Operation Manual 11/2004
Contents
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4. STOELTING A Polar Ware Company OPTIMA 111 OWNER S MANUAL Manual No 513588R1 Nov 2004 Need Parts or Service Our Technicians are factory trained and are certified in the Stoelting Technicare program CALL A Distributor Phone No Model No Serial No Purchase Date Start Up Date OWNER S MANUAL FOR MODEL OPTIMA STOELTING SOFT SERVE COUNTER MODEL GRAVITY FREEZER This manual provides basic information about the freezer Instructions and suggestions are given covering its operation andcare The illustrations and specifications are not binding in detail Wereserve the rightto 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 atthe following location STOELTING LLC Tele 920 894 2293 502 Hwy 67 Kiel WI 53042 1600 Fax 920 894 7029 TABLE OF CONTENTS SECTION DESCRIPTION PAGE 1 INTRODUCTION 1 1 Despi nee nee 1 1 2 Specifications ee ee 1 2 INSTALLATION INSTRUCTIONS 2 1 Safely Precautions a c er ee 3 2 2 Shipm nt and ternera 4 23 Freezer ee 4
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6. 24 Floor Stand Instala nn ae 2 5 Installing Permanent Wiring 5 3 INITIAL SET UP AND OPERATION 3 1 Operator s Safety aid 7 3 2 Operating Controls and nen see 7 9 9 A a EY 8 3 4 Freeze Down and ae ee ee 9 35 MIX TOIT VI Are 10 3 5 Removing Mix From FIGS usu 10 37 Cleaning The 11 3 8 Disassembly of Freezer Parts ana 11 3 9 Cleaning The Freezer Pas anne ee os 12 3 10 Sanitize Freezer and Freezer Parts ds 12 3 11 Assembly of 12 3 12 Ro tine CIS AIMAR 13 3 13 Preventive Maintenance ae ee 14 3 14 Extended Storage 16 4 TROUBLESHOOTING CHARTS sa 17 5 REPLACEMENT PARTS nn ae 21 LIST OF ILLUSTRATIONS FIGURE TITLE PAGE 1 Model Optima 111 Freezer sici n ii dae 1 2 SPCCINICALONS u EM 1 3 Warning Label LOCations u en 3 4 Leveling add ene tie ned 4 5 Space and Ventilation Requirements u uuu uu u aaa 4 6 Electrical Pig u l eb 4 7 Installing Tray and COVEN sau a se ana 4 8 Floor SIl8nd anat airtel at ee 5 9 Power Cord Connection EUER 5 10 op M 7 11 Mix Inlet Hegulator asa eie en 9 1
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9. 901726 616 61 AM 169ZZ Ly 99Gvc 00006 071896 890 LL 606 910993 949 216 640942 5842 16 899179 086 1 68 000679 20010Z 629 216 829 216 N d bunjeols Ic 0c 61 81 4 91 SL vL el Ora rrr sf LO OR OO O gt 91 1 eo STOELTING A Polar Ware Company WARRANTY SOFT SERVE 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 plant in Kiel Wisconsin or again at Stoelting s option refund of the purchase price of the affect
10. OF CHLORINE TEST STRIPS Test strips are used to determine concentrations of active chlorine in sanitizing solutions To use the strips tear off a small portion and submerge it into the sanitizing solution Then compare the color change to the color key on the side of the test strip dispenser to determine the approximate chlorine concentration The ideal concentration of chlorine needs to be 100 ppm as stated by the FDA NOTE Follow the directions on the container for proper concentration There are two main factors that contribute to falling chlorine concentrations in a sanitizing solution 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 NWARNING NEVER ATTEMPT TO REPAIR OR PERFORM MAINTENANCE ON FREEZER UNTIL THE MAIN ELECTRICAL POWER HAS BEEN DISCON NECTED DAILY 1 The exterior should be kept clean at all times to preserve the lustre of the stainless steel A mild alkaline cleaner is recommended Use a soft cloth or sponge to apply the cleaner CAUTION DO NOT USE ACID CLEANERS STRONG CAUS TIC COMPOUNDS OR ABRASIVE MATERIALS TO CLEAN ANY PART OF THE FREEZER EXTERIOR OR PLASTIC PARTS WEE
11. 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
12. error Barrel sensor Hopper sensor Drive motor Flashing CLEAN light is not an error It indicates the freezer is in the CLEAN mode To exit turn the OFF ON switch to the OFF position 20 SECTION 5 REPLACEMENT PARTS 5 1 HOW TO ORDER PARTS To assure receipt of the proper replacement parts supply your dealer or distributor with the following information Part Number 208401 208135 208381 208467 324107 324105 324106 324108 324141 324584 368140 508135 508048 Model number of equipment Serial number of model stamped on nameplate Part number part name and quantity needed Com mon part names and numbers are listed in this manual Description Brush 2 54cm 1 diameter Brush 10cm 4 diameter Brush 95cm 3 8 diameter Brush 80cm 5 16 diameter Decal Hazardous Moving Parts Decal Electrical Shock Hazard Decal Applicable Electrical Code Decal Caution Decal Caution Rotation Blade Decal Adequate Ventilation Air Filter Petro Gel Lubricant Spline Lubricant Common Wearable Parts 381804 694255 624598 625133 624607 624678 666786 149003 232734 152371 Auger Flights 5 Auger Flight Springs 5 O Ring Spigot 2 O Ring Door 1 O Ring Carburetor 2 O Ring Auger Rear Seal 1 Rear Seal w insert 1 Front Auger Bushing 1 Rosette Cap 1 V Belt 2 21
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14. 2 een PX eet aa aaa aa 9 13 Sanitizing Hopper sea a id 9 14 Draining Solution cui es 9 15 Dispensing Product u ana 10 16 Removing Mix Inlet Regulator usrssssssnsnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnn nennen 10 17 Draining MIX uyu ea 10 18 Auger Flight Wear amp Front Auger Support Bushing 11 19 Removing Front Door 11 20 Front Door Disassembly nie 11 21 Removing Auger SUP POM tees nennen 11 22 Auger Shaft Removal utasa ies 12 23 Removing OF RING eet 12 24 Cleaning Freezer Barrel esse sss eerie 12 25 Exploded VIEW or Augen vsu is natn s tenet eed bu n e e rus 13 26 Exploded View of Front Do0 sessies een 13 27 IPSI dare cio 13 SECTION 1 DESCRIPTION AND SPECIFICATIONS 1 1 DESCRIPTION The Stoelting Optima 111 counter freezer is gravity fed The freezer is equipped with fully automatic controls to provide a uniform product The freezer is designed to operate with almost any type of commercial soft serve or non dairy mixer available including ice milk ice cream yogurt and frozen dietary desserts This manual is designed to assist qualified service personnel and opera tors in the installation operation and maintenance of the Stoelting Model Optima 111 gravity freezer Figure 1 Model Optima 111 Freez
15. 60 1 cm a 31 5 8 80 3 cm SIDE VIEW FRONT VIEW Figure 2 Specifications 1 MODEL OPTIMA 111 COUNTER MODEL GRAVITY FREEZER DIMENSIONS Freezer 19 11 16 50 cm wide x 31 5 8 80 3 cm deep x 37 7 16 95 cm high Crated 28 3 4 73 cm wide x 38 3 4 98 4 cm deep x 43 109 2 cm high WEIGHT Freezer 310 lbs 140 6 kg Crated 400 Ibs 181 4 kg ELECTRICAL Description 0111 Voltage AC 1 PH 208 230 Total Run Amps 12 70 Drive Motor 2 HP Use 20 amp HACR circuit breaker Automatic safeguard circuit built into electronic control protects major freezercomponents under abnormal operating conditions COOLING Air cooled self contained Right to left air flow HFC friendly refrigerant HOPPER SIZE 6 5 gallons 24 6 liters BARREL SIZE 1 gallon 3 8 liters SECTION 2 INSTALLATION INSTRUCTIONS 2 1 SAFETY PRECAUTIONS If danger warning or caution labels are needed indicate Do not attempt to operate the freezer until the safety the part number type of label location of label and precautions and operating instructions in this manual are quantity required along with your address and mail to read completely and are thoroughly understood STOELTING INC ATTENTION Customer Service Commercial Products Division 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 env
16. E CARRIER IS RESPON SIBLE FOR ALL DAMAGE IN TRANSIT WHETHER VISIBLE OR CONCEALED Do not pay the freight bill until the freezer 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 requestinspection 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 FREEZER INSTALLATION 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 spirit level on top of the freezer at each corner to check for level condition If adjustment is 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 Fig 4 rs E Figure 4 Leveling and requires correct ventilation 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 Fig 5 CAUTION FAILURE TO PROVIDE ADEQUATE VENTILATION WILL VOID WARRANTY D Placethe OFF ON switch inthe OFF position Fig 10 The freezer is equi
17. KLY 1 Check O Rings and rear seal for excessive wear and replace if necessary 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 MONTHLY A CAUTION THE FREEZER HAS AN AIR COOLED CON DENSER AND MUST HAVE PROPER AIR CIRCU LATION DO NOT PLACE RIGHT SIDE OF FREEZER ANY CLOSER THAN 3 INCHES FROM THE WALL FAILURE TO CLEAN THE CON DENSER FILTER ON A REGULAR BASIS MAY RESULT IN SERIOUS FREEZER DAMAGE AND COULD VOID FREEZER WARRANTY 1 Remove the phillips head screws from the lower side ofthe right side panel and pull the side panel down and out 2 Removethe condenser filter and clean in warm soapy water Rinse in clean water and squeeze dry taking care not to damage the filter in any way 3 Replace the condenser filter and side panel E SEMI ANNUALLY 1 Checkdrive belt for proper tension 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 A CAUTION DO NOT OVER LUBRICATE RESULTING DAM AGE COULD CAUSE MOTOR FAILURE 3 14EXTENDED STORAGE Refer to the following steps for storage of the freezer over any long period of shutdown time A Turn the OFF ON switch to the OFF position B Disconnect unplug from the electrical supply source C Clean thoroughly with a warm detergent all parts that com
18. OPERATION This section covers the recommended operating proce dures to be followed for the safe operation of the freezer A B C Sanitize just prior to use Place the OFF ON switch in the OFF position With spigot open pour approximately 1 gallon 3 8 liters of mix into the hopper Allow the mixto flush out about 8 ounces 0 23 liters of sanitizing solution and liquid mix Close the spigot Fill hopper with approximately 6 5 gallons 24 6 liters of pre chilled 40 F or 4 C mix CAUTION DO NOT OVERFILL THE HOPPER MIX LEVEL MUST NOT BE HIGHER THAN THE AIR INLET TUBE ON THE MIX INLET REGULATOR Thefreezer barrel will automatically fill until itis about 1 2 full If freezer barrel does notfill check for obstruc tion in the mix inlet regulator If freezer barrelfills 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 Place the OFF ON switch in the ON position then press the PUSH TO FREEZE switch until the freezer starts NOTE After the gearmotor starts there is a 3 second de lay before the compessor starts G After about 6 to 10 minutes the freezer will shut OFF and the green lens will illuminate 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 H Fornormal dispensing m
19. REEZER REQUIRES ADEQUATE VENTILATION LOUVERED PANELS REQUIRE 3 CLEARANCE 7 Irre LkG STB R OR WARRANTY WILL E BE VOIDED CONSULT OWNERS MANUAL FOR id MIR COMPLETE INFORMATION zus C ro HPR to LKG _ CYCLE SET ser CTT I rs Iz Des rora current CC ames WIRED ACCORDING TO REFRIGERANT DESIGN PRESSURE C Cs mo Psie tow Testo f 2 WIRING DIAGRAM RYAN NANUFACTURED UNDER ONE DR a ip m Y ee apa z 4383417 4221177 4171819 p ide CANADA DISPENSERS 1123799 224193 949970 OTHER PATENTS PENDING 528542 N 5206556 RECOMMENDED CLEANING b SANITIZING CHECKLIST DANGER ELECTRIC SHOCK HAZARD DISCONNECT FROM THE SOURCE OF ELECTRICAL SUPPLY IN BUILDING BEFORE SERVICING UNIT LA AS E OTE A dar ATE 5 10 MINUTES MAXIM E CAUTION y zn ELECTRIC WIRING MATERIALS ARRANGEMENT amp GROUNDING MUST CONFORM WITH NATIONAL AND OTHER APPLICABLE ELEC CODES Figure 3 Warning Label Locations 3 2 2 SHIPMENT AND TRANSIT Thefreezer has been assembled operated andinspected 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 TH
20. anufacturer s instructions NOTE Stoelting Inc has found that STERA SHEEN GREEN LABEL SANITIZER AND CLEANER does an effective job of properly sanitizing and cleaning a soft serve freezer We therefore include a sample with each new freezer Other products may be as effective For further information refer to cleaning and sanitizing information Section 3 13 CAUTION PROLONGED CONTACT OF SANITIZER WITH FREEZER MAY CAUSE CORROSION OF STAIN LESS STEEL PARTS In general sanitizing may be conducted as follows A Push the mix inlet regulator into hopper with air inlet long tube toward the front of the freezer Fig 11 Figure 11 Mix Inlet Regulator Prepare 2 gallons 7 5 liters of sanitizing solution following manufacturer s instructions Pour into hop per with mix inlet regulator in place Place the OFF ON toggle switch in the ON position while pressing the CLEAN switch Check for leaks Fig 12 Figure 12 Clean Control Clean sides of hopper mix inlet regulator and under side of hopper cover using a sanitized soft bristle brush dipped in the sanitizing solution Fig 13 1 Figure 13 Sanitizing Hopper Afterfive minutes place a bucketunderthe spigot and open spigotto drain sanitizing solution When solution has drained press the CLEAN snap switch to stop the auger Allow the freezer barrel to drain completely Fig 14 i 4 i Figure 14 Draining Solution 3 4 FREEZEDOWN AND
21. ch is a snap switch When the switch is pushed the refrigeration system will be OFF and the auger will rotate for cleaning When the switch is pushed again the auger will stop and the CLEAN light will flash indicating the freezer is in the CLEAN mode To exit the CLEAN mode turn the OFF ON switch to the OFF position If the freezer is left in CLEAN for more than 20 minutes or is pushed three times in ten seconds it will go in error To reset place the CLEAN OFF ON switch in the ON position and allow the error light to flash a minimum of 10 minutes Then turn to off wait 5 seconds and turn on F DRIVEMOTOROVERLOAD The internal DRIVE MOTOR OVERLOAD will trip ifthe drive motor is overloaded It will reset after approxi mately 10 12 minutes If the drive motor continues to trip referto Troubleshooting Sec 4 G RED MIX LOW LENS Thered MIX LOW lightis designedto alertthe operator to a low mix condition The lens will illuminate with approximately one gallon of mix in the hopper When the MIX LOW lens is lit refill hopper immediately NOTE Failure to refill hopper immediately may result in operational problems Skim excess foam with a sanitized utensil Failure to skim foam can affect low mix light operation H HOLDREADY SWITCH The HOLD READY switch is a push button switch When pushedin andheldfor5 seconds the hold ready mode will be activated and the word HOLD will illum inate on the touch pad The product will remain ready t
22. connect the green ground wire from the adjustment is necessary level the stand by turning grounding stud Fig 9 the bottom part of each caster in or out then tighten E I the lock nut C Place supports under freezer then remove the 4 legs and replace with the rubber stud plate mounts pro vided Mounts must be fully tightened to the freezer D Place the freezer base gasket on the floor stand with the connected seam to the back and angle side up Center the gasket side to side and 1 3 4 inches from the rear of the floor stand E Place the freezer on the floor stand with the front of the freezer to the door end All 4 stud plate mounts must engage the holes in the floor stand Secure the mounts with the nuts and washers provided Fig 8 Figure 9 Power Cord Connection STO amp TNG C Remove the power cord wu D Install permanent wiring according to local code a E Replace the side panel Figure 8 Floor Stand SECTION 3 INITIAL SETUP AND OPERATION 3 1 OPERATOR S SAFETY PRECAUTIONS 3 2 OPERATING CONTROLS AND INDICATORS SAFE OPERATION IS NO ACCIDENT Observe these Before operating the freezer it is required that the rules operator know the function of each operating control Refer to Figure 10 for the location of the operating controls on the freezer For the information regarding flashing indicator lights refer to the troubleshooting section A Know the freezer Read and understand th
23. cteria Can be effective on clean surfaces only DOES NOT clean or remove milkstone NOTE Using a SANTITIZER on an unclean surface will not guarantee a clean and safe frozen dessert machine Proper Daily Maintenance The Only Way to Assure Food Safety and Product Quality Proper daily maintenance can involve a wide variety of products and procedures Overall the products and procedures fall into three separate categories Please note that this is a brief overview intended for informational purposes only 1 CLEANING This involves draining mix from the freezer barrel and rinsing the machine with water Next a cleaner is run through the machine Then the machine is disassembled and removable parts are taken to the sink for cleaning 2 MILKSTONE REMOVAL Since 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 3 SANITIZING After the machine has been cleaned and contains no milkstone the machine is reassembled Then a FDA approved sanitizing solution is run through the machine to kill bacteria The machine is then ready for food p
24. e Operating Instructions B Notice all warning labels on the freezer C Wear proper clothing Avoid loose fitting gar ments and remove watches rings or jewelry which could cause a serious accident A WARNING THE OFF ON SWITCH MUST BE PLACED IN THE OFF POSITION WHEN DISASSEMBLING FOR CLEANING OR SERVICING THE FREEZER MUST BE DISCON NECTED FROM ELECTRICAL SUPPLY BEFORE RE MOVING ANY ACCESS PANEL D Maintain a clean work area Avoid accidents by cleaning up the area and keeping it clean E Stay alert at all times Know which switch push button or control you are about to use and what dE A SPIGOT SWITCH effect it is going to have The SPIGOT switch will automatically actuate the Disconnect electrical cord for maintenance Never attempt to repair or perform maintenance on the freezer until the main electrical power has been disconnected 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 ortemperature Do not operate under unsafe operating condi y tions Never operate the freezer if unusual or exces sive noise or vibration occurs STOELTING HOLD READY SWITCH A ox SPIGOT SWITCH Behind Panel CONSISTENCY TEMPERATURE OFF O ADJUSTMENT POWER SWITCH PUSH TO FREEZE CLEAN Figure 10 Control
25. e 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 orin the freezer barrel during the shutdown period D Remove disassemble and clean the front door mix inletregulator and auger parts Place the auger flights and the front auger support bushing in a plastic bag with a moist paper towel to preventthem from becom ing brittle 16 SECTION 4 TROUBLESHOOTING CHARTS PROBLEM Freezer does not run Freezer does not run PUSH TO FREEZE light flashes in sequence of four Freezer does not run PUSH TO FREEZE light flashes in sequence of five Freezer will not shut off Product is too soft 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 Freezer has been left in the CLEAN mode for more than 30 minutes CLEAN switch has been activated 3 times within 10 seconds Low torque error No mix in hopper 2 Mix inlet regulator not allowing mix to flow into barrel Sensor problem 1 Not enough mix in hopper 2 Drive belt failure 3 Consistency temperature setting is too firm 4 Consistency temperature control failure 5 Alcohol content in cocktail mix is too high 6 Reduced air flow 7 Refrigeration problem 1 Product is being dispensed when the PUSH TO FREEZE light is illuminated r
26. ed 2 No vent space for free flow of cooling air 3 Air temperature entering condenser is above 100 F 4 Condenser is dirty 5 Consistency setting too soft 6 Stabilizers in mix are broken down 7 Auger is assembled wrong 8 Reduced air flow 9 Refrigeration problem POSSIBLE CAUSE REMEDY Supply power to freezer Replace or reset If condition continues see notes 1 or 2 Turn OFF ON switch to OFF for 15 minutes then restart Reset high pressure cut out Assemble front door in place Let light flash for 10 minutes then place the OFF ON switch to the OFF position to reset Leave OFF ON switch in the ON position for 10 minutes then place the OFF On switch to the OFF position to reset Place the OFF ON switch to the OFF position to reset Fill hopper with mix Remove mix inlet regulator clean sanitize and replace Call distributor for service Fill hopper with mix Replace drive belt Readjust Refer to Page 9 for location Call distributor for service Replace Call distributor for service Reduce percent of alcohol content Check for proper air flow thru the condenser Check system Call distributor for service Press the PUSH TO FREEZE push button Wait until the green light illuminates before dispensing A minimum of 3 inches of vent space required See paragraph 2 3 Change location or direct hot air away fr
27. ed equipment and during the first twelve 12 months of the warranty period deinstallation reinstallation of the affected component from into the equipment Those obligations remedies are subject to the conditions that Buyer a signs and returns to Stoelting upon installation the Checklist Warranty Registration Card for the affected equipment b gives Stoelting prompt written notice of any claimed breach of warranty within the applicable warranty period and c delivers the affected equipment to Stoelting or its designated service location in its original packaging crating also within that period Buyer shall bear the cost and risk of shipping to and from Stoelting s plant or designated service location 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 ASIS 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
28. er 1 2 SPECIFICATIONS 18 3 8 19 11 16 46 7 50 0 cm i 9 E i Cc gt Be E 34 7 16 i 87 5 cm EJ 321 16 37 7 16 81 5 cm 95 0 cm 50 8 cm Y Y Y Y 23 5 8 1 2 5 cm E
29. ironment The labels have been designed to withstand washing and cleaning All labels must remain legible for the life of the freezer Labels should be checked periodi cally to be sure they can be recognized as warning labels DANGER ELECTRIC SHOCK HAZARD ra DISCONNECT FROM THE SOURCE OF ELECTRICAL SUPPLY IN o dorr POWER on py HOLD s BUILDING BEFORE SERVICING P ell HAZARDOUS MOVING PARTS LA DO NOT OPERATE UNIT WITH 2 E L1 OUTER COVERING REMOVED 8 ATTENTION Lael 5 o o o This freezer has foam insulation that n has been formed with refrigerant gas The insulation may emit refrigeroni wes vapors which could deceive leod detectors and give false reodings ATTENTION a ares HAZARDOUS ROTATING BLADES PUSHBUTTON DISPLAY HEAT SENSITIVE THERMISTOR LOCATED 0 OPERATE UNIT WITH ms UNDER THIS FRONT DOOR DR SPIGOT REMOVED 1 C se m MUST NOT EXCEED 220 NEAR n m sp THERMISTOR HEAT SINK MUST BE USED WHEN BRAZING ON EVAPORATOR m ste OUTLET CHECK RESISTANCE BEFORE css REMOVAL OF THERMISTOR SEE SERVICE MANUAL T ATTENTION 5 DJ veo sev 6 Co sm F
30. 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 asmall 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 must be screwed into the flights com pletely to provide proper compression Fig 25 Figure 25 Spring Installation CAUTION DO NOT PLACE THE MIX INLET REGULATOR INTO THE HOPPER BEFORE INSTALLING THE AUGER m Install the two plastic flights onto rear of the 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 support into the front of the auger with one leg of the support pointing straight up Install the spigot body with O Rings into the front door from bottom Fig 26 Push straight up until the spigot is in place Figure 26 Exploded View of Front Door Install the front door on the freezer studs then hand tighten the circular knobs CAUTION FINGER TIGHTEN THE CIRCULAR KNOBS EVENLY DO NOT OVERTIGHTEN KNOBS Look for the proper seal between the freezer barrel O Ring and front do K Install the mix inlet regulator into the free
31. n warm mild detergent water and clean with brushes provided Rinse all parts with clean hot water CAUTION DO NOT DAMAGE PARTS BY DROPPING OR ROUGH HANDLING B Washthe hopper and freezer barrel with warm deter gent water and brushes provided Fig 24 Figure 24 Cleaning Freezer Barrel C 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 of 100 parts per million to sanitize the parts before assembly B Place all parts in the sanitizing solution then remove and let air dry C Using this sanitizing solution and the large barrel brush provided sanitize the rear of the barrel by dipping the brush in the sanitizing solution and brushing 3 11 ASSEMBLY OF FREEZER To assemble the freezer parts refer to the following steps NOTE Petro 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 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 lubri cation Then apply athin film of sanitary lubrication to exposed surfaces of the O Rings Apply athin film of sanitary lubricantto metal part of rear seal Also apply athin film of sanitary
32. o serve andthe freezer will not go to idle To return to normal operation push and hold for 5 seconds I 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 counter clockwise for faster flow J FRONTDOORINTERLOCK SWITCH When the door is securely fastened the freezer will operate normally When the front door is removed the drive and compressor will not run 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 using it WARNING THE UNITED STATES DEPARTMENT OF AGRI CULTURE AND THE FOOD AND DRUG ADMINIS TRATION 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 quan tities of no less than 2 gallons 7 5 liters of 120 F water Allow sanitizer to contact the surfaces to be sanitized for 5 minutes Any sanitizer must be used only in accordance with the m
33. om freezer Clean See paragraph 3 7 Readjust Call distributor for service Remove mix clean sanitize and freeze down with fresh mix Remove mix clean reassemble sanitize and freeze down Check for proper air flow thru the condenser Check system Call distributor for service Product is too firm Product does not dispense Drive belt slipping or squealing Low overrun Front door leaks Hopper will not maintain mix temperature below 45 7 C No mix in hopper 2 Small portions are being dispensed in a short time Consistency temperature setting is too firm Consistency temperature control failure Line voltage fluctuating No mix in hopper Mix inlet regulator tube is plugged Special mix inlet regulator needed for mix being used Capacity of freezer is being exceeded Drive motor overload tripped Drive belt failure Freeze up Auger will not turn Worn drive belt 2 Freeze up Auger will not turn Mix inlet regulator missing Mix inlet regulator O ring missing Mix inlet regulator air tube blocked Product breakdown 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 Consistency control on board needs to be adjusted Consistency control failure EPR val
34. ove the spigot handle fully open 60 Fig 15 2 P Figure 15 Dispensing Product A CAUTION REFRIGERATION IS AUTOMATICALLY ACTI VATED WHEN THE SPIGOT IS OPENED CLOSE THE SPIGOT COMPLETELY AFTER DISPENS ING The freezer is designed to dispense the product at a reasonable draw rate If the freezer is overdrawn the result is a soft product or a product that will not dispense at all If this should occur allow the freezer torun for approximately 30 seconds before dispensing additional product After awhile the operator will sense or feel when the freezer is beginning to fall behind and will slow down on the rate of draw so as not to exceed the capacity J Donotoperate the freezer when the MIX LOW lightis on or with less than 1 3 4 inches 4 4 cm of mix in the hopper Refill the hopper immediately 3 5 MIX INFORMATION Mix can vary considerably from one manufacturer to another Differences inthe amountof butter fat content and quantity and quality of other ingredients have a direct bearing on the finished frozen product A change in freezer performance that cannot be explained by a technical problem may be related to the mix Proper product serving temperature varies from one manufacturer s mix to another Soft serve mixes should provide a satisfactory product in the 18 to 20 F 7 to 6 C range shake mixes 24 to 28 F 4 to 2 C When checking the temperature stir the thermometer in the frozen product
35. pped with an air cooled condenser Figure 5 Space and Ventilation Requirements Connect the power cord The plug is designed for 208 or 230 volt 20 amp duty Check the nameplate on your freezer for proper supply The unit must be connected to aproperly grounded receptacle The electrical cord furnished as part of the freezer has a three prong grounding type plug Fig 6 The use of an extension cord is not recommended if necessary use one with asize 12 gauge or heavier with ground wire Do not use an adapter to get around grounding requirement Figure 6 Electrical Plug CAUTION DO NOT ALTER OR DEFORM PLUG IN ANY WAY F Install the drip tray drain tray hopper cover and other miscellaneous parts on the freezer Fig 7 Figure 7 Installing Tray and Cover 4 2 4 FLOOR STAND INSTALLATION 2 5 INSTALLING PERMANENT WIRING To install the 0111 onto the floor stand follow the steps outlinedbelow If permanent wiring is required by local codes the follow ing procedure must be performed A Uncrate the floor stand and place in an upright posi AN WARNING tion NOTE DISCONNECT FREEZER FROM THE SOURCE er OF ELECTRICAL SUPPLY BEFORE SERVICING Detailed instructions are included with each floor stand A Remove the right side panel B Place a spirit level across the top of the stand to check B Disconnect the wires from the terminal for level condition side to side and front to back If block Dis
36. reparation As a recommended cleaner and sanitizer for your frozen dessert machine STERA SHEEN has proven to be one of the best daily maintenance products for CLEANING Thorough removal of all solids including butterfat and milk fat MILKSTONE REMOVAL Complete removal of milkstone SANITIZING FDA approved no rinse sanitizer for food contact surfaces Additional Information THE USE OF DELIMERS A delimer is a strong acid that has the ability to dissolve milkstone This type of chemical may become necessary once high levels of milkstone have developed While these products are very effective for removing HIGH levels of milkstone they are not ideal for two reasons 1 PRODUCT SAFETY Strong acids are dangerous chemicals 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 it s equivalent there is no need for the use of a DELIMER NOT USE BLEACH BLEACH HAS ABSOLUTELY NO CLEANING PROPERTIES BLEACH IS CORROSIVE It can and will damage components of the machine causing premature wear and metal corrosion DO GENERAL PURPOSE CLEANERS General purpose cleaners do not have the ability to remove milkstone Milkstone will become a problem if not remedied with additional products and procedures THE USE
37. s 7 OFF ONSWITCH The OFF ON switch is a two position toggle switch used to supply power to the control circuit When the switch is in the OFF position nothing will run When the switch is in the ON position the freezer will be in the idle mode until a switch is activated C PUSHTO FREEZE SWITCH The PUSH TOFREEZE switch is a snap switch used to start the freezing cycle During initial freeze down the OFF ON switch is placed inthe ON position Then the PUSH TO FREEZE switch is pressed until the drive motor and compressor come ON NOTE After the gearmotor starts there is a 3 second de lay before the compressor starts During the normal operation the red PUSH TO FREEZE switch light will illuminate after the freezer has been idle for the preset cycles Before drawing product press the PUSH TO FREEZE switch ifitis illuminated Wait until the green lightis illuminated before dispens ing NOTE If the freezer shuts off and the PUSH TO FREEZE light flashes you have an error condition Turn the OFF ON swtich to the OFF position correct the problem and turn the freezer back on See Trouble shooting D GREENLIGHT The green lightis used to indicate that the product has reached the proper consistency or temperature andis ready to be dispensed NOTE If the PUSH TO FREEZE red light is illuminated push the PUSH TO FREEZE switch and wait until the green light illuminates before dispensing E CLEAN SWITCH The CLEAN swit
38. s 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 ITIS BEST TO CONTROL MILKSTONE ON A DAILY BASIS BEFOREIT CAN BECOME A SIGNIFICANT FOOD SAFETY PROBLEM In addition to food safety milkstone can cause premature wear to machine parts which can add to costs for replacement parts or possibly more expensive repairs if worn machine parts are not replaced once they have become excessively worn Important Differences Between Cleaning and Sanitizing CLEANING vs SANITIZING It is important to distinguish between cleaning and sanitizing Although these terms may sound synonymous they are not BOTH are required for adequate food safety and proper machine maintenance CLEANING Is the removal of soil materials from a surface Is a prerequisite for effective sanitizing NOTE An UNCLEAN surface will harbor bacteria that can defy sanitizing efforts Bacteria can develop and resist sanitizing efforts within a layer of soil material milkstone Thorough cleaning procedures that involve milkstone removalare critical for operators of frozen dessert machines SANITIZING Kills ba
39. steps A Close the spigot and fill the hopper with 2 gallons 7 5 liters of cold tap water B Place the OFF ON switch in the ON position while pushing the CLEAN switch to rotate the auger C Allowthe water to agitate for approximately 5 minutes NOTE If freezer is left in CLEAN for more than 20 minutes it will go to error D Openthe spigot to drain the water Remember to place a bucket or container under the spigot to catch the water When the water has drained turn the OFF ON switch to the OFF position Allow the freezer barrel to drain completely E Repeat Steps A through D using a mild detergent solution 3 8 DISASSEMBLY OF FREEZER PARTS CAUTION PLACE THE OFF ON TOGGLE SWITCH IN THE OFF POSITION BEFORE DISASSEMBLING FOR CLEANING OR SERVICING Inspection for worn or broken parts should be made at every disassembly of the freezer for cleaning or other purposes All worn or broken parts should be replaced to ensure safety to both the operator and the customer and to maintain good freezer performance and a quality prod uct Two normal wear areas are the auger flights and front auger support Fig 18 Frequency of cleaning must com ply with the local health regulations Figure 18 Auger Flight Wear and Front Auger Support Bushing Wear To disassemble the freezer refer to the following steps A Remove hopper cover and drain tray Fig 19 B Remove the mix inlet regulator from the hopper by pulling
40. straight up C Remove the front door by turning off the circular knobs and then pulling the front door off the studs 1 Hopper Cover Figure 19 Removing Front Door O Remove the rosette then remove the spigot body from the front door by pushing the spigot body through the bottom of the front door Fig 20 Figure 20 Front Door Disassembly i Remove the front auger support and bushing Fig 21 Figure 21 Removing Auger Support F Removethe auger assembly from the freezer Fig 22 Pull the auger out of the freezer barrel slowly As the auger is being pulled out carefully remove each ofthe plastic flights with springs Nr Figure 22 Auger Shaft Removal G Keep the rear of the auger shaft tipped up once it is clear of the freezer to avoid dropping rear seal H Remove the rear seal Wipe socket lubricant from the drive end rear of the auger with a cloth or paper towel J Removeall O Rings from parts be first wiping off the lubricant using aclean paper towel Thensqueeze the O Ring upward with a dry cloth Fig 23 When a loop is formed roll out of the O Ring groove N WARNING DO NOT USE ANY TYPE OF SHARP OBJECT TO REMOVE THE O RINGS Figure 23 Removing O Ring 3 9 CLEANING THE FREEZER PARTS 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 A Place all parts i
41. to read the true temperature 10 Mix does not improve with age Old mix or mix that has been stored at too high temperature can result in a finished product that is less than satisfactory from the appearance and taste standpoint To retard bacteria growth in dairy based mixes the best storage temperature range is between to 40 F 2 2 to 4 4 C Some products tend to foam more than others If excess foam should occur skim off with a sanitized utensil and discard Periodically stir the mix in the hopper with a sanitized utensil 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 Fig 16 d Figure 16 Removing Mix Inlet Regulator B Place the OFF ON rocker switch in the ON position and push the CLEAN switch to rotate the auger Allow the mix to agitate in freezer barrel until the mix has become a liquid about 5 minutes C Drainthe liquid mix by opening the spigot A bucket or container should be placed under the spigot to catch the liquid mix Fig 17 D Place the OFF ON switch in the OFF position i f Figure 17 Draining Mix 3 7 CLEANINGTHE FREEZER NOTE The frequency of cleaning the freezer and freezer parts must comply with local health regulations After the mix has been removed from the freezer the freezer mustbe cleaned Toclean the freezer refer to the following
42. ve needs adjustment Refrigeration problem Hopper cover not fitted properly 18 Fill hopper with mix Allow freezer to sit idle for 5 minutes before dispensing Readjust Refer to Page 9 for location Call distributor for service Replace Call distributor for service Check Call distributor for service Fill hopper with mix Unplug using small sanitized brush Order special mix inlet regulator Slow up on the draw rate Automatic reset Wait 15 to 30 minutes Replace drive belt Turn OFF ON switch to OFF for 15 minutes then restart Call distributor for service Turn OFF ON switch to OFF for 15 minutes then restart Replace mix inlet regulator Replace mix inlet regulator O ring Clean with sanitized brush Fill freezer with fresh product Tighten knobs See paragraph 3 11 Remove spigot and check ring Replace front door 1 2 3 Replace rings 4 5 Call distributor for service Replace Call distributor for service Adjust EPR valve Check system Call distributor for service Check hopper cover for proper fit ERROR CODE SYSTEM CODE P T F LIGHT FLASHES MEANING Sequence of one Sequence of two Sequence of three Sequence of four Sequence of five Sequence of six Sequence of seven Referto Page 17 for Troubleshooting NOTE Program board Power board Low torque error Clean
43. zer with the air tube to the front of the freezer Fig 27 L Install hopper cover and drain tray Figure 27 Mix Inlet Regulator 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 notuse 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 A Cleaning and Sanitizing Information 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 cleaning and sanitizing frozen dessert machines This information is meant to supplementa comprehensive food safety program Soil Materials Associated with Frozen Dessert Machines MILKFAT BUTTERFAT As components of ice cream frozen custard mix these soils will accumulate on the interior surfaces of the machine and its parts Fats are difficult to remove and help attribute to milkstone build up MILKSTONE Is a white gray film that forms on equipment and utensils 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 i
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