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Stoelting O231 Service Manual

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Model O231
SERVICE MANUAL
Manual No.
513646
Sept. 2010

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Summary of Contents for Stoelting O231

  • Page 1 Model O231 SERVICE MANUAL Manual No. 513646 Sept. 2010...
  • Page 3 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 Customer Service: 888.429.5920...
  • Page 4 CAUTION If you need to replace a part, use genuine Stoelting The signal word “CAUTION” indicates a potentially parts with the correct part number or an equivalent hazardous situation, which, if not avoided, may result part.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section Description Page Introduction Description ....................1 Specifications ..................... 1 Installation Instructions Safety Precautions ..................5 Shipment and Transit ................. 5 Machine Installation ..................5 Installing Permanent Wiring ................ 5 Initial Set-Up and Operation Operator’s Safety Precautions ..............7 Operating Controls and Indicators ...............
  • Page 6 Section Description Page Refrigeration System Refrigeration System .................. 25 Refrigerant Recovery and Evacuation ............25 Refrigerant Charging ................... 26 Compressor ....................27 Condenser ....................28 Valves ......................28 Thermostatic Expansion Valve (TXV) ..............28 Automatic Expansion Valve (AXV) ............... 29 Check Valve ......................

  • Page 7: Introduction

    SECTION 1 INTRODUCTION 1.1 DESCRIPTION The Stoelting O231 floor machine is gravity fed. The machine is equipped with the IntelliTec2 control which provides a uniform product. The 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.
  • Page 8 SPECIFICATIONS O231 Water Cooled O231 Air Cooled Dimensions Machine with crate Machine with crate 26'' (66,0 cm) 40-1/4'' (102,2 cm) 26'' (66,0 cm) 40-1/4'' (102,2 cm) width 62-1/2'' (158,8 cm) 64-1/2'' (163,8 cm) 62-1/2'' (158,8 cm) 64-1/2'' (163,8 cm) height...

  • Page 11: Installation Instructions

    Machines that have a water cooled condenser customer must place claim for damages and/or shortages require 1/2" NPT supply and drain fittings. in shipment with the carrier. Stoelting, Inc. cannot make any claims against the carrier. 2.4 INSTALLING PERMANENT WIRING To install wiring follow the steps below: 2.3 MACHINE INSTALLATION...

  • Page 13: Initial Set-Up And Operation

    SECTION 3 INITIAL SET-UP AND OPERATION 3.1 OPERATOR’S SAFETY PRECAUTIONS 3.2 OPERATING CONTROLS AND INDICATORS SAFE OPERATION IS NO ACCIDENT; observe these rules: Before operating the machine, it is required that the operator know the function of each operating control. Refer Know the machine.

  • Page 14: Important Information Regarding Cleaning And Sanitizing

    A. INTELLITEC2 TOUCHPAD Main Power On/Off The Main Power button is used to supply power to the IntelliTec2 control, the freezing cylinder circuits and the storage refrigeration system. When the machine is first plugged in, the control defaults to the On status with power to the hopper only.
  • Page 15 CLEANING ADDITIONAL INFORMATION · Is the removal of soil materials from a surface. THE USE OF DELIMERS · Is a prerequisite for effective sanitizing. A delimer is a strong acid that has the ability to dissolve milkstone. This type of chemical may become necessary NOTE once high levels of milkstone have developed.

  • Page 16: Disassembly Of Machine Parts

    3.4 DISASSEMBLY OF MACHINE PARTS B. DISASSEMBLY OF AUGER Remove the front auger support and bushing. Before using the machine for the first time, complete machine disassembly, cleaning and sanitizing procedures Remove the auger assembly from the machine. need to be followed. Routine cleaning intervals and proce- Pull the auger out of the machine barrel slowly.

  • Page 17: Sanitizing Machine Parts

    3.6 SANITIZING MACHINE PARTS Use Stera-Sheen or equivalent sanitizing solution mixed according to manufacturer’s instructions to provide a 100 parts per million strength solution. Mix sanitizer in quantities of no less than 2 gallons of 90° to 110°F (32°C to 43°C) water. Any sanitizer must be used only in accordance with the manufacturer’s instructions.

  • Page 18: Sanitizing

    3.9 SANITIZING 3.10 FREEZE DOWN AND OPERATION Sanitizing must be done after the machine is clean and just Sanitize immediately before use. before the machine is filled with mix. Sanitizing the night Make sure the display shows the freezing cylinder before is not effective.

  • Page 19: Mix Information

    3.11 MIX INFORMATION Mix can vary considerably from one manufacturer to an- other. Differences in the amount of butterfat content and quantity and quality of other ingredients have a direct bearing on the finished frozen product. A change in machine performance that cannot be explained by a technical problem may be related to the mix.

  • Page 21: Maintenance And Adjustments

    Following are the keypad sequences for the three levels The Service Contact Information screen provides the name available. and telephone number for service. The default is Stoelting Associate Press the right arrow then the SEL button. Technical Customer Service. The Manager level can change...

  • Page 22: Performance Screens

    D. Fine Consistency Adjustment B. Performance (2 of 2) Product consistency can be adjusted by the Associate The Performance screens display the current status of the level by using the Fine Consistency Adjustment screen. machine. This screen shows the current ambient tempera- Increasing the Fine Consistency number increases the ture, storage temperature and number of cycles since the product consistency (firmer product).
  • Page 23 This menu contains settings for the CutIn and CutOut, D. Advanced Settings (2 of 2) cycles in serve mode and auger cycle times. This screen is available to the Technician level. Cylinder can be changed by pressing the SEL button. CutOut Consistency is a number that represents how thick or thin the product in the freezing cylinder is.

  • Page 24: Utilities Screens

    F. Storage Settings (2 of 2) The Temperature Units setting changes the units dis- played to Fahrenheit or Celsius. The Service Contact Information option changes the service contact details. The Touchpad Lockup option is used to lock and unlock the keypad for self serve locations. H.
  • Page 25 Selecting Left or Right Output Control goes to a screen that B. Restore Factory Settings allows motors, solenoids or the compressor to be individu- ally activated. Activate by moving the cursor to the desired component and press the SET button. The Restore Factory Settings screen will revert all settings to their original values.

  • Page 26: Errors & Statistics Screens

    F. Export C. Machine Statistics (3 of 10) The Export screen allows you to export all the data and The Machine Statistics screen 3 of 10 provides the time and statistics stored in the control. Connect a USB flash drive date that the freezing cylinder was last cleaned.
  • Page 27 F. Machine Statistics (6 of 10) I. Machine Statistics (9 of 10) The Machine Statistics screen 6 of 10 shows the total run The Machine Statistics screen 9 of 10 shows the amount time for the compressor and counts the total cycles. There of time the pump hose has been in use and when the last is an option to reset the timer and the screen shows when reposition was completed.

  • Page 28: Updating Firmware

    Connect the USB flash drive to the display module. Connect power to the machine. The firmware will automatically update and the display will say "Stoelting Soft Serve" along with the new version number. NOTE Figure 4-1 Belt Tension Adjustment If the display does not show the new revision num- ber, make sure the .rom file is in the top level of the...

  • Page 29: Condenser Cleaning

    CONDENSER CLEANING 4.12 EXTENDED STORAGE The O231 has two condensers. An air-cooled or water- Refer to the following steps for storage of the machine over cooled condenser and a condensing unit for the hopper. any long period of shutdown time:...

  • Page 31: Refrigeration System

    5.1 REFRIGERATION SYSTEM NOTE For qualified service personnel only. Anybody work- The O231 has three separate refrigeration systems; one for ing with refrigerants must be certified as a Techni- each freezing cylinder and one for the hoppers. cian TYPE I as required by 40 CFR 82 Subpart F...

  • Page 32: Refrigerant Charging

    After recovery is complete, deactivate the solenoid NOTE by exiting the Testing and Manual Operation screens. The refrigeration system of the O231 is critically charged. Be sure to charge the system to the weight B. EVACUATING THE REFRIGERATION SYSTEM listed on the machine’s information plate.

  • Page 33: Compressor

    5.4 COMPRESSOR Remove the panels to gain access to the compressor terminals. The O231 has three hermetic reciprocating compressors: Remove the protective cover from the compressor two for the freezing cylinders and one for the hoppers.(Refer terminals. Disconnect the three terminals; C to Figure 5-2 and 5-3).

  • Page 34: Condenser

    Connect a gauge to the Schrader valve on the 5.5 CONDENSER suction line. The O231 is available with either an air-cooled or a water- Connect a thermocouple to the suction line next to cooled condenser. The capacity of the machine is directly the evaporator.

  • Page 35: Automatic Expansion Valve (Axv)

    TXV REMOVAL Install bulb on suction line exiting the evaporator using existing clamp. The bulb has an indent which Remove the side panel. must be placed against the tubing. NOTE WARNING Good contact between the bulb and the suction line is necessary for proper operation of the valve.

  • Page 36: Check Valve

    If the pressure reading is lower than expected, check to see if there is a low refrigerant charge or if there is a restriction in the system. NOTE The AXV is the LAST component to adjust in the refrigeration system. The AXV can be adjusted after the steps above are completed.

  • Page 37: Evaporator Pressure Regulator (Epr)

    HIGH PRESSURE CUTOUT TEST E. EVAPORATOR PRESSURE REGULATOR (EPR) Connect a gauge to the Schrader valve on the There is one EPR in the refrigeration system (Refer to discharge line. Figure 5-9). It is located on the suction line of the hopper evaporators and regulates evaporator refrigerant pressure.

  • Page 38: Water Valve (Water Cooled Models Only)

    EPR REPLACEMENT Leave the suction and discharge ports open to prevent pressure buildup during water valve removal. To replace the EPR, perform the following procedures: Unsweat the capillary tube from the discharge line. Apply a heat sink (wet cloth) to the EPR. Remove the clamps from the water lines at the With an open port, braze the EPR into the system.
  • Page 39 ACTIVATING A SOLENOID SOLENOID MAGNETIC COIL INSTALLATION To activate a solenoid, follow these steps: To replace the magnetic coil, perform the following proce- dures: Turn the machine on by pressing the Main Power Off/On button. Push the coil on to the solenoid valve stem. Press the right arrow, SET, then the SEL button to Connect the two electrical wires to the magnetic access the technician level on the control.

  • Page 40: Filter Drier

    5.8 FILTER DRIER The filter drier must be replaced every time the refrigeration system is opened for service. A new filter drier improves operation of the entire refrigeration system by stopping the circulation of moisture and by removing harmful contami- nants (Refer to Figure 5-12).

  • Page 41: Electrical And Mechanical Control Systems

    The boards are connected by two screws. CONTACTORS The O231 has a total of six contactors. Each side of the machine has a contactor for the compressor, drive motor and IntelliTec2 control. The contactor for the IntelliTec2...

  • Page 42: Drive Motor

    Set the belt tension to 40 DRIVE MOTOR lbs. The O231 has two drive motors. They are used to rotate the Using a straightedge, align the drive motor pulley auger assemblies. An internal, normally closed, centrifugal with the gearbox pulley.

  • Page 43: Capacitors

    C. DRIVE MOTOR INSTALLATION Disconnect the bleeder resistor from the circuit. Place the drive motor in position and install the four Measure the capacitance across the terminals. mounting bolts. The results should be as follows: Place the pulley and key on the motor shaft. Rating NOTE Part...

  • Page 44: Condenser Fan Motor (Air-Cooled Only)

    CONDENSER FAN MOTOR (AIR- COOLED ONLY) The fan motor is connected to a toggle switch located behind the left side panel. The switch is connected to a buck-boost transformer. The switch must be set to the correct position based on input voltage. The buck-boost transformer is connected to an overload protector.

  • Page 45: Spigot Switch

    SPIGOT SWITCH SPIGOT SWITCH ADJUSTMENT Turn the machine off by pressing the Main Power The spigot switch is a normally closed, held open switch. On/Off button. When a spigot is pulled, the spigot switch sends a signal to the IntelliTec2 control to start the auger drive and Remove the header panel.

  • Page 46: Temperature Control Sensor

    Using a pencil, mark the spigot glide 1/4” from the when the temperature of the sensor equals the Cut In T value spigot housing. Adjust the switch to activate when on the control, a freezing cycle will start. the spigot handle moves the glide to the mark. When troubleshooting a sensor, refer to the wiring diagram Fully tighten the retaining screws.

  • Page 47: Troubleshooting

    SECTION 7 TROUBLESHOOTING 7.1 ERROR CODES Ice crystals in the hopper can clog the mix inlet regulator and prevent mix from entering the freezing When the machine experiences a problem, one of the cylinder. Thoroughly thaw mix per manufacturer's following error codes will be displayed on the control panel. recommendations.
  • Page 48 The Freezing Cylinder Sensor Error (E5) indicates The Hopper Sensor Error (E6) will not occur on the a failure of the barrel sensor or if the sensor is out O231. of range. If the control panel displays an E5, press ERROR CODE 7 - DRIVE MOTOR...
  • Page 49 ERROR CODE 11 - PRIME The Prime Error (E11) will not occur on the O231. ERROR CODE 12 - LEFT HOPPER SENSOR The Left Hopper Sensor Error (E12) indicates a failure of the hopper sensor or if the sensor is out of range.

  • Page 50: Troubleshooting - Machine

    7.3 TROUBLESHOOTING - MACHINE PROBLEM POSSIBLE CAUSE REMEDY 1 Power to machine is off. 1 Supply power to machine. 2 Blown fuse or tripped circuit. 2 Replace or reset. Machine does not 3 Freeze-up (auger will not turn). 3 Turn off machine for 15 minutes, then restart. run.

  • Page 51: Replacement Parts

    Decal - Attention Heat Sensitive 324686 Decal - Danger Automatic Start 324728 Decal - Contactor Identification 324803 Decal - Domed Stoelting Logo (Large) (Header Panel) 324888 Decal - Fan Motor Reset 324896 Decal - Contactor Identification 324901 Decal - Transformer Switch...

  • Page 52: Auger Shaft And Faceplate Parts

    8.2 AUGER SHAFT AND FACEPLATE PARTS 694255 381804 149003 666786 624678-5 3156795 3170644 625133 2147799 2177428 624677-5 2187812 2187811 624598-5 624664-5 624614-5 744252 417006 744273...
  • Page 53 8.2 AUGER SHAFT AND FACEPLATE PARTS (CONTINUED) Part Description Quantity 149003 Bushing - Front Auger Support 232734 Cap - Rosette - Teardrop 314477 Cover - Hopper 381804 Auger Flight 417006 Grid - Drip Tray (Metal) 482019 Knob - Front Door (Black) 624598-5 O-Ring - Outside Spigot - Black (5 Pack) 624614-5...

  • Page 54: Spigot Assembly

    8.3 SPIGOT ASSEMBLY 2158082 718773 570961 428045 696044 2187805 Part Description Quantity 428045 Knob - Spigot Handle (Black) 570961 Pin - Cotterless Clevis (Spigot Handle) 696044 Spring - Torsion (Spigot Handle) 718773 Switch - Limit (Spigot) 2158082 Glide - Spigot Socket 2187805 Handle - Spigot (Handle Only) 8.4 PANELS AND SCREWS...

  • Page 55: Electrical Panels

    8.5 ELECTRICAL PANELS 295282 231058 231057 618142 743654 295281 332563 202235 719128-SV 482004 Part Description Quantity 202235 Circuit Breaker 229148 Cable - IntelliTec2 230654 Capacitor (Fan Motor) 231057 Capacitor - Run (#282018 Compressor) 231058 Capacitor - Start (#282018 Compressor) 295281 Contactor (Compressor / Drive) 295282 Contactor (IntelliTec2 Board)

  • Page 56: Internal Components

    8.6 INTERNAL COMPONENTS 2183006 614232 521513 521516 521514 2147034 152236 2202029 762978 762449 1145153 458009 230622 231075 522869 762604 285073 2171962 284082 718686 282019-SV 357102 718794 342008...
  • Page 57 8.6 INTERNAL COMPONENTS (CONTINUED) Part Description Quantity DR-0010 Drier - Filter (1/4" OD) (Cap Tube) 152236 Belt - Gripnotch (AX36) (Each) 230622 Capacitor - Start (#522856 Motor) 231075 Capacitor - Run (#522856 Motor) 282018-SV Compressor - Copeland 1 PH (No Capacitors) 282019-SV Compressor - Copeland 3 PH 284082...

  • Page 58: Wiring Diagrams

    8.7 WIRING DIAGRAMS...
  • Page 63 PURPOSE. 3. Remedies: Stoelting’s sole obligations, and Buyer’s sole remedies, for any breach of this warranty shall be the repair or (at Stoelting’s option) replacement of the affected component at Stoelting’s plant in Kiel, Wisconsin, or (again, at Stoelting’s option) refund of the purchase price of the affected equipment, and, during the first twelve (12) months of the warranty period, deinstallation/reinstallation of the affected component from/into the equipment.

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