Stoelting O231, Service Manual

Page 1: ...Model O231 SERVICE MANUAL Manual No 513646 Sept 2010 ...

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Page 3: ...s built prior to date of change DO NOT ATTEMPT to operate the machine until instructions and safety precautions in this manual are read completely and are thoroughly understood If problems develop or questions arise in connection with installation operation or servicing of the machine contact Stoelting Stoelting Foodservice Equipment 502 Highway 67 Kiel WI 53042 1600 U S A Main Tel 800 558 5807 Fa...

Page 4: ...pecific safety information the following safety defini tions are provided to assist the reader The purpose of safety symbols is to attract your at tention to possible dangers The safety symbols and their explanations deserve your careful attention and understanding The safety warnings do not by themselves eliminate any danger The instructions or warnings they give are not substitutes for proper ac...

Page 5: ...mbly of Machine Parts 10 3 5 CleaningDisassembledParts 10 3 6 Sanitizing Machine Parts 11 3 7 CleaningtheMachine 11 3 8 AssemblingMachine 11 3 9 Sanitizing 12 3 10 FreezeDownandOperation 12 3 11 MixInformation 13 4 Maintenance and Adjustments 4 1 Accessing Control Readings and Settings 15 4 2 NavigationandModifyingSettings 15 4 3 UserInterfaceScreens 15 4 4 PerformanceScreens 16 4 5 Settings Scree...

Page 6: ...dels Only 32 5 7 Solenoid 32 5 8 FilterDrier 34 6 Electrical and Mechanical Control Systems 6 1 Intellitec2Control 35 6 2 Contactors 35 6 3 DriveMotor 36 6 4 Capacitors 37 6 5 Gearbox 37 6 6 CondenserFanMotor Air CooledOnly 38 6 7 Spigot Switch 38 6 8 TemperatureControlSensor 40 7 Troubleshooting 7 1 ErrorCodes 41 7 2 Troubleshooting 41 7 3 Troubleshooting Machine 44 8 Replacement Parts 8 1 Decals...

Page 7: ...O231 is designed to operate with almost any type of commercial soft serve or non dairy mixes available including ice milk ice cream yogurt and frozen dietary desserts Thismanualisdesignedtoassistqualifiedserviceperson nelandoperatorsintheinstallation operationandmainte nance of the Stoelting O231 gravity machine 1 2 SPECIFICATIONS Figure 1 1 Model O231 Figure 1 2 Specifications ...

Page 8: ...gs with 1 inlet and 1 outlet Maximum water pressure of 130 psi Minimum water flow rate of 3 GPM Ideal EWT of 50 70 F 730 lbs 331 1 kg 3 PH O231 Water Cooled 640 lbs 290 2 kg 1 PH 64 1 2 163 8 cm 33 1 4 84 5 cm 730 lbs 331 1 kg 3 PH Machine Menu Display O231 Basic Consistency Cutout Cut In Temp 19 5 F Cycles until sleep 20 count Stir On 15 seconds Stir Off 300 seconds Advanced Stdby On time 10 seco...

Page 9: ...higher than 99 the freezer will start up in the Serve mode 3 Sensor failure will keep the control in Serve and Standby modes only 4 A freeze cycle will reset the stir cycle Temperature CutIn Temperature CutOut Consistency Freezing Cycle Sleep 2 CutIn Standby Time Sleep 2 CutIn Standby On Time Standby Off Time Sleep 2 Cutout IntelliTec2 Control Modes of Operation Standby Mode Sleep 1 Mode Serve Mod...

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Page 11: ...carrier within 10 days and request inspection The customer must place claim for damages and or shortages in shipment with the carrier Stoelting Inc cannot make any claims against the carrier 2 3 MACHINE INSTALLATION WARNING Installation must be completed by a qualified electrician refrigeration specialist Incorrect installation may cause personal injury se vere damage to the machine and will void ...

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Page 13: ...ir or perform maintenance on the machine until the main electrical power has been disconnected G Donotoperateunderunsafeoperatingconditions Neveroperatethemachineifunusualorexcessive noise or vibration occurs 3 2 OPERATING CONTROLS AND INDICATORS Before operating the machine it is required that the operatorknowthefunctionofeachoperatingcontrol Refer toFigure3 1forthelocationoftheoperatingcontrolso...

Page 14: ...se the dispense rate 3 3 IMPORTANT INFORMATION REGARDING CLEANING AND SANITIZING Softservemachinesrequirespecialconsiderationwhenit comes to food safety and proper cleaning and sanitizing The following information specifically covers issues for cleaning and sanitizing frozen dessert machines This informationismeanttosupplementacomprehensivefood safetyprogram SOIL MATERIALS ASSOCIATED WITH FROZEN D...

Page 15: ... of all solids including butterfat and milk fat MILKSTONE REMOVAL Complete removal of milkstone SANITIZING FDA approved no rinse sanitizer for food contact surfaces ADDITIONALINFORMATION 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 effec...

Page 16: ...geroutofthemachinebarrelslowly As theaugerisbeingpulledout carefullyremoveeach of the plastic flights with springs 3 Keeptherearoftheaugertippeduponceitisclear of the freezing cylinder to prevent the rear seal assembly from dropping 4 Wipe the spline lubricant off of the hex end of the auger with a paper towel Remove the rear seal assembly Fig 3 5 5 Unscrew the springs from the auger flights 3 5 C...

Page 17: ... sanitizing solution for 5 minutes then remove and let air dry completely before assembling in machine 3 7 CLEANING THE MACHINE Theexteriorshouldbekeptcleanatalltimestopreservethe luster of the stainless steel A high grade of stainless steel hasbeenusedonthemachinetoeasecleanup Toremove spilled or dried mix wash the exterior with 90 to 110 F 32 C to 43 C detergent water and wipe dry Do not use hig...

Page 18: ...I When the solution has drained press the CLEAN buttontostoptheauger Allowthefreezingcylinder to drain completely The machine is now sanitized and ready for adding mix 3 10 FREEZE DOWN AND OPERATION A Sanitize immediately before use B Makesurethedisplayshowsthefreezingcylinder is off If it is not press the On Off Left or On Off Right button to turn it off C Fill the hopper with at least 2 5 gallon...

Page 19: ...oduct serving temperature varies from one manufacturer s mix to another Mixes should provide a satisfactoryproductinthe20 Fto24 Frange Dietandlow carbmixestypicallyfreezetoproperconsistencyathigher temperatures When checking the temperature stir the thermometer in the frozen product to get an accurate reading Old mix or mix that has been stored at too high a temperature can result in a finished pr...

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Page 21: ...sstheSETbuttontochangethe value Use the arrow keys to change the value Press the SET button to save the changes TheSELbuttonchangesthecylinderselectiononscreens that show the cylinder Pressing the left arrow button from any menu will go back onescreen PressingtheleftarrowbuttonattheMainMenu screen goes to the Current Status screen 4 3 USER INTERFACE SCREENS A Current Status TheCurrentStatusscreeng...

Page 22: ...freezingcylinderis Ahighernumber means the product is thicker Go to the Modify Operating Settings menu to change the operating setting Cylinder Temperature This is the current suction line temperature of the selected cylinder MotorAmps This is the current motor amps of the selected cylinder Input Voltage This is the current voltage of the selected cylinder and will only show the voltage when the m...

Page 23: ...ing determines the total amount of time in Standby Mode Sleep 1 Drive On is the amount of time that the auger rotates during the stir cycle in Sleep 1 Mode Sleep1DriveOffistheamountoftimebetweenstircycles in Sleep 1 Mode D Advanced Settings 2 of 2 TheAdvancedSettingsmenucontainsstandbyandsleep modeadjustmentsandisavailabletotheTechnicianlevel Press the left arrow to go to the first screen Sleep 2 ...

Page 24: ...s The User Preferences menu contains language options temperatureunits servicecontactinformationandtouchpad lockup The screen is available to the Manager and Tech nicianlevels The Language setting changes the language displayed English is the only language currently available The Temperature Units setting changes the units dis played to Fahrenheit or Celsius The Service Contact Information option ...

Page 25: ...Statistics screen will clear all the statistics in memory SelectingLeftorRightOutputControlgoestoascreenthat allowsmotors solenoidsorthecompressortobeindividu allyactivated Activatebymovingthecursortothedesired component and press the SET button SelectingLeft RightMonitoringgoestoscreensthatshow current statistics of the selected cylinder The Test Monitoring screens can be used for immediate feedb...

Page 26: ... mix error The screen shows a running total the totalforthepreviousdayandthetotalforthepreviousweek C Machine Statistics 3 of 10 TheMachineStatisticsscreen3of10providesthetimeand datethatthefreezingcylinderwaslastcleaned Thisvalue is recorded when the Clean button is pressed on the touchpad Thescreenalsoshowshowlongthemostrecent clean mode lasted D Machine Statistics 4 of 10 The Machine Statistics...

Page 27: ...asdone Theresetshouldbeusedifthedrive motor is changed H Machine Statistics 8 of 10 The Machine Statistics screen 8 of 10 shows the total run time for the pump and counts the total cycles There is an option to reset the timer and the screen shows when the last reset was done The reset should be used if the pump is changed I Machine Statistics 9 of 10 The Machine Statistics screen 9 of 10 shows the...

Page 28: ...y will say Stoelting Soft Serve along with thenewversionnumber NOTE If the display does not show the new revision num ber make sure the rom file is in the top level of the USB flash drive The rom file cannot be in any folders within the flash drive 4 9 DRIVE BELT TENSION ADJUSTMENT To check belt tension refer to Figure 4 1 and follow the steps below A Remove the back panel B Use a Burroughs Belt T...

Page 29: ...nta tivemaintenanceguide The United States department of agriculture and the food anddrugadministrationrequirethatlubricantsusedinfood zones be certified for this use Use lubricants only in accordance with the manufacturer s instructions A Daily checks Check for any unusual noise or condition and repairimmediately B Monthly checks Checkthecondenserfordirtandcleanifnecessary C QuarterlyChecks Check...

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Page 31: ...operly recover and evacuatetherefrigerationsystem Donotpurgerefrigerant into the atmosphere NOTE For qualified service personnel only Anybody work ing with refrigerants must be certified as a Techni cian TYPE I as required by 40 CFR 82 Subpart F and hold all State and or local refrigerant handling certifications In addition all handling storage and disposal of refrigerants must be in accordance wi...

Page 32: ...t maintain a standing vacuum test with the vacuum pump off gauge increases towards atmosphere find the leak fix it and evacuateagain 11 Afterevacuatingiscomplete deactivatethesolenoid by exiting the Testing and Manual Operation screens 5 3 REFRIGERANT CHARGING Refer to the following procedures to properly charge the refrigerationsystem Stoeltingrecommendsliquidrefriger antcharging NOTE For qualifi...

Page 33: ... S B COMPRESSORREMOVAL A Disconnect the machine from electrical supply beforeremovinganypanelsforservicing B Remove the back panel C Removetheprotectivecoverfromthecompressor terminals and disconnect the wires D Recover refrigerant charge per the instructions in Section 5 2 E Leave the suction and discharge ports open to prevent pressure buildup during compressor removal F Remove six inches of ins...

Page 34: ...ndenser requires cool clean water to function properly Inlet and discharge lines must be 3 8 ID minimum CONDENSERTESTING The condenser can be checked for leaks using the bubble test or using a leak detector 5 6VALVES A THERMOSTATICEXPANSIONVALVE TXV TheThermostaticExpansionValve TXV isusedtometer therefrigeranttothefreezingcylinderevaporator Itdoesso by maintaining a constant pressure in the evapo...

Page 35: ...ounding lines G Replace the drier per the instructions in Section 5 9 H EvacuatethesystempertheinstructionsinSection 5 2 I RechargethesystempertheinstructionsinSection 5 3 B AUTOMATIC EXPANSION VALVE AXV YG2MODELSONLY TheAutomaticExpansionValve AXV isusedtometerthe refrigeranttothefreezingcylinderevaporatorinYG2model machines Itdoessobymaintainingaconstantpressurein the evaporator The self regulat...

Page 36: ...XV into the system C Remove the heat sink from the AXV E Replace insulation to the AXV and surrounding lines F Replace the drier per the instructions in Section 5 9 G EvacuatethesystempertheinstructionsinSection 5 2 H RechargethesystempertheinstructionsinSection 5 3 C CHECKVALVE Themachinehas2magneticcheckvalves RefertoFigure 5 6 Each valve is positioned in the suction line and preventsbackflowofr...

Page 37: ...er to Figure 5 9 It is located on the suction line of the hopper evaporatorsandregulatesevaporatorrefrigerantpressure EPRTESTANDADJUSTMENT Adjustment to the EPR must be made when the hopper refrigerationisrunning A Disconnect the machine from electrical supply beforeremovinganypanelsforservicing B Remove the left side panel C Connect a gauge to the Schrader valve on the suction line between the ho...

Page 38: ...arge line A Turnoffanddisconnectthewatersupply Blowout the water lines with compressed air or CO2 B Recover refrigerant charge per instructions in Section 5 2 C Leave the suction and discharge ports open to preventpressurebuildupduringwatervalveremoval D Unsweatthecapillarytubefromthedischargeline E Remove the clamps from the water lines at the valve F Removethetwoscrewsholdingthewatervalveto thef...

Page 39: ... G A leaking valve seat may also show frost on the liquid line tubing just past the solenoid and before theevaporator SOLENOIDMAGNETICCOILREMOVAL A Remove the side panel B Disconnect the electrical wires C Remove the retainer screw from the top of the solenoid and pull the magnetic coil off SOLENOIDMAGNETICCOILINSTALLATION To replace the magnetic coil perform the following proce dures A Push the c...

Page 40: ...e filter drier as possible and remove drier C Cap the ends of the drier using the plugs from the newdrier NOTE The drier must be capped to prevent moisture from the environment FILTERDRIERREPLACEMENT A Position the filter drier so the arrow is pointing toward the direction of refrigerant flow pointing away from the condenser B Apply a heat sink wet cloth to the filter drier C With the suction and ...

Page 41: ...machines and the condensing unit for the hoppers Allofthecontactorsarelocatedintheelectricalboxbehind the right side panel The IntelliTec2 control sends electronic signals to trigger the contactors Separate signals are used to control each drivemotorcontactorandeachcompressorcontactor The signalstothecontactorsarestaggered sothedrivemotor will always start three seconds before the compressor By st...

Page 42: ...s Theyareusedtorotatethe augerassemblies Aninternal normallyclosed centrifugal switch starts the drive motor The motors have an internal thermaloverload A DRIVE MOTOR TEST 1 Turn the machine off by pressing the Main Power Off On button and disconnect the machine from the electrical supply 2 Remove the back panel and a side panel 3 Loosenthebelttensionadjustmentnutandremove the belt 4 Connect power...

Page 43: ...lsforservicing 2 Remove leads from the capacitor terminals 3 Using insulated pliers discharge the capacitor with a 20KΩ 5W resistor across the terminals NOTE Discharge the capacitor even if there is a bleeder resistor across the terminals There may be an open in the bleeder resistor preventing it from working properly 4 Pull the capacitor out of its holder and replace 5 Connect the leads to the te...

Page 44: ...FANMOTORREPLACEMENT 1 Disconnectmachinefromelectricalsupplybefore removinganypanelsforservicing 2 Remove a side panel and the header panel 3 Traceanddisconnectthebrownandbluewireson the fan motor 4 Removethefanguardandthefanmotorassembly 5 Remove the torx screws from the fan guard 6 Remove the bolts holding the fan guard to the condensershroud C FANMOTORINSTALLATION 1 Rotate the fan motor so the m...

Page 45: ...one for each side When testing the center spigot there should be two audible clicks occurring almost simulta neously SPIGOT SWITCH TESTING ELECTRICAL 1 Disconnecttheswitchfromthecircuitbyunplugging the connectors 2 Check resistance readings across the common COM andnormallyclosed NC terminals When the spigot is closed the resistance should show anopen Whenthespigotisopened theswitchwill close and ...

Page 46: ...ardmonitorsthisvalue In ServeMode Figure 6 8 Temperature Sensor Resistance 10K Ohms F Resistance F Resistance 22 176950 40 26100 20 165200 42 24725 18 154300 44 23400 16 144200 46 22175 14 134825 48 21000 12 126125 50 19900 10 118050 52 18875 8 110550 54 17900 6 103550 56 17000 4 97075 58 16125 2 91025 60 15325 0 85400 62 14550 2 80150 64 13825 4 75275 66 13150 6 70725 68 12500 8 66475 70 11875 10...

Page 47: ...that the mix is brokendown cleanandsanitizethemachineand replace the mix with fresh product Ice crystals in the hopper can clog the mix inlet regulatorandpreventmixfromenteringthefreezing cylinder Thoroughlythawmixpermanufacturer s recommendations Tocheckforicecrystals pour asmallamountofproductfromthehopperthrough a clean and sanitized sieve or strainer If ice crystals are in the mix check the te...

Page 48: ...er to expire then press the On Off button for the cylinder to turn it back on Inaircooledcondensermodels checktheairfilter to make sure it is clean Replace or clean the filter asrequired Checkforproperairclearancearound the machine Refer to the machine s Owner s Manual for clearances Check the condenser for blockage andbesurecondenserfanisfunctioning On water cooled condenser models check for prop...

Page 49: ...sensor resistance with the table as reference If measuredvaluedoesnotcoincidewithavalue on the table 400 ohms replace the sensor ERRORCODE13 RIGHTHOPPERSENSOR TheRightHopperSensorError E13 indicates a failure of the hopper sensor or if the sensor is out of range If the control panel displays an E13 press the On Off button for the cylinder to turn it off then back on If the control panel still disp...

Page 50: ...le sanitize and freeze down 7 Product break down 7 Drain clean and sanitize machine Fill with fresh mix 8 Refrigeration problem 8 Check system See Section 5 1 No mix in hopper 1 Fill hopper with mix 2 Drive motor overload tripped 2 Wait for automatic reset 3 Drive belt failure 3 Replace drive belt 4 Freeze up Auger will not turn 4 Turn off cylinder wait for 15 minutes then restart 1 Worn drive bel...

Page 51: ...125 Decal Danger Electric Shock Hazard 1 324141 Decal Caution Rotating Blades 1 324200 Decal High Pressure Cut Out 1 324208 Decal Attention Refrigerant Leak Check 1 324509 Decal Cleaning Instructions 1 324566 Decal Wired According To 1 324584 Decal Adequate Ventilation 3 1 324594 Decal Attention Heat Sensitive 4 324686 Decal Danger Automatic Start 1 324728 Decal Contactor Identification 1 324803 D...

Page 52: ...46 8 2 AUGER SHAFT AND FACEPLATE PARTS 3170644 149003 3156795 381804 694255 624678 5 666786 625133 2177428 2187812 2187811 624664 5 624614 5 624598 5 417006 744273 744252 2147799 624677 5 ...

Page 53: ...64 5 O Ring Middle Center Spigot Black 5 Pack 1 624677 5 O Ring Mix Inlet Black 5 Pack 4 624678 5 O Ring Rear Seal Black 5 Pack 2 625133 O Ring Front Door Red 2 666786 Seal Rear Auger Black 2 694255 Spring Auger Flight 5 744252 Tray Drain Black Plastic 1 744273 Tray Drip 1 2147799 Mix Inlet Assembly 3 16 Hole Extended Length 2LA 2 2177428 Door w Pins 1 2187811 Spigot Body Center 1 2187812 Spigot B...

Page 54: ...Part Description Quantity 647899 Screw Panel Side Front 647900 Screw Panel Rear 2202040 Panel Rear Air Cooled 1 2202041 Panel Left Hand Side Air Cooled 1 2202042 Panel Right Hand Side Air Cooled 1 2202043 Panel Header 1 2202045 Panel Upper Front 1 2202047 Panel Drip Tray Support 1 2202089 Panel Front Lower Air Cooled 1 2202255 Panel Rear Water Cooled 1 2202256 Panel Left Hand Side Water Cooled 1 2...

Page 55: ...ompressor 2 295281 Contactor Compressor Drive 4 295282 Contactor IntelliTec2 Board 2 332563 Board Display Module 1 482004 Knob Spigot Adjustment 3 618142 Relay 282018 Compressor 2 718776 Switch Door Interlock 1 719128 SV Switch Membrane Strip Touchpad Ribbon 1 743654 Transformer Booster 1 8 5 ELECTRICAL PANELS 295282 295281 231058 231057 618142 743654 202235 332563 482004 719128 SV ...

Page 56: ...50 152236 284082 285073 342008 357102 458009 522869 614232 718686 718794 762449 762604 1145153 2147034 282019 SV 2202029 521514 521513 521516 230622 231075 762978 2183006 8 6 INTERNAL COMPONENTS 2171962 ...

Page 57: ...t Glass 2 521513 Board Program IntelliTec2 1 521514 Board Relay IntelliTec2 1 521516 Board Program Relay IntelliTec2 1 522856 Motor Drive 1 PH 2 522869 Motor Drive 3 PH 2 614232 Speed Reducer 2 718539 Switch Toggle 208 230V 1 718686 Switch Pressure High Pressure Cutout Hopper 1 1 718794 Switch High Pressure Barrels 2 2 762449 Valve Expansion 2 762490 Valve Expansion YG2 Models 2 762604 Valve Solen...

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Page 63: ...ions remedies are subject to the conditions that Buyer a signs and returns to Stoelting upon installation the Start Up and Training Checklist for the affected equipment b gives Stoelting prompt written notice of any claimed breach of warranty within the applicable warranty period and c delivers the affected equipment to Stoelting or its designated service location in its original packaging crating...