabinet Power switch ON, press and hold the SEL button for at least 8 seconds. While still holding SEL, press the left arrow () button, and then release both buttons. The display will read “Display”.
2. Press the up arrow () button to navigate to the Supply V screen.
NOTE
The buck-boost transformer is only for the fan motor.
B. FAN MOTOR REPLACEMENT
1. Disconnect machine from electrical supply before removing any panels for servicing.
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.
2. Remove a side panel and the header panel.
3. Trace and disconnect the brown and blue wires on the fan motor.
4. Remove the torx screws from the fan guard.
5. Remove the bolts holding the fan guard to the condenser shroud.
6. Remove the fan guard and the fan motor assembly.
C. FAN MOTOR INSTALLATION
1. Move the fan into place.
2. Insert the fan motor wires through the hole in the fan guard and move the fan guard into place.
3. Install the fan guard to the shroud with the four bolts.
4. Rotate the fan motor so the wires are towards the front of the machine. This will line up the holes to attach the fan to the fan guard.
5. Install the fan to the fan guard using the torx screws.
6. Wire the fan motor according to the wiring diagram. The buck-boost transformer must be connected if necessary (see above regarding checking voltage).
3. If the voltage is 215 or less, then the buck-boost transformer needs to be connected.
4. If the voltage is above 215, then the buck-boost transformer should not be connected.
NOTE
The voltage reading must be taken to ensure the fan motor works properly.
6.7 CAB CONDENSER FAN MOTOR
A. FAN MOTOR REPLACEMENT
1. Shut the machine down and remove mix from the freezing barrel and cab.
2. Disconnect machine from electrical supply.
Remove
Screws
Pivot Point
Figure 6-7 Cab Fan Shroud
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3. Remove the mix containers and sliding drawer from the cab.
4. Disconnect the tubing from the mix transfer line and the air line at the top of the cab.
5. Pull thermistor out of the clip and thread it up through the hole in the fan shroud.
6. Remove the two screws at the front of the cab shroud and pivot the shroud downward. Remove the shroud.
7. Remove the two fan bracket screws and disconnect wires on the fan motor.
8. Connect the wires to the new fan motor.
9. Attach the two screws to the fan motor bracket.
10. Thread thermistor through hole in fan shroud and attach it to the clip.
11. Align the two pins at the top rear of the cab to the pivot points on the evaporator shroud.
12. Install the evaporator shroud with the two screws.
13. Install all tubes and replace sliding drawer and mix containers.
6.8 SWITCHES
A. 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.
NC
COM
2. The clicking sound should be within the fi rst 1/2” of the spigot glide movement (Refer to Figure 6-8). 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.
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.
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.
Spigot Glide
Figure 6-8 Spigot Cam Assembly
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.
Figure 6-9 Spigot Switch Replacement
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SPIGOT SWITCH REPLACEMENT
1. Remove the header panel.
2. Remove the dispense rate adjuster knob located below the header panel. (Refer to Figure 6-9)
3. Remove the two Phillips head screws that attach the spigot cam assembly to the panel. Remove the assembly.
4. Disconnect the connector from the switch and remove the switch.
5. Install the replacement switch onto the handle assembly. Do not fully tighten the retaining screws at this time.
6. 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.
7. Fully tighten the retaining screws.
8. Attach the connector to the spigot switch.
9. Position the spigot handle assembly in the electrical box and fasten securely with the two Phillips head screws.
10. Replace the dispense rate adjuster knob and tighten.
11. Replace the header panel and secure with the two Phillips head screws.
B. PUMP PRESSURE SWITCH
The pump pressure switch maintains 21-24 psig in the mix line.
PUMP PRESSURE SWITCH TEST
1. Turn off the pump motor.
2. Open the spigot to relieve air pressure in the system.
3. Connect a gauge between the 1/4” ID tubing and the air line into the cab. The air line is at the top rear of the cab.
4. Turn on the pump motor.
5. The motor should cutout when the gauge reads 24 psig ±1.
6. Open the spigot and monitor the gauge. The motor should cutin when the gauge reads 21 psig ±1.
C. CAB DOOR MAGNETIC REED SWITCH
The cab door magnetic reed switch is a normally closed held open switch. When the cab door is opened, the switch sends a signal to the control to stop refrigeration to the cabinet. This prevents the evaporator from icing up.
Cab Door
1/4”
Figure 6-11 Cab Door Switch (Side View)
REED SWITCH TEST
1. Place the Main Power OFF/ON switch and both Freezing Cylinder OFF/ON switches in the OFF position.
2. Refer to the wiring diagram and remove the wires at terminals 5 and 9 of the left control board.
3. Check resistance readings across the wires. When the cab door is closed, the resistance should show an open. When the cab door is opened, the resistance should be 0 ohms.
4. Reconnect the wires to the control board.
Switch
Attach Pressure
Gauge
Figure 6-10 Attaching Gauge to Pump
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REED SWITCH REPLACEMENT
1. Place the Main Power OFF/ON switch and both Freezing Cylinder OFF/ON switches in the OFF position.
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.
2. Refer to the wiring diagram and remove the wires at terminals 5 and 9 of the control board.
3. Remove the switch bracket and unscrew the switch from the bracket.
4. Remove the old switch from the machine.
5. Route the wires of the new switch through the machine to the control board.
7. Install the new switch into the bracket. Hand tighten the nuts on the switch so that the switch sticks out of the bracket 1/4”.
NOTE
Make sure the switch protrudes from the bracket by 1/4” so that the door will properly seal and the magnet will make contact with the switch.
8. Install the switch bracket to the machine.
9. Test the switch to ensure it makes contact with the door magnet and ensure the door closes and seals properly.
6. Refer to the wiring diagram and connect the yellow wires to the control board.
6.9 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 6-12 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.
°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 6-12 Resistance Related to Temperature
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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 Extended Run Time
4 Clean
5 Barrel Sensor
6 Hopper Sensor
7 Drive Motor
8 Cab Sensor
9 High Pressure Cutout
10 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 Freezing Cylinder Off-On switch must be placed in the Off position and back in the On position before the affected side of 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 fl uctuating supply voltages typically cause this error. The error can also be caused by faulty motor or starting components that 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 machine’s mix container or from product breakdown. Another common cause results from a restriction preventing mix from entering the freezing cylinder. Check the mix in the cabinet. 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 liquid mix container can clog the
mix inlet system 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 of the machine’s cabinet.
Check the condition of the neoprene hose running
through the mix pump head. If it shows signs of wear, rotate or replace it as outlined in Section
3.
In air cooled machines, the Run Time Error may
indicate that airfl ow within the machine has reduced or stopped. Check the sides and top of the machine for anything that would restrict airfl ow.
The Run Time Error may also occur if airfl ow within
the machine has reduced or stopped. Check the sides and top of the machine for anything that would restrict airfl ow. Check the condenser fi lter and clean if necessary. Check the evaporator for frost that could restrict airfl ow.
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 turn the Right Side & Cabinet Power switch Off and back On.
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 refl ect 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 fl ash and read Restart. To clear the Clean Error immediately, turn the Freezing Cylinder Off-On 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.
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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 the error code, refer to the freezer’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
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
Error Code 6 - Hopper Sensor (single hopper machines)
The Hopper Sensor Error (E6) will not occur on
the O431 machine.
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 Freezing Cylinder Off-On switch Off and back On. If the error returns, use the freezer’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) indicates a cabinet
temperature sensor failure or. This error will also appear in an extreme out of range condition (<
-34°F or > 99°F). If the control panel displays an E8, turn the Freezing Cylinder Off-On switch Off and back On. If the control panel still displays the error condition code, refer to the wiring diagram and the temperature sensor value table. Check each lead of the sensor to ground for continuity. If continuity is found, replace the sensor. Place a thermocouple in the cabinet evaporator discharge airstream (outlet air fl ow). Compare temperature to sensor resistance using the table as reference. If CutIn/CutOut values do not coincide with the values on the table, replace the sensor.
Error Code 9 - High Pressure Cutout
High Pressure Cutout Errors (E9) are usually
caused by a dirty or ineffi cient condenser.
In air cooled condenser models, check the air fi lter
to make sure it is clean. Replace or clean the fi lter as required. Check for proper air clearance around the freezer. Refer to the freezer’s Owner’s Manual for clearances. Check the condenser for blockage, and be sure condenser fan is functioning.
In water cooled condenser models check for
proper water fl ow.
After the cause of the error is determined and
corrected, turn the Freezing Cylinder Off-On switch Off and back On.
Error Code 10 - Auxiliary Sensor
An Auxiliary Temperature Sensor Error (E10)
occurs if the temperature sensor on the control board fails. Turn the Freezing Cylinder Off-On switch Off and back On.
Figure 7-1 Temperature Sensor Resistance
(10K Ohms)
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Error Code 11 - Low Temperature
The Low Temperature Error (E11) occurs when the
temperature of the gas refrigerant at the freezing cylinder 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 freezing cylinder tends to freeze solid. When the temperature on the freezing cylinder lowers to the preset value, the IntelliTec control will display an E11.
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 fl ash in an alternating
sequence under any error codes. Clear the error and turn the Freezing Cylinder Off-On switch Off and back On.
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7.3 TROUBLESHOOTING - MACHINE
PROBLEM POSSIBLE CAUSE REMEDY
1 Power to machine is off. 1 Supply power to machine.
Machine does not run.
Machine will not shut off.
Product is too fi rm.
2 Freeze-up (auger will not turn). 2 Turn Clean/Off/On switch Off for 15 minutes,
then restart.
3 Front door not in place. 3 Assemble front door in place.
1 Drive belt failure. 1 Replace drive belt.
2 Consistency temperature setting is too
rm.
3 Refrigeration problem. 3 Check system. (Call distributor for service)
1 CutOut Consistency setting too high 1 Adjust the CutOut Consistency (See Section 3)
2 Turn Consistency Adjustment knob counter-
clockwise.
Product is too soft.
Product does not dispense.
Drive belt slipping or squealing.
Rear auger seal leaks.
Front door leaks.
1 No vent space for free fl ow of cooling
air.
2 Condenser is dirty. 2 Clean the condenser. (See Section 3)
3 CutOut Consistency setting too low 3 Adjust the CutOut Consistency (See Section 3)
4 Auger is assembled incorrectly. 4 Remove mix, clean, reassemble, sanitize and
5 Refrigeration problem. 5 Check system. (Call distributor for service)
1 No mix in hopper. 1 Add mix to the hopper.
2 Drive motor overload tripped. 2 Wait for automatic reset. (If condition
3 Drive belt failure. 3 Replace drive belt.
4 Freeze-up (Auger will not turn). 4 Turn off cylinder, wait for 15 minutes, then
1 Worn drive belt. 1 Replace drive belt.
2 Freeze-up (Auger will not turn). 2 Turn off cylinder, wait for 15 minutes, then
3 Not tensioned properly. 3 Adjust belt tension
1 Outside surface of rear auger seal is
lubricated.
2 Rear seal missing or damaged. 2 Check or replace.
3 Seal o-ring missing, damaged or
installed incorrectly.
4 Worn or scratched auger shaft. 4 Replace auger shaft.
1 Front door knobs are loose. 1 Tighten knobs.
2 Spigot parts are not lubricated. 2 See Section 3.
3 Chipped or worn spigot o-rings. 3 Replace o-rings.
4 O-rings or spigot installed wrong. 4 Remove spigot and check o-ring.
5 Inner spigot hole in front door nicked
or scratched.
1 A minimum of 3” of air space at the back. (See
Section 2)
freeze down.
continues, call distributor for service.)
restart.
restart.
1 Clean lubricant from outside of rear seal,
lubricate inside of seal and reinstall.
3 Check or replace.
5 Replace front door.
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7.4 TROUBLESHOOTING - MIX PUMP
PROBLEM POSSIBLE CAUSE REMEDY
1. Power to pump is off. 1. Supply power to pump.
2. Low voltage. 2. Check for low voltage.
3. Mix pump hose jammed inside black cover/clamp.
Pump motor does not run.
4. Pump motor overloaded. 4. Allow internal thermal overload to reset;
5. Pressure switch on pump is defective. 5. Check mechanical operation and continuity of
6. Defective motor/capacitor. 6. Check motor amperage draw and/or capacitor.
7. Defective toggle switch. 7. Check continuity; repair or replace.
Note 1: A properly working pump will fi ll an 8 oz. cup with mix in about 9 seconds.
3. Disconnect pump from power source. Remove four cover/clamp thumb screws. Separate cover/clamp halves and remove outer half. Remove jammed hose. Clean and re-install cover/clamp and tighten four thumb screws securely. Allow motor thermal overload to reset.
determine overload cause and repair.
pressure switch.
Replace motor or capacitor.
Pump operates but cylinder will not fi ll.
Overrun too low or no overrun.
Note 2: Immediately after a bag change the pump may be unable to reestablish it’s prime with the system at operating pressure. In this case, turn the pump off. Draw 2-3 pints to reduce system pressure to zero. Turn pump on. Purge remaining air in mix bag and pick-up hose.
Important: before connecting the pick-up hose to the mix bag, remove as much air from the mix bag as possible.
1. Out of Mix. 1. Replenish mix supply.
2. Mix pump hose kinked inside black cover/clamp.
3. Hoses assembled incorrectly. 3. Refer to diagram for correct hose connections.
4. Mix pump hose service life is exceeded.
5. Mix pump hose not connected to machine.
6. Ice crystals in mix. 6. Completely thaw mix prior to use.
7. Mix bag drawn against adapter. 7. Ensure bag is clear of pick-up tube.
8. Foreign objects in mix. 8. Clear blockage. Use fresh mix.
9. Check valve is backwards. 9. Observe fl ow arrow for proper orientation.
1. Overrun setting too low. 1. Increase overrun setting.
2. Air leak. 2. Tighten all hose clamps.
3. Air compressor not pumping air. 3. Contact local Stoelting Distributor.
4. Air check valve in backwards. 4. Check arrow for direction of fl ow.
2. Disconnect pump from power source. Remove four cover/clamp thumb screws. Separate cover/clamp halves and remove outer half. Remove jammed hose. Clean and re-install cover/clamp and tighten four thumb screws securely. Allow motor thermal overload to reset.
4. Reposition/replace mix pump hose. See Section 4.9
5. Connect mix pump hose to machine.
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PROBLEM POSSIBLE CAUSE REMEDY
Overrun too high.
Replacement mix pump hose won’t feed through pump.
Air exiting mix pick­up hose.
Dispensed product air “pops”
Mix leakage from pump.
1. Mix pump hose service life is exceeded.
2. Out of mix. 2. Replenish mix supply.
3. Overrun setting too high. 3. Decrease overrun setting.
4. Pick-up leg of mix pump hose is collapsing.
1. Feeding hose into discharge hole of mix pump cover.
2. Hose ends not cut squarely. 2. Carefully cut hose end off squarely (no tails).
3. Force feeding too quickly. 3. Gently and slowly assist feeding of hose up
4. Pump motor not running. 4. Turn on motor switch.
1. Pickup tube check valve missing. 1. Contact local Stoelting Distributor.
1. Overrun setting too high. 1. Decrease overrun setting.
2. Mix pump hose service life is exceeded.
3. Overdrawing the machine’s capacity. 3. Reduce dispense rate.
4. Recent low mix condition. 4. Open spigot fully and allow excess air to
CAUTION: To prevent mix pump damage from dried mix deposits, immediately disassemble and clean pump.
1. Mix pump hose service life is exceeded.
Note: The action of the air compressor rocking arm creates a repetitive clicking sound during operation. This is normal.
1. Reposition/replace mix pump hose.
4. Reposition hose.
1. Feed hose into suction side of cover.
into pick-up hose side of cover.
2. Reposition/replace mix pump hose.
escape.
1 Remove mix pump hose. Disconnect pump
from power source. Remove mix pump cover/ clamp. Clean the rollers a small amount of soapy water. Clean mix from pump. See Section 4.2 for hose replacement.
Pump is noisy/ squeaking.
Mix in air hoses.
Note: The peristaltic mix pump has three squeeze rollers that use self lubricating bearings. If squeaking exists with the mix pump hose in place and stops with the hose removed, the squeeze roller bearings can be lubricated using a silicone based spray. Remove the mix pump hose. Disconnect pump from electrical power. Remove four cover/clamp thumbscrews. Remove entire cover/clamp as one unit. Spray silicone based lubricant on each end of each squeeze roller. Spin rollers to work lubricant into bearings. Repeat as needed.
Caution: Do not use cleaning/dissolving type lubricants like wd-40. These lubricants are not bearing friendly and will accelerate bearing wear.
1. Air/mix tee above black cover/clamp. 1. Air/mix tee must be below black cover/clamp.
2. Air leak. 2. Tighten all hose clamps.
3. Mix hose on wrong air/mix tee fi tting. 3. Refer to diagram for correct hose connections.
4. Pressure control manifold o-ring leak. 4. Check o-ring and manifold; replace as
required.
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SECTION 8
REPLACEMENT PARTS
8.1 BRUSHES, DECALS AND LUBRICATION
Part Description Quantity
208135 Brush - 4" X 8" X 16" (Barrel) 1 208380 Brush - 1/4" X 3" X 14" 1 208387 Brush - 1/2" X 5" X 24" 1 208465 Brush - 1" X 3-1/2" X 18" 1 208467 Brush - 3/8" X 1" X 5" 1 236050 Card - Cleaning Instruction 1 324065 Decal - Water Inlet 1 324105 Decal - Caution Electrical Shock 3 324106 Decal - Caution Electrical Wiring Materials 1 324107 Decal - Caution Hazardous Moving Parts 2 324141 Decal - Caution Rotating Blades 1 324208 Decal - Attention Refrigerant Leak Check 2 324346 Decal - Caution Hazardous Moving Parts 2 324509 Decal - Cleaning Instructions 1 324566 Decal - Wired According To 1 324584 Decal - Adequate Ventilation 3" 2 324686 Decal - Danger Automatic Start 2 324799 Decal - Pump Off / On 2 324803 Decal - Domed Stoelting Logo (Large) (Header Panel) 1 324804 Decal - Domed Stoelting Swirl (Header Panel) 1 324825 Decal - Main Freezer Power 1 324826 Decal - Cab Off 1 324827 Decal - Freezing Cylinder 2 324888 Decal - Fan Motor Reset 1 324901 Decal - Transformer Reset 1 508048 Lubricant - Spline (2 oz Squeeze Tube) 1 508135 Petrol Gel - 4 oz Tube 1 513635 Manual - Owner’s 1
8.2 SPIGOT EXTENSION
Part Description Quantity
232734 Cap - Rosette 4 624677-5 O-Ring - Spigot Extension - Black (5 Pack) 3 2177072 Extension - Spigot - 1.5" ­ 2177073 Extension - Spigot - 2.5" 3 2177074 Extension - Spigot - 3.2" -
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8.3 AUGER SHAFT AND FRONT DOOR
Part Description Quantity
149003 Bushing - Front Auger Support 2 381804 Auger Flight 10 417006 Grid - Drip Tray (Metal) 1 482004 Knob - Air Bleed Valve 2 482019 Knob - Front Door 4 624520-5 O-Ring - Air Bleed Valve - Black (5 Pack) 2 624598-5 O-Ring - Outside Spigot - Black (5 Pack) 4 624614-5 O-Ring - Top & Bottom Center Spigot - Black (5 Pack) 2 624664-5 O-Ring - Middle Center Spigot - Black (5 Pack) 1 624678-5 O-Ring - Rear Seal & Rear Seal Adapter - Black (5 Pack) 4 625133 O-Ring - Front Door - Red 2 667868 Seal - Rear Auger (Orange) 2 694200 Spring - Air Bleed Valve 2 694255 Spring - Auger Flight 10 744273 Tray - Drip 1 2183083 Auger Shaft 2 2183106 Valve - Air Bleed 2 2183110 Door w/Pins & Air Bleed Valve 1 2187880 Adapter - Rear Seal 2 3158086 Spigot Body - Center 1 3159696 Spigot Body - Outer 2 3170644 Support - Front Auger 1
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8.4 CAB TUBING ASSEMBLY
Part Number Description Quantity
264235 Clamp - Metal (1/4" ID Tubing) 8 264241 Clamp - Metal (1/2" ID Tubing) 4 264243 Clamp - Metal (3/8" ID Tubing) 4 375819 Elbow - Barbed (3/8"- 1/4") 2 376041 Tee Connector - 3-Way (Stainless) 2 558114 Mix Container Only 2 624607-5 O-Ring - Check Valve Body - Black (5 Pack) 4 694247 Spring - Cone (Cab Check Valve) 2 696152 Clip - Lock (Check Valve) 2 756067 Tubing - 1/4" ID - Clear - Air Line (25' Increments) (Per Inch) 13" (2) 756079 Tubing - 3/8" ID - Clear - Mix Line (25' Increments) (Per Inch) 24" (2) 756088 Tubing - 1/2" ID - Clear - Mix Line (25' Increments) (Per Inch) 6" (2) 756204 Tubing - 1/4" ID - Pump (50' Box Only) (Per Inch) ­ 756204-40 Tubing - 1/4" ID - Pump (Pre-Cut 40" Piece) 8 762256 Check Valve - Mix Outlet (Cab) 2 1183187 Check Valve - Mix In Line (Outer) 2 2177274 Clip - Retaining (Mix Probe To Cover) 2 2202059 Pick-Up Tube - Mix 2 3183101 Cover - Rear (Mix Container) 2 3183343 Cover - Front (Mix Container) 2
55
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8.5 SPIGOT CAM ASSEMBLY
Part Number Description Quantity
428045 Knob - Spigot Handle (Black) 3 570961 Pin - Cotterless Clevis (Spigot Cam) 3 696044 Spring - Torsion (Spigot Cam) 3 718773 Switch - Spigot Cam 4 2158082 Glide - Spigot Socket 3 2158260 Handle - Spigot (Metal Only) 3
8.6 STAINLESS STEEL PANELS
Part Number Description Quantity
647653 Screw - Panel (Header & Top) & Cab (Door Handle) ­ 647899 Screw - Panel (Side, Rear & Front Shroud) ­ 2183762 Panel - Rear 1 2187071 Panel - Top (Water-cooled) 1 2187091 Panel - Top (Air-Cooled) 1 2187281 Panel - Header 1 4183072 Panel - Left Hand Side 1 4183073 Panel - Right Hand Side 1
56
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8.7 REAR
598032
763181
284085
230654
718794
762359
152238
598031
763017
558004
282062
743654
357102
Part Number Description Quantity
152237 Belt - Gripnotch (AX35) (Each) (50 Hz) ­ 152238 Belt - Gripnotch (AX34) (Each) (60 Hz) 2 230654 Capacitor (Fan Motor) 1 282062 Compressor - 1 PH - 60 Hz (Scroll) (No Capacitors) 1 282076 Compressor - 1 PH - 50 Hz (No Capacitors) ­ 284085 Condenser - Air-Cooled 357102 Motor - Fan (w/Blade & Guard) (Air-Cooled Condenser) 1 558004 Condensate Pan 1 598031 Pulley - Drive Motor (60 Hz) 2 598032 Pulley - Speed Reducer (50/60 Hz) 2 598072 Pulley - Drive Motor (50 Hz) ­ 718794 Switch - High Pressure Cutout 1 743654 Transformer - Booster 1 762359 Valve Core (Schrader) 763017 Valve - Hot Gas Bypass 1 763181 Valve - Water 1 778027 Wrench - Allen (Cab) 1
57
778027
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8.8 RIGHT
718539
614233
2187264
302042
272065 763423
522858-SV
762275
Part Number Description Quantity
231078 Capacitor - Run (#522858 Motor) 2 231095 Capacitor - Start (#522858 Motor) 2 272065 Valve Coil - Solenoid (#763423 Valve) 302042 Cord - Power 1 368325 Filter - Air (Condenser) 1 522858-SV Motor - Drive (60 Hz) 2 522859 Motor - Drive (50 Hz) ­ 614233 Speed Reducer 2 718539 Switch - Toggle (208/230) 1 762275 Valve - Magna Check (Cab) 2 763423 Valve - Solenoid (1/2") (Suction Side) (Has 2) 2 2187264 Evaporator Assembly 1 2187817 Motor - Fan (Air-Cooled Condenser) 1
58
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8.9 LEFT
762481
763422 763482
762457-SV
342008
458010
Part Number Description Quantity
342008 Drier (Liquid Line) 1 458010 Indicator - Liquid Line 1 493042 Flasher - Indicator Light (Cab On - Off) 1 762481 Valve - Expansion (Has 2) 2 762457-SV Valve - Expansion (w/Orifi ce) (Cab) 1 763422 Valve - Solenoid (1/4") (Liquid Line) (Has 3) 3 763482 Valve Coil - Solenoid (#763422) 3
59
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8.10 FRONT PANEL AND HEADER PANEL
718895
493041
744276
521686-230
295017
332541
718532
719025-SV
202235
718532
Header Panel - Back
744142
230638
618180
295017
230653
Part Number Description Quantity
202235 Circuit Breaker 1 230638 Capacitor - Start (#282062 Compressor) 1 230653 Capacitor - Run (#282062 Compressor) 1 231048 Capacitor - Run (#282076 Compressor) ­ 231049 Capacitor - Start (#282076 Compressor) ­ 295017 Contactor (45CG20AG) (Drive Motor / Compressor / Cab) 3 332541 Board - Display Module (Display Only) 2 493041 Indicator Light (Cab On - Off) 1 521686-230 Program Board - IntelliTec (208V / 230V) 2 618180 Relay (#282062 & #282076 Compressor) 1 718532 Switch - Toggle (Freezing Cylinder On-Off) 4 718776 Switch - Door Interlock 1 718895 Switch - Rocker (Cab On-Off) 1 719025-SV Switch - Membrane Strip 2 744142 Transformer 1 744276 Tray - Drain 1 765214 Varistor Harness 6 2187085 Support - Drip Tray 1
60
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8.11 CAB INTERIOR
522307-SV
162048
2187296
128311
128312
396449
3177231
719123-SV
4183338
736084
284095
672724
2187306
Part Number Description Quantity
128311 Hinge - Door (Top & Bottom) (Cab) 2 128312 Mix Container Holder Assembly w/Rollers (Cab) 1 162048 Blade - Fan (Evaporator) (Cab) 1 266018 Clip - “J” (Hose Holder) (Cab) 2 284095 Evaporator (Cab) 1 396449 Gasket - Door (Cab) 1 522307-SV Motor - Fan (Evaporator Assembly) (Cab) 1 647674 Screw - Door Hinge (Cab) ­ 672724 Sensor - Capacitive (Cab) 2 719123-SV Switch Only - Cab Door (Hamlin Reed Switch) (Cab) 1 736084 Thermometer (Cab) 1 2187296 Guard - Fan (Cab) 1 2187306 Door Assembly - Foamed (Cab) 1 2187926 Motor - Fan (Evaporator Assembly) (50 Hz) (Cab) ­ 3177231 Handle - Door (Cab) 1 4183338 Mix Container Drawer (Cab) 1
61
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8.12 PUMP PARTS
Part Number Description Quantity
128295 Rocker Arm Assembly w/Screw 2 369037 Fitting - Flared Brass - Air Inlet 2 376035 Tee Connector - Air Pressure Switch 2 432003-SV Valve Head Only w/Tubes 2 522229 Motor - Pump 2 538306 Nut - Motor Mounting 8 644065 Screw - Rocker Arm 2 650146 Set Screw - Pulley 4 652412 Screw - Shoulder (Crank Arm Roller Assembly) 2 653042 Screw - Thumb (Cover Clamp) 8 667896 Seal - Bumper (Piston) 2 717928 Switch - Pressure 2 762246 Check Valve - Air Line (Stainless) 2 766058 Washer - Lock - Motor Mounting 8 1171860 Spring - Check Valve 2 1171861-SV Needle Valve w/o Ring 2 1171862 Screw - Air Filter Retainer 2 1171863 Valve Guide 2 1171864 O-Ring - Needle Valve 2 1171866 Screw - Valve Head 10 1171867 O-Ring (Pump Cylinder Sleeve) 2 1171868 Reed Valve 2 1171870 Cylinder Sleeve 2 1171871 Spring - Piston 2 1171872 Piston Spring Seat 2 1171873 Piston 2 1171874 Ball Bearing - Single (Pump Rocker Arm) 2 1171955 Set Screw - Eccentric 2 1171956 Washer - Crank Arm - Nylon 2 1171958 Filter - Air 2 1171959 O-Ring (Piston) 2 1171977 Roller (Crank Arm) 2 1171978 Screw - Crank Arm 2 1171979 Crank Arm 2 1171980 Pulley - Large 2 1171981 Eccentric 2 1171982 Knob - Crank Arm Overrun Setting 2 1171983 Dial - Crank Arm Overrun Setting 2 1171984 Pointer - Crank Arm Overrun Setting 2 1171985 Dowel Pin - Rocker Arm 2 1171986 Flange Bearing - Rocker Arm 4 1171987 Wick - Rocker Arm 2 1171988 Collar - Rocker Arm Dowel Pin 2 1171989 Pulley - Small 2 1171990 Belt 2 1171994 Sleeve Bearing - Crank Arm 2 1177033 Bumper Ring (Piston) 2 1177034 Air Filter Retainer - Top 2 1177035 Air Filter Retainer - Bottom 2 1177036 Washer - Air Filter Retainer 2 1177037 Screw - Air Filter 2 1177681 Rocker Arm 2 2177812 Roller Carrier Assembly Kit 2 2183067 Pump Body Casting 2 3171952 Cover - Clamp (Two Piece Black) 2 4183089 Pump Assembly w/Motor 2
62
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8.12 PUMP PARTS (CONTINUED)
128295
1171983
1171981
1171986
644065
1171874
1177681
1171861-SV
1171866
1171955
1171864
1171863
1171987
1171984
1171862
432003-SV
1171868 1171867
1171870
1177037
1171860
762246
1171985
1171986
1177034
1171958
1177035
1177036
369037
717928
653042
376035
1171988
3171952
2177812
1171982
1171977
1171866
1171979
652412
1171978
1171994
1171956
766058
522229
650146
1171989
538306
1171871
1177033
1171959
667896
1171873
1171872
1171980
1171990
650146
63
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8.13 PART KITS
Part Number Description Quantity
1177436 Air Compressor Kit (Reed Valve, Piston & Cylinder Sleeve) (Cab) -
128296 Piston & Cylinder Sleeve 1 1171860 Valve Spring 1 1171861-SV Needle Valve w/O-Ring 1 1171863 Valve Guide 1 1171864 O-Ring 1
1183624 O-Ring & Bearing Kit -
149003 Bushing - Front Auger Support 2 624520 O-Ring - Air Bleed Valve - Black 3 624598 O-Ring - Spigot - Black 5 624607 O-Ring - Check Valve Body - Black 6 624614 O-Ring - Top & Bottom Center Spigot - Black 4 624664 O-Ring - Middle Center Spigot - Black 3 624677 O-Ring - Spigot Extension - Black 4 624678 O-Ring - Rear Seal - Black 5 625133 O-Ring - Front Door - Red 2
2177917 Brush Kit -
208135 Brush - 4" x 8" x 16" (Barrel) 1 208380 Brush - 1/4" x 3" x 14" 1 208387 Brush - 1/2" x 5" x 24" 1 208401 Brush - 1" X 3" X 10" 1 208465 Brush - 1" x 3-1/2" x 18" 1 208467 Brush - 3/8" x 1" x 5" 1
764385 Valve Kit - Water Valve Repair ­ 1177990 Caster Kit - 4" (Set of 4) - 2171962 Sensor Probe Kit ­ 2177812 Roller Carrier Assembly Kit (Cab) ­ 2187932 Switch Kit - Cab Door (Hamlin Reed Switch) (Cab) -
64
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8.14 REFRIGERATION DIAGRAM AND WIRING DIAGRAM
65
Page 74
66
Page 75
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 Stoeltings 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
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