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Model F231 SERVICE MANUAL

1. ur gt T 6 50 8 cm 15 1 2 5 1 8 CONNECTION 39 3 cm 12 9 cm 29 1 2 74 8 cm FRONT VIEW SIDE VIEW REAR VIEW Figure 1 2 Specification Machine with crate 19 1 4 48 9 cm 40 1 4 102 2 cm 58 1 4 148 0 64 1 2 163 8 cm 28 71 1 cm 33 1 4 84 5 cm 1 Phase 208 240 VAC 60Hz 3 Phase 208 240 VAC 60Hz approximately 12A approximately 10A NEMA 6 20P power cord provided NEMA L15 20P power cord provided lon 1 Phase 220 240 VAC 50Hz 12 000 Btu hr R 404A Two 3 4 hp Air cooled units require 3 7 6 cm air space on both sides Water cooled units require 1 2 N P T water and drain fittings Fittings Maximum water pressure of 130 psi Minimum water flow rate of 3 GPM Ideal EWT of 50 70 F Two 3 gallon 11 35 liters Two 0 85 gallon 3 22 liters Advanced Storage Storage 37 5 F Men Displ F23 HSPA aJ SE H Enable Control Consistency Consistenc
2. Troubleshooting MXX Troubleshooting Troubleshooting Machine Replacement Parts Decals and Lubrication ere ride Panels and SOS WS isso Auger Shaft and Faceplate Parts 0 22 2222 Internal Components gedingt sd lactea SECTION 1 INTRODUCTION 1 1 DESCRIPTION The Stoelting F231 floor machine 15 gravity fed The machine is equipped with the Intellilec2 control which provides a uniform product The F231 15 designed to operate with almost any type of commercial soft serve or non dairy mixes available including milk cream yogurt and frozen dietary desserts This manual is designed to assist qualified service per sonnel and operators in the installation operation and maintenance of the Stoelting F231 gravity machine gt _ gen ty eg _ be 7 ae i Figure 1 1 Model F231 1 2 SPECIFICATIONS 19 1 4 HEIGHT DISTANCES 1 DUE TO CASTERS 48 9 cm 58 1 4 61 9 cm 148 0 cm 56 142 2 cm 52 3 4 38 9 cm 133 9 cm 28 71 1 cm er
3. dee s dee s 9polN Aqpueis 9AJ8S SPOIN 9AJeg y 106195 10 323384 HSNd y 106195 10 323384 HSNd y I 106195 10 373384 OL y uoneJedo JO SAPO N 0IIV0 229 8I C199LI8 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 la bels have been put there to help maintain a safe working environment Thelabels have been designed to withstand washing and cleaning All labels must remain legible for the life ofthe machine Labels should be checked periodi cally 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 Themachine has been assembled operated and inspected at the factory Upon arrival at the final destination the entire machine must be checked for any damage which may have occurred during transit With the method of packaging used the machine should arrive in excellent condition THE CARRIER IS RESPON SIBLE FOR ALL DAMAGE IN TRANSIT WHETHER
4. Y Freezing Cylinder S3 Evaporator Check Valve Access 1 Fiting EH Drier low side Liquid Line Solenoid Thermistor Probe Suction Line Hopper Evaporators Solenoid rg Liquid Line Solenoid Y Freezing Cylinder Evaporator Check Valve Access Fitting low side Liquid ins Solenoid Access Fitting high side Check Valve 14 psig Access Fitting low side High Pressure Cutout 445 psig cutout 350 psig cutin Compressor Figure 5 1 Water Cooled Refrigeration System 25 Suction Line TXV S Pu em Fitting low side Water Cooled Condenser A REFRIGERANT RECOVERY 1s Disconnect the machine from electrical supply before removing any panels for servicing Remove all panels Connect the recovery unit to the suction and discharge service valves of the compressor Connect power to the machine Turn the machine on by pressing the Main Power Off On button Press the right arrow SET then the SEL button to access the technician level on the control Activate the Liquid Solenoid and the Refer Solenoid on the left side and right side Activating the solenoids is done through the Left Output Control and Right Output Control menus which are located under Utilities in the Testing and Manual Operation screen Refer to Sectio
5. N Co N C N C C C Resistance 176950 165200 154300 144200 134825 126125 118050 110550 103550 97075 91025 85400 80150 75275 70725 66475 62500 58800 55325 52100 49075 46250 43600 41125 38800 36625 34575 32675 30875 29175 27600 22 20 18 16 14 12 10 O EN WE EN 8 CA O O Figure 6 7 Temperature Sensor Resistance 10K Ohms 40 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 2 High Torque 3 Run Time 4 Clean 8 Freezing Cylinder Sensor 6 Hopper Sensor single hopper machines 7 Drive Motor 8 Cab Sensor 9 High Pressure Cutout 10 Ambient Sensor 11 Prime cab units only 12 Left Storage Sensor 13 Right Storage Sensor Toreturn the machine to normal operation any error caus ing condition must be corrected and the freezing cylinder must be turned off and on again using the On Off Left or On Off Right button 7 2 TROUBLESHOOTING ERROR CODE 2 HIGH TORQUE If the control panel displays a High Torque Error 22 the drive motor is running at a high load for 10 or more seconds Very low and or fluctuating supply voltages typically cause this error The error can also be caused by faul
6. Calibration must be done with water or liquid mix in the freezing cylinder Do not try to calibrate with frozen mix in the freezing cylinder R Press the SEL button to calibrate the motors for both freezing cylinders NOTE If the motors do not start cycle the power and try again S Press the left arrow to exit the Utilities menu and go the Main Menu screen T Go to the Modify Settings screen scroll to the User Preferences option and press SEL at the Service Contact Information screen U Scroll to the serial number and press the SET button Enterthe serial numberforthe machine by scrolling through the numbers The serial number is found on the information plate located on the side or back of the machine If the last digit is a blank scroll past the z for the blank space 4 9 DRIVE BELT TENSION ADJUSTMENT To check belt tension refer to Figure 4 4 and follow the steps below Hazardous voltage Make sure the machine is off when disassembling for servicing The machine must be disconnected from electrical supply before removing any access panel Failure to disconnect power before servicing could result in death or serious injury A Remove the back panel B Use a Burroughs Belt Tension Gauge to set the tension for the drive belt Set the belt tension to 35 40 Ibs C If an adjustment is necessary loosen the four motor plate retaining nuts adjust belt tension then retighten the four nuts Usin
7. The IntelliTec2 control sends electronic signals to trigger the contactors Separate signals are used to control each drive motor contactor and the compressor contactor The signals to the contactors are staggered so the drive motor will always start 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 A CONTACTOR TESTS The following tests will show if a contactor is working properly Figure 6 2 Display Board Listen for the contactor to close When the spigot is opened or the Push To Freeze button is pressed the drive motor contactor will close After three seconds the compressor contactor will close Check to ensure contactor is receiving signal Read voltage across the coils of the contactor during a freezing cycle Voltage should be about 230V Ifthere is no voltage reading referto Section 7 Troubleshooting Figure 6 1 IntelliTec2 Control Board 35 6 3 DRIVE MOTOR The F231 has two drive motors They are used to rotate the auger assemblies An internal normally closed cen trifugal switch starts the drive motor The motors have an internal thermal overload A DRIVE MOTOR TEST 1 Turn the machine off by pressing the Main Power Off On button and disconnect the machine from the electrical supply Hazardous voltage Make sure the machine is off when disassembling for servicing The machine must
8. Replace insulation around valve Replace the filter drier Refer to Section 5 8 for details G Evacuate and recharge system per instructions in Section 5 2 33 5 8 FILTER DRIER The filter drier must be replaced every time the refrigeration system is opened for service A new filter drier improves operation of the entire refrigeration system by stopping the circulation of moisture and by removing harmful con taminants Refer to Figure 5 12 Figure 5 12 Filter Drier FILTER DRIER REMOVAL A Recover refrigerant charge per instructions in Section 5 2 B Cut the refrigeration line as close to the filter drier as possible and remove drier C Cap the ends of the drier using the plugs from the new drier NOTE The drier must be capped to prevent moisture from the environment FILTER DRIER REPLACEMENT A Position the filter drier so the arrow is pointing toward the direction of refrigerant flow pointing away from the condenser B Apply a heat sink wet cloth to the filter drier C With the suction and discharge ports open braze the filter drier into the system D Evacuate the system per instructions in Section 5 2 E Recharge the system per instructions in Section 5 3 5 9 CAPILLARY TUBE The capillary tube meters refrigerant flow in the mix line evaporator Refer to Figure 5 13 The amount of flow is dependent on the length and of the capillary tube as well as the refrigerant charge
9. eo STOELTING FOODSERVICE EQUIPMENT Model F231 SERVICE MANUAL Manual No 513659 Rev 1 INTELLITEC2 FIRMWARE VERSION UPDATE LOG The list below shows the history of the firmware versions in the IntelliTec2 control The information in this manual refers to Version 20 27 VERSION 20 27 CURRENT VERSION Released on 12 28 10 Added Unit Serial Number to Service Contact Information and Modify Contact Information Added Clean Warning to Clean Options VERSION 20 15 Released 11 23 10 Added Enable Control to Basic Settings Removed Enable CutOut Temp from Basic Settings Changed CutOut Consistency to CutOut Consistency Offset Added Consistency Offset Moved Sleep 1 Drive On and Sleep 1 Drive Off to Factory Settings from Advanced Settings Moved Stir On and Stir Off to Advanced Settings from Factory Settings Added Storage Refrigeration to Storage Settings Storage changed to 37 5 F was 37 F Moved Pressure Sensing and Liquid Sensing to Factory Settings Added Clean Options to Utilities page 1 Moved Clean Lockout to Clean Options from Utilities page 1 Added Clean History Log to Clean Options VERSION 17 19 Released on 9 8 10 Note They are few initial machines with 15 19 8 23 10 where cutout consistency was 70 then pulleys were changed Two machines with 16 19 had 60 as cutout limit then some minor internal reset timers were changed and 17 19 released on 9 8 10 Consistency Limit chang
10. 152234 Belt Gripnotch AX33 1 per Side 2 162077 Blade Fan Air Cooled Condenser 1 229148 Cable IntelliTec2 Control Board to Display Board 1 230633 Capacitor Run 50 Hz 1 230649 Capacitor Start 50 Hz 1 231079 Capacitor Start 1 231084 Capacitor Run 1 231107 Cap Tube 1 272065 Valve Coil Solenoid 2763423 Valve 2 282032 Compressor Copeland 1 PH 60 Hz R404A No Capacitors 1 284084 Condenser Air Cooled 1 284104 Condenser Water Cooled 1 295112 Contactor Compressor Drive 3 342004 Drier Liquid Line 1 342020 Drier Hopper Liquid Line Cap Tube 1 368140 Filter Air Condenser 1 458003 Sight Glass 1 521513 Board Program IntelliTec2 1 521514 Board Relay IntelliTec2 1 521516 Board Program Relay IntelliTec2 1 522291 Motor Fan Air Cooled Condenser 1 522858 SV Motor Drive 1 PH 2 598032 Pulley Speed Reducer 2 598540 Pulley Drive Motor 2 614233 Speed Reducer 2 618142 Relay 50 Hz 1 618157 Relay 1 718537 Switch Limit Door Interlock 1 718794 Switch High Pressure Cutout 1 762359 Valve Core Schrader 3 762454 Valve Expansion 2 762490 Valve Expansion 2 762978 Valve EPR 1 763017 Valve Hot Gas Bypass 1 763181 Valve Water 1 763422 Valve Solenoid 1 4 Liquid Line 3 763423 Valve Solenoid 1 2 Suction Side 2 763482 Valve Coil Solenoid 763422 3 764385 Valve Kit Water Valve Repair 1158090 SV Switch Door Interlock 1 2202316 Evaporator Hop
11. 314453 381804 417006 482019 624598 5 624614 5 624664 5 624677 5 624678 5 625133 666786 694255 744262 744273 2149243 01 2177072 2177073 2177074 2177428 3158086 3159696 3170644 4157968 8 3 AUGER SHAFT AND FACEPLATE PARTS CONTINUED Description Bushing Front Auger Support Cap Rosette Teardrop Cover Hopper Auger Flight Grid Drip Tray Metal Knob Front Door Black O Ring Outside Spigot Black 5 Pack O Ring Top amp Bottom Center Spigot Black 5 Pack O Ring Middle Center Spigot Black 5 Pack O Ring Mix Inlet Black 5 Pack O Ring Rear Seal Black 5 Pack O Ring Front Door Red Seal Rear Auger Black Spring Auger Flight Tray Drain Black Plastic Tray Drip Mix Inlet Assembly 3 16 Hole Extended Length 2LA Extension Spigot 1 5 Extension Spigot 2 5 Extension Spigot 3 2 Door w Pins Spigot Body Center Spigot Body Outer Support Front Auger Auger Shaft 47 Quantity gt gt gt 5 8 4 INTERNAL COMPONENTS 2310 763422 231095 763482 272065 CG ZIEL gt ms 763423 gt D e Si T FN sl 342020 29 48 8 4 INTERNAL COMPONENTS CONTINUED Part Description Quantity
12. DISASSEMBLY OF FRONT DOOR 1 Turnthe machine off by pressing the Main Freezer Power Off On button on the IntelliTec2 control Remove the knobs on the front door Remove the front door by pulling it off the studs Remove the spigot through the bottom ofthe front door Remove all o rings from parts by first 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 Figure 3 4 Removing O Ring B DISASSEMBLY OF AUGER 13 2 Remove the front auger support and bushing 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 flights with springs Keep the rear of the auger tipped up once it is clear of the freezing cylinder to prevent the rear seal assembly from dropping Wipe the spline lubricant off of the hex end of the auger with a paper towel Remove the rear seal assembly Fig 3 5 Unscrew the springs from the auger flights Figure 3 5 Rear Seal Assembly 3 4 CLEANING DISASSEMBLED PARTS Disassembled machine parts require complete cleaning sanitizing and air drying before assembling Local and state health codes will dictate the procedure required Some state health codes require a four sink process pre wash wash rinse sanitize air dry while others require a three sink process without the pre wash step The
13. F Check for leaks 1 Check for leaks at the front door seals 2 Check the drain tray located under the front door for leaks coming from the rear of the rear auger seal G Using a sanitized soft bristle brush or equivalent dipped in sanitizing solution clean the hopper sides mix inlet regulator and underside of the hopper cover H After five minutes open the spigot to expel sanitizing solution Drain all of the solution from the machine When the solution has drained press the CLEAN button to stop the auger Allow the freezing cylinder to drain completely The machine is now sanitized and ready for adding mix 3 9 FREEZE DOWN AND OPERATION A Sanitize immediately before use B Make sure the display shows the freezing cylinder is off If itis not press the On Off Left or On Off Right button to turn it off C Fill the hopper with at least 2 5 gallons of mix D Place a container under the spigot and open the spigot to allow the mix to flush out about 8 ounces 0 23 liters of sanitizing solution and liquid mix Press the On Off button for the cylinder F Press the PUSH TO FREEZE button NOTE After the drive motor starts there is a 3 second delay before the compressor starts G When the product is at 75 consistency the display will read SERVE Open the spigot to dispense product NOTE If the product consistency needs to be adjusted use the Technician passcode and go to the Basic Set
14. Figure 5 13 Capillary Tube and Drier Assembly CAPILLARY TUBE REMOVAL NOTE The capillary tube assembly contains a drier The entire assembly must be removed A Recover refrigerant charge per instructions in Section 5 2 B Leave a port open to prevent pressure buildup during capillary tube removal C Remove foam insulation from the capillary tube at the evaporator inlet C Unsweat the capillary tube and remove CAPILLARY TUBE REPLACEMENT A Position the capillary tube in the refrigeration system B Apply a heat sink wet cloth to the capillary tube and drier assembly C With the suction and discharge ports open braze the capillary tube into the system D Replace foam insulation to the capillary tube at the evaporator inlet E Evacuate the system per instructions in Section 9 2 Recharge the system per instructions in Section 5 8 34 NOTE wiring diagram is available in Section 8 6 1 INTELLITEC2 CONTROL The IntelliTec2 control consists of three main components a control board a display board and a membrane switch touchpad The control board is modular and consists of a program board and a relay board The two boards make it easy to service and replace The boards are connected by two screws 6 2 CONTACTORS The F231 has a total of three contactors One for the com pressor and one for each drive motor The contactors are located in the electrical box behind the right side panel
15. sensor resistance with the table as reference If measured value does not coincide with a value on the table 500 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 lesistance 76 78 38 100 Figure 7 1 Temperature Sensor Resistance 10K Ohms O Co M gt gt C 4 10 12 14 16 18 _ EA 8 12 14 16 18 38 Kio CO 42 ERROR CODE 6 HOPPER SENSOR The Hopper Sensor Error E6 will not occur on the F231 ERROR CODE 7 DRIVE MOTOR If the control panel displays a Drive Motor Error E7 the control does not sense the drive motor Press the On Off button for the cylinder to turn it off then back on If the error returns use the machine s wiring diagram and check connections at the IntelliTec control and at the motor An E7 may also be the result of a faulty drive motor contactor ERROR CODE 8 CAB SENSOR A Cab Sensor Error E8 will not occur on the F231 ERROR CODE 9 HIGH PRESSURE CUTOUT High Pressure Cutout Errors E9 are usually caused by a dirty or inefficient condenser If the control panel displays an E9 press the On Off button for the cylinder to turn it off Wait for 8 10 minutes for the machine pressures st
16. 2 E EVAPORATOR PRESSURE REGULATOR EPR There is one EPR in the refrigeration system Refer to Figure 5 8 It is located on the suction line of the hopper evaporators and regulates evaporator refrigerant pressure Figure 5 8 EPR Valve EPR TEST AND ADJUSTMENT Adjustment to the EPR must be made when the hopper refrigeration is the only part of the system running A Turn the machine off by pressing the Main Power Off On button B Connect a gauge to the Schrader valve on the suction line between the hopper evaporators and the EPR C Press the Main Power OFF ON button to turn the machine power on Listen for the hopper compressor to start D If the gauge does not read 60 2 then adjustment 15 needed Remove the plastic cap and loosen the locknut on the EPR Using a small screwdriver turn the adjustment screw counterclockwise 1 2 turn then adjustas necessary Turnthe valve stem clockwise for higher pressure or counterclockwise for lower pressure 5 Allow the system to stabilize for 5 minutes to ensure pressure remains stable EPR REMOVAL A Remove the left side panel and front panel B Recover refrigerant charge per instructions in Section 5 2 C Leave the suction and discharge ports open to prevent pressure buildup during EPR removal D Unsweat the EPR and remove EPR REPLACEMENT To replace the EPR perform the following procedures A Apply a heat sink wet cloth to the EPR B With an open
17. Cleaning Instructions Caster Non Locking 4 Each Caster Locking 4 Each Decal Water Inlet Decal Caution Rotating Shaft Decal Caution Electrical Shock Decal Caution Electrical Wiring Materials Decal Caution Hazardous Moving Parts Decal Danger Electric Shock Hazard Decal Caution Rotating Blades Decal Attention Refrigerant Leak Check Decal Cleaning Instructions Decal Wired According To Decal Adequate Ventilation 3 Decal Attention Heat Sensitive Decal Danger Automatic Start Decal Domed Stoelting Logo Large Header Panel Decal Rear Light Decal USB Port Lubricant Spline 2 oz Squeeze Tube Petrol Gel 4 oz Tube Manual Owner s O Ring amp Bushing Kit 8 2 PANELS AND SCREWS Description Screw Header Panel Screw Sides amp Rear Panel Screw Upper Front Panel Panel R H Side Air Cooled Panel L H Side Air Cooled Panel Rear Air Cooled Panel Header Panel Upper Front Panel Lower Front Panel R H Side Water Cooled Panel L H Side Water Cooled Panel Rear Water Cooled 45 Quantity 1 ARO JS NINI Quantity 2 gt 8 3 AUGER SHAFT AND FACEPLATE PARTS 2149243 01 C amp D UU es 624598 5 46 Part 149003 232734
18. IntelliTec2 control Refer to Section 4 6 for details High pressure cutout should trip when pressure reaches 445 psig 9 HIGH PRESSURE CUTOUT REMOVAL A Remove the left side panel B Recover refrigerant charge per instructions in Section 5 2 C Leave the suction and discharge ports open to prevent pressure buildup during removal D Unsweat capillary tube from suction line E Disconnect terminals from high pressure cutout HIGH PRESSURE CUTOUT REPLACEMENT A With the suction and discharge ports open braze the capillary tube to the discharge line C Replace the drier per the instructions in Section 5 9 D Braze bulb into place on suction line E Evacuate the system perthe instructions in Section 5 2 F Recharge the system per the instructions in Section 5 3 G Connectthe terminals to the high pressure cutout H Attach the high pressure cutout using the two screws with star washers D HOT GAS BYPASS The hot gas bypass valve 15 installed parallel to the com pressor and helps to regulate the compressor temperature Refer to Figure 5 7 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 Figure 5 7 Hot Gas Bypass HOT GAS BYPASS ADJUSTMENT Adjustment the hot gas bypass must be made when the hopper refrigeration is the only part of the
19. Most of the dirt will cling to the wet towel D An alternative method isto clean with a condenser brush and vacuum NOTE If the condenser is not kept clean refrigeration ef ficiency will be lost 4 11 PREVENTATIVE MAINTENANCE It is recommended that a preventative maintenance schedule be followed to keep the machine clean and operating properly The following steps are suggested as a preventative maintenance guide The United States department of agriculture and the food and drug administration require that lubricants used in food zones be certified for this use Use lubricants only in accordance with the manufacturer s instructions A 4 12 Daily checks Check for any unusual noise or condition and repair immediately Monthly checks Check the condenser for dirt and clean II necessary Quarterly Checks Check drive belts for wear and tighten belts II necessary EXTENDED STORAGE Refer to the following steps for storage of the machine over any long period of shutdown time A Clean all the parts that come in contact with mix thoroughly with a warm detergent water Rinse in clear water and dry all parts Do not sanitize NOTE Do not let cleaning solution stand in the freezing cylinder or hopper during the shutdown period B Remove disassemble and clean the front door auger shaft Leave disassembled during the shutdown period Placethe auger flights and auger supportbushing in
20. PRIME The Prime Error E11 will not occur on the F231 ERROR CODE 12 LEFT HOPPER SENSOR The Left Hopper Sensor Error E12 indicates a failure of the hopper sensor or if the sensor 15 out of range If the control panel displays an E12 press the On Off button for the cylinder to turn it off then back on If the control panel still displays the error condition code refer to the machine s wiring diagram and the Temperature Sensor Chart Figure 4 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 lf measured value does not coincide with a value on the table 400 ohms replace the sensor ERROR CODE 13 RIGHT HOPPER SENSOR The Right Hopper Sensor Error E13 indicates a failure of the hopper sensor or if the sensor is out of range If the control panel displays an E13 press the On Off button for the cylinder to turn it off then back on If the control panel still displays the error condition code refer to the machine s wiring diagram and the Temperature Sensor Chart Figure 4 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 Co
21. Removal TXV REPLACEMENT To replace the TXV perform the following procedures A Position the I XV with a heatsink into the system B With the suction and discharge ports open braze the TXV into the system Remove the heat sink from the I XV E Replace insulation to the TXV and surrounding lines F Replace the drier per the instructions in Section 5 9 G Evacuatethe system perthe instructions in Section 5 2 H Recharge the system per the instructions in Section 5 3 B CHECK VALVE The machine has 3 magnetic check valves Refer to Figure 5 5 Each valve is positioned in the suction line and prevents backflow of refrigerant into the evapora tor If there is reversed flow the product in the freezing cylinder softens and liquid refrigerant can flood into the compressor on startup If a check valve needs to be replaced use a heat sink wet cloth when installing the new valve to prevent damage Figure 5 5 Check Valve C HIGH PRESSURE CUTOUT The high pressure cutout stops the compressor if the discharge pressure reaches the cutout 445 psig for the freezing cylinders It is an automatic reset when the pres sure drops below 350 psig HIGH PRESSURE CUTOUT TEST A Connect a gauge to the Schrader valve on the discharge line 29 Figure 5 6 High Pressure Cutout B Disconnect cooling In a water cooled machine shut off the water supply In an air cooled machine shut off the fan motor in the
22. 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 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 tempera ture can result in a finished 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 SECTION 4 MAINTENANCE AND ADJUSTMENTS This sectionis intended to provide maintenance personnel with a general understanding ofthe machine adjustments It is recommended that any adjustments in this section be made by a qualified person 4 1 ACCESSING CONTROL READINGS AND SETTINGS The readings and settings on the Intellilec2 control are accessed by using a keypad sequence Press the left arrow button from the Current Status screen to access the passcode input screen The specific readings and parameters available depend on the keypad sequence entered The lowest level 15 Associate and has limited access The Manager level has access to the majority of screens except Utilities 2 of 2 The Technician level has full access to the control including the Associate and Manager level options Following
23. a plastic bag with a moist paper towel This will prevent them from becoming brittle if exposed to dry air over an extended period of time over 30 days 23 24 SECTION 5 REFRIGERATION SYSTEM 5 1 REFRIGERATION SYSTEM NOTE The F231 refrigeration systems have two functions For qualified service personnel only Anybody work Medium Temperature Maintaining mix temperature in the hopper ing with refrigerants must be certified as a Techni cian TYPE l as required by 40 CFR 82 Subpart F and hold all State and or local refrigerant handling Low Temperature Producing and maintaining certifications In addition all handling storage and high quality product in the freezing cylinders disposal of refrigerants must be in accordance with The system is designed for efficient use with R404A Environmental Protection Agency EPA guidelines refrigerant The proper charge is indicated on the infor and standards and all State and local guidelines mation plate and standaras 5 2 REFRIGERANT RECOVERY AND EVACUATION Refer to the following procedures to properly recover and evacuate the refrigeration system Do not purge refriger Hazardous voltage ant into the atmosphere Make sure the machine is off 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 Thermistor uu NN
24. and before the evaporator SOLENOID MAGNETIC COIL REMOVAL A 8 C Remove the side panel Disconnect the electrical wires Remove the retainer 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 pro cedures A Connect the two electrical wires to the magnetic coil B Push the coil on to the solenoid valve stem C Make sure there isn t any foam insulation between the valve coil and valve body Trim any excess insulation D Install retainer screw onto top of coil SOLENOID VALVE REMOVAL A Identify and disconnect the two wires from the solenoid coil B Remove the retainer holding the coil to the solenoid body and remove the coil C Recover refrigerant charge per instructions in Section 5 2 D Remove insulation around valve and attached refrigeration lines E Apply heat sinks wet cloth to the insulated refrigerant lines near the valve F Leave a port open to prevent pressure buildup during solenoid removal 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 refrigerant flow B Apply a heatsink wet cloth to the solenoid valve C With the suction and discharge ports open braze the solenoid into the system D Remove the heat sink from the valve
25. are the keypad sequences for the three levels available Associate Press the right arrow then the SEL button Manager Press the right arrow up arrow then the SEL button Technician Press the rightarrow SET then the SEL button 4 2 NAVIGATION AND MODIFYING SETTINGS Navigating through the IntelliTec2 screens is done with the arrow keys on the touchpad After positioning the cursor on a desired menu press the SEL button to select that option If the option is a setting press the SET button to change the value Use the arrow keys to change the value Press the SET button to save the changes The SEL button changes the cylinder selection on screens that show the cylinder Pressing the left arrow button from any menu will go back one screen Pressing the left arrow button at the Main Menu screen goes to the Current Status screen 4 3 USER INTERFACE SCREENS A Current Status 01 01 01 12 34 56 Serve Sleep 1 Current Status Left Right Storage Left Storage Right _ Service Company 13 The Current Status screen gives an overview of the machine s operation IL shows the mode of the freezing cylinders and the storage refrigeration If there is an error the error text description replaces the status information The Service Contact Information screen is accessed from the Current Status screen Move the cursorto the Service Contact Information option and press the SEL button B Service Contact Informatio
26. as they will mar the finish Use a soft cloth or sponge to apply the solution For best results wipe with the grain of the steel A Clean the rear seal surface from inside of the freezing cylinder B Using sanitizing solution and the large barrel brush provided sanitize the freezing cylinder by dipping the brush in the sanitizing solution and brushing the inside of the freezing cylinder C Remove the drip tray by pulling from the front panel Clean and replace the drip tray 3 7 ASSEMBLING MACHINE To assemble the machine parts refertothe following steps NOTICE Petrol Gel sanitary lubricant or equivalent must be used when lubrication of machine parts 15 specified NOTICE The United States Department of Agriculture and the Food and Drug Administration require that lubri cants used on food processing equipment be certi fied for this use Use lubricants only in accordance with the manufacturer s instructions Assemble all o rings onto parts dry without lubrication Then apply a thin film of sanitary lubricant to exposed surfaces of the o rings 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 Lubricate the inside metal surface of the rear seal and install it onto the auger shaft DO NOT lubricate the outside of the rear auger seal Fig 3 6 Lubricate the hex drive end of the
27. auger with a small amount of spline lubricant Asmall container of spline lubricant is shipped with the machine Screw the springs onto the studs in the plastic flights The springs must be screwed into the flights completely to provide proper compression Install the two plastic flights onto the rear of the auger and insert it part way into the freezing cylinder Install the remaining plasticflights push the auger into the freezing cylinder and rotate slowly until the auger engages the drive shaft Figure 3 6 Lubricate Rear Seal Apply athin layer of sanitary lubricantto 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 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 Apply a thin film of sanitary lubricant to the door seal o ring and fit it into the groove on the rear of the front door Place the front door assembly on the mounting studs and the push front door againstthe machine carefully Secure the front door to the machine by placing the knobs on the studs and tightening until finger tight Do not overtighten A proper o ring seal can be observed through the transparent front door 3 8 SANITIZING Sanitizing must be done after the machine is cle
28. be disconnected from electrical supply before removing any access panel Failure to disconnect power before servicing could result in death or serious injury Remove the back panel and a side panel Loosenthe belttension adjustment nut and remove the belt Connect power to the machine 5 Turn the machine on by pressing the Main Power Off On button 6 Press the right arrow SET then the SEL button to access the technician level on the control 7 Activate the drive motor through the Left Output Control or Right Output Control menus which are located under Utilities in the Testing and Manual Operation screen Refer to Section 4 for details 8 Go to the Test Monitoring screen under Utilities The motor current should be as follows Single Phase Machines 6 1 6 3 Amps Three Phase Machines 4 0 4 2 Amps NOTE The motor amps are based on 230VAC supply voltage 9 Afterthe test stop the motor by exiting the Testing and Manual Operation section Turn the machine off and disconnect from the electrical supply 10 Install the belt and tighten the tension bolt 11 Use a Burroughs Belt Tension Gauge to set the tension for the drive belt Set the belt tension to 35 40 lbs 12 Using a straightedge align the drive motor pulley with the gearbox pulley Tighten the two allen head screws 36 7 8 9 Tension Adjustment Figure 6 3 Belt Tension Adjustment DRIVE MOTOR REMOVAL Disconnectmach
29. 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 per sonal 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 equip ment property damage NOTICE The signal word NOTICE indicates information or procedures that relate directly or indirectly to the safety or personnel or equipment property TABLE OF CONTENTS Section Description Page 1 Description and Speci
30. freezing cycle Storage CutOut is the temperature at which the storage refrigeration cycle stops This is how low the temperature will get before ending the storage freezing cycle The Storage Offset value is added to the storage tem perature reading to determine if storage refrigeration starts with a freezing cycle This setting helps prevent short cycling and saves energy The Storage Off setting determines the time between storage refrigeration cycles during a sensor failure The Storage On setting determines the length of a stor age refrigeration cycle during a sensor failure Storage Settings 2 of 2 Storage Settings 2 of 2 00 min 0 min 00 0 000 min Max On Recovery Too Warm Too Warm _ Storage _ Storage _ Storage _ Storage This Storage Settings menu contains storage refrigeration parameters and is available to the Manager and Techni cian levels Press the left arrow to go to the first screen The Storage Max On setting is the maximum time that a storage refrigeration cycle will run The Storage Recovery setting is the minimum time between storage refrigeration cycles if the Storage Max On time ends the cycle The Storage Too Warm values are the temperature and amount of time When the temperature is above the set temperature for the set period the Storage too Warm message will be displayed G User Preferences User Preferences _ Language _ Temp Units English Farenheit F
31. numbers Cutln Consistency Offset is a number that represents the point which a freezing cycle will start in Consistency Consistency style The actual cutout value is the sum of this number and the Motor Zero Load number Temperature is the suction line temperature the cylinder when a freezing cycle will start in Temperature Consistency or Temperature Temperature style CutOut Temperature isthe suction line temperature in the cylinder when a freezing cycle will stop in Temperature Temperature style Cycles In Serve Mode is a count of the number of freez ing cycles C Advanced Settings 1 of 2 Advanced Settings 1 of 2 Cylinder Right _ Standby On Time 0000 0000 000 0000 0000 sec sec min sec sec _ Standby Off Time _ Standby Time _ Stir On _ Stir Off The Advanced Settings menu contains standby and sleep mode adjustments and is available to the Manager and Technician levels Press the right arrow to go to the second screen Cylinder can be changed by pressing the SEL button The Standby On Time setting determines the length of the freezing cycle in Standby Mode The Standby Off Time setting determines the length between freezing cycles in Standby Mode The Standby Time setting determines the total amount of time in Standby Mode Stir On is the amount of time that the auger rotates during the stir cycle Stir cycles occur in Serve Mode Standby Mode and Sleep 2 Mode Stir Off i
32. open to prevent pressure buildup Braze the suction and discharge line to the compressor G Connect the wires to the compressor terminals H Replace the drier per the instructions in Section 5 9 Evacuatethe system perthe 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 F231 comes with either an air cooled or a water cooled condenser The capacity of the machine is directly related to keeping the condenser clean and free of debris The air cooled condenser is a copper tube and aluminum fin type The machine must have a minimum of 3 of clear ance on both sides for proper air flow The water cooled condenser is a tube and shelltype This condenser requires cool clean water to function properly Inlet and discharge lines must be 3 8 ID minimum CONDENSER TESTING The condenser can be checked for leaks using the bubble test or using a leak detector 5 6 VALVES A THERMOSTATIC EXPANSION VALVE TXV The Thermostatic Expansion Valve TXV is used to meter the refrigerant to the freezing cylinder evaporator It does so by maintaining a constant pressure in the evaporator Theself regulating TXV is presetby the manufacturer and adjustment is not recommended Figure 5 3 Figure 5 3 TXV 28 TXV TESTING amp ADJUSTMENT NOTE The bulb has an indent which must be positioned against the tubing Good contact
33. port brazethe EPR into the system C Remove the heat sink from the hot gas bypass D Replace the filter drier Refer to Section 5 8 for details E Evacuate and recharge system per instructions in Section 5 2 F WATER VALVE WATER COOLED MODELS ONLY The water valve monitors refrigerant pressure and opens on an increase of pressure The opening point pressure is the refrigerant pressure required to lift the valve disc off the valve seat Figure 5 9 WATER VALVE ADJUSTMENT A Remove the right side panel B Connect a gauge to the compressor discharge Schrader valve C Connectthe machine to the electrical supply start the refrigeration cycle and read the pressure D The proper gauge reading should be 225 235 psig Figure 5 9 Water Valve 31 The exit water temperature should be 95 107 F E If the water temperature and high side pressure are too low the opening point pressure should be increased to slow the water flow Turn the adjustment screw counterclockwise F If the water temperature and high side pressure are too high the opening point pressure should be decreased to increase the flow of water Turn the adjustment screw clockwise WATER VALVE REMOVAL The water valve is connected to the refrigeration system by capillary tube brazed to the discharge line A Turn off and disconnect the water supply Blow out the water lines with compressed air or B Recover refrigerant charge per instru
34. system running NOTE Before adjusting the hot gas bypass check the EPR valve and adjust if necessary A Turn the machine off by pressing the Main Power On Off button B Connect a gauge to the Schrader valve on the suction line next to the compressor Wait until the gauge stops moving D Unscrew the seal cap from the top of the valve E Using a 5 16 Allen wrench adjust the valve counterclockwise to decrease pressure and clockwise to increase pressure NOTE Each 3607 turn will change the pressure about 6 psig F Adjust the hot gas bypass valve to 14 psig 1 G Wait 2 minutes to ensure pressure remains stable H Hand tighten seal cap to valve HOT GAS BYPASS REMOVAL A Remove the left side panel 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 heatsink 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 heatsink wet cloth to the hot gas bypass B With an open port braze the hot gas bypass into the system C Remove the heat sink from the hot gas bypass D Replace the filter drier Refer to Section 5 8 for details E Evacuate and recharge system per instructions in Section 5
35. ENOID BLUE LEFT LIQUID SOLENOID 87 BLUE 2202858 WD CAUTION DISCONNECT POWER SUPPLY BEFORE SERVICING 91 HOPPER SOLENOID RIGHT 81780 DRIVE COIL 95 R O RIGHT LIQUID SOLENOID 96 O 97 COMPRESSOR CONTACTOR RIGHT SUCTION SOLENOID 60 BLUE W WHITE STRIPE A GREEN W YELLOW STRIPE PINK W BLACK STRIPE 61 9 PIN L3 11 OUTPUTS LEFT SPIGOT SWT a 107 CENTER SPIGOT SWT 108 109 CENTER SPIGOT SWT 114 111 RIGHT SPIGOT SWT A LEFT CYL SENSOR LC BLUE BLACK AMBIENT SENSOR A BROWN W WHITE STRIPE ORANGE W WHITE STRIPE BLUE RIGHT HOPPER SENSOR RH o P 114 LEFT HOPPER SENSOR LH BLACK BLUE W WHITE STRIPE DOOR INTERLOCK SWT 15 HPC SWT RIGHT CYL SENSOR RC PURPLE W WHITE STRIPE 116 117 BLUE BLACK LEFT SUCTION SOLENOID WHITE DRIVE MOTOR WIRING e sromTNG Ser 11 2 13 INTERLOCK AUTION KIEL WISCONSIN U S A 53042 ELECTRICAL WIRING DIAGRAM NC HELD OPEN PLUG END VIEW OF MODEL 231 10912 30912 SPIGOT SWITCHES CONNECTORS is a DISCONNECT POWER SUPPLY DIAGRAM NO 2202859 WD 2 2 0 2 5 9 WD BEFORE SERVICING 52
36. ENS A Performance 1 of 2 Performance 1 of 2 Cylinder Right 000 00 000 0 F 00 000 000 0V Consistency Cylinder Temp Motor Amps Input Voltage The Performance screens display the current status of the machine These screens are available to the Manager and Technician levels Press the right arrow to go to the second screen Cylinder The performance information displayed is forthe selected cylinder To change cylinders press the SEL button Consistency This is the current consistency number of the selected cylinder The consistency number represents how thick or thin the product in the freezing cylinder is A higher number means the product is thicker Go to the Modify Operating Settings menu to change the operating setting Cylinder Temperature This is the current suction line temperature of the selected cylinder Motor Amps This is the current motor amps of the selected cylinder Input Voltage This is the current voltage of the selected cylinder Only shown when the drive motor is running 14 B Performance 2 of 2 Performance 2 of Cylinder Right 000 0 F 000 0 F 000 Ambient Temp Storage Temp Number of Cycles Error Status No Error The Performance screens display the current status of the machine This screen shows the current ambient temperature storage temperature and number of cycles since the Push to Freeze button was pressed orthe spigot was pulled Press the left arr
37. VISIBLE OR CONCEALED Do not pay the freight bill until the machine has been checked for damage Have the carrier note any visible damage on the freight bill If concealed damage and or shortage is found later advise the carrier within 10 days and request inspection The customer must place claim for damages and or shortages in shipment with the carrier Stoelting Inc cannot make any claims against the carrier 2 3 MACHINE INSTALLATION Installation must be completed by a qualified electrician refrigeration specialist Incorrect installation may cause personal injury severe damage to the machine and will void fac tory warranty Installation of the machine involves moving the machine close to its permanent location removing all crating set ting in place assembling parts and cleaning A Uncrate the machine 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 of space on both sides for proper circulation Fig 2 1 Machines that have water cooled condenser require 1 2 NPT supply and drain fittings Figure 2 1 Space and Ventilation Requirement
38. _ Service Contact Information _ Contact Information USB Update The User Preferences menu contains language options temperature units service contact information and touch pad lockup The screen is available to the Manager and Technician levels The Language setting changes the language displayed English is the only language currently available The Temperature Units setting changes the units dis played to Fahrenheit or Celsius The Service Contact Information option is used to change the service contact details including service company name and number and machine serial number 16 H Time and Date Time and Date 00 00 00 AM 00 00 00 off 12 HR Time Date Daylight Savings Clock Type Date Format _ Modify Time and Date The Time and Date menu shows the time and date set tings The Manager and Technician levels can change the time and date by using the Modify Time and Date option Utilities 1 of 2 _ Product Selection _ Adjust LCD Contrast _ Touchpad Lockup _ Export Machine Stats _ Clean Options Next Utilities Menu Utilities 2 of 2 Testing and Manual Operation Motor Zero Load Calibration Clear Error Log Clear Statistics Restore Factory Defaults Restore Motor Table Defaults Reset Unit Configuration 4 6 UTILITIES SCREENS The Utilities menu gives access for various settings and operations in the control The Utilities menu is available to Technician and Manager levels The Ma
39. abilize and an the internal timer to expire then press the On Off button for the cylinder to turn it back on In air cooled condenser models check the air filter to make sure itis clean Replace or clean the filter as required Check for proper air clearance around the machine Refer to the machine s Owner s Manual for clearances Check the condenser for blockage and be sure condenser fan is functioning On water cooled condenser models check for proper water flow through the condenser coil After the cause of the error is determined and corrected press the On Off button for the cylinder to turn it off then back on ERROR CODE 10 AMBIENT SENSOR The Ambient Temperature Sensor Error E10 indicates a failure of the condenser air inlet temperature sensor or if the sensor is out of range II the control panel displays an E10 press the On Off button for the cylinder to turn it off then back on If the control panel still displays the error condition code refer to the machine s wiring diagram and the Temperature Sensor Chart Figure 7 1 Check each lead of the sensor to ground for continuity If continuity is found replace the sensor To check the resistance of the sensor place a thermocouple on the suction line at the exitofthe 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 ERROR CODE 11
40. an and just before the machine is filled 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 certified for this use When sanitizing the machine refer to local sanitary regu lations 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 quanti ties 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 A Prepare 2 gallons of Stera Sheen sanitizing solution following the manufacturer s instructions B C D Install the mix inlet regulator into the hopper Pour the sanitizing solution into the hopper Make sure the display shows the freezing cylinder is off If it is not press the On Off Left or On Off Right button to turn it off NOTE If the freezing cylinder is not off the control will not go into Clean mode This is to protect from ac cidentally going into Clean mode Press the CLEAN button
41. are metal part on the compressor such as any copper line leading to or from the compressor and check terminals C R and S F231 has a hermetic reciprocating compressor Refer to Figure 5 2 NOTE The compressor is equipped with an internal over load protector Ifthe compressor is warm and ohm meter readings indicate an open winding allow up to one hour for overload to reset B COMPRESSOR REMOVAL Disconnect the machine from electrical supply before removing any panels for servicing B Remove the front panel C Removethe protective coverfromthe compressor Figure 5 2 Compressor terminals and disconnect the wires D Recover refrigerant charge per the instructions in Section 5 2 A WINDING TEST E Leave the suction and discharge ports open to To test the compressor motor windings for possible prob prevent pressure buildup during compressor lems perform the following steps removal A Disconnect the machine from electrical supply Remove six inches of insulating tubing on the suction line going to the compressor and unsweat the suction and discharge line from the compressor Hazardous voltage G Remove the four nuts and washers from the base of the compressor Make sure the machine 15 off when disassembling for servicing The machine must be disconnected H Remove the compressor through the front of the from electrical supply before removing any access machine panel Failure to disconnect powe
42. are o REO ES PEU 21 4 9 Drive Belt Tension 0 22 2 22 4 10 Condenser irm T morado 22 4 11 Preventative Maintenance 23 4 12 Extended Sto sen eee 23 Section 5 5 1 5 2 5 3 5 4 5 5 5 6 Description Refrigeration System Refrigeration System Refrigerant Recovery and Refrigerant Charging A m o erer EE VI Thermostatic Expansion Valve X cu High Pressure o Evaporator Pressure Regulator Water Valve Water Cooled Models e e O capillary TUDE Electrical and Mechanical Control Systems CZ Conto Sor gt gt yA _ ___32 lt Condenser Fan Motor Air Cooled ee 1 Temperature Control Sensor
43. between the bulb and the suction line is necessary for proper operation of the valve The bulb must also be well insulated Connect a gauge to the Schrader valve on the suction line Connect a thermocouple to the suction line next to the evaporator Immediately before the refrigeration cycle ends the gauge should read between 18 22 psig The superheat should be 7 10 F If the pressure reading is higher than expected and the superheat is low check to see if there is an overcharge of refrigerant Ifthe pressure readingis lowerthan expected and the superheat is high check to see if there is a low refrigerant charge or if there is a restriction in the system NOTE The TXV is the LAST component to adjust in the refrigeration system The TXV can be adjusted after the steps above are completed When adjusting do not turn the valve over 1 4 turn 90 Turn the valve stem clockwise to increase the superheat or counterclockwise to decrease the superheat TXV REMOVAL A Disconnect the machine from electrical supply before removing any panels for servicing Remove the front panel B Recover refrigerant charge per instructions in Section 5 2 C Leave the suction and discharge ports open to prevent pressure buildup during TXV removal D Remove any insulation from the TXV and immediate surrounding lines E Apply a heat sink wet cloth to the valve dome Figure 5 4 F Unsweat the TXV and remove Figure 5 4 TXV
44. creen shows when the last reset was done The reset should be used if the pump is changed I Machine Statistics 9 of 10 Machine Statistics 9 of 10 Cylinder Right 0000 hr 100 hr 00 00 00 00 00 00 AM _ Reset Hose Service Time Current Hose Usage Hose Service Limit Last Hose Reposition The Machine Statistics screen 9 of 10 shows the amount of time the pump hose has been in use and when the last reposition was completed There is also an option to reset the hose timer NOTE The hose timer must be reset each time the hose is repositioned or replaced to keep an accurate record of the hose service time J Machine Statistics 10 of 10 Machine Statistics 10 of 10 Last Unit Power Up 00 00 00 00 00 00 Avg Power KWH Day O Watts The Machine Statistics screen 10 of 10 shows when the machine was last powered on The screen also gives an average power consumption per day K Error History Error History 25 oT 25 Type Date Cylinder Cylinder Sensor 00 00 00 00 00 00 AM Right _ Status At Time of Error _ Help The ErrorHistory screen showsthe lasterrorthat occurred The screen shows the type of error the time and date and the cylinder that had the error Up to 25 errors are stored Press the up or down arrow to scroll through the errors Select the Status at Time of Error option to view data for the time the error occurred The Help option explains the error and provides quick troubleshooting tip
45. ctions 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 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 proce dures 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 Connect the water supply line and turn on water supply Check for leaks the water lines If there no leaks turn off the water supply G Replace the filter drier Refer to Section 5 8 for details H Evacuate and recharge system per instructions in Section 5 2 Turn on the water and check for leaks in the water lines with the refrigeration system running J Adjust the valve as necessary 5 7 SOLENOID Solenoid valves are installed on the liquid and suction lines of each freezing cylinder evaporator and on the liquid line of the hopper evaporators Refer to Figure 5 10 and Figure 5 11 A solenoid valve has a magnetic coil that when energized lifts a plunger and allows refrigerant to flow The solenoids ar
46. e activated by the IntelliTec control and determine which evaporator receives refrigeration The suction line solenoid prevents refrigerant flow in the evaporator when the suction pressure drops due to the operation of the other evaporators in the system ACTIVATING A SOLENOID To open a solenoid follow these steps A Turn the machine on by pressing the Main Power Off On button Press the right arrow SET then the SEL button to access the technician level on the control Navigate to the Left Output Control or Right Output Control menu which is located under Utilities in the Testing and Manual Operation screen Refer to Section 4 for details B Activate the solenoid by moving the cursor to the Liquid Solenoid option and pressing the SET button NOTE Any energized component will deenergize after leaving the Testing and Manual Operations menu SUCTION LINE SOLENOID TESTING To check for leaking valve seats follow the procedure outlined below The liquid line solenoid must remain open for this test NOTE Machine barrels must NOT contain frozen product for this test A Turn the machine off by pressing the Main Power On Off button B Attach a gauge to the Schrader valve located after the evaporator of the side being tested C Turn the machine on by pressing the Main Power Off On button D Turn the opposite side Freezing Cylinder on by pressing the On Off Left or On Off Right button NOTE If checking the s
47. e bleeder resistor preventing it from working properly 4 Pull the capacitor out of its holder and replace 5 Connect the leads to the terminals of the new capacitor 6 5 GEARBOX A GEARBOX INSPECTION Inspect the gearbox and listen for unusual noise A grind ing sound generally indicates a bad gear B GEARBOX REMOVAL 1 Disconnect machine from electrical supply before removing any panels for servicing 2 Remove the back panel and the side panel Remove the four nuts holding the support bracket and remove the bracket Remove the belts Remove the bolts while holding the gearbox assembly and remove it C GEARBOX INSTALLATION 1 Place the gearbox in position from the rear of the machine Fasten the bolts through the gearbox to the rear of the barrel 2 Mount the pulley on the gearbox shaft and align with the motor pulley then tighten the allen head Screws 3 Install the belt Use a Burroughs Belt Tension Gauge to set the tension for the drive belt Set the belt tension to 35 40 108 5 Using straightedge align the drive motor pulley with the gearbox pulley Tighten the two allen head screws 6 Install the support bracket to the gearbox CONDENSER FAN MOTOR AIR COOLED ONLY A FAN MOTOR REPLACEMENT 1 Disconnectmachine from electrical supply before removing any panels for servicing Remove a side panel and the header panel Trace and disconnect the black and white wires
48. ed to 60 was 110 for 1 phase 80 for 3 phase Moved Stir On and Stir Off to Factory Settings from Basic Settings Enable CutOut Temp and CutOut Temp moved to Basic Settings from Factory Settings Sleep 1 Drive Off changed to 600 seconds was 300 seconds e Sleep 2 Cutln changed to 33 F was 38 F Sleep 2 CutOut changed to 30 5 F was 30 F continued on next page VERSION 17 19 CONTINUED Storage CutOut changed to 32 F was 31 F Storage Offset changed to 4 F was 2 F Storage Off Time changed to 13 min was 2 min Storage On Time changed to 130 sec was 200 sec Storage Max On changed to 3 min was 10 min Storage Recovery changed to 4 min was 1 min Clean Lockout Period moved to Factory Settings from Storage Settings Touchpad Lockup moved to Utilities from User Preferences Date Format added to Time and Date Added second Utilities page Changed Utilities page 1 to be accessible to Manager passcode Testing and Manual Operation Restore Factory Defaults Clear Error Log and Clear Statistics moved to Utilities page 2 from page 1 Added Product Selection Export Machine Stats to Utilities page 1 Removed Clear EEPROM Map from Utilities Added Motor Zero Load Calibration Restore Motor Table Defaults and Reset Unit Configuration to Utilities page 2 Service Manual For F231 Stoelting Floor Model Gravity Machine This manual provides basic information about the machine Instructio
49. efore removing any panels for servicing Hazardous voltage Make sure the machine is off 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 Remove a lead from one ofthe capacitor terminals Using insulated pliers discharge the capacitor by connecting a 20 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 4 Disconnect the bleeder resistor from the circuit 5 Measure the capacitance across the terminals The results should be as follows Rating Part MFD VAC Drive Motor Start 231095 500 MFD 125 VAC Drive Motor Run 231078 50 MFD 370 VAC Compressor Start 231079 145 174 MFD 220 VAC Compressor Start 230649 130 156 MFD 250 VAC Compressor Run 231084 30 MFD 370 VAC Compressor Run 230633 30 MFD 370 VAC B CAPACITOR REPLACEMENT T Disconnect machine from electrical supply before removing any panels for servicing Remove leads from the capacitor terminals Using insulated pliers discharge the capacitor with a 20 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 th
50. fications 1 1 cc 1 1 2 V 2 2 Installation Instructions 2 1 SEENEN 5 2 2 Snipment and RUNE 5 2 3 Machine I I II 0 D 5 2 4 Installing Permanent 5 3 Initial Set Up and Operation 3 1 Operators Safety Ee tele ido Lid wn aan 7 3 2 Operating Controls and 7 3 3 Disassembly of Machine 8 3 4 Cleaning Disassembled Parts 9 3 5 Sanitizing Machine Parts reuso iio 9 3 6 Cleaning the Machine 9 3 7 Assembling the Machine uk 10 3 8 IMG eo OC EA 10 3 9 Freeze Down and Operation 11 3 10 O 11 4 Maintenance and Adjustments 4 1 Accessing Control Readings and Settings 13 4 2 Navigation and Modifying Settings 13 4 3 User Interface 13 4 4 Performance TR T ic 14 4 5 Settings 14 4 6 _ gt _ S ena Salsa MESA _ _ ____ _ 16 47 Errors 8 Statistics 19 4 8 Updating Firmw
51. following procedures are a general guideline only Consult your local and state health codes for the procedures required in your location A Prepare Stera Sheen or equivalent in 2 gallons of 90 to 110 F 32 to 43 C water following manufacturers instructions Place all parts in the solution and clean with provided brushes B Rinse all parts with clean 90 to 110 F 32 to 43 C water 5 Wash the hopper freezing cylinder with the Stera Sheen solution and brushes provided D Clean the rear seal surfaces from the inside of the freezing cylinder with the Stera Sheen Solution 3 5 SANITIZING MACHINE PARTS A Use Stera Sheen or equivalent sanitizing solution 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 UD Place all parts in the sanitizing solution for 5 minutes then remove and let air dry completely before assembling in machine 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 Stera Sheen solution and wipe dry Do not use highly abrasive materials
52. g a straightedge check that the drive motor pulley is aligned with the speed reducer pulley Align the pulley if necessary NOTE Belt life will be increased if new drive belts are tightened after two or three weeks of operation 22 Tension Adjustment Nut N o Figure 4 1 Belt Tension Adjustment D 4 10 CONDENSER CLEANING AIR COOLED MACHINES The F231 has an air cooled or water cooled condenser The air cooled condenser is a copper tube and aluminum fin type Condensing is totally dependent upon airflow A plugged condenser or restrictions in the louvered panel will restrict airflow This will lower the capacity of the system and damage the compressor The condenser must be kept clean of dirt and grease The machine must have a minimum of 3 7 6 cm of ventilation on the sides of the unitforfree flow of air Make sure machine is not pulling over 100 F 37 C air from other equipment in the area The water cooled condenser 15 a tube and shell type The condenser needs a cool clean supply of water to properly cool the machine inlet and discharge lines must be 3 8 I D minimum The air cooled condenser requires periodic cleaning To clean refer to the following procedures A Visually inspect the condenser for dirt B If the condenser is dirty place a wet towel over the condenser C Using compressed air or CO tank blow out the dirt from the back of the condenser
53. he Clean Options Menu gives access to the Clean His tory Log and Clean Lockout options Clean History Log 32 of 32 Cylinder Right Clean Log ID 0 00 00 00 00 00 00 Clean Total Time 000 min The Clean History Log screen shows the date time and duration of the last 32 clean cycles Clean Lockout Clean Lockout Disabled This option will enforce cylinder cleaning Are you sure you want to do that _ No Cancel Clean Lockout _ Yes Enable Clean Lockout The Clean Warning and Clean Lockout screens are used to enable the clean warning mode or the clean lockout mode When one of the modes 15 enabled and the machine 5 not cleaned within a specified period the machine will either display a warning for warning mode or remain in sleep mode and not go into serve mode for lockout mode Testing and Manual Operation Testing and Manual Operation Select below for testing _ Left Output Control _ Right Output Control _ Left Right Monitoring The Testing and Manual Operation menu provides access for individual components to be energized to assist with troubleshooting There are also test monitoring screens that provide details of the machine status during testing Any energized component will deenergize after leaving the Testing and Manual Operations menu Testing and Manual Ops Drive Motor Fan Motor Liquid Solenoid Compressor Refer Solenoid Aux Solenoid Pump Motor Selecting Left or Right Output Con
54. he spigot cam assembly to the panel Remove the assembly Disconnect the connector from the switch and remove the switch Install the replacement switch onto the handle assembly Do notfully tighten the retaining screws at this time 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 Fully tighten the retaining screws Attach the connector to the spigot switch 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 39 6 8 TEMPERATURE CONTROL SENSOR The temperature control sensor is a thermistor used to sense the temperature of the suction line As the suction line temperature increases the internal resistance of the thermistor will decrease Refer to Figure 6 7 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 Whentroubleshooting a sensor refertothe wiring diagram and remove the wires from the control board Measure the resistance of the sensor and compare it with the table below If the resistance is not within this range replace it 9
55. ine from electrical supply before removing any panels for servicing Remove the back panel and the side panel Remove the electrical cover plate from the back of the motor Identify mark wires and remove them from the motor Loosen the belt tension adjustment bolt and remove the belt Refer to Figure 6 3 Remove the motor mounting bolts Loosen the two allen head screws from the pulley Remove the pulley and key from the motor shaft C DRIVE MOTOR INSTALLATION Place the drive motor in position and install the four mounting bolts 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 Install the belt and tighten the tension adjustment bolt Use a Burroughs Belt Tension Gauge to set the tension for the drive belt Set the belt tension to 35 40 Ibs Using a straightedge align the drive motor pulley with the gearbox pulley Tighten the two allen head screws Install wiring according to wiring diagram located behind the left side panel Install electrical cover plate on the motor Install back and side panels 6 4 CAPACITORS The compressor start and run capacitors are only on single phase machines They are accessible by removing the right side panel The start and run capacitors for the drive motors are mounted directly onto each motor body A CAPACITOR TEST 1 Disconnect machine from electrical supply b
56. ly and listen for a click when the spigot switch closes 2 The clicking sound should be within the first 1 2 of the spigot glide movement Refer to Figure 6 5 If the switch does not close an adjustment may be necessary NOTE The center spigot has two switches one for each side When testing the center spigot there should be two audible clicks occurring almost simultane ously SPIGOT SWITCH TESTING ELECTRICAL Disconnect the switch from the circuit by unplugging the connectors 2 Check resistance readings across the common COM and normally closed NC terminals When the spigot is closed the resistance should show an open When the spigot is opened the switch will close and the resistance should be O ohms SPIGOT SWITCH ADJUSTMENT 1 Turn the machine off by pressing the Main Power On Off button Remove the header panel Loosen the bolts on the spigot switch Using a pencil mark the spigot glide 1 4 from the spigot housing 5 Adjustthe switch to activate when the plastic glide reaches the mark 6 Fully tighten the retaining bolts and remove mark from spigot glide SWITCH DISPENSE RATE ADJUSTER SWITCH ADJUSTMENT MARK PHILLIPS HEAD SCREW Figure 6 6 Spigot Switch Replacement SPIGOT SWITCH REPLACEMENT 1 2 Remove the header panel Remove the dispense rate adjuster knob located below the header panel Refer to Figure 6 6 Remove the two Phillips head screws that attach t
57. mpare temperature and sensor resistance with the table as reference lf measured value does not coincide with a value on the table 400 ohms replace the sensor 7 3 TROUBLESHOOTING MACHINE Power to machine is off Supply power to machine Machine does not 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 tool2 Turn Consistency Adjustment knob counter firm clockwise 3 Refrigeration problem 3 Check system Call distributor for service Product is too firm 1 CutOut Consistency setting too high 1 Adjust the CutOut Consistency See Section 3 1 No vent space for free flow of cooling 1 minimum of 3 of air space at the back See air Section 2 2 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 Remove mix clean reassemble sanitize and freeze down 5 Refrigeration problem 5 Check system Call distributor for service 1 Nomix in hopper 1 Add mix to the hopper 2 Drive motor overload tripped 2 Wait for automatic reset If condition Product does not continues call distributor for service dispense 3 Drive belt failure 3 Replace drive belt 4 Freeze up Auger will not turn Turn
58. n Service Contact Information Name Stoelting Telephone Number 920 894 2293 Unit Serial Number 00000000 Version 00 00 00 00 The Service Contact Information screen provides the name and telephone number for service The default 15 Stoelting Technical Customer Service The Manager and Technician levels can change the default by selecting the Modify Contact Information option or by uploading the info txt file C Main Menu Main Menu Technician Level Access Fine Consistency Adjustment Performance Modify Settings Utilities Errors and Statistics The Main Menu screen provides access to the readings and settings on the IntelliTec2 control To access the Main Menu use one ofthe keypad sequences from Section 4 1 The example above shows the options available when entering the Manager or Technician keypad sequence The Associate will only see the Fine Consistency Adjust ment option D Fine Consistency Adjustment Fine Consistency Adjustment Cylinder Changing the fine consistency change the firmness of the product Consistency CutIn Limit Consistency CutOut Limit _ Fine Consistency Right Product consistency can be adjusted by the Associate level by using the Fine Consistency Adjustment screen Increasing the Fine Consistency number increases the product consistency firmer product The Consistency Limits show the Fine Consistency ad justment added to the Consistency number 4 4 PERFORMANCE SCRE
59. n 4 for details CAUTION The solenoid valves must be energized to allow all refrigerant to be recovered and to prevent injury when brazing Operate the recovery unit per manufacturer s instructions After recovery is complete deactivate the solenoids by exiting the Testing and Manual Operation screens B EVACUATING THE REFRIGERATION SYSTEM 1 2 Close any open ports in the refrigeration system Connect a vacuum gauge to one of the Schrader valves next to an evaporator Connect the evacuation unit to the suction and discharge service valves of the compressor Connect power to the machine Turn the machine on by pressing the Main Power Off On button Press the right arrow SET then the SEL button to access the technician level on the control Activate the Liquid Solenoid and the Refer Solenoid on the left side and right side Activating the solenoids is done through the Left Output Control and Right Output Control menus which are located under Utilities in the Testing and Manual Operation screen Refer to Section 4 for details 26 8 Evacuate the system until the gauge reads 300 microns of mercury 300u Hg for 5 continuous minutes 10 If the system will not maintain a standing vacuum test with the vacuum pump off gauge increases towards atmosphere find the leak fix it and evacuate again 11 After evacuating is complete deactivate the solenoids by exiting the Testing and Manual Operation sc
60. nager level will only have access to the first screen The Technician level has access to both screens NOTE Entering the Utilities 2 of 2 screen automatically shuts off the freezing cylinders Product Selection Cylinder Current Product Type CutOut Consistency CutIn Consistency Press Set to change selection Press Sel to accept selection A Product Selection The Product Selection screen changes Consis tency and CutOut Consistency to a predetermined value depending on the product type Adjust LCD Contrast 0123456789 ABCDEFGHIJKLMNOPQRSTUVWXY Z Press A Y to change B Adjust LCD Contrast The Adjust LCD Contrast screen adjusts the contrast be tween the background lighting and the text on the screen C Touchpad Lockup Touchpad Lockup Touchpad Status Unlocked Do you want to lock keys _ No _ Yes Unlock Touchpad Lock Touchpad The Touchpad Lockup is used to lock and unlock the keypad for self service locations D Export Machine Stats Export Machine Stats This will export statistics data to stats txt file Please insert USB flash memory Are you sure you want to do that No Yes The Export Machine Stats screen allows you to export all the data and statistics stored in the control Connect a USB flash drive to the port on the side of the machine and select the yes option 17 Clean Options Clean Options Clean History Log Clean Warning Clean Lockout T
61. ns and suggestions are given covering its operation and care The illustrations and specifications 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 pro vide new parts for freezers built prior to date of change DO NOT ATTEMPT to operate the machine until instructions and safety precautions in this manual are read completely and are thoroughly understood II problems develop or questions arise in connection with installation operation or servicing of the machine contact the com pany at the following location STOELTING Ph 800 558 5807 502 Hwy 67 Kiel WI 53042 Fax 920 894 7029 C 2011 Stoelting LLC All Rights Reserved 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 specific safety information the following safety defini tions are provided to assist the reader The purpose of safety symbols 15 to attract your tention to possible dangers The safety symbols and their explanations deserve your careful attention and understanding The safety warnings do not by themselves eliminate any
62. nspection 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 flights on a regular basis Fig 3 3 and replace as needed Frequency of cleaning must comply with the local health regulations Figure 3 3 Auger Flight Wear To disassemble the machine refer to the following steps A REMOVING MIX For the first time cleaning the machine skip to part B Disassembly of Front Door 1 Press the Clean button After mix has melted about 5 minutes open the spigot to drain the mix Fill the hopper with 2 gallons 8 liters of cool tap water Press the Clean button to run the machine After 30 seconds press the Clean button again to stop the auger Drain the water out of the machine NOTE If the water does not arain clear repeat steps 2 4 Use Stera Sheen or equivalent sanitizing solution 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 Pour the sanitizer into the hopper Using brushes provided scrub the hopper After 5 minutes drain the sanitizer out of the freezing cylinder B
63. off cylinder wait for 15 minutes then restart 1 Worn drive belt 1 Replace drive belt Drive belt slipping 2 Freeze up Auger will not turn 2 Turn off cylinder wait for 15 minutes then restart 3 Not tensioned properly 3 Adjust belt tension 1 Outside surface of rear auger sealis 1 Clean lubricant from outside of rear seal lubricated lubricate inside of seal and reinstall Rear auger seal 2 Rear seal missing or damaged 2 Check or replace leaks Seal o ring missing damaged or 3 Check or replace installed incorrectly d Worn or scratched auger shaft Replace auger shaft 1 Front door knobs are loose 1 Tighten knobs 2 Spigot parts are not lubricated 2 See Section 3 Exontdoorleake 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 5 Replace front door or scratched 44 Part 208135 208380 208401 208467 236059 244138 244139 324065 324103 324105 324106 324107 324125 324141 324208 324509 324566 324584 324594 324686 324803 324908 324909 508048 508135 513658 1159501 Part 647658 647660 649114 2202322 2202323 2202324 2202327 2202328 2202329 2202458 2202459 2202460 SECTION 8 REPLACEMENT PARTS 8 1 DECALS AND LUBRICATION Description Brush 4 X 8 X 16 Barrel Brush 1 4 X 3 X 14 Brush 1 X 3 X 10 Brush 3 8 X 1 X 5 Card
64. olenoid on the left side press the On Off Right button For the right side press the On Off Left button E Start a freezing cycle of the opposite side by pressing the Push To Freeze button or by pulling the spigot handle 32 Figure 5 10 Liquid Line Solenoid Valve Figure 5 11 Suction Line Solenoid Valve Ifthe pressure drops more than 3 psi in 30 seconds on the side being tested the suction line solenoid valve seat leaks and should be replaced Repeat the procedure for the other side LIQUID LINE SOLENOID TESTING The following test will check if a liquid line solenoid has a leaking valve seat The power to the solenoid is dis connected and refrigerant flow is monitored through the system If the valve seat does not leak the suction pres sure during the test will be low A Attach a gauge to the Schrader valve on the suction line B Turn the machine on by pressing the Main Power Off On button Press the right arrow SET then the SEL button to access the technician level on the control Navigate to the Left Output Control or Right Output Control menu which is located under Utilities in the Testing and Manual Operation screen Refer to Section 4 for details Activate the compressor by moving the cursor to the compressor option and pressing the SET button The gauge should read well below 21 psig after 1 minute A leaking valve seat may also show frost on the liquid line tubing just pastthe solenoid
65. on the fan motor 4 Loosen the set screw on the fan blade 5 Remove the bolts from the fan motor mounting plate and remove the motor Figure 6 4 Air Cooled Condenser B FAN MOTOR INSTALLATION de Attach motor to the mounting plate with the three bolts 2 Place fan blade on motor shaft Make sure the motor shaft does not extend past the hub of the fan blade Tighten the set screw NOTE The fan blades must be at least 3 8 from the fins on the condenser 3 Ensure purple wire is terminated Ensure red wire is terminated with blue wire Route the white and black wires through the side panel to the compressor contactor Connect black wire to the T1 terminal 1 Connect white wire to the T2 terminal 6 7 SPIGOT SWITCH The spigot switch is a normally closed held open switch When a spigot is pulled the spigot switch sends a signal to the IntelliTec2 control to start the auger drive and refrig eration 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 Intelli Tec2 continues a freezing cycle until the product reaches consistency Spigot Glide Figure 6 5 Spigot Cam Assembly Center Spigot 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 slow
66. ontrolled with the On Off Left and On Off Right switches Push to Freeze Button Pressing the PUSH TO FREEZE button initiates Serve Mode Clean Button The CLEAN button initiates Clean Mode Arrow Buttons lt 11 gt U The arrow buttons are used by technicians to navigate through the control readings and settings B 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 C DISPENSE RATE ADJUSTOR The dispense rate adjustor is located under the header panel to the immediate rightofthe spigothandles Turning the knob counterclockwise will decrease the dispense rate D MIX LOW LIGHTS The mix low lights are located at the back of the F231 There is a light for each freezing cylinder A steady light signifies a low mix condition A blinking light signifies an error The light will automatically turn off when the condi tion has been resolved E USB ACCESS PORT The USB access port is located on the right side panel of the machine The port is used by technicians to import firmware and export machine statistics 8 3 3 DISASSEMBLY OF MACHINE PARTS Before using the machine for the first time complete machine disassembly cleaning and sanitizing proce dures need to be followed Routine cleaning intervals and procedures must comply with the local and state health codes I
67. or for frost that could restrict airflow The compressor will run continuously if a solenoid valve fails to open This could be due to loose wiring magnetic coil failure a stuck valve or a faulty control board After the cause of the problem is found and remedied press the On Off button for the cylinder to turn it off then 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 04 This condition does not reflect a problem with the machine itself The Clean Error has been programmed into the controller as a safeguard to protect the machine from potential damage caused by the machine being accidentally left in Clean Mode To clear the Clean Error press the On Off button for the cylinder to turn it off then back on ERROR CODE 5 FREEZING CYLINDER SENSOR The Freezing Cylinder Sensor Error E5 indicates a failure of the barrel sensor or if the sensor is out of range If the control panel displays an E5 press the On Off button forthe cylinder to turn it off then back on If the control panel still displays the error code refer to the machine s wiring diagram and the Temperature Sensor Chart Figure 7 1 Check each lead of the sensor to ground for continuity If continuity is found replace the sensor To check the resistance of the sensor place a thermocouple on the suction line at the exit of the freezing cylinder Compare temperature and
68. ow to go to the first screen 4 5 SETTINGS SCREENS A Modify Operating Settings Modify Operating Settings _ Basic Settings _ Advanced Settings _ Storage Settings _ User Preferences _ Time and Date This menu provides access to view and change the differ ent operating settings on the machine The Manager and Technician levels have access to these screens B Basic Settings Basic Settings Cylinder Right Enable Control Consist Consist CutOut Consist Offset 000 000 00 0 00 0 F 000 CutIn Consist Offset CutIn Temp CutOut Temp Cycles In Serve Mode This menu contains settings for the control style Cutln and CutOut cycles in serve mode and auger cycle times This screen is available to the Technician level Cylinder can be changed by pressing the SEL button The Enable Control setting determines the cutin and cutout style The options are Consistency Consistency Temperature Consistency or Temperature Temperature Setting the control to Consistency Consistency enables Serve 2 Mode instead of Serve 1 Mode Serve 2 Mode extends the post stir to prevent short cycling the com pressor and a possible misread of the consistency in the freezing cylinder CutOut Consistency Offset is a number that represents the point at which a freezing cycle will end in Consistency Consistency or Temperature Consistency style The actual cutout value is the sum of this number the Cutin Consistency Offset and the Motor Zero Load
69. per Assembly 1 49 8 5 SPIGOT ASSEMBLY Part Description 428045 Knob Spigot Handle Black 570961 Pin Cotterless Clevis Spigot Cam 696044 Spring Torsion Spigot Cam 718773 Switch Limit Spigot 2158082 Glide Spigot Socket 2187805 Handle Spigot Handle Only 8 6 FRONT 482004 Part Description 332563 Board Display Module Display Only 482004 Knob Spigot Adjustment 90 Quantity 3 CO WW CO GW CO Quantity 1 3 8 7 WIRING DIAGRAMS LEFT DRIVE MOTOR eC sromTNG KIEL WISCONSIN U S A 53042 ELECTRICAL WIRING DIAGRAM MODEL F231 3812 1812 30212 DIAGRAM NO 2202858 WD LEFT CYL SENSOR LC RIGHT CYL SENSOR RC BLUE BLUE RIGHT HOPPER SENSOR RH pLug AMBIENT SENSOR A DRIVE MOTOR WIRING BLACK BLACK LEFT HOPPER SENSOR LH _ BLACK FAN MOTOR 60 BLUE W WHITE STRIPE GREEN W YELLOW STRIPE DOOR INTERLOCK SWITCH NC OPEN SPIGOT SWITCHES HOPPER SOLENOID BLUI 81 80 PINK W BLACK STRIPE 61 LEFT SPIGOT SWT CENTER SPIGOT SWT 108 109 CENTER SPIGOT SWT BROWN W WHITE STRIPE 116 ORANGE W WHITE STRIPE SPIGOT 4 BLUE W WHITE STRIPE DOOR INTERLOCK SWT 114 HPC SWT PURPLE W WHITE STRIPE 116 TEMP PROBES SWITCH INPUTS LG FA GHEE L1 2 31 1121314 PLUG END OF CONNECTORS RIGHT DRIVE GRA 95 R Q RIGHT LIQUID SOLENOID 987 97 RIGHT SUCTION SOL
70. r before servicing Removethe four rubber compressor mounts from could result in death or serious injury the compressor I Crimp and braze all open ports of the old compressor before removing any panels for servicing NOTE B Remove the front panel A compressor returned to Stoelting with any open ports will void the warranty ALWAYS crimp and braze ports on a compressor that has been re moved C COMPRESSOR INSTALLATION C Removethe protective coverfromthe compressor terminals Disconnect the three terminals C common R run and S start D Connect to the and R terminals on the compressor Resistance through the run Make sure the machine is disconnected from the winding should be 1 160 10 electrical supply before removing any panels for E Connect an ohmmeter to the C and S terminals SES on compressor Resistance through the start Install the four rubber mounts on the compressor winding should be 3 100 10 Install the compressor into the machine fitting the base over the four bolt holes D Install the four washers and nuts onto the bolts and tighten securely 27 Remove all tubing plugs from the replacement compressor NOTE The compressor plugs protect the compressor from moisture in the air Do not remove the plugs until you are ready to install The compressor must not be opened to the atmosphere for more than 10 minutes F Leave the suction and discharge ports
71. reens 5 3 REFRIGERANT CHARGING Refer to the following procedures to properly charge the refrigeration system Stoelting recommends liquid refrigerant charging NOTE For qualified service personnel only Anybody work ing with refrigerants must be certified as a Techni cian TYPE l as required by 40 CFR 82 Subpart F and hold all State and or local refrigerant handling certifications In addition all handling storage and disposal of refrigerants must be in accordance with Environmental Protection Agency EPA guidelines and standards and all State and local guidelines and standards A Ensure the electrical supply has been removed before continuing B If the system has been opened or if there was a leak refer to Section 5 2 Refrigerant Recovery and Evacuation to evacuate the system prior to charging C Refer to machine s information plate for total charge requirements NOTE The refrigeration systems of F231 is critically charged Be sure to charge the system to the weight listed on the machine s information plate D Forliquid refrigerant charging connect refrigerant cylinder to the discharge Schrader valve of the compressor E Energize all five solenoid valves There are three liquid line solenoids and two suction line solenoids F Add the proper amount of refrigerant according to the machine s information plate 5 4 COMPRESSOR Tocheckifwindings are shorted to ground connect one ohmmeter lead to a b
72. s L Status at Time of Error Status at Time of Error Operating Mode Off Mix Levels Full Level Consistency 000 00 000 00 000 0 F 000 Input Voltage Motor Amps Ambient Temp Cylinder Temp The Status at Time of Error screen gives data for the time the error occurred 4 8 UPDATING FIRMWARE Before starting make sure there 15 liquid mix or water in the freezing cylinder The calibration steps cannot be completed with frozen product in the freezing cylinders Firmware is contained in a rom file which be down loaded from the extranet website or sent via email Down load the rom file onto the top level of a USB drive don t put the file in a folder and don t change the name of the file and follow the instructions below NOTE Updating firmware will not affect any parameter set ting in the control Any setting changes made prior to changing the firmware will be retained To reset all settings go to the Restore Factory Settings screen A Unplug the machine from electrical power NOTE On a dual power supply machine unplug both sides 21 Connect the USB flash drive to the port on the machine Depending on the model the USB port will be located 1 On the side of the machine Remove the plug 2 Behind the header panel Remove the panel and locate the USB connector on the display module Connect power to the machine On a dual power supply machine only the left side need
73. s 2 4 INSTALLING PERMANENT WIRING To install wiring follow the steps below A Refer to the nameplate on the side panel of the machine for specific 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 bottom of the machine C Install permanent wiring according to local code 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 C Notice all warning labels on the machine Wear properclothing Avoid loose fitting garments and remove watches rings or jewelry that could cause a serious accident Maintain a clean work area Avoid accidents by cleaning up the area and keeping it clean 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 Disconnect power for maintenance Never attempt to repair or perform maintenance on the machine until the main electrical power has been disconnected Do notoperate underunsafe operating conditions Neveroperate the machine if unusual or excessive noise or vibration occurs e Intellitec2 Control See Figure 3 2 m _ 3 2 OPERATING CONTROLS AND INDICATORS Before operating the machine it is required that the op erator know the f
74. s the amount of time between stir cycles Stir cycles occur in Serve Mode Standby Mode and Sleep 2 Mode 15 D Advanced Settings 2 of 2 Advanced Settings 2 of Cylinder Right 00 0 F 00 0 F 0000 sec _ Sleep 2 CutIn _ Sleep 2 CutOut _ Default Off Time The Advanced Settings menu contains standby and sleep mode adjustments and is available to the Manager and Technician levels Press the left arrow to go to the first screen Sleep 2 Cutln is the temperature that a freezing cycle starts in Sleep 2 Mode Sleep 2 CutOut is the temperature that a freezing cycle stops in Sleep 2 Mode Default Off Time is the maximum time between freezing cycles during Serve Mode or Serve 2 Mode E Storage Settings 1 of 2 Storage Settings 1 of 2 Active 00 0 F 00 0 F 00 F 00 min 0000 sec Storage Storage Storage Storage Storage Storage Refirgeration CutIn CutOut Offset Off Time On Time This Storage Settings menu contains storage refrigeration parameters and is available to the Technician level Press the right arrow to go to the second screen Storage Refrigeration can be set to Active or Suspend Active is the normal setting Suspend is used only for troubleshooting and setting an Never have refrigera tion set to Suspend during normal operation Storage is the temperature at which the storage refrigeration cycle starts This is how warm it will get before starting a storage
75. s the total time including serve mode and sleep mode that the freezing cylinder was operating with a low mix error The screen shows a running total the total for the previous day and the total for the previ ous week C Machine Statistics 3 of 10 Machine Statistics 3 of 10 Cylinder Right Last Clean Cycle 00 00 00 00 00 00 AM Last Clean Total Time 0000 min The Machine Statistics screen 3 of 10 provides the time and date that the freezing cylinder was last cleaned This value is recorded when the Clean button is pressed on the touchpad The screen also shows how long the most recent clean mode lasted D Machine Statistics 4 of 10 Machine Statistics 4 of 10 Cylinder Right 0000 min 0000 min 0000 min 0000 0000 sec Spigot Open Total Last 24hrs Last 7days Spigot Total Cycles Average Spigot Open The Machine Statistics screen 4 of 10 shows the total time that the spigot has been open during serve mode The screen shows a running total the total for the previous day and the total for the previous week The screen also shows the total times that the spigot has been opened E Machine Statistics 5 of 10 Machine Statistics 5 of 10 Cylinder Estimated Serve Amount Last 24hrs Last 7days Last Serve Reset Right 0000 gal 0000 gal 0000 gal 00 00 00 00 00 00 AM _ Reset Serve Amount The Machine Statistics screen 5 of 10 gives the estimated serve amount of the freezing cylinder based on the time
76. s to be connected The display should say Stoelting Foodservice Equipment in a large font and the new firmware version will be displayed at the bottom NOTE II the display does not show the Stoelting Food service Equipment text make sure the rom file is in the top level of the USB flash drive The rom file cannot be in any folders within the flash drive From the Current Status screen press the left arrow button to get to the passcode entry screen Enter the technician password to the control by pressing the right arrow SET then the SEL button Navigate to the Utilities menu and selectthe Next Utilities Menu Go to the Reset Unit Configuration option and press the SEL button On the Reset Unit Configuration screen select the Yes option and press the SEL button Confirm the control settings are the same as the values in the table below Machine Machine Type Motor Type F231 309 2 3 Saal 2 3 Machine amp Motor Types Scroll the cursor down to the Accept option and press the SEL button The screen will read Restoring This process takes about three minutes Once the control has completed this step it will automatically restart Enter the technician password to the control by pressing the right arrow SET then the SEL button Navigate to the Utilities menu and select the Next Utilities Menu Q Gotothe Motor Zero Load Calibration option and press the SEL button NOTE
77. the spigot is open during serve mode The estimation 15 also calculated forthe previous day and the previous week The screen gives an option to reset the serve amount and shows when the last reset was done Machine Statistics 6 of 10 Machine Statistics 6 of 10 Cylinder Compressor Run Time Compressor Cycles Right 0000 hr 0000 Last Compressor Reset 00 00 00 00 00 00 _ Reset Compressor Time The Machine Statistics screen 6 of 10 shows the total run time for the compressor and counts the total cycles There is an option to resetthe timer and the screen shows when the last reset was done The reset should be used if the compressor is changed G Machine Statistics 7 of 10 Machine Statistics 7 of 10 Cylinder Motor Run Time Motor Cycles Right 0000 hr 0000 Last Motor Reset 00 00 00 00 00 00 _ Reset Motor Time The Machine Statistics screen 7 of 10 shows the total run time for the drive motor and counts the total cycles There is an option to reset the timer and the screen shows when the last reset was done The reset should be used if the drive motor is changed H Machine Statistics 8 of 10 Machine Statistics 8 of 10 Cylinder Pump Run Time Pump Cycles Right 0000 hr 0000 Last Pump Reset 00 00 00 00 00 00 AM _ Reset Pump Time The Machine Statistics screen 8 of 10 shows the total run time for the pump and counts the total cycles There is an option to reset the timer and the s
78. tings menu Adjust the CutOut Consistency higher to increase the consistency or lower to decrease the consistency Make adjustments in increments of 5 for best results H The machine dispenses product at a reasonable draw rate If the machine is overdrawn the result is a soft product or a product that will not dispense at all If this occurs allow the machine to run for approximately 30 seconds before dispensing more product 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 Do not operate machine when the MIX LOW message is displayed Refill the mix container immediately NOTE The machine has a standby and sleep mode After a preset number of freezing cycles it will enter the standby mode followed by sleep mode and remain there until someone draws product or presses the PUSH TO FHEEZE button In the sleep mode the machine will keep the product below 41 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 MIX INFORMATION Mix can vary considerably from one manufacturer to another Differences in the amount of butterfat content and quantity and quality of other ingredients have a direct bearing on the finished frozen product A change in machine performance that cannot be explained by
79. trol goes to a screen that allows motors solenoids or the compressor to be individually activated Activate by moving the cursor to the desired component and press the SET button Selecting Left Right Monitoring goes to screens that show current statistics of the selected cylinder The Test Monitoring screens can be used for immediate feedback when troubleshooting For example the spigot switch can be tested by opening the spigot and observing if the status text changes from Closed to Open Test Monitoring 1 of 3 Cylinder CRC Errors Dis IO Motor Voltage Motor Current I V Phase Angle Frequency Consistency Right 0 6791 0 0 V 0 000 0 0 0 0 Hz 0 0 Test Monitoring 2 of 3 Cylinder CRC Errors Dis IO Ambient Temp Cylinder Temp Hopper Temp Pressure Sensor Pressure Sw Right 0 12 00 0 009 0 LC 0 Test Monitoring 3 of 3 Cylinder CRC Errors Dis IO Cabinet Door Right 0 12 Closed Closed Closed NO LOW Spigot Door Hi Pressure Liquid Level 18 G Motor Calibration Motor Calibration _ Left Press Sel to Start Current Zero Load _ Right Press Sel to Start Current Zero Load The Motor Calibration screen is used when a motor is replaced or the control firmware is updated Move the cursor to the correct option and press the SEL button to calibrate the motor to the control H Clear Error Log Clear Error Log This will clear the error log Are you s
80. ty motor or starting components which could produce a high amp draw ERROR CODE 3 RUN TIME The Run Time Error E3 occurs when the compressor runs continuously for an extended period This error could happen if the cutout parameter is not attained This error is generally caused by very low mix levels in the hopper or from product breakdown Another common cause results from a restriction preventing mix from entering the freezing cylinder Check the mix on the affected freezing cylinder 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 41 Ice crystals in the hopper can clog the mix inlet regulator and prevent mix from entering the freezing cylinder Thoroughly thaw mix per manufacturer s recommendations To check for ice crystals pour a small amount of product from the hopper through a clean and sanitized sieve or strainer If ice crystals are in the mix check the temperature of the walk in cooler where the mix is stored or the temperature of the machine s hopper If the hopper is below 34 F 1 C adjust the temperature by raising the Storage Cutout value in the Storage Settings menu The Run Time Error may also occur ifairflow within the machine has reduced or stopped Check the sides and top of the machine for anything that would restrict airflow Check the condenser filter and clean if necessary Check the evaporat
81. unction 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 INTELLITEC2 TOUCHPAD High voltage will shock burn or cause death The OFF ON switch must be placed in the OFF position prior to disassembling for cleaning or servicing Do not operate machine with panels removed Main Power On Off The Main Power button is used to supply power to the IntelliTec2 control the freezing cylinder circuits and the storage refrigeration system When the machine is first plugged in the control defaults to the On status with power to the hopper only If the Main Power On Off button is pressed when the machine is on the machine will turn off and a status message will be displayed on the screen Dispense Rate Adjustor 1 2 Figure 3 1 Machine Controls 7 MAFF LEFT CLEAN E SET Figure 3 2 IntelliTec2 Control Help Pressing the Help button will display help information dependant on the cursor s location Pressing the Help button again will exit the help screen Selection Button SEL The SEL button is used by technicians to select menu options Set Button SET The SET button is used by technicians to save changes when modifying control settings On Off Button Power to the freezing cylinders can then be c
82. ure you want to do that NO The Clear Error Log screen will clear all the errors in memory Clear Statistics Clear Statistics This will clear the statistics Are you sure you want to do that NO The Clear Statistics screen will clear all the statistics in memory J Restore Motor Table Defaults Restore Motor Table Defaults This will reset all motor tables to the original factory configurations Are you sure you want to do that No _Yes The Restore Motor Table Defaults screen allows you to restore the motor defaults 4 7 ERRORS amp STATISTICS SCREENS Errors and Statistics _ Machine Statistics _ Error History The Errors amp Statistics menu gives the Technician access to machine statistics and error history A Machine Statistics 1 of 10 Machine Statistics 1 of 10 Cylinder Time in Serve Mode Last 24hrs Right 0000 hr 0000 min 0000 hr 0000 hr 0000 min 0000 hr Last 7days Time in Off Mode Last 24hrs Last 7days The Machine Statistics screen 1 of 10 shows the time in serve mode and time in sleep mode The screen shows a running total the total for the previous day and the total for the previous week for both statistics 19 B Machine Statistics 2 of 10 Machine Statistics 2 of 10 Cylinder Right 0000 hr 0000 min 0000 hr Total Low Mix Run Last 24hrs Last 7days The Machine Statistics screen 2 of 10 shows the low mix running time This i
83. y CutOut Consist Offset R 404A W C 32 oz A C 42 oz One Cylinder 18 22 psig Both Cylinders 22 27 psig Hopper Only 14 psig 225 235 psig 14 psig only hopper running 68 70 psig 9U3 SISUOS 1n Qin esn V109 AousISISUOD pue 9ua sisuoy A 9ua sIsuo5 JO SI 9AJeg Um pue eui 101 SI BPO 145 y 19891 BJOAD 8789II p qpue s pue ay dae eun rej 10 98 ui dn PEJS 187898II oul 66 195 58 2 66 MOJ9Q 195 SI 5 10 ay uaym 998 si dn ueijs ay s 2 0 ay uoee ur 11615 y 810M 19591 S9 o 9 ICLIII0 sy V 0IV 1 seu y 104 19010 VII s jobids e Jo 5 si 373384 OL aun Aue 51858 deals Aqpuelis dee s nun 59I2 V915I5V 00 momo qpuels deals V915I5 00 10 2 1 HO dea s 999 C gpuels

Model F231 SERVICE MANUAL

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