Stoelting O111 User's Manual
Contents
1. Replace shaft Tighten knobs See Section 3 Replace o rings Remove spigot and check o ring Replace front door Call distributor for service Call distributor for service SECTION 5 REPLACEMENT PARTS 5 1 HOW TO ORDER PARTS B Serial number of model stamped on nameplate To assure receipt of the proper replacement parts supply C Part number part name and quantity needed your dealer or distributor with the following information Common part names and numbers are listed in this manual A Model number of equipment BRUSHES DECALS AND LUBRICATION pee ON 208135 Brush 4 x 8 x 16 Barrel 208380 Brush 1 4 x 3 x 14 208401 Brush 1 X 3 X 10 208467 Brush 3 8 x 1 x 5 324803 Decal Domed Stoelting Logo Large Header Panel 324804 Decal Domed Stoelting Swirl Header Panel 324825 Decal Main Freezer Power 508048 Hex Drive Anti Seize Spline Lubricant 20z Tube 508135 Petro Gel 40z Tube 2183079 Small Parts Kit 21 O111 REPLACEMENT PARTS 625133 314477 3159696 624598 d 2149243 he 624677 482019 666786 624678 2183083 149003 3170644 744276 744283 22 O111 REPLACEMENT PARTS EE 624678 5 O Ring Rear Seal Black 5 Pack i ow emm ome eem 666786 Seal Rear Auger Black E 4e 3 RRE 2149243 Mix Inlet Assembly 3 16 Hole Standard Length 2A 23 1 Gi STOELTING FOOD SERVICE EQUIPMENT WARRANTY SOFT SERVE2. 80 cm deep x 37 5 95 2 cm high Crated 28 75 73 cm wide x 38 75 98 4 cm deep x 43 109 2 cm high WEIGHT Freezer 310 lbs 140 5 kg Crated 380 Ibs 172 4 kg ELECTRICAL Description Optima 1 11 Voltage AC 1 PH 208 230V Total Run Amps 13 00 Drive Motor 1 5 HP Use 20 amp HACR circuit breaker Automatic safeguard circuit built into electronic control protects major freezer components under abnormal operating conditions COOLING Air cooled requires minimum 3 7 6 cm air clearance on right and left hand side No clearance needed in the rear Water cooled required 3 8 I D water supply line and 3 8 I D drain line minimum HOPPER 6 5 Gallons 24 6 liters refrigerated and insulated 2 SECTION 2 INSTALLATION INSTRUCTIONS 2 1 SAFETY PRECAUTIONS If danger warning or caution labels are needed indicate the part number type of label location of label and quantity Do not attempt to operate the freezer until the safety required along with your address and mail to precautions and operating instructions in this manual are read completely and are thoroughly understood STOELTING INC ATTENTION Customer Service 502 Hwy 67 Kiel Wisconsin 53042 Take notice of all warning labels on the freezer The labels have been put there to help maintain a safe working environment The labels have been designed to withstand washing and cleaning All labels mustremain legible for the life ofthe freez
3. Error Code 4 Clean If the freezer is left in the Clean Mode for more than 20 minutes the control panel will display a Clean Error Error 04 This condition does not reflect a problem with the freezer itself The Clean Error has been programmed into the controller as a safeguard to protect the freezer from potential damage caused by the freezer being accidentally left in Clean Mode The control will attempt to restart itself after 5 minutes The display will then flash and read Restart To immediately clear the Clean Error place the Main Power Off On switch in the Off position and back in the On position After the Clean Error has been cleared the freezer will start a refrigeration cycle to protect the product in case the clean button was pressed by mistake Error Code 5 Freezing Cylinder Sensor The Freezing Cylinder Sensor Error E5 indicates a failure of the barrel sensor or an extreme out of range condition lt 34 F or gt 99 F If the control paneldisplays an E5 place the Freezing Cylinder Off On switch in the Off position and back in the On position If the error persists contact your Authorized Stoelting Distributor for further assistance NOTE When the freezer encounters a Freezing Cylinder Sensor Error the freezer will continue to run using preset timers This mode will allow the operator to continue serving product until the freezer can be serviced Error Code 6 Hopper Sensor single hopper freez
4. The Stoelting Optima 111 counterfreezeris gravity fed The freezer is equipped with fully automatic controls to provide auniform product The freezer is designed to operate with almost any type of commercial soft serve or non dairy mix available including ice milk ice cream yogurt and frozen dietary desserts This manual is designed to assist quali fied service personnel and operators in the installation operation and maintenance of the Stoelting O111 gravity freezer Figure 1 1 Model O111 Freezer 19 11 16 50 0 cm Ut msi hr j D SS 5 Beon h 9 ff E e x i L1 L SESS SSS 32 1 16 37 7 16 2 2 x 81 5 cm 95 0 cm e a SSE os SSE DSSS i rd ur i ap 7 7 si 20 a SE 50 8 cm Se 2 c 5 S E IE _ E m e eg Sam c 5 ST ES 23 5 8 1 2 5 E 60 1 cm 31 5 8 SE 80 3 cm SIDE VIEW FRONT VIEW Figure 1 2 Freezer Specifications 1 MODEL OPTIMA 111 COUNTERMODEL GRAVITY FREEZER DIMENSIONS Freezer 19 50 2 cm wide x 31 5
5. 1 PRODUCT USE As the chlorine in the solution is being used chlorine concentrations fall TIME As time passes small amounts of chlorine evaporate from the solution That is why you can smell it Sanitizing solutions should not be allowed to fall below 100 ppm chlorine New solutions should be mixed once old solutions become ineffective B DAILY 1 The exterior should be kept clean at all times to preserve the luster of the stainless steel A mild alkaline cleaner is recommended Use a soft cloth or sponge to apply the cleaner CAUTION Do not use acidic cleansers strong caustic com pounds or abrasive materials to clean any part of the freezer exterior or plastic parts Use of these types of cleaners will cause equipment damage C WEEKLY Check o rings and rear seal for excessive wear and replace if necessary 2 Remove the drip tray by gently lifting up to disengage from the support and pulling out Clean behind the drip tray and front of the freezer with a soap solution D QUARTERLY High voltage will shock burn or cause death Turn off and lock out main power disconnect before ser vicing Do not operate machine with panels re moved The air cooled condenser is a copper tube and aluminum fin type Condensing is totally dependent upon airflow A plugged condenser filter condenser or restrictions in the louvered panel will restrict airflow This will lower the capacity of the system and damage t
6. SHAKE FREEZERS Scope Stoelting LLC warrants to the first user the Buyer that the freezer cylinders hoppers compressors drive motors speed reducers auger and auger flights of Stoelting soft serve shake freezers will be free from defects in materials and workmanship under normal use and proper maintenance appearing within five 5 years and that all other components of such equipment manufactured by Stoelting will be free from defects in material and workmanship under normal use and proper maintenance appearing within twelve 12 months after the date that such equipment is originally installed Disclaimer of Other Warranties THIS WARRANTY IS EXCLUSIVE AND STOELTING HEREBY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE Remedies Stoelting s sole obligations and Buyer s sole remedies for any breach of this warranty shall be the repair or at Stoelting s option replacement of the affected component at Stoelting s plantin Kiel Wisconsin or again atStoelting s option refund ofthe purchase price ofthe affected equipment and during the first twelve 12 months ofthe warranty period deinstallation reinstallation of the affected component from into the equipment Those obligations remedies are subject to the conditions that Buyer a signs and returns to Stoelting upon installation the Checklist Warranty Registration Card for the affected equipment b gives Stoelting prompt
7. and pressthe PUSH TO FREEZE button NOTE After the drive motor starts there is a 3 second de lay before the compressor starts LEDs The membrane switch featurestwo lights a green LED and an amber LED The green LED is lit during serve mode During freeze down the green LED is not lit When product consistency approaches 7596 in the freezing cylinder the green LED flashes The amber LEDis lit during all other modes In the event of an error or when the freezing cylinderis off both LEDs will alternatively flash NOTE If the freezer shuts off and alternating green and amber lights are flashing the freezer is in an error condition If the LCD displays an error turn the Main Freezer Power OFF ON switch to the OFF posi tion correct the problem Refer to Troubleshooting in Section 4 and turn the freezer back on CLEAN Button The CLEAN button will stop all refrigeration and start auger rotation A CLEAN message will display on the LCD screen and a 5 minute timer begins To exit the CLEAN mode press the CLEAN button again If the freezer is left in CLEAN for more than 20 minutes it will go into an error to prevent damage to the freezing cylinder When this error occurs refrigeration will start to prevent mix spoilage To reset place the Main Freezer Power OFF ON switch in the OFF position and back in the ON position Mix Low Light Indicator G The MIX LOW message will appear on the LCD display to alertthe opera
8. front ofthe freezer allows the operator to adjust the freezing cylinder to create the desired product consistency A Place the FREEZING CYLINDER OFF ON switch in the ON position B Press the SET button on the Control Panel once Fine Adj will appear on the LCD screen Fig 3 12 9 STOELTING fA Polar Ware Company Figure 3 13 Product Consistency Control C Press the up arrow button 4 until the desired consistency setting is displayed The higher the number the greater the product consistency firmness When the digit reaches 9 pressing the up arrow button ft again will change the value to 0 Press SET to save the value The 0 setting cannot be set D Press the SET button once to save the setting change and return to the current mode display 3 16 LOCKING OUT CONTROL PANEL The IntelliTec control has a tamper proof mode to prevent unauthorized use When set all buttons on the control panel are disabled To lock out the control panel A Press and hold the PUSH TO FREEZE button for 5 seconds B While still holding the PUSH TO FREEZE button press the CLEAN button once FREEZE TT 9 STOELTING SE A Polar Ware Company Figure 3 14 Locked Control Display In Serve Mode Release both buttons An asterisk will appear after the word MODE on the display indicating that the control is in the lock out mode Fig 3 13 To unlock the control panel repeat steps A B and C SECTION A TROUBLESHOO
9. is in place before adding mix C With spigot open pour approximately 1 gallon 3 8 liters of fully thawed mix into the hopper Allow the mix to flush out about 8 ounces 0 23 liters of sanitizing solution and liquid mix Close the spigot D Fill hopper with approximately 3 gallons 11 4 liters of pre chilled 40 F or 4 C mix NOTE Do not overfill the hopper Mix level must not be higher than the air inlet tube on the mix inlet regula tor 9 STOELTING 4f A Polar Ware Company Figure 3 5 During Freezing Cycle J Do not operate the freezer when the MIX LOW light is on or with less than 1 3 4 inches 4 4 cm of mixin the hopper Refillthe hopper immediately NOTE The freezer has standby and sleep modes When the freezer is not used after a preset number of freezing cycles it will enter the standby mode fol lowed by sleep mode and remain there until some one draws a product or presses the PUSH TO FREEZE button In the sleep mode the freezer will keep the product below 41 F 53C Sleep modes are not to be used in place of cleaning and sanitiz ing Frequency of cleaning and sanitizing is deter mined by Federal State and local regulatory agen cies 3 5 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 freezer performance
10. place will dam age the mix inlet regulator Figure 3 11 Auger Springs Install the two plastic flights onto rear ofthe auger and insert part way into freezer barrel Install the remaining plastic flights push the auger into the freezer barrel and rotate slowly until the auger engages the drive shaft Install the bushing and auger supportinto the front of the auger with one leg of the support pointing straight up Figure 3 11 Front Door Parts H Install the spigot body with o ring into the front door from bottom Fig 3 11 Push straight up until the spigot is in place I Install the front door on the freezer J Install the circular knobs on the freezer studs Overtightening or uneven tensioning of circular knobs may cause damage to front door and cause leaking Hand tighten circular knobs evenly K Look for the proper seal between the freezer barrel o ring and front door L Install the mix inlet regulator into the freezer with the air tube to the front of the freezer M Install hopper cover and drain tray 3 12 ROUTINE CLEANING To remove spilled or dried mix from the freezer exterior simply wash in the direction of the finish with warm soapy water and wipe dry Do not use highly abrasive materials as they will mar the finish 3 13 PREVENTIVE MAINTENANCE It is recommended that a maintenance schedule be fol lowed to keep the freezer clean and operating properly Cleaning and Sanitizing Informa
11. that cannot be explained by a technical problem may be related to the mix Proper product serving temperature varies from one manufacturer s mixto another Softserve mixes generally provide satisfactory product from 18 to 20 F 7 to 6 C shake mixes 24 to 28 F 4 to 2 C When checking the temperature stir the thermometer in the frozen product to read the true temperature Old mix or mix that has been stored at elevated tempera tures will produce poor quality product with a badtaste and unacceptable appearance To retard bacteria growth in dairy based mixes the best storage temperature range is between 36 to 40 F 2 2 to 4 4 C Some products tend to foam more than others If foam appears in the hopper skim off with a sanitized utensil and discard Periodically stir the mix in the hopper with a sanitized utensil to help prevent excess foam 3 6 REMOVING MIX FROM FREEZER To remove the mix from the freezer refer to the following steps A Remove the mix inlet regulator from the hopper by pulling straight up B Press the CLEAN button to rotate the auger Allow the mix to agitate in freezer barrel until the mix has become a liquid about 5 minutes C Drain the liquid mix by opening the spigot A bucket or container should be placed under the spigot to catch the liquid mix D Place the Main Freezer Power OFF ON switch in the OFF position 3 7 CLEANING THE FREEZER NOTE The frequency of cleaning the free
12. written notice of any claimed breach of warranty within the applicable warranty period and c delivers the affected equipmentto Stoelting or its designated service location inits original packaging crating also within that period Buyer shall bear the cost and risk of shipping to and from Stoelting s plant or designated service location Exclusions and Limitations This warranty does not extend to parts sometimes called wear parts which are generally expected to deteriorate and to require replacement as equipment is used including as examples but not intended to be limited to o rings auger seals auger support bushings and drive belts All such parts are sold AS IS Further Stoelting shall not be responsible to provide any remedy under this warranty with respect to any component that fails by reason of negligence abnormal use misuse or abuse use with parts or equipment not manufactured or supplied by Stoelting or damage in transit THE REMEDIES SET FORTH IN THIS WARRANTY SHALL BE THE SOLE LIABILITY STOELTING AND THE EXCLUSIVE REMEDY OF BUYER WITH RESPECT TO EQUIPMENT SUPPLIED BY STOELTING AND IN NO EVENT SHALL STOELTING BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WHETHER FOR BREACH OF WARRANTY OR OTHER CONTRACT BREACH NEGLIGENCE OR OTHER TORT OR ON ANY STRICT LIABILITY THEORY
13. TING 4 1 ERROR CODES When the freezer experiences a problem one of the following error codes will be displayed on the control panel Each error code directs you to the system location of the malfunction ERROR CODE MALFUNCTION 1 Soft High Torque Extended Run Time Clean Barrel Sensor Hopper Sensor Drive Motor ON o Om FR C bh Cab Sensor 9 10 11 Toreturn the freezer to normal operation any error caus ing condition must be corrected and the Freezing Cylinder Off On switch must be placed in the Off position and back in the On position before the affected side of the freezer will return to normal operation High Pressure Cutout Auxiliary Sensor Low Temperature 4 2 TROUBLESHOOTING Error Code 1 Soft Error The Soft Error E1 is an internal control board error that is logged for future analysis The refrigeration is never stopped and the freezer will continue to operate normally Error Code 2 High Torque If the control panel displays a High Torque Error E2 the controller has sensed that the drive motor is running at 12596 of the preset CutOut amp setting for 10 or more seconds This may be due to the product consistency adjustment being set too high Place the Main Power OFF ON switch in the OFF position wait until the product inthebarrelthawsto areasonably softconsistency and return the switch to the ON position Follow the instructions in Section 3 to reduce the product consistency by a few levels If the
14. aS VE VE YRK UNE Ee 21 LIST OF ILLUSTRATIONS FIGURE TITLE PAGE 1 1 ModelO111 Freezer TE 1 1 2 Freezer Specifications ormi orisi dioiii eaten ka eee deed 1 2 1 Warning Label Locations sssessssseeeeeeenemee nennen nnne 3 2 2 Space and Ventilation Requirements seeessseessieeesresetieestiressrrnettntttnnntsrnnnssennnnt 4 2 3 Electrical Plug eege e dat ei tel dec ENEE e E ladies 4 3 1 Freezer Controls et e reti gout cue ei E nna ail ace eae Meee ieee 5 3 2 Intellitec Controli mini ana aya ege aea tore ad ee 7 3 3 Mix Inlet Regulator e cete nm du ndis 7 34 Sanitizing Hoppet mineira ai nei iaaa ea tex Le dpt te ms e ede 8 3 5 During Freezing Cycle simian iniiai dedain ta datana i aa aaa enne nnne nnn nnns 8 3 6 Auger Flight Weie nceann a reo deeem a e a nae AS 10 3 7 Removing Auger Support ssssssssssssssseseeeeee nennen enne nter 10 3 8 Removing Auger Shaft and Flights sssssssseeeeeeeenns 10 3 9 Removing O RING ise essen rcc itti ee EE dope ee rr amer en dO Re du a 10 3 10 Cleaning Freezer Barrel sssssssssssessseeee nennen enn nennen snnt 11 3 11 Auger Spring Stn tic detect rdi enia Doce etd ext Ca PU enu eae a ea 11 3 12 Front Door Parts eene de eite deese Lope E Y e eet 12 3 13 Product Consistency Control 15 3 14 Locked Control Display In Serve Mode 15 SECTION 1 DESCRIPTION AND SPECIFICATIONS 1 1 DESCRIPTION
15. age 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 FREEZERINSTALLATION Installation of the freezer involves moving the freezer close to its permanent location removing all crating setting in place assembling parts and cleaning A Uncrate the freezer B Accurate leveling is necessary for correct drainage of freezer barrel and to insure correct overrun Place a bubble level on top of the freezer at each corner to check for level condition If adjustmentis necessary level the freezer by turning the bottom part of each leg in or out Then separate freezer base gasket and install with seam to the back and angle to the top C If the freezer is equipped with an air cooled condenser correctventilation is required The right side of the freezer is the air intake and left side discharge Both sides must have 3 clearance the top requires 10 of clearance CAUTION Failure to provide adequate ventilation will void war ranty Figure 2 2 Space and Ventilation Requirements D The freezer has been assembled operated andinspected E F Place the OFF ON switch in the OFF position Connect the power cord to the proper power supply Theplugis designedfor 208 or 230 volt 20 amp duty Check the nameplate on your freezer for proper supply The unit mus
16. amage 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 INTRODUCTION e WR eh DE 1 DE decis eiecit REESE E S IU IL 1 2 INSTALLATION INSTRUCTIONS 2 1 Safety e EE 3 2 2 ohipment and ME EE 4 2 9 Freezer Installation EE 4 3 INITIAL SET UP AND OPERATION 3 1 Operator s Safety Precautions EEN 5 3 2 Operating Controls and ae ie E 5 9 9 D E Te RES 7 344 Freeze Down and Operation EE 8 end memciucmedmccrlc Cm 9 3 6 Removing Mix From Freezer o aede ote eon isch ee et dede x QE 9 3 7 Cleaning The Freezer cael EE 9 3 8 Disassembly of Freezer Parts ege ees nre rasa dese entr x nn NENNEN 9 3 9 Cleaning The Freezer Parts s eecccceeeeeeeseeececeeeeeeeenensneceeeeeeeeesesssceeeeeeeeeees 10 3 10 Sanitize Freezer and Freezer Parts ee 11 3 11 Assembly of Freezer eise tereti rtr tein ene cina r pr Rene in UAR EEnE He DIS M OK red ee 11 3 12 Routine Gleanings sided be te cebat aet uu cU 12 3 13 Preventive Maintenance AAA 12 3 14 le EE ee 14 3 15 Product Consistency Adjustment ssssssssssssseeeenenenneeennnnn 15 3 16 Locking Reegel 15 4 TROUBLESHOOTING CHARTS A Oe EEE EAE eneen TA E 17 4 2 Troubleshooting Error Codes EE 17 4 3 Troubleshooting Charts EE 19 5 REPLACEMENT PARTS sxssissk csakcs Gs cabin nu rc rau rV ed kia cud ik aad daa d EE
17. cQ STOELTING FOOD SERVICE EQUIPMENT O111 IntelliTec Models OWNER S MANUAL Manual No 513588 1 Sept 2006 Owner s Manual For O111 Stoelting Counter Model Gravity Freezer Shake and Frozen Beverage This manual provides basic information about the freezer Instructions 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 freezer without notice and without incurring any obligation to modify or provide new parts for freezers built prior to date of change DO NOT ATTEMPT to operate the freezer until instructions and safety precautions in this manual are read completely and are thoroughly understood If problems develop or questions arise in connection with installation operation or servicing of the freezer contact the company at the following location STOELTING LLC Ph 800 558 5807 502 Hwy 67 Kiel WI 53042 Fax 920 894 7029 A Few Words About Safety Safety Information Read and understand the entire manual before operating or maintaining Stoelting equipment This Owner s 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 definitions are provided to assist the read
18. d rinsing the machine with water Next acleaneris run through the machine Then the machine is disassembled and removable parts are taken to the sink for cleaning MILKSTONE REMOVAL Since almost all cleaners do not have the ability to remove milkstone the use of a delimer becomes necessary Although this procedure may not be needed on a daily basis it will usually follow the cleaning procedure It requires letting a delimer solution soak in the machine for an extended period of time Individual parts are also soaked in a deliming solution for an extended period of time more about delimers in Additional Information SANITIZING Afterthe machine has been cleaned and contains no milkstone the machine is reassembled Then a FDA approved sanitizing solutionis run throughthe machineto kill bacteria The machine is then ready for food preparation As a recommended cleaner and sanitizer for your frozen dessert machine STERA SHEEN has provento be one of the best daily maintenance products for CLEANING Thorough removal of all solids including butterfat and milk fat MILKSTONE REMOVAL Complete removal of milkstone SANITIZING FDA approved no rinse sanitizer for food contact surfaces Additional Information THE USE OF DELIMERS A delimer is a strong acid that has the ability to dissolve milkstone This type of chemical may become necessary once high levels of milkstone have developed While these products are very effecti
19. de 11 Low Temperature The Low Temperature Error E11 occurs when the temperature ofthe gas refrigerantatthe barrel sensor falls below 20 F or 34 F depending on model Although the freezer will not shut down the active freezing cycle will immediately end This error usually occurs when the freezer continues to run in a low mix condition or if the freezer runs out of mix The product towards the front of the barrel tends to freeze solid When the temperature on the freezing cylinder lowers to the preset value the IntelliTec control will display an E11 ALTERNATING FLASHING CONTROL PANEL LIGHTS The display panel lights will flash in an alternating sequence under any error codes Clear the error and place the Freezing Cylinder Off On switch in the Off position and back in the On position 4 3 Troubleshooting Charts PROBLEM POSSIBLE CAUSE REMEDY Freezer does not run Freezer will not shut off Product is too soft Product is too firm Product does not dispense Power to freezer is off Fuse or circuit if blown or tripped Freeze up auger will not turn High pressure cut out tripped Front door not in place Not enough mix in hopper Drive belt failure Consistency temperature setting is too firm Refrigeration problem No vent space for free flow of cooling air Air temperature entering condenser is above 100 F Condenser is dirty Consistency setting too so
20. e can cause premature wear to machine parts which can add to costs for replace ment parts or possibly more expensive repairs if worn machine parts are not replaced once they have become excessively worn Important Differences Between Cleaning and Sanitizing CLEANING vs SANITIZING Itisimportantto distinguish between cleaning and sanitiz ing Although these terms may sound synonymous they are not BOTH are required for adequate food safety and proper machine maintenance CLEANING Is the removal of soil materials from a surface Is a prerequisite for effective sanitizing NOTE An UNCLEAN surface will harbor bacteria that can defy sanitizing efforts Bacteria can develop and resist sanitizing efforts within a layer of soil material milkstone Thorough cleaning pro cedures that involve milkstone removal are critical for operators of frozen dessert machines SANITIZING Kills bacteria Can be effective on clean surfaces only NOTE Using a SANITIZER on an unclean surface will not guarantee a clean and safe frozen dessert machine Proper Daily Maintenance The Only Way to Assure Food Safety and Product Quality Proper daily maintenance can involve a wide variety of products and procedures Overall the products and pro cedures fall into three separate categories Please note that this is a brief overview intended for informational purposes only 1 CLEANING This involves draining mix from the freezer barrel an
21. e rear of the barrel by dipping the brush in the sanitizing solution and brushing the rear of the barrel 3 11 ASSEMBLY OF FREEZER To assemble the freezer parts refer to the following steps NOTE Petrol Gel sanitary lubricant or equivalent must be used when lubrication of parts is specified NOTE The United States Department of Agriculture and the Food and Drug Administration require that lu bricants used on food processing equipment be cer tified 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 lubrication to exposed surfaces of the o rings Apply a thin film of sanitary lubricant to metal part of rear seal Also apply a thin film of sanitary lubricant inside and outside of the front auger support bushing Assemble the rear seal onto the auger with the large end to the rear Be sure the o ring is in place before installing the rear seal Lubricate the auger drive rear with a small amount of white socket lubricant A small container of socket lubricant is shipped with the freezer Screw the springs onto the studs in plastic flights Springs mustbe screwedinto the flights completely to provide proper compression Fig 3 10 CAUTION E F Do not place the mix inlet regulator into the hopper before installing the auger Attempting to install the auger with the mix inlet regulator in
22. er The purpose of safety symbols is to attract your attention to possible dangers The safety symbols and their explanations deserve your careful attention and understanding The safety warnings do not by themselves eliminate any danger The instructions or warnings they give are not substitutes for proper accident prevention measures If you need to replace a part use genuine Stoelting parts with the correct part number or an equivalent part We strongly recommend that you do not use replacement parts of inferior quality A Safety Alert Symbol This symbol Indicates danger warning or caution Attention is required in order to avoid serious personal injury The message that follows the symbol contains important information about safety Signal Word Signal words are distinctive words used throughout this manual that alert the reader to the existence and relative degree of a hazard A 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 A 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 situa tion which if not avoided may result in equipment property d
23. er Labels should be checked periodically to be sure they can be recognized as warning labels This freezer has foom insulotion that hos been formed with refrigerant gas The i 1 insulation may emit refrigerant vapors H il WIRING DIAGRAM which could deceive leok detectors ond a REV give tolse readings nan o o DANGER ATTENTION ELECTRIC SHOCK HAZARD DISCONNECT FROM THE SOURCE OF ELECTRICAL SUPPLY IN BUILDING BEFORE SERVICING UNIT news T ATTENTION oc WIRED ACCORDING TO CAUTION HAZARDOUS MOVING PARTS DO NOT OPERATE UNIT WITH OUTER COVERING REMOVED 324107 NCAUTION Cm m Om eee ATIENTION h x HAZARDOUS ROTATING BLADES DO NOT OPERATE UNIT WITH FRONT DOOR OR SPIGOT REMOVED ines i H T EE 9 i i ii i ELECTRIC WIRING MATERIALS ARRANGEMENT amp GROUNDING MUST CONFORM WITH NATIONAL AND OTHER APPLICABLE ELEC CODES 324106 Figure 2 1 Warning Label Locations 3 2 2 SHIPMENT AND TRANSIT at the factory Upon arrival at the final destination the complete freezer must be checked for any damage which may have occurred during transit With the method of packaging used the freezer should arrive in excellent condition THE CARRIER IS RESPON SIBLE FOR ALL DAMAGE IN TRANSIT WHETHER VIS IBLE OR CONCEALED Do not pay the freight bill until the freezer has been checked for damage Havethe carrier note any visible damage on the freight bill If concealed damage and or short
24. error persists contact your Authorized Stoelting Distributor for further assistance Error Code 3 Run Time The Run Time Error E3 occurs when the compressor runs continuously for 30 minutes without the product reaching consistency in Serve Mode or if the product does not reach proper temperature in Sleep 2 Mode This error is generally caused by very low mix levels in the freezer s mix container or from product breakdown Another common cause results from a restriction preventing mix from entering the freezing cylinder Check the mix in the hopper If the level mix is low add mix If there is a possibility that the mix is broken down clean and sanitize the freezer and replace the mix with fresh product Ice crystals in the hopper can clog the mix inlet system and prevent mix from entering the freezing cylinder Thoroughly thaw mix per manufacturer s recommendations To check for ice crystals pour a small amount of product in the 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 freezer s cabinet The Run Time Error may also occur if airflow within the freezer has reduced or stopped Check the sides and top of the freezer for anything that would restrict airflow If the error persists after attempting to clear it contact your Authorized Stoelting Distributor for further assistance
25. ers The Hopper Sensor Error E6 indicates a failure of the hopper sensor or an extreme out of range condition 34 F or gt 99 F If the control panel displays an E6 place the Freezing Cylinder Off On switch in the Off position and back in the On position If the error persists contact your Authorized Stoelting Distributor for further assistance Error Code 7 Drive Motor If the control panel displays a Drive Motor Error E7 the control does not sense current coming fromthe drive motor Place the Freezing Cylinder Off On switch in the Off position and back in the On position If the error persists contact your Authorized Stoelting Distributor for further assistance Error Code 8 Cab Sensor A Cab Sensor Error E8 will not occur on the E111 or F111 freezer 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 on an air cooled freezer checkfor proper airclearance around the freezer If the error persists contact your Authorized Stoelting Distributor for further assistance Error Code 10 Auxiliary Sensor An Auxiliary Temperature Sensor Error R10 occurs if the temperature sensor on the control board fails Place the Freezing Cylinder Off On switch in the Off position and back in the On position If the error persists contact your Authorized Stoelting Distributor for further assistance Error Co
26. ft Stabilizers in mix are broken down Auger is assembled wrong Refrigeration problem No mix in hopper Consistency temperature setting is too firm Line voltage fluctuating No mix in hopper Mix inlet regulator tube is plugged Capacity of freezer is being exceeded Drive motor overload tripped Drive belt failure Freeze up Auger will not turn Supply power to freezer Replace or reset Turn CLEAN OFF ON switch to OFF middle position for 15 minutes then restart Wait for switch to reset 10 minutes Assemble front door in place Fill hopper with mix Replace drive belt Turn Consistency Adjustment knob counter clockwise Check system Call distributor for service A minimum of 3 inches of vent space required See Section 2 Change location or direct hot air away from freezer Clean See Section 3 Turn Consistency Adjustment knob clockwise Remove mix clean sanitize and freeze down with fresh mix Remove mix clean reassemble sanitize and freeze down Check system Call distributor for service Fill hopper with mix Turn Consistency Adjustment knob counter clockwise Check Call distributor for service Fill hopper with mix Unplug using small sanitized brush Slow up on the draw rate Reset If condition continues call distributor for service Re
27. he compressor The condenser must be kept clean of dirt and grease The freezer must have a minimum of 3 7 5 cm of ventilation on the right and left sides of the unit for free flow of air Make sure the freezer is not pulling over 100 F 37 C air from other equipment in the area The water cooled condenser is a tube and shell type The condenser needs a cool clean supply of water to properly coolthe freezer inlet and discharge lines must be 3 8 I D minimum Thecondenser and condenser filter require periodic clean ing To clean refer to the following procedures 1 Remove the Phillips head screw from the bottom of the right side panel and then slide the panels down and out Toremove the condenser filter grasp the top and pull off Visually inspect for dirt If the filter is dirty shake or brush excess dirt off the filter and wash inwarm soapy water Once the filter is clean rinse thoroughly in warm clear water and shake dry taking care not to damage the filter in any way Figure 28 Visually inspect the condenser for dirt by shining alightthrough the coil from the back inside of the condenser Ifthe condenseris dirty place a wettowel overthe front outside of the condenser Using a vacuum carefully clean the condenser coil from the inside and outside of the freezer A stiff bristled brush may help in releasing debris from between the condenser coils E SEMI ANNUALLY 1 Check drive belt for proper ten
28. hock burn or cause death The E Stay alert at all times Know which switch push button or control you are about to use and what effect it is going to have OFF ON switch must be placed in the OFF position prior to disassembling for cleaning or servicing Do not operate machine with cabinet panels removed F Disconnect electrical cord for maintenance Never attempt to repair or perform maintenance on the freezer until the main electrical power has been disconnected IntelliTec Control See Figure 3 2 Figure 3 1 Gesten Controls Spigot Switch The spigot switch will automatically actuate the auger drive and refrigeration systems when the spigot is opened to dispense product When the spigot is closed the drive motor and compressor will remain on until the product in the barrel reaches the proper consistency Main Freezer Power OFF ON Switch The Main Freezer Power OFF ON switch is a two position toggle switch used to supply powerto the control circuit When the switch is in the OFF position power will not be supplied to the control board or refrigeration system When the switch is in the ON position the freezer will operate in the freezing mode or cleaning mode The freezer will be in the sleep mode until a switch is activated PUSH TO FREEZE Button The PUSH TO FREEZE button is used to initiate the serve mode To start the freezer place the Main Freezer Power OFF ON switch in the ON position
29. nd de lay before the compressor starts G After about 6 to 10 minutes the product will be at consistency and the LCD screen will display SERVE The product is ready to serve Freeze down time may be longer for some frozen diet dessert mixes High ambient temperatures may extend freeze down time Figure 3 4 Sanitizing Hopper D Clean sides of hopper mix inlet regulator and Bh Par normal BS pensi pul ihe spigot handig down to fully open the spigot underside of hopper cover using a sanitized soft bristle brush dipped in the sanitizing solution Fig NOTE 3 4 Refrigeration is automatically activated when the E After five minutes place a bucketunderthe spigot spigot is opened Close the spigot completely after andopenspigotto drain sanitizing solution When dispensing solution has drained press the CLEAN button to stop the auger Allow the freezer barrel to drain completely Thefreezeris designedto dispensethe product at areasonable draw rate Ifthe freezeris overdrawn the resultis a soft productor a productthat will not dispense at all If this should occur wait until the 3 4 FREEZE DOWN AND OPERATION bars fill the lower section of the display Fig 3 5 This section covers the recommended operating proce dures to be followed for the safe operation of the freezer A Sanitize just prior to use B Place the Main Freezer Power OFF ON switch in OSE RIE the OFF position NOTE Make sure the mix inlet regulator
30. nitizer must be used only in accordance with the manufacturer s instructions CAUTION Do not allow sanitizer to remain in contact with stain less steel freezer parts for prolonged periods Pro longed contact of sanitizer with freezer may cause corrosion of stainless steel parts In general sanitizing may be conducted as follows A Prepare Stera Sheen Green Label Sanitizer or equivalent according to manufacturer s instructions to provide a 100ppm strength solution Mix the sanitizer in quantities of no less than 2 gallons of 90 to 110 F 82 to 43 C water Any sanitizer must be used only in accordance with the manufacturer s instructions B Push the mix inlet regulator into hopper with air inlet long tube toward the front of the freezer Fig 3 3 C Place the Main Freezer Power OFF ON toggle switch in the ON position and press the CLEAN switch Check for leaks Figure 3 3 Mix Inlet Regulator E The freezer barrel will automatically fill until it is about 1 2 full If freezer barrel does not fill check for obstruction in the mix inlet regulator If freezer barrel fills over 1 2 full indicated by low overrun check for leaks at the mix inlet regulator o ring or check if the mix inlet regulator was installed correctly or that the freezer is level F Place the Main Freezer Power OFF ON switch in the ON position then pressthe PUSHTO FREEZE switch NOTE After the drive motor starts there is a 3 seco
31. place drive belt Turn CLEAN OFF ON switch to OFF middle position for 15 minutes then restart 4 3 Troubleshooting Charts continued PROBLEM POSSIBLE CAUSE REMEDY Drive belt slipping or squealing Low overrun Rear auger seal leaks Front door leaks Hopper will not maintain mix temperature below 40 F CH Worn drive belt Freeze up Auger will not turn Auger is assembled wrong Mix inlet regulator missing Mix inlet regulator o ring missing Mix inlet regulator air tube blocked Product breakdown Outside surface of rear auger seal is lubricated Rear seal missing or damaged Seal o ring missing damaged or installed incorrectly Worn or scratched shaft Front door knobs are loose Spigot parts are not lubricated Chipped or worn spigot o rings O rings or spigot installed wrong Inner spigot hole in front door nicked or scratched Hopper temperature set too warm Refrigeration problem 20 Replace drive belt Turn CLEAN OFF ON switch to OFF middle position for 15 minutes then restart Remove mix clean sanitize and freeze down with fresh mix Replace mix inlet regulator Replace mix inlet regulator o ring Clean with sanitized brush Fill freezer with fresh product Clean lubricant from outside of rear seal lubricate inside of seal and reinstall Check or replace Check or replace
32. seal Place all loose parts in a pan or container and take to the wash sink for cleaning To clean freezer parts refer to the following steps l Wipe socket lubricant from the drive end rear of the auger with a cloth or paper towel Figure 3 10 Cleaning Freezer Barrel Prepare detergent water by mixing 2 oz of Palmolive detergent or equivalent in 2 gallons of 90 to 110 F 32 to 43 C water Place all parts in detergent solution and clean with provided brushes Rinse all parts with clean 90 to 110 F 32 to 43 C water Wash the hopper and freezing cylinder with the 90 to 110 F 32 to 43 C detergent water and brushes provided Refer to Figure 3 9 Clean the rear seal surfaces from the inside of the freezing cylinder with the 90 to 110 F 32 to 43 C detergent water Clean the drip tray and insert with a soap solution Rinse with clean hot water 3 10 SANITIZE FREEZER AND FREEZER PARTS A Use a sanitizing solution mixed according to manufacturer s instructions to provide 100 parts per million strength solution Mix sanitizer in quantities of no less than 2 gallons 7 5 liters of 120 F water Allow the sanitizer to contact the surfaces to be sanitized for 5 minutes Any sanitizer must be used only in accordance with the manufacturer s instructions Place all parts in the sanitizing solution then remove and let air dry Using this sanitizing solution and the large barrel brush provided sanitize th
33. sion Push belt in with one finger belt should deflect about 3 8 2 Lubricate condenser fan motor with S A E 20 weight oil Three to six drops is required CAUTION Do not over lubricate resulting damage could cause motor failure 3 14 EXTENDED STORAGE Referto the following steps for storage of the freezer over any long period of shutdown time A Turn the Main Freezer Power OFF ON switch to the OFF position B Disconnect unplug from the electrical supply source C Clean thoroughly with a warm water detergent all parts that come in contact with the mix Rinse in clean water and dry parts Do not sanitize NOTE Do not let the cleaning solution stand in the hopper or in the freezer barrel during the shutdown period D Remove disassemble and clean the front door mix inlet regulator and auger parts Place the auger flights and the front auger support bushing inaplastic bag with a moist papertowelto prevent them from becoming brittle In a water cooled freezer disconnect water lines anddrain water With aflathead screwdriver hold the water valve open and use compressed air to clear the lines of any remaining water 3 15 PRODUCT CONSISTENCY ADJUSTMENT The Intelli Tec control monitors the consistency firmness of the product mix in the freezing cylinder by monitoring the drive motor amp draw When consistency is reached the drive motor and refrigeration system will shut off The control panel on the
34. sistency adjustment procedures Left Arrow Button Pressing any button on the control panel will automatically illuminate the display The backlight willturn off several seconds after use To keepthe display constantly lit press and hold the left lt button for five seconds The backlightfunction can be resetto normal operation in the same manner Up Arrow Button TT Pressing this button will change the value of the product consistency Refer to Section 3 15 for consistency adjustment procedures 3 3 SANITIZING Sanitizing must be done after the freezer is cleaned and just before the hopper is filled with mix Sanitizing the night before is not effective However you should always clean the freezer and parts after each use THE UNITED STATES DEPARTMENT OF AGRI CULTURE AND THE FOOD AND DRUG ADMIN ISTRATION REQUIRE THAT ALL CLEANING AND SANITIZING SOLUTIONS USED WITH FOOD PROCESSING EQUIPMENT BE CERTIFIED FOR THIS USE When sanitizing the freezer refer to local sanitary regula tions for applicable codes and recommended sanitizing products and procedures The frequency of sanitizing must comply with local health regulations Mix sanitizer according to manufacturer s instructions to provide a 100 parts per million strength solution Mix sanitizer in quantities of no less than 2 gallons 7 5 liters of 90 to 110 F 32 to 43 C water Allow sanitizer to contact the surfaces to be sanitized for 5 minutes Any sa
35. t be connected to a properly grounded receptacle The electrical cord furnished as part of the freezer has a three prong grounding type plug Fig 2 3 The use of an extension cord is not recommended if necessary use one with asize 12gaugeorheavier with ground wire Do notuse an adapter to get around grounding requirement 208 230V 115V 20 Amp 20 Amp Do not alter or deform electrical plug in any way Altering the plug to fit into an outlet of different con figuration may cause fire risk of electrical shock product damage and will void warranty Install the drip tray drain tray hopper cover and other miscellaneous parts on the freezer SECTION 3 INITIAL SETUP AND OPERATION 3 1 OPERATOR S SAFETY PRECAUTIONS G Do not operate under unsafe operating conditions SAFE OPERATION IS NO ACCIDENT observe these Ee rules noise or vibration occurs A Know the freezer Read and understand the 3 2 OPERATING CONTROLS AND INDICATORS Operating Instructions Before operating the freezer itis required that the operator know the function of each operating control Refer to C Wear proper clothing Avoid loose fitting garments Figure 3 1 forthe location of the operating controls on the and remove watches rings or jewelry which could freezer cause a serious accident B Notice all warning labels on the freezer D Maintain a clean work area Avoid accidents by cleaning up the area and keeping it clean High voltage will s
36. the customer and to maintain good freezer perfor mance and a quality product Check the wear line on the auger flights on a regular basis Fig 3 6 and replace as needed Frequency of cleaning must comply with the local health regulations Figure 3 6 Auger Flight Wear To disassemble the freezer refer to the following steps N Y A Remove hopper cover and drain tray Figure 3 8 Removing Auger Shaft and Flights B eas die ragiatoriromthe hopper by J Remove all o rings from parts by first wiping off Pee nee the lubricant using a clean paper towel Then C Remove the front door by turning the circular squeeze the o ring upward with a dry cloth Fig 3 knobs and then pulling the front door off the studs 8 When a loop is formed roll out of the o ring D Remove the rosette cap from the front door Push groove the spigot body through the bottom of the front door and remove CAUTION E Removethe front auger support and bushing Fig E Do not use any type of sharp object to remove the d o rings Figure 3 7 Removing Auger Support F Remove the auger assembly from the freezer Fig 3 8 Pull the auger out of the freezer barrel di slowly As the auger is being pulled out carefully Figure 3 9 Removing O Ring remove each of the plastic flights with springs G Keep the rear of the auger shaft tipped up once it is clear of the freezer to avoid dropping rear seal 3 9 CLEANING THE FREEZER PARTS H Remove the rear
37. tion Soft serve freezers require special consideration when it comes to food safety and proper cleaning and sanitizing The following information has been compiled by Purdy Products Company makers of Stera Sheen Green Label Cleaner Sanitizer and specifically covers issues for clean ing and sanitizing frozen dessert machines This informa tion is meant to supplement a comprehensive food safety program Soil Materials Associated with Frozen Dessert Machines MILKFAT BUTTERFAT As components of ice cream frozen custard mix these soils will accumulate on the interior surfaces of the machine and its parts Fats are difficultto remove and help attribute to milkstone buildup MILKSTONE Is a white gray film that forms on equip ment andutensils that come in contact with dairy products These films will accumulate slowly on surfaces because of ineffective cleaning use of hard water or both Milkstone is usually a porous deposit which will harbor microbial contaminants and eventually defy sanitizing efforts Once milkstone has formed it is very difficult to remove Without using the correct product and procedure it is nearly impossible to remove a thick layer of milkstone NOTE general purpose cleaners DO NOT remove milkstone This can lead to high bacteria counts and a food safety dilemma IT IS BEST TO CONTROL MILKSTONE ON A DAILY BASISBEFOREIT CANBECOMEA SIGNIFICANT FOOD SAFETY PROBLEM In addition to food safety milkston
38. torto alow mix condition The message will display when there is approximately one gallon of mix leftinthe hopper When the MIX LOW message is displayed refill hopper immediately NOTE Failure to refill hopper immediately may result in operational problems DISPENSE RATE ADJUSTERS The dispense rate adjuster limits the opening of the spigot To adjust product dispense rate turn the adjusting knob clockwise for slower flow and counterclockwise for faster flow It takes at least five complete turns of the adjusting knob to make a noticeable difference in the dispense rate FRONT DOOR SAFETY SWITCH The front door safety switch prevents the auger from turning when the front door is removed The switch is open when the door is not in place and closed when the door is properly installed MENU NAVIGATION BUTTONS Push to Freeze Green Light Amber Light Clean Switch SEL Button SET Button Left Arrow Button Up Arrow Button el STOELTING V Polar Ware Company Figure 3 2 IntelliTec Control The Menu Navigation Buttons allow the user to display information regarding the freezer s status of operation as well as adjust product consistency Selection Button SEL The SEL button is not functional in the normal operation mode This button is only used by service technicians for freezer calibration Set Button SET Pressing this button will save a change made to the product consistency setting Referto Section 3 15 for con
39. ve for removing HIGH levels of milkstone they are not ideal for two reasons 1 PRODUCT SAFETY Strong acids are dangerous chemicals and handling them requires safety MACHINE DAMAGE Strong acids will attack metal and rubber causing premature wear of parts The use of a delimer needs to be closely monitored to avoid damage to machine surfaces and parts With proper daily use of STERA SHEEN or its equivalent there is no need for the use of a DELIMER DO NOT USE BLEACH BLEACH HAS ABSOLUTELY NO CLEANING PROPERTIES BLEACH IS CORROSIVE Itcan and will damage components of the machine causing premature wear and metal corrosion GENERAL PURPOSE CLEANERS General purpose cleaners do not have the ability to re move milkstone Milkstone will become a problem if not remedied with additional products and procedures THE USE OF CHLORINE TEST STRIPS Test strips are used to determine concentrations of active chlorine in sanitizing solutions To use the strips tear off a small portion and submerge it into the sanitizing solution Then compare the color change to the color key on the side of the test strip dispenser to determine the approximate chlorine concentration The ideal concentration of chlorine needs to be 100 ppm as stated by the FDA NOTE Follow the directions on the container for proper con centration There are two main factors that contribute to falling chlo rine concentrations in a sanitizing solution
40. zer and freezer parts must comply with local health regulations After the mix has been removed from the freezer the freezer must be cleaned To clean the freezer refer to the following steps A Fill the hopper with 2 gallons 7 5 liters of tap water B Place the Main Freezer Power OFF ON switch in the ON position and press the CLEAN switch The auger will start to rotate C Allow the water to agitate for approximately 30 Seconds NOTE If freezer is left in CLEAN for more than 20 minutes the display will show an error code To reset place the Main Freezer Power OFF ON switch in the OFF position and back in the ON position D Open the spigot to drain the water Remember to place a container under the spigot to catch the water When the water has drained place the switch in the OFF position Allow the freezing cylinder to drain completely E Prepare detergent water by mixing 2 oz of Palmolive detergent or equivalent in 2 gallons of 90 to 110 F 32 to 43 C water Repeat steps A through D using the detergent solution 3 8 DISASSEMBLY OF FREEZER PARTS Hazardous Moving Parts Revolving auger shaft can grab and cause injury Place the Main Freezer Power OFF ON switch in the OFF position before disassembling for cleaning or servicing Inspection for worn or broken parts should be made each time the freezer is disassembled All worn or broken parts should be replaced to ensure safety to both the operator and
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