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Vollrath Stoelting Endura 111 Service Manual

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Model E111 & F111
SERVICE MANUAL
Manual No.
513531-2
Dec. 2005

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  • Page 1 Model E111 & F111 SERVICE MANUAL Manual No. 513531-2 Dec. 2005...
  • Page 3 This manual provides basic information about the machine. Instructions and suggestions are given covering its operation and care. The illustrations and specifi cations are not binding in detail. We reserve the right to make changes to the machine without notice, and without incurring any obligation to modify or pro- vide new parts for machines built prior to date of change.
  • Page 4 A Few Words About Safety Safety Information Safety Alert Symbol: Read and understand the entire manual before This symbol Indicates danger, warning or caution. operating or maintaining Stoelting equipment. Attention is required in order to avoid serious per- sonal injury. The message that follows the symbol This manual provides the operator with information contains important information about safety.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION DESCRIPTION PAGE SECTION 1 INTRODUCTION Description ..................1 Specifications ................. 1 SECTION 2 INSTALLATION INSTRUCTIONS Safety Precautions ................. 3 Shipment and Transit ..............4 Freezer Installation ................. 4 Floor Stand Installation ..............5 Installing Permanent Wiring ............5 SECTION 3 INITIAL SET-UP AND OPERATION Operator’s Safety Precautions ............
  • Page 6 4.19 Solenoid Valve Removal ..............26 4.20 Solenoid Valve Installation .............. 26 4.21 Refrigerant Charge (All Models) ............. 26 SECTION 5 CONTROLS Control System Type 4 ..............27 Power Board ................... 27 Program Module ................27 Contactors ..................34 Spigot Switch .................. 34 Spigot Switch Removal ..............
  • Page 7 LIST OF ILLUSTRATIONS FIGURE TITLE PAGE Model Endura/Futura 111 Freezer ............1 Specifications ..................1 Warning Label Locations ................ 3 Leveling the Freezer ................4 Space and Ventilation Requirements ............4 Electrical Plug ..................4 Installing Tray and Cover ................ 4 Floor Stand .....................
  • Page 8 T.X.V. (Thermostatic Expansion Valve) ..........20 Bulb Removal ..................21 T.X.V. Removal ..................21 Bulb Installation ..................22 Filter Drier ....................22 E.P.R. Schrader Access Fitting .............. 22 E.P.R. Valve Adjustment ................ 23 E.P.R. Valve and Lines ................23 Filter Drier ....................24 Capillary Tube and Drive Assembly ............

  • Page 9: Description

    SECTION 1 DESCRIPTION AND SPECIFICATIONS 1.1 DESCRIPTION The Stoelting Endura/Futura 111/112 counter freezers are gravity fed. The freezers are equipped with fully automatic controls to provide a uniform product. The freezers are 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.
  • Page 10 MODEL ENDURA/FUTURA 111/112 COUNTER MODEL GRAVITY FREEZER DIMENSIONS: Freezer: 15" (38 cm) wide x 28.6" (72 cm) deep x 35.6" (90 cm) high Crated: 19.5" (50 cm) wide x 33" (84 cm) deep x 40" (102 cm) high WEIGHT: Freezer: 230 lbs. (140 kg) Crated: 275 lbs.

  • Page 11: Installation Instructions

    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.

  • Page 12: Shipment And Transit

    2.2 SHIPMENT AND TRANSIT The freezer has been assembled, operated and inspected 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.

  • Page 13: Floor Stand Installation

    2.4 FLOOR STAND INSTALLATION 2.5 INSTALLING PERMANENT WIRING To install the E or F111/112 onto the floor stand, follow the If permanent wiring is required by local codes, the follow- steps outlined below: ing procedure must be performed. A. Uncrate the floor stand and place in an upright posi- WARNING tion.

  • Page 15: Initial Setup And Operation

    SECTION 3 INITIAL SETUP AND OPERATION G. Do not operate under unsafe operating condi- 3.1 OPERATOR'S SAFETY PRECAUTIONS tions. Never operate the freezer if unusual or exces- SAFE OPERATION IS NO ACCIDENT; Observe these sive noise or vibration occurs. rules: A.

  • Page 16: Sanitizing

    A. SPIGOT SWITCH F. DRIVE MOTOR OVERLOAD The SPIGOT switch will automatically actuate the The internal DRIVE MOTOR OVERLOAD will trip if the auger drive and refrigeration systems when the spigot drive motor is overloaded. It will reset after approxi- is opened to dispense product.

  • Page 17: Freeze Down And Operation

    In general, sanitizing may be conducted as follows: E. After five minutes, place a bucket under the spigot and open spigot to drain sanitizing solution. When solution A. Push the mix inlet regulator into hopper with air has drained, press the CLEAN snap switch to stop the inlet (long) tube toward the front of the freezer auger.

  • Page 18: Mix Information

    G. After about 6 to 10 minutes the freezer will shut OFF Mix does not improve with age. Old mix, or mix that has and the green lens will illuminate. The product is ready been stored at too high temperature, can result in a to serve.

  • Page 19: Cleaning The Freezer

    3.7 CLEANING THE FREEZER To disassemble the freezer, refer to the following steps: NOTE A. Remove hopper cover and drain tray (Fig. 19). The frequency of cleaning the freezer and freezer B. Remove the mix inlet regulator from the hopper by parts must comply with local health regulations.

  • Page 20: Cleaning The Freezer Parts

    F. Remove the auger assembly from the freezer (Fig. 22). 3.9 CLEANING THE FREEZER PARTS Pull the auger out of the freezer barrel slowly. As the Place all loose parts in a pan or container and take to the auger is being pulled out, carefully remove each of the wash sink for cleaning.

  • Page 21: Routine Cleaning

    A. Assemble all "O" Rings onto parts dry, without lubri- cation. 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.

  • Page 22: Preventive Maintenance

    3.13 PREVENTIVE MAINTENANCE CLEANING vs. SANITIZING It is important to distinguish between cleaning and It is recommended that a maintenance schedule be fol- sanitizing. Although these terms may sound lowed to keep the freezer clean and operating properly. synonymous, they are not. BOTH are required for adequate food safety and proper machine A.
  • Page 23 3. SANITIZING – After the machine has been THE USE OF CHLORINE TEST STRIPS cleaned and contains no milkstone, the machine is reassembled. Then a FDA-approved “Test strips” are used to determine concentrations of sanitizing solution is run through the machine to active chlorine in sanitizing solutions.

  • Page 24: Extended Storage

    D. MONTHLY 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.

  • Page 25: Refrigeration System

    SECTION 4 REFRIGERATION SYSTEM WARNING REFRIGERATION SYSTEM BOTH SUCTION SIDE SOLENOIDS MUST BE ACTIVATED FOR PROPER PURGING OF The refrigeration system (Fig.28) is a dual-purpose SYSTEM. USE POWER CORD PART NUMBER system. 430119 OR EQUIVALENT FOR DIRECT CONNECTION. Figure 28. Refrigeration System...

  • Page 26: Evaporators

    The system is designed to efficiently operate both the hopper and evaporator simultaneously at different temperatures. The proper charge is indicated on the nameplate and on the compressor. The compressor has an internal high-pressure bypass. This bypass eliminates the need for a high-pressure cutout switch.

  • Page 27: Condensers

    5. Connect the ohmmeter to terminals C and S. ventilation on the right and left sides of the unit for free flow Resistance through the start winding should be 7.77 of air (Figure 33). Make sure the freezer is not pulling over to 8.93 ohms with the ohmmeter set at ohms x 1.

  • Page 28: Adjustment

    Figure 35. T.X.V. (Thermostatic Expansion Valve) T.X.V. ADJUSTMENT Figure 34. Condenser Inspection T.X.V. adjustment is not recommended. Any attempt to adjust the T.X.V. will cause the freezer to be totally 4. If the condenser is dirty, place a wet towel over the out of calibration.

  • Page 29: Installation

    T.X.V. INSTALLATION To replace the T.X.V., perform the following proce- dures: CAUTION WHEN PLACING THE T.X.V., A HEATSINK (WET CLOTH) MUST BE USED TO PREVENT DAMAGE TO THE VALVE. 1. Position the T.X.V. with heatsink so the liquid line and suction line correspond with the proper valve ports.

  • Page 30: Hopper

    4.10 E.P.R. VALVE ADJUSTMENT To adjust the E.P.R. valve, refer to the following procedures: 1. Remove the Phillips head screws from the bottom of the front panel and remove the panel by sliding down and out. 2. Remove the cap from the E.P.R. Schrader access fitting (Figure 40).

  • Page 31: Removal

    3. Remove the foam insulation from the surrounding lines. 4. Apply a heatsink (wet cloth) to the E.P.R. valve. 5. Unsweat the two refrigeration lines. 6. Remove the E.P.R. valve with the heatsink. Figure 41. E.P.R. Valve Adjustment 4.12 E.P.R. VALVE INSTALLATION 7.

  • Page 32: Capillary Tubes

    4. Remove the capillary tube drier assembly. 4.15 CAPILLARY TUBE INSTALLATION 1. Position the capillary tube drier assembly so the drier inlet tube is in position to be brazed. Braze using the appropriate material. 2. Position the capillary tube and braze the tube to the hopper inlet using the appropriate material.

  • Page 33: Solenoid Valve

    5. Once the capillary tube drier assembly and filter drier are installed, the refrigeration system must be leaked checked, purged and evacuated to 500 microns of mercury or less. 4.16 SOLENOID VALVE To check for leaking valve seats, follow the procedure outlined below.

  • Page 34: Solenoid Magnetic Coil Installation

    3. Remove the retainer from the top of the solenoid and 5. Apply a heatsink (wet cloth) to the valve body and pull the magnetic coil off. unsweat the two joints. Remove the valve body. NOTE 4.20 SOLENOID VALVE INSTALLATION The retainer may be a screw, nut, or clip.

  • Page 35: Controls

    SECTION 5 CONTROLS CONTROL SYSTEM TYPE 4 contactors. The power board has a third relay; it is used to transfer power to control the liquid line solenoid valve. The relay will close after 2 hours of red light idle causing The control system is the brain of the freezer.
  • Page 36 Figure 50. Power Board...
  • Page 37 Figure 51. Program Module...
  • Page 38 Figure 52. Membrane Switch Panel Display Board When the cycle switch SW1 is placed in the ) start at the end of the set off time. The freezer position, the control will go through a self-test will remain on until brought to consistency. After sequence and the results will be displayed the selected number of operating cycles, the control will operate in idle mode strictly by On/...
  • Page 39 E. Control Calibration NOTE Values below are default values only. Values for your freezer can be found inside the decorative header panel or in the information packet behind the left side panel DIGIT DISPLAY WORD PUSH BUTTON NOTES FUNCTION ACTION NOTE Self-Test Push-button actuation enters...
  • Page 40 DIGIT DISPLAY WORD NOTES PUSH BUTTON FUNCTION ACTION Ninth push-button actuation Rotate calibrate to adjust Hopper Temp. hopper temperature set point 25 Used for separate hopper - 45°F (-4+7°C). °F refrigeration system only. Tenth push-button actuation Rotate calibrate to adjust Barrel Temp.
  • Page 41 F. Error Conditions Spigot Switch. The Spigot Switch is a normally closed held open switch. When the spigot is opened, the switch will close starting the freezer. When the rotary switch SW1 is rotated to the Self-Test position (calibrate “0”), the control will be in the test mode.

  • Page 42: Contactors

    H. Freezer Operation and run until the preset barrel temperature is reached, then after the preset On time, stop. When the spigot is opened, the drive will start Consistency Mode. When the Off/On Switch is immediately and the compressor 3-4 seconds placed in the On position, the red Push-To- later.

  • Page 43: Spigot Switch Installation

    1. Loosen the two Phillips head screws from the bottom FRONT DOOR INTERLOCK of the decorative panel and slide the panel down and SWITCH REMOVAL out. 1. Remove the front door assembly. 2. Disconnect the electrical wires and remove the switch by removing the two retaining screws, nuts, and 2.

  • Page 44: Front Door Interlock Switch Assembly

    5.10 FRONT DOOR INTERLOCK 5.12 TOUCH PAD SWITCH MODULE SWITCH ASSEMBLY REMOVAL 1. Assemble the replacement switch to the bracket and 1. Use a 5/64” Allen wrench to remove the retaining secure in the same position as the old one. screw located at the bottom of the module.

  • Page 45: Sensor

    3. Place the switch module into the housing top first, then the bottom. 4. Replace the retaining screw using a 5/64” Allen wrench. 5.14 SENSOR The sensor monitors refrigerant gas temperature exiting the evaporator. Figure 58. Foam Insulation Removal 5.15 SENSOR REMOVAL 5.

  • Page 46: Preparation For Major Component Removal

    NOTE 5.19 CONDENSER FAN MOTOR REMOVAL The sensor must be installed without air gaps and must not contact the evaporator raps. If there are any air gaps or if the sensor contacts the rap, the 1. Remove the Phillips head screw from the back panel, freezer will not function properly.

  • Page 47: Condenser Fan Motor Installation

    5.21 DRIVE MOTOR The drive motors are designed specifically for their application. The drive motors are used to rotate the auger assembly. The start and run capacitors are located on the motors. An internal normally closed centrifugal switch starts the drive motor. The drive motor is equipped with a thermal overload protector.

  • Page 48: Drive Motor Installation

    3. Turn the motor and remove the electrical cover plate. NOTE Identify and disconnect the four electrical wires You must have proper alignment or short belt life (Figure 63). will result. 4. Use an Allen wench to loosen the pulley setscrew. 5.

  • Page 49: Speed Reducer Installation

    5. Remove the speed reducer from the freezer. Then, NOTE using an Allen wrench, loosen the setscrew and You must have proper alignment or short belt life remove the pulley and key. will result. 5.26 SPEED REDUCER INSTALLATION 4. Check for any wires and/or copper tubing that may have been pushed out of place.

  • Page 50: Compressor Installation

    NOTE Rubber mounts are not always furnished with replacement compressors. 8. Check the compressor for a burnout condition using an acid test kit. If acid is found, clean out the system per the compressor manufacturer’s instructions (Figure 71). E111 F111 Figure 69.

  • Page 51: Final Assembly Of Freezer

    4. Install the replacement compressor into the freezer 11.Purge and evacuate the refrigeration system to 50 fitting the base over the four studs. microns of mercury for approximately 30 minutes. 5. Install the four washers and nuts onto the studs and 12.Accurately charge the system with refrigerant per the tighten securely.

  • Page 53: Troubleshooting

    SECTION 6 TROUBLESHOOTING Troubleshooting can be difficult. The TROUBLESHOOTING INDEX below gives a list of possible problems. To make a repair to a problem, make reference to the cause and correction on the page indicated. ALL REPAIRS MUST BE MADE BY A QUALIFIED SERVICE TECHNICIAN. This list of problems, causes and corrections will only give an indication of where a possible problem can be and what repairs are needed.

  • Page 54: Dispensing, Servability And Overrun

    6.3.16 Freezer will not leave present mode 6.3.17 Touch Pad lights do not work; freezer operates normally 6.3.18 Compressor discharge pressure too high 6.3.19 Compressor running too hot; trips on overload protector 6.3.20 Compressor suction pressure too high 6.3.21 Compressor suction pressure too low 6.3.22 Freezer refrigerant charge is low 6.4 Control Displayed...

  • Page 55: Barrel And Hopper Mix Temperature Maintenance

    Control ‘LKG’ temperature is too high/low....Control ‘LKG’ temperature should approximately equal or ..................slightly exceed the desired product serving temperature; ..................change accordingly (refer to control setup procedure in ..................subsection 3.2). Mix inlet regulator leaking air and/or mix...... Check and/or replace missing, worn, or damaged o-rings ..................

  • Page 56: Electro-Mechanical

    6.2.2 FROZEN PRODUCT ON HOPPER WALLS CAUSE CORRECTION Heavy freezer usage ............. There is no correction required if the E.P.R. valve setting is ..................correct. Some product freezing to the walls during heavy freezer ..................operation is normal. E.P.R. valve needs adjusting........Make appropriate adjustment. Refer to Refrigeration Section 4, ..................
  • Page 57 6.3.3 RED CLEAN LIGHT IS FLASHING CAUSE CORRECTION CLEAN was deactivated by depressing the CLEAN switch; control is awaiting your next command ..............Turn power OFF then ON to leave CLEAN mode or depress ode operation..................CLEAN again to continue CLEAN m 6.3.4 HOLD READY SWITCH WILL NOT WORK CAUSE CORRECTION...
  • Page 58 6.3.8 COMPRESSOR STARTS AND RUNS, BUT SHORT CYCLES ON OVERLOAD PROTECTOR CAUSE CORRECTION Low voltage to unit ............Determine reason and correct. Improperly wired ............Check wiring against diagram. Overload protector defective ......... Replace overload protector. Capacitor defective ............Check start/run capacitor. Replace if defective. Excessively high discharge pressure ......
  • Page 59 6.3.13 FREEZER REFREEZES TOO OFTEN IN GREEN LIGHT MODE CAUSE CORRECTION Ambient temperature is high ......... Move or direct hot air away from freezer. Control ‘LKG’ temperature is too high/low ....Control ‘LKG’ temperature should approximately equal or slightly ..................exceed the desired product serving temperature; change accord- ..................
  • Page 60 6.3.16 FREEZER WILL NOT LEAVE PRESENT MODE CAUSE CORRECTION Loose or defective touch pad connection..... Repair the touch pad connection. 6.3.17 TOUCH PAD LIGHTS DO NOT WORK: FREEZER OPERATES NORMALLY CAUSE CORRECTION Touch pad defective ............. Replace touch pad. Loose or improper connections to the touch pad ..
  • Page 61 6.3.20 COMPRESSOR SUCTION PRESSURE TOO HIGH CAUSE CORRECTION Expansion valve setting grossly out of adjustment ..............*Replace expansion valve. NOTE Expansion valve setting is preset for optimum balance of flow to barrel and hopper- DO NOT ATTEMPT TO ADJUST THE VALVE SETTING. Refrigerant overcharge ..........

  • Page 62: Control Displayed Error Conditions

    ..................STEP 2: Empty barrel and hopper of all product. Rinse hopper ..................and barrel with cool water using a sanitized bucket. Refill freezer ..................with 35° to 45° mix until hopper is full with mix inlet regulator in ..................place. Upon freeze-down, the sightglass should clear within the ..................
  • Page 63 6.4.7 ERROR 07: DRIVE MOTOR (P.T.F. LIGHT FLASHES IN SEQUENCE OF SEVEN) CAUSE CORRECTION Drive motor overload is open........Determine cause for overload. Wait 15 to 20 minutes for auto- ..................matic reset of overload. Turn power OFF then ON to clear error ..................

  • Page 65: Replacement Parts

    SECTION 7 REPLACEMENT PARTS 7.1 HOW TO ORDER PARTS To assure receipt of the proper replacement parts, sup- ply your dealer or distributor with the following informa- B. Serial number of model, stamped on nameplate tion: C. Part number, part name and quantity needed. Com- A.

This manual is also suitable for:

Stoelting futura 111Stoelting endura 112Stoelting futura 112Stoelting e111Stoelting f111

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