Model E157/E257/F257 SERVICE MANUAL
Contents
1. ITEM STOELTING PN QTY DESCRIPTIDN 2119012 INDICATOR ASSY LIQUID LEVEL e 314216 COVER PLASTIC 3 314217 COVER PLASTIC SLIDING DOOR 4 232086 CAP DRIVE INJ MOLDED 624737 RING 1 1 2X1 7 8X3 16 70 DUR 6 5276 SEALER RING 7 3309 18 2 NUT WING 403 8 4111592 DIVIDER PLATE 9 2146244 BAF WELDMENT 0 2146251 WASHER SPECIAL ANTI LIFT 11 4146238 AGITATOR WELDMENT e 1142520 LOWER BUSHING 3 2171810 DRIVE SHAFT ASSY 4 1127494 TOP EVAP BUSHING 9 3113940 BUT TRAY 6 5332 e PA LOWER SIDE 7 696130 e CK CLIP FOR VALVE 8 490701 4 EG 9 71856 SWITCH GGLE 15 125V 20 3146277 02 ASSEMBLY el 230624 CAPACITUR START 270 384MF 165V el 618530 RELAY COMPRESSOR 2217 22 282022 SV COMPRESSOR 115V 60Hz 1PH 23 3146291 DRIVE UNIT ASSEMBLY 24 1133960 SPRING AND EYE BOLT ASSY 25 231062 CAPACITOR RUN 4MFD 370 VOLTS 26 200037 BRACKET MOTOR MTG CSLUSH 27 522031 TOR GEAR 1 12HP 115 60 50 28 371016 P R 1 8X3 4 CARBON STI 29 1171812 DRIVE TOR EXTENSI ASSY 30 1170735 BRACKET CAPACITOR 31 625456 RING RETAINING 1 375X 050 32 766539 WASHE 33 2149065 BEARING WASHER 34 294482 TORQUE CONTRO 35 718149 SWITCH LIMIT SIMULATED ROLLER 36 649175 8 SCREW TAP IZ4 2O0UNC X 1 2 TRS 37 3149024 REAR WER PANE 38 284010 CONDENSER 39 4158331 FAN SHROUD W ORIFICE 40 162070 BLADE FAN 10 IN DIA 41 522833 FA TOR 42 3156682 FAN BRACKET 42. kasa asas usa a 13 20 Removing Agitator Assembly and Lower Bushing 13 21 Removing Divider Plate from Agitator Fingers 14 22 Removing Drive Sha ciclista een ak dan ea 14 23 Exploded View of Divider Plate and Agitator 14 24 LubricatingDrivo Shaft u deae pe ee ken pas senk pk Si dane ki asap enda Ao DEEN 15 25 Installing Divider Plate and Agitator 16 26 Proper Installation of Sealer nennen nnne 16 LIST OF ILLUSTRATIONS 27 Correct and Incorrect Alignment of Vertical Center Post Guide Hole 16 28 External Parts To Be Cleaned u 19 30 Removing Compressor Terminal Cover nennen nnne nnne 23 91 Check Windind aa u itt E erige A dake veas da 23 32 Check Winding To Ground s y kat ken defo a kk Elena 23 83 Nee 24 Remove Cap eL 24 NET ie EE 25 96 AJUSTA oin k RUN n va ak et E ee Nuka es 25 Elter Drier Replacement cela ee ceed 26 88 Torque Control eiii EP 27 39 Tensi n SPA EEN 27 40 Removing Torque Control ui Aaa 28 41 FanR mOVAIL ceci A ke pe e 29 42 Disconnect et teta a ed HERES Ede DIRE ee aa 29 43 Drive M
3. Figure 19 G For removal and disassembly of the divider plate Removing Sealer Ring andapitator assembly reter ta the following steps 3 Toremove the divider plate and agitator assembly the WARNING divider plate must be first rotated counterclockwise to PLACE THE ON OFF STIRONLYSWITCHINTHEOFF Wnlockandiitoutofthe product cylinder POSITION AND DISCONNECT THE FREEZER FROMELECTRICAL SUPPLY SOURCE 4 Once the divider plate and agitator assembly are lifted off the vertical product cylinder center post and 1 Remove the drive cap and O ring from the agitator out of the product cylinder remove the divider plate tube Fig 18 assembly and anti lift disc Remove the plastic agitator bushing from the bottom of the product cylinder center post by lifting up and out of the product cylinder Fig 20 Refer to Figure 23 for an O exploded view Figure 18 Removing Drive Cap and O Ring 2 Remove the sealer ring by squeezing the looped Figure 20 section and lifting out of the product cylinder Fig 19 Removing Agitator Assembly and Lower Bushing 13 5 Unscrew the divider plate from the agitator fingers andremove Fig 21 Figure 21 Removing Divider Plate from Agitator Fingers 6 Remove the drive shaft by pulling straight up and out ofthe vertical center post Fig 22 Figure 23 Exploded View of Divider Plate and Agitator Assembly 7 Place all loose parts in a pan or container and ta
4. 1 4 13 10 5 m 15 38 1 19 25 48 9 Figure 3 Figure 4 Model E257 Front Model E257 Side NOTE Figures in parenthesis are in centimeters 2 SECTION 2 INSTALLATION INSTRUCTIONS 2 1SAFETY PRECAUTIONS Do not attempt to operate the freezer until the safety precautions and operating instructions in this manual are read and completely understood Take notice of all warning labels on the freezer Figures 6 amp 7 Thelabels havebeen putthereto help maintain a safe working environment 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 periodically to be sure they can be recognized as warning labels If danger warning or caution labels are needed indicate the part number type of label location of label and quantity required along with your distributor 2 2 SHIPMENT AND TRANSIT The freezer has been assembled operated and inspected at the factory Upon arrival at the final destina tion the complete freezer must be checked for any damage which may have occurred during transit With the method of packaging used the freezer should arrive in excellent condition THE CARRIER IS RESPONSIBLE 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 da
5. MODELS E157 E257 F257 324105 DECAL CAUTION ELECTRIC SHOCK 324393 DECAL STOELTING SWIRL 324548 DECAL ADEQUATE VENTILATION E257 F257 Floor Model 324649 DECAL ADEQUATE VENTILATION E157 Counter Model 723516 TAG ATTN SET TIMER 723526 TAG READ MANUAL 723529 TAG CAUTION 723537 TAG SANITARY CLEAN 21 22 SECTION 5 REFRIGERANT COMPONENTS AND ADJUSTMENTS 5 1 REFRIGERATION SYSTEM This section is intended to provide qualified refrigeration technicians with a general understanding ofthe refrigera tion system it s components and adjustments It is recom mendedthatany work done on the freezer be performed by aqualifiedrefrigeration technician 5 2 COMPRESSOR A Winding Test To testthe compressor motor windings for possible prob lems perform the following steps WARNING DISCONNECT FREEZER FROM ELECTRICAL SUPPLY BEFORE SERVICING 1 Remove the two Philips head screws from the bottom ofthe back panel and slide the side panel down back and out Removethecompressorterminalcover by insert ing a standard screwdriver under the terminal cover and retaining frame pry out side then hold with your hand while prying the other side Figure Figure 30 Removing Compressor Terminal Cover 3 Removeretaining clip and cover 4 Removethe three wires from the compressor terminals Setyour ohmmeter at X1 and connectthe ohmme ter to terminals C and R to check resistance through run windings Refer to Figure
6. 47 762411 VALVE AUTOMATIC EXPANSION 48 202002 BREAKER 1 POLE 2 17006 GRATING GRID FOR DRIP TRAY 90 744273 TRAY DRIP WHITE 91 4172883 DRIP TRAY SUPPORT 41 N 5 MM 23 LS MWAN 8 Figure 52 Model F257 Exploded View 42 9 5 MODEL F257 PARTS LIST
7. Y STOELTING FOODSERVICE EQUIPMENT Model E157 E257 F257 SERVICE MANUAL Manual No 513565 Rev 2 June 2003 SERVICE MANUAL FOR MODEL E157 E257 amp F257 STOELTING SLUSH FREEZER This manual provides basic information aboutthe freezer Instructions and suggestions are given covering its operation and care The illustrations and specifications are not binding in detail We reserve the right to make changes to the freezer without notice and without incurring any obligation to modify or provide new parts for freezers built prior to date of change DO NOT ATTEMPT to operate the freezer until instructions and safety precautions in this manual are read completely andare thoroughly understood If problems develop or questions arise in connection with installation operation or servicing of the freezer contact your distributor Stoelting LLC Tele 920 894 2293 502 Hwy 67 Kiel WI 53042 1600 Fax 920 894 7029 TABLE OF CONTENTS SECTION DESCRIPTION PAGE SECTION 1 INTRODUC TION EET 1 1 1 DESCHIBIIONS A 1 1 2 Specifications E 1 SECTION2 INSTALLATION INSTRUCTIONS 2 ea a 3 2 1 Safety ET TEE 3 2 2 ld 3 2 3 Freezer Installation WEN 3 2 4 Adjusting Cup DISPENSES vi u ine kon bd nee ashaku ai bin 7 SECTION3 INITIAL SET UP AND OPERATION e psi m p a KH 9 3 1 Operator s Safety Precautions nene 9 3 2 Op
8. repair or replace as necessary MIBETOO NGM uuu E Take Brix reading Fill with properly mixed product FAN MOU ruining u uuu on eee a esee Check fan and replace if necessary Restricted air flow to freezer Louvered side panel required 6 15 2 cm clearance for air intake and top requires 10 25 4 cm clearance for discharge Dirty condenser filter 4424 112 Clean filter Dirty uuu u Clean condenser Tension spring on torque control not set correctly Spring length should be 3 1 16 3 1 8 long 3 5 8 for the F257 Adjust if necessary Micro switch on torque control defective Check and replace micro switch Shortage of refrigerant Fix leak and add refrigerant 24 Hour Timer not set for compressor operation Reset timer 8 17 EXCESSIVE ICE CRYSTALS ABOVE DIVIDER PLATE Sealer ring not installed or installed incorrectly Install sealer ring correctly Frozen product being poured into cylinder Do Not pour frozen product into cylinder EH RECS Drain mix Refill with properly mixed product 8 18 SPIGOT LEAKING OR STUCK Spigot O rings defective or missing Drain mix to below spigot level Remove spigot clean replace o rings as needed
9. 31 for com pressorterminals Setyourohmmeterat X1 and connectthe ohmme ter to terminals C and S to check resistance through the start windings 23 Figure 31 Check Windings NOTE Check your compressor handbook for proper val ues Available from compressor manufacturer 7 To check if windings are shorted to ground con nectone ohmmeterleadto a bare metal part onthe compressor and check terminals C R and S Fig 32 Volt Ohm Meter Leads Figure 32 Check Winding to Ground 5 3 CONDENSER The condenser is a air cooled copper tube and aluminum fin type Condensing is totally dependent upon air flow A plugged condenser or restrictions in the louvered side panel will restrict air flow CAUTION AIR RESTRICTIONS WILL LOWER THE CAPAC ITY OF THE SYSTEM AND DAMAGE THE COM PRESSOR The condenser must be kept free of dirt and grease The freezer MUST have a minimum of 6 15 2 cm of ventilation at all louvered panels for free flow of air Make sure the freezer is not pulling over 100 F 37 air from other equipmentin the area NOTE Slush Freezers can not operate at temperatures over 120 F ambient The optional condenser filter and condenser require peri odic cleaning To clean referto the following procedures 1 Remove the condenser filter from the lower front panel and visually inspect for dirt If the filter is dirty shake or brush excess dirt off the filter and wash in warm soapy water Once
10. DEFACE OR PAINT OVER ANY DECALS THEY ARE THERE FOR YOUR SAFETY CAUTION THIS DEVICE MUST BE PLUGGED INTO A GROUNDED RECEPTACLE TO PREVENT SHOCK HAZARD 324113 Behind Sani tray DANGER CAUTION HAZARDOUS KONIN PARIS DISCONNECT FROM THE SOURCE OF DO NOT OPERATE UNIT WITH OUTER COVERING REMOVED 2 BUILDING BEFORE 324105 CAUTION THIS DEVICE MUST BE PLUGGED INTO A PROPERLY GROUNDED RECEPTACLE TO PREVENT ELECTRICAL SHOCK HAZARD TAMPERING WITH THE PLUG OR USING VOLTAGES OTHER THAN THE SPECIFICATIONS ON I D PLATE WILL VOID YOUR WARRANTY REFER TO OWNER S MANUAL FOR INSTALLATION INSTRUCTIONS Figure 6 Warning Label Locations E157 IMPORTANT NOTICE TO OPERATOR BEFORE INSTALLING EQUIPMENT READ THE OWNER S MANUAL CAREFULLY TAKE NOTE OF ALL INSTRUCTIONS AND CAUTION DECALSONTHIS EQUIPMENT GOOVERTHE MANUAL THOROUGHLY AND POINT OUT ALL DECALS TO YOUR EMPLOYEES SO THEY UNDERSTAND HOW TO SAFELY OPERATETHIS EQUIPMENT DO NOT REMOVE DEFACE OR PAINT OVER ANY DECALS THEY ARE THERE FOR YOUR SAFETY Affixed to condenser shroud CAUTION HAZARDOUS MOVING PARTS DO NOT OPERATE UNIT WITH OUTER COVERING REMOVED 324107 CAUTION THIS DEVICE MUST BE PLUGGED INTO A GROUNDED RECEPTACLE TO PREVENT SHOCK HAZARD Affixed to condenser shroud 324113 DANGER ELECTRIC SHOCK HAZARD DISCONNECT FROM THE SOURCE OF ELECTRICAL SUPPLY IN BUILDING BEFORE SERV
11. REPLACEMENT PARTS AND REFERENCE DRAWINGS 37 9 1 HOw to Order Parts ise as 37 9 2 Spigot Assembly Parts usya uu gu ze ee aan 37 9 3 Mod l E157 Parts ee ld asa 39 9 4 Model E257 Parts Ei 41 9 5 Model F257 Partei 43 LIST OF ILLUSTRATIONS Figure Title Page 1 Model E15 FROM uuu oak 2 2 ModelE157 SIB kane oi e canada 2 3 ModelE257 E25 FORE labs ae rea qawa ecards 2 4 Model A app aa sa 2 EAT 3 6 Wa rningiLabelllocations E15 ru ee is 4 7 Warning Label Locations 257 257 5 8 Space 8 Ventilation Requirements U a 6 S MEME Ct alll Te LE 6 10 A 6 11 Adjusting Cup Dispensers AA 7 12 OperatingiGOntrolS EL 9 13 Remove Drip Tray and aver UL au aus nn ano aaa nennen tense 11 u u dad 11 15 Removing 12 16 Removing Spigot O Ring from 5 12 17 Cut away View of Spigot 12 18 Removing Drive 13 19 Removing Sealer Ring
12. all times to preserve the lustre of the stainless steel A mild alkaline cleanser is recommended Use a soft cloth or sponge to apply the cleanser CAUTION DO NOT USE ACID CLEANERS STRONG CAUSTIC COMPOUNDS OR ABRASIVE MATERIALS TO CLEAN ANY PART OF THE FREEZER EXTERIOR OR PLASTIC PARTS 2 Clean the sani tray by lifting up out and rinsing and replacing B WEEKLY 1 Removethe sani tray and cover Clean behind the drip tray with a soap solution 2 Check all O Rings for excessive wear and replace if necessary C MONTHLY CAUTION THE FREEZER HAS AN AIR COOLED CONDENSER AND MUST HAVE PROPER AIR CIRCULATION DO NOT PLACE THE E257 FLOOR MODEL FREEZER ANY CLOSER THAN SIX 6 INCHES 15 2 CM FROM THE WALL THE COUNTER MODEL FREEZER REQUIRES A 3 7 6 CM CLEARANCE ONTHESIDES A 1 2 5CM CLEAR ANCE ATTHEREAR ANDA 10 25 4 CM CLEARANCE AT THE TOP FAILURE TO CLEAN THE CONDENSER FILTER MAY RESULTIN SERIOUS FREEZER DAMAGE AND COULD VOID THEWARRANTY CONDENSER CLEANING 1 Forthe floor models remove the sani tray and insert Remove the two phillips head screws from the lower front panel and pull panel down and out Blow the dirt out from the opposite side of the condenser using an air tank CO 2 tank or vacuum 2 Forthe counter model remove the six phillips head screws from the back panel Then clean the con denser using the same method as on the floor model 3 12 EXTENDED STORAGE Refer to the following steps f
13. are being formed in the product cylinder As the drive motor torque increases due to the formation of ice crystals the left hand arm of the control bracket will gradually move to the right and contact the left hand micro switch The compressor will SHUT OFF approximately 71 to 81 seconds after the arm maintains contact with the micro switch This prevents eratic freeze down and rapid recycling of the compressor See Figure 38 for a visual description of the compo nents involved in this operation A Consistency Adjustment Thetension spring Fig 39 located onthe right side ofthe freezer is used to adjust the product consistency To increase product consistency increase the spring tension by turning the eyebolt nut clockwise one turn To decrease product consistency decrease the spring tension by turning the eyebolt nut counterclockwise one turn 27 Left Hand Control Bracket Arm Right Hand Control Right Hand ON Micro Switch 2 Left Hand OFF Micro Switch Viewed from Back Figure 38 Torque Control _3 1 16 3 1 8 3 5 8 F257 Viewed from Right Side Figure 39 Tension Spring NOTE The tension spring is adjusted atthe factory to 3 1 8 inches 3 5 8 for the F257 If further adjustment is necessary turn the eyebolt nut one turn at a time in the desired di rection B Micro Switch Removal Should either the right or the left micro switch be found to be defective either switch can be replace
14. breaker in building Check for blown fuse or tripped circuit in building amp replace Reset switch is in the cut out down position Put reset switch in normal operating position up ON OFF STIR ONLY switch has a loose wire or LEER Check repair or replace switch 8 11 DRIVE MOTOR OVERLOAD TRIPS FREEZER SHUTS DOWN WHEN RUNNING Dirty condenser uu u een Clean condenser Improper Brix readings 4402441112 Refill with product that has Brix reading between 11 13 Consistency setting is too firm Adjust tension spring Improper refrigerant charge Adjust charge Large voltage Changes Check supply voltage Torque control not stopping Check torque control 8 12 COMPRESSOR WILL NOT RUN BUT DRIVEMOTOR RUNS Voltage is too Check voltage See Nameplate No power to compressor Check wire harness terminal and switches in compressor circuit and replace or repair Compressor start capacitor is defective Test capacitor and replace if necessary Overload protector is tripped Check amp test overload If amps are
15. head screws from the back side panel and pull panel down and out Model E257 Remove the left side and back panel Model E157 2 Remove the cap from the Schrader valve on the com pressor Fig 34 3 Install a 0 100 P S I G gauge onto the Schrader valve Fig 35 Figure 34 Remove Cap 4 Startthe refrigeration cycle and read the pressure NOTE Freezer must be full of product and past initial freeze down Figure 35 Install Gauge 5 Pressure gauge reading should be E E157 E257 E157 E257 2217 F257 R12 R12 R22 R22 R502 R404A Head Suction Pressure See See Chart Chart 42 Below Below 6 Ifthe pressure gauge reading does notfall within those specifications proceed with the following steps 7 Remove the cap the the A X V and using a small wrench turn the adjusting screw 1 4 turn 90 counter clockwise for more cooling or 1 4 turn 90 clockwise for less cooling Fig 36 8 Allow the system to level out for three to five minutes before taking another pressure reading 9 Should the reading still not fall within specifications repeat steps 8 and 9 until the correct reading is obtained 10 Once the correct reading is obtained replace the cap Remove the pressure gauge from the Schrader valve and replace the Schrader valve cap 11 Replace the rear panel B A X V Removal CAUTION IF IT IS NECESSARY TO REPLACE THE A X V A HEAT SINK WET CLOTH MUST BE USED T
16. normal replace overload Compressor relay if defective Test relay and replace if necessary Toggle switch is in STIR ONLY position Place toggle switch in ON the stirring amp freezing position Compressor problem Refer to Subsections 8 1 through 8 9 Compressor is defective Check compressor and replace if necessary Torque control defective Check and replace torque control 24 Hour Timer not set for compressor operation Reset timer 8 13 PRODUCT DISPENSES INCORRECTLY Trapped air under divider plate Remove trapped air Lower half of cylinder is frozen to agitator Mix too lean Thaw and refill with correct mix Freezer is being overdrawn Slow down rate of draw Upper half of cylinder is frozen Mix too lean in upper cylinder Thaw fill with correct mix 35 8 14 PRODUCT IS TOO THIN Ambient temperature is above 100 F 37 7 Move or direct hot air away from freezer Freezer is being overdrawn Slow down the rate of draw Clean condenser Fan is stuck
17. the filter is clean rinse thoroughly in warm clean water and shake excess water outtaking care not to damage the filter in any way Install the filter back onto the front panel 2 For Model E257 remove the sani tray and insert Remove the two phillips head screws from the lower front panel and pull panel down and out 3 Visually inspect the condenser for dirt by shining a light through the coil from the back of the condenser Fig 33 Figure 33 Check Condenser 4 If the condenser is dirty place a damp towel over the condenser 5 Using compressed air or CO tank blow out the dirt fromthebackofthe condenser Mostofthe dirt will cling to the wet towel 6 Analternative method of cleaning the condenser is to use a condenser brush and vacuum NOTE If the condenser is not kept clean loss of refrigeration efficiency will result causing extended run time or inad equate product consistency 7 Forthe Model E157 remove the phillips head screws from the back panel and remove the panel Clean the condenser following steps 4 6 above PRODUCT CYLINDER EVAPORATOR An automatic expansion valve A X V is used to control the refrigerant flow to the freezing area of the product cylinder The adjustable A X V is preset at the factory If the product is too thick or too thin an A X V adjustment may be necessary A A X V Adjustment To adjust the A X V refer to the following procedures 1 Remove the two philips
18. the freezer if unusual or excessive noise or vibration occurs 3 2 OPERATING CONTROLS AND INDICATORS Before operating the freezer itis required that the operator know the function of each operating control and indicator Refer to Figure 12 forthe locations ofthe operating controls and indicators WARNING THE STIRRING ONLY OFF STIRRING amp FREEZING SWITCH MUST BE PLACED IN THE OFF POSITION WHEN DISASSEMBLING FOR CLEANING OR SERVIC ING THE FREEZER MUST BE DISCONNECTED FROM ELECTRICAL SUPPLY BEFORE REMOVING ANY AC CESS PANELS ONLY A QUALIFIED SERVICE TECH NICIAN MAY REMOVE ACCESS PANELS ren a Here Em STIRRING ONLY OFF RESET 24HRTIMER HIGH PRESSURE MANUAL STIRRING amp FREEZING SWITCH BATTERY BACKUP RESETSWITCH TOGGLE SWITCH Figure 12 Operating Controls 9 A STIRRINGONLY OFF STIRRING 8 FREEZING SWITCH The STIRRING ONLY OFF STIRRING amp FREEZ ING switch is a three position toggle switch used to control the operation of the refrigeration system and agitator When the switch is placed in the STIR RING ONLY position the refrigeration system will be off and the agitator will rotate for cleaning or if stirring is required when the store is closed When the switch is placed in the OFF position the refrigeration system and agitator will be off The switch should be placed inthe STIRRING amp FREEZING position for normal operation B RESET SWITCH The reset switch is a two position br
19. to close 4 22 222 4 Determine reason and correct Replace relay if necessary Compressor motor has a winding open or shorted Replace compressor Internal mechanical trouble in compressor Replace compressor 8 8 COMPRESSOR STARTS BUT DOES NOT SWITCH OFF OF START WINDING Inproperly wired TEE Check wiring against diagram Low voltage to unit kiy doe an a Determine reason and correct Excessive high discharge pressure Check for restrictions Compressor motor has a winding open or shorted Replace compressor Internal mechanical trouble in compressor Replace compressor 8 9 COMPRESSOR START CAPACITOR OPEN SHORTED OR BLOWN x y Replace relay Prolonged operation on start cycle due to low voltage TO UNE nenne Determine reason and correct Prolonged operation on start due to improper relay Replace relay Excessive short cycling Determine reason and correct Improper Determine correct size and replace LOOS tn tanto en entire eat Locate and correct 8 10 FREEZER WILL NOT START Freezer is unplugged Plugin freezer Toggle switch in OFF position Place toggle switch in ON or STIR ONLY position Blown fuse or tripped circuit
20. 3 3159575 FRONT WER PANE 44 423013 GUARD SWITCH SLUSHFREEZER 45 739533 TIMER 24 HR 21 AMP SPDT 46 718686 SWITCH PRESSURE 47 768411 VALVE AUTOMATIC EXPANSION 48 202002 BREAKER 1 POI 49 295252 C ACTOR SINGLE POLE 25 FLA 90 417006 GRATING GRID FOR DRIP TRAY 91 744273 TRAY DRIP WHITE oe 4172883 DRIP TRAY SUPPORT 43 44
21. C 314217 COVER PLASTIC SLIDING DOOR 4 232086 CAP DRIVE INJ MOLDED 624737 RING 1 1 2X1 7 8X3 16 70 DUR 6 5276 SEALER RING 7 9309 16 2 NUT WING 403 8 4111592 DIVIDER PLATE 2 elelose BAF ASSEMBLY 0 767519 WASHER SPECIAL ANTI LIFT 11 4109212 BLADE AGITATUR e 221164 BUSHING AGITATOR 3 2171810 DRIVE SHAFT ASSY 4 1127494 P EVAP BUSHING 9 3113940 BOTT TRAY 6 dE e PANEL LOWER SIDE 7 696130 e CK CLIP FOR VALVE 8 49070 4 EG 9 71856 SWITCH GG 15AMP 125V 20 3146277 02 VAPDORATOR ASSEMBLY el 231092 CAPACITOR START 145 175MFD Al el 618164 RELAY PICKUP 17 80AMPS DROPOUT ee eseble Sv COMPRESSOR e3 3146291 DRIVE UNIT ASSEMBLY 24 1133960 SPRING AND EYE BOLT ASSY eo 231062 CAPACITOR RUN 4MFD 8370 VOLTS 26 200037 BRACKET MOTOR SLUSH 27 522031 TOR GEAR 1 12HP 115 60 50 28 571016 PIN R 1 8 4 CARBON STI 29 1171812 DRIV TOR EXTENSI ASSY 30 1170735 BRACKET CAPACITUR 31 625456 RING RETAINING 1 375X 050 32 766539 WASHER 33 2149065 BEARING WASHER 34 294482 TORQUE CONTRO 35 718149 SWITCH LIMIT SIMULATED ROLLER 36 649175 8 SCREW TAP 1 4 20UNC X 1 2 TRS 37 3149024 REAR WER PANE 38 284010 CONDENSER 39 4158331 FAN SHROUD W ORIFICE 40 162070 BLADE FAN 10 IN DIA 41 522833 FA TOR 42 3156682 FAN BRACKET 43 3159575 FRONT WER PANE 44 423013 GUARD SWITCH SLUSHFREEZER 45 739533 TIMER 24 HR 21 AMP SPDT 46 718702 SWITCH PRESSURE
22. Drive Motor 1 12 HP Drive Motor COMPRESSOR 2500 BTUH 2500 BTUH 5200 BTUH frozen product output frozen product output frozen product output Approx 11 total running Approx 11 total running Approx 9 total running amps amps amps Use 15 Amp circuit breaker Use 15 Amp circuit breaker Use 15 Amp cirucit breaker COOLING Air cooled requires minimum Requires unobstructed front Requires unobstructed front 3 7 6 cm air clearance on and 6 minimum 15 2 cm and 6 minimum 15 2 cm sides and 1 2 5 cm at rear clearance at back of unit No clearance at back of unit No of unit clearance needed on side of clearance needed on side of unit unit HOPPER 10 gallons 37 9 liters 10 gallons 37 9 liters 10 gallons 37 9 liters A transformer is required if voltage is over 126 5 volts or under 103 volts Under normal operating conditions 21 25 79 4 3475 88 35 12 5 31 8 gt AIR IN 1 NS T Y 4 29 10 8 25 25 64 7 5 19 0 Ie 15 38 1 Figure 1 Figure 2 Model E157 Front Model E157 Side 58 1 47 1
23. Fig 13 D With a bucket placed below the drain spigot pull the spigot to dispense Fig 14 E When liquid product is completely drained empty the bucket into the sink Any remaining ice can be removed by circulating warm water through barrel 3 4 DISASSEMBLY AND CLEANING OF FREEZER PARTS CAUTION PLACE THE ON OFF STIR ONLY SWITCH IN THE OFF POSITION AND DISCONNECT THE FREEZER FROM ELECTRICAL SUPPLY SOURCE BEFORE SERVICING ORCLEANING 10 Figure 13 Removing Drip Tray and Cover Figure 14 Draining Product Inspection for worn or broken parts should be made during every disassembly of the freezer for cleaning or other purposes Allworn or broken parts should be replaced to ensure safety to both the operator and the customer and to maintain good freezer performance as well as a quality product NOTE Frequency of cleaning MUST comply with local health regulations The exterior of the freezer must be kept clean at all times to preserve the luster of the stainless steel A mild alkaline cleanser is recommended Use a soft cloth or sponge to apply the cleanser NOTE Do notuse acid cleaners strong caustic compounds or abrasive materials to clean any plastic or stainless steel parts of the freezer exterior A Remove the dispensers from the side of the freezer by pulling straight up Clean the cup dispensers and dispenser lids with a mild alkaline cleanser and soft cloth or spo
24. ICING UNIT 324105 CAUTION THIS DEVICE MUST BE PLUGGED INTO A PROPERLY GROUNDED RECEPTACLE TO PREVENT ELECTRICAL SHOCK HAZARD TAMPERING WITH THE PLUG OR USING VOLTAGES OTHER THAN THE SPECIFICATIONS ON I D PLATE WILL VOID YOUR WARRANTY REFER TO OWNER S MANUAL FOR INSTALLATION INSTRUCTIONS 723529 Figure 7 Warning Label Locations E257 D Thefloor model freezers are equipped with air cooled CAUTION condensers and require correct ventilation The frontof DO NOT ALTER OR DEFORM PLUG IN ANY WAY the freezer is the air intake and must be unobstructed Air discharges outofthe rearofthe unit Do notobstruct the discharge Allow a 6 15 2 cm clearance behind the unit Fig 8 CAUTION FAILURE TO PROVIDE ADEQUATE VENTILATION WILL VOID WARRANTY o 2 Figure 9 Electrical Plug 6 MIN BEHIND FREEZER G Install the drip tray support drip tray drip tray grid cover andmiscellaneous parts onthe freezer Fig 10 y gt gt gt EB Figure 8 Space and Ventilation Requirements E Place the ON OFF STIR ONLY toggle switch in the OFF position This switch is located on the lower left of the freezer under the drip tray and cover F Connectthe power cord The plugis designed for 115 volt 15 amp duty The unit must be connected to a properly grounded rec
25. NN a LOOP TO REAR OF FREEZER EVAP Figure 50 Model E157 Exploded View 38 9 3 MODEL E157 PARTSLIST ITEM STOELTING PN DESCRIPTION 21190102 INDICATOR ASSY LIQUID LEVE 2 314216 COVER PLASTIC 3 314217 COVER PLASTIC SLIDING DOOR 4 232086 CAP DRIVE INJ MOLDED 3 624737 RING 1 1 2X1 7 8X3 16 70 DUR 6 2076 SEALER RING 7 2309 18 NU
26. O PREVENT DAMAGE TO THE VALVE 1 Assuming the side and rear panels have been removed perform the following procedures for removing the A X V Figure 36 Adjust A X V WARNING DISCONNECT FREEZER FROM ELECTRICAL SUPPLY SOURCE BEFORE SERVICING 2 Recover the refrigerant charge then leave a port open to prevent pressure build up during A X V removal Remove foaminsulation from surrounding lines 4 Apply a heat sink wet cloth to the A X V 5 Unsweat the A X V from its connecting lines 6 Remove the A X V with the heat sink C T X V Replacement To replace the A X V perform the following procedures CAUTION WHEN REPLACING THE A X V A HEAT SINK WET CLOTH MUST BE USED TO PREVENT DAMAGE TO THE VALVE 1 Position the A X V with heat sink so the refrigeration line correspond with the proper valve ports 2 Braze lines to the A X V using the appropriate brazing material 3 Remove the heat sink from the A X V 4 Replace any foam insulation to the surrounding lines 5 Once the A X V is installed the refrigeration system must be purged and evacuated to 50 microns of mer for approximately 30 minutes 25 6 Break the vacuum to 0 P S I G with dry nitrogen then with an open replace the filter drier using the appropriate brazing material Fig 37 7 Once the filter drier has been replaced repeat the evacuation and recharging procedures Figu
27. RATING GRID FOR DRIP TRAY 53 744273 TRAY DRIP WHITE 94 4172883 DRIP TRAY SUPPORT 39 5 MWN DA 8 Figure 51 Model E257 Exploded View 40 9 4 MODEL E257 PARTS LIST ITEM STOELTING PN QTY DESCRIPTION 2119012 INDICATUR ASSY LIQUID LEVEI e 314216 COVER PLASTI
28. T WING 403 8 4111592 DIVIDER PLATE 9 2121522 BAF F ASSEMBLY 0 767519 WASHER SPECIAL ANTI LIFT 11 4109212 REE BLADE AGITATOR 2 221164 BUSHING AGITATOR 3 2171810 DRIVE SHAFT ASSY 4 1127494 P EVAP BUSHING 3 3113940 BOT TRAY 6 2159570 WER PANE 7 696130 CK CLIP FOR VALVE 8 324107 DECAL CAUTION VING PARTS 2 2159689 RIGHT LOWER PANE 20 3146277 02 EVAPORATOR ASSEMBLY el 618164 RELAY PICKUP 17 80AMPS DROPOUT 21 831092 CAPACITOR START 145 175MFD ee 282012 COMPRESSOR 23 282012 SV DRIVE UNIT ASSEMBLY 24 1133960 SPRING AND EYE ASSY 25 231062 CAPACITOR RUN 4MFD 370 VOLTS 26 200037 BRACKET MOTOR MTG SLUSH 27 522031 TOR GEAR 1 12HP 115 60 50 28 571016 PIN R 1 8X3 4 CARBON STL 29 1171812 DRIVE TOR EXTENSI ASSY 30 1170735 BRACKET CAPACITUR 31 2149065 BEARING WASHER 32 766539 WASHER 33 625456 RING RETAINING 1 375X 050 34 294482 TORQUE CONTROL 35 718149 SWITCH LIMIT SIMULATED ROLLER 36 3158351 BACK PANEL 37 284010 CONDENSER 38 4158331 FAN SHROUD W ORIF ICE 39 162070 BLADE FAN 10 IN DIA 40 522833 FA TOR 41 3156682 FAN BRACKET 42 3159569 FRONT PANEL 43 3158345 CONDENSER SUPPOR 44 3159478 SIDE PAN 45 739533 IMER 24 HR 21 AMP SPDT 46 718702 SWITCH PRESSURE 47 718561 GGLE SWITCH 48 202002 BREAKER CIRCT 1 POLE 49 762411 VALVE AUTOMATIC EXPANSION 50 3159479 P ENCLOSURE 31 423013 GUARD SWITCH SLUSHFREEZER 20 417006 G
29. ace p si bis Contact your local power company 8 2 COMPRESSOR RELAY DEFECTIVE OR BURNED OUT Incorrect relay en Incorrect mounting angle Line voltage too high or too low 1096 Excessive short cycling Relay being influenced by loose vibrating mounting Incorrect run capacitor n Check and replace m Remount relay in correct position bi kaa Contact your local power company T Determine reason and correct Remount rigidly Replace with proper capacitor 8 3 COMPRESSOR STARTS AND RUNS BUT SHORT CYCLES ON OVERLOAD PROTECTOR Low voltage to Overload protector defective Excessive discharge pressure Suction pressure too high Compressor too hot return gas hot Compressor motor has a winding shorted 8 4 COMPRESSOR RUNS CONTINUOUSLY Shortage of refrigerant Torque control defective in hopper too Tension spring on torque Restriction in refrigeration system Restricted a
30. acket through the side of the freezer and align the holes in the fan brackets with the holes in the condenser fan shroud attached to the freezer frame Fig 48 P Fastening Screws Figure 48 Fan Installation 2 Using a 5 16 nut driver or a phillips head screwdriver install the four screws securing the fan supports to the mounting brackets Connectthe condenser fan lead wires 32 SECTION 8 TROUBLESHOOTING Troubleshooting can be difficult The TROUBLESHOOTING INDEX on the preceding page gives a list of possible problems To make a repair to a problem make reference to the cause and correction on the page indicated This list of problems causes and corrections will only give an indication of where a possible problem can be and what repairs are needed Normally more or other repair work is needed beyond the recommendations in the list Remember that a problem is not normally caused by only one part but by the relation of one part with other parts This list is only a guide and cannot give all possible problems and corrections The technician must find the problem and its source then make the necessary repairs In the event the Troubleshooting Guide does not help to correct the service problem the factory Service Department should be contacted Write or call STOELTING INC Tele 920 894 2293 502 HWY 67 800 558 5807 KIEL WI 53042 Fax 920 894 7029 INDEX DESCRIPTION PAGE 8 1 Compressor run capacitor open Sh
31. d by performing the following procedures WARNING DISCONNECT FREEZER FROM ELECTRICAL SUPPLY SOURCE BEFORE SERVICING 1 Remove the necessary panels Model E257 back panel Model E157 left side panel 2 Using a 5 16 wrench remove the two nuts and star washers from the torque control mounting bracket Fig 40 4 D HH Figure 40 Removing Torque Control 3 Removethe torque control from the mounting bracket by pushing the assembly toward the left side of the freezeruntilthe mounting studs are clear of the mount ing bracket Then pull the assembly down and towards you 4 Using a 1 4 wrench remove the two nuts from the rear ofthe defective micro switch 5 Remove the micro switch from the mounting studs and disconnect from the connector C Micro Switch Replacement 1 Connect a serviceable micro switch to connector 2 Install micro switch onto the mounting studs and fasten with the two hex nuts Tighten nuts snugly with 1 4 wrench Do not over tighten 3 Position torque control behind the mounting bracket and allow the two studs to be pushed through the holes in the mounting bracket 4 Install the two star washers and nuts onto the mount ing studs Tighten nuts snugly with a 5 16 wrench Do not over tighten a Replace the back panel 28 SECTION 7 MAJOR COMPONENT REMOVAL AND INSTALLATION 7 1 INTRODUCTION 2 Disconnectthe lead wire from the drive motor capacitor This section covers the remo
32. eaker switch This switch is used to protect the freezer from mechanical damage The switch must be in the NORMAL OPERATING POSITION up before the freezer will operate Any time a condition occurs which causes the agitator drive motor to draw excessive current the reset switch will automatically switch to the OVERLOAD CUT OUT FREEZER NOT OPERAT ING position This will shut down the freezing and agitation action of the freezer to protect the agitator drive motor from burning out Should the reset switch ever trip out move the STIRRING ONLY OFF STIRRING amp FREEZ ING toggle switch to the STIRRING ONLY position Then move the reset switch back to NORMAL OPERATING POSITION up andallowthe freezer to stir without refrigeration for five minutes After five minutes of stirring return the STIRRING ONLY OFF STIRRING amp FREEZING switch to the STIRRING amp FREEZING position C 2A4HOUR TIMER To program the timer rotate program disc in the direction of the arrows to align the correct day time with the time of day mark Then pull out for Off time or push in for On time Each actuator is equivalent to 15 minutes time Check for AM PM centered between 12and 12 rotating disc Ata 6 00 setting the indicator will point to AM or PM D HIGH PRESSURE MANUAL RESET SWITCH The HIGH PRESSURE MANUAL RESET SWITCHisa safety switch designed to protect the compressor from damage dueto excessive head pressure Whentripped the lever will be
33. eptacle The electrical cord furnished as part of the freezer has a three prong grounding type plug Fig 9 The use of an extension cordis notrecommended If one mustbe used useone with a wire size 12 gauge or heavier with a ground Do Figure 10 not use an adaptor to avoid grounding equipment Installing Drip Tray and Cover 2 4 ADJUSTING CUP DISPENSERS To adjust the cup dispensers install the size cup desired into the dispenser and turn the wing nuts on the dispenser mounting bracket until enough tension is applied to the rim of the cup to keep it from dropping out Fig 11 Do notover tighten the wing nuts WINGNUTS Figure 11 Adjusting Cup Dispensers SECTION 3 INITIAL SET UP AND OPERATION 3 1 OPERATOR SSAFETY PRECAUTIONS A Knowthe freezer Read and understand the Operating Instructions Notice all warning labels on the freezer Wear proper clothing Avoid loose fitting garments and remove watches rings or jewelry which could cause a serious accident Maintain a clean work area Avoid accidents by cleaning up the area and keeping it clean Stay alert at all times Know which switch push button or control you are about to use and what effect it is going to have Disconnect electrical cord for maintenance Never attempt to repair or perform maintenance on the freezer until the main electrical power has been disconnected G Do not operate under unsafe operating conditions Never operate
34. erating Controls and sse eene 9 3 3 Draining the Freezer for Disassembling and Cleaning 10 3 4 Disassembly and Cleaning of Freezer Parts seen 10 3 5 Sanitizing the Freezers and Freezer Parts a 15 3 6 Assembly Of Freeze avwa ke oodd ana cati ka Ra ae bu d anc kar ba ace ed ago band 15 3 7 ileal MONN AAWON ee 17 3 8 Freeze DOWN and Operation su ponet is os 17 3 9 DISPeNSINQ F AOU ejt Em 17 3 10 Routine Cleaning 22 17 3 11 Preventative Maintenance 17 3 12 Extended Storage ini Ada 18 SECTION4 DECAES AND TA Scsi ee 21 4 1 How To Order Decals and Tags a cnc 21 SECTION5 REFRIGERANT COMPONENTS AND ADJUSTMENTS 23 5 1 Refrigeration System eee ia 23 5 2 tm 23 5 3 nel ES 23 SECTION6 ELECTRICAL SYSTEM OPERATION AND ADJUSTMENTS 27 6 1 Pe MUN PM D a iaa 27 6 2 El ctronic Torque Control iiio eske kenn Ra 27 SECTION7 MAJOR COMPONENT REMOVAL AND INSTALLATION 29 7 1 RE 29 7 2 Condenser Fan Removal inn 29 7 3 Drive Motor Removal uu uu uuu kaqa iat 29 7 4 Compressor Removal an ea aA tie aod d Iz ved dak ane 29 7 5 30 7 6 Drive Motor Installation co
35. ier using the appropriate brazing material Fig 46 Filter Drier Figure 46 Remove Filter Drier 12 Purge and evacuate the refrigeration system to 50 microns of mercury for approximately 30 minutes 13 Accurately charge the system with the amount and type of refrigerant indicated on the freezer Model I D plate 14 Leak check all fittings and connections 7 6 DRIVEMOTORINSTALLATION To install a serviceable drive motor perform the following procedures WARNING DISCONNECT FREEZER FROM ELECTRICAL SUPPLY SOURCE BEFORE SERVICING With the necessary panels removed for removal of a defective drive motor install the drive motorthrough either side of the freezer and position mounting flange over the bearing and line up the three holes Install the three socket head screws securing the mounting flange to the freezer and tighten Connect the wire leading from the drive motor to the reset switch Connectthe lead wire to the drive motor capacitor Connect tension spring and adjust to 3 1 16 3 1 8 Fig 47 31 3 1 16 3 1 8 3 5 8 F257 Figure 47 Tension Spring 6 Replace necessary panels 7 CONDENSER FAN INSTALLATION To install a serviceable condenser fan perform the follow ing procedures WARNING DISCONNECT FREEZER FROM ELECTRICAL SUPPLY SOURCE BEFORE SERVICING 1 Assuming the necessary panels have been removed to remove a defective condenser fan install a new con denser fan br
36. ir flow to freezer Filter ONY y ei ie ine a Fan not running Dirty condenser 2 MIX TOO a a eerte 8 5 UNIT NOISY Drive cap will not stay in place Loose parts MOUNTINGS Agitator drive shaft not lubricated TubingratileS 2 21 cootra Mix too gat eed tie rns Bent fan causing vibration Fan motor bearings worn Agitator fingers are bentt Internal compressor spring broken Lower agitator bushing is missing 86 COMPRESSOR WILL NOT START Line disconnect switch open Overload protector tripped Torque control defective Contactor defective Wiring improper or loose 24 Hour Timer not set for compressor operation Bee Determine reason and correct Sege Replace overload akt Check ventilation restrictions in cooling medium restrictions in refrigeration system Check for overcharge Adjust or replace expansion valve EM Check refrigerant charge fix leak add refrige
37. ition B Although servable product can be obtained after the freezer has been run for 1 hour the best quality ice crystals will develop after the freezer has been running for several more hours 3 9 DISPENSING PRODUCT To dispense product correctly refer to the following steps A Select the desired cup size B Dispense flavor concentrate into the cup first by pushing the flavor pump down Use one squirt of flavor for small cups two squirts for medium cups and three squirts for large cups C Place cup under and against the spigot D Pull the spigot out E Fillthe cup The gravity flow from the spigot will automatically mix the flavor concentrate with the neutral base mixture as it is dispensed F When the cup is full push the spigot in 3 10 ROUTINE CLEANING To remove spilled or dried mix from the freezer exterior simply wash in the direction of the finish with warm soapy water or a mild alkaline cleanser and a soft cloth or sponge Do notuse abrasive materials as they will mar the finish of the freezer Refer to Figure 28 for all external parts of the freezer to be cleaned 3 11 PREVENTATIVE MAINTENANCE Itis recommended that the following maintenance sched ule be followed to keep the freezer clean and operating properly CAUTION NEVER ATTEMPT TO REPAIR OR PERFORM MAINTE NANCE ON THE FREEZER UNTIL THE MAIN ELECTRI CAL POWER HAS BEEN DISCONNECTED 17 A DAILY 1 The exterior should be kept clean at
38. ke them to the wash sink filled with warm soapy water forcleaning CAUTION DO NOT DAMAGE PARTS BY DROPPING OR ROUGH HANDLING NOTE Do not attempt to wash the inside of the vertical product cylinder center post 8 Wash the inside of the product cylinder with warm soapy water using the brush provided Figure 22 Removing Drive Shaft 14 3 5 SANITIZING THE FREEZER AND FREEZER PARTS After the freezer parts have been soaked and washed in warm soapy water they should be rinsed thoroughly in cleanwater All parts must be sanitized before assembling with a USDA certified food grade sanitizing solution 50 parts per million of free available chlorine or equivalent is accept able A Mix a sanitizing solution of 50 parts per million to sanitize all loose parts before assembling B Place all loose paris in this solution then remove and let air dry C Using this sanitizing solution and the brushes pro vided sanitize the product cylinder and product outlet by dipping the brush in the sanitizing solution and scrubbing these areas D After assembling the freezer Section 3 6 mix approx imately gallons 11 3 liters of sanitizing solution and pour into the product cylinder Brush the walls of the cylinder above the divider plate with brushes provided to sanitize this reservoir area E Setthe STIRRING ONLY OFF STIRRING amp FREEZING switch in the STIRRING ONLY position and allow to stir for five minu
39. lubricate and install Dried mix in Spigot assembly Drain mix to below spigot level Remove spigot retainer and spigot Disassemble clean with hot water and brush Lubri cate reassemble and install Fill with liquid mix 36 SECTION 9 REPLACEMENT PARTS AND REFERENCE DRAWINGS The parts and wiring diagrams illustrated on the following 9 1 HOW TO ORDER PARTS pages pertain to models current with the printing of this To assure receipt of the proper replacement parts manual supply your dealer or distributor with the following information For your convenience a wiring diagram decal has been affixed to the electrical box or electrical box cover for A Modelnumber of equipment your model B Serial number of model stamped on nameplate If the wiring decal on your model is missing or has been damaged please contact Stoelting Inc Service C Partnumber part name and quantity needed Department for a replacement Common parts names and numbers are listed in this manual 9 2 SPIGOT ASSEMBLY PARTS Ref No Part No Description 1 1147688 Shaft amp Plug Assembly SM 813A 2 1120265 Shaft Spacer 232002 Retainer Cap for Spigot Valve 4 624607 O Ring 5 482024 Knob 6 694400 Spring 4 1120918 Splash Deflector for Spigot 2 VETE Figure 49 Exploded View of Spigot Assembly 37 O ll TAB FROM
40. mage and or shortage is found later advise the carrier within 10 days and request inspection The customer must place claim for damages and or shortages in shipment with the carrier 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 The floor model freezers must be placed ina solid level position To level the freezer turn the bottom part of each leg in or out Place a level on top of the hopper with the cover removed to check whether or not the freezer is level Fig 5 NOTE Accurate leveling is necessary to insure proper operation andcorrect drainage of freezer barrel C The counter model freezer must be placed on a solid level surface Place the rubber pad furnished under the freezer to create a seal to that surface The counter model freezer is air cooled and discharges at the top ALLOUVERED PANELS MUST have 3 of clearance on sides of unit 10 of clearance at the top and 1 clearance at rear of unit for proper cooling pua Figure 5 Adjustable Leg IMPORTANT NOTICE TO OPERATOR BEFORE INSTALLING EQUIPMENT READ THE OWNER S MANUAL CAREFULLY TAKE NOTE OF ALL INSTRUCTIONS AND CAUTION DECALSON THIS EQUIPMENT GOOVER THE MANUAL THOROUGHLY AND POINT OUT ALL DECALS TO YOUR EMPLOYEES SO THEY UNDERSTAND HOW TO SAFELY OPERATETHIS EQUIPMENT DO NOT REMOVE
41. nge Removethe driptray support driptray driptray grid by lifting up and out Clean the drip tray parts in the same manner as the cup dispenser Remove the two piece cover and mix level probe assembly and clean Remove the flavor pumps from the bottles and pump warm soapy water through them Then clean the bottles and pumps normally E To remove the upper and lower spigot assemblies remove the retaining clip and pull the spigot assem blies straight out of the product outlet Fig 15 11 Figure 15 Figure 16 Removing Spigot Assembly Removing Spigot O Ring from Spigot body O RING SPLASH DEFLECTOR SPRING SHAFT FOR SPIGOT SPACER VA 224 SHAFT amp PLUG RETAINERCAPFOR ASSEMBLY SPIGOT VALVE Figure 17 Cut away View of Spigot Assembly 12 1 With a clean dry towel wipe excess lubricant from the spigot assembly and O ring Firmly grasp the spigot assembly with both hands and squeeze the O ring upward Fig 16 When aloopis formed roll the O ring out of the groove towardthe end of the spigotassembly See Fig 17 fora cutaway view of the spigot assembly CAUTION DO NOT USE ANY TYPE OF SHARP OBJECT TO REMOVE ANY O RINGS 2 Place all loose parts in a pan or container and take them to the wash sink filled with warm soapy water for cleaning 3 Wash the product outlet with warm soapy water using the brush provided
42. or motor is defective Check repair or replace Temperature adjusting tension spring too loose Adjust tension spring Refrigerant is low or leaking Check refrigerant charge Add if necessary Expansion valve is defective Check adjust or replace expansion valve 8 15 AGITATOR DOES NOT ROTATE Drive cap pin not engaged or cap missing Align half holes in drive shaft and agitator tube Drive motor overload tripped off Turn freezer off for 5 minutes then reset Agitator stuck 2 Check for locked or bent fingers Thaw product in freezer if frozen No power to drive motor UU II an Check wire harness and switches in drive circuit and repair or replace Drive motor is defective 1 Check and replace if necessary 8 16 NOICE CRYSTALS ON INITIAL FREEZE DOWN Toggle switch in OFF or STIR ONLY position Place toggle switch in the stirring amp freezing position Reset switch is in the cut out down position Place reset switch in normal operating position Blown fuse in building or no input power to freezer Check for blown fuse or input power to freezer Broken wire loose connection or defective switch Check and test
43. or storage of the freezer over any long period of time A Placethe STIRRING ONLY OFF STIRRING amp FREEZING switch in the OFF position B Disconnect unplug the freezer from the electrical supply source C With a warm detergent solution thoroughly clean all parts that come in contact with neutral base mix or flavors Rinse in clear water and dry all parts Do not sanitize NOTE Do not let cleaning solution or products stand in the product cylinder during shutdown period D Remove disassemble and clean the spigot assem blies and lower bushing Place these parts in a plastic bag with a moist paper towel to prevent them from becoming brittle 18 CUP DISPENSERS AND LIDS Ee COVERS LIQUID LEVELINDICATOR _ wan sn en I Fi AVORBOTTLES DRIP TRAY SUPPORT DRIP TRAY DRIP TRAY GRID Mo Rocard o y gt ALL PANELS Figure 28 External Parts To Be Cleaned 19 20 SECTION 4 DECALS AND TAGS 4 1 HOW TO ORDER DECALS AND TAGS To assure receipt of the proper warning decals supply your dealer or distributor with the following information A Model number of equipment B Serial number of model stamped on nameplate C Part number decal description and quantity needed Common warning decal names and numbers are listed below
44. orted or DIOWN 35 8 2 Compressor relay defective or burnedout eene nnne nnns nnne nens 35 8 3 Compressor starts and runs but short cycles on overload protector 35 84 Gompressorrunscontinously nein 35 8 5 Unit el 35 8 6 Compressor Will MOU Stall reellen 35 8 7 Compressor will not start hums but trips on overload protector 2 36 8 8 Compressor starts but does not switch off of start 36 8 9 Compressor start capacitor open Shorted or blown 36 8 10 Freezer will norta uc corr need tec ede D re one ren EX en EE ag de eu ERE ka kw 36 8 11 Drive motor overload trips freezer shuts down when running 36 8 12 Compressor will not run but drive motor runs 36 8 13 Product dispenses eu 36 8 14 Product iS LOO TMM rss eue E 37 8 15 Agitator OCS notrolale u er LEE 37 8 16 Noicecrystals on initial freeze down 37 8 17 Excessive ice crystals above 37 8 18 Spigot leaking OF StUCK 37 8 1 COMPRESSOR RUN CAPACITOR OPEN SHORTED OR BLOWN CAUSE Improper capacitor Excessively high line voltage 110 ofrated max CORRECTION nS Determine correct size and repl
45. otor Hemoval l tede t pesas Do 29 44 CompressorHeimov l Lag ne aeui kk ke a ct ua pen DEO eee E Cus E Cua EE 30 ET E 30 46 R rmoveFilterDrmeru u u aid 31 47 Tensi n SPA A L swa won EA 31 48 Fanilnstallation eke o ge pa REDI 31 49 Exploded View of Spigot Assembly 37 ModellE15 Exploded View een ree eta 38 51 ModelE257 Exploded VISW root ede n ee ee 40 52 Model F 257 Exploded V W u vas ede vo eget eter ee d a a a redet eae dat 42 SECTION 1 INTRODUCTION 1 1 DESCRIPTION Models E157 E257F257 freezers are gravity fed The This manualis designedto assist qualified service person freezers are equipped with fully automatic controls to neland operators in the installation operation and mainte provide a uniform product The freezers are designed to nance ofthe Models E157 E257 F257 freezers operate with most neutral bases and concentrated flavors 1 2 SPECIFICATIONS E157 COUNTER E257 FLOOR F257 FLOOR MODEL FREEZER MODEL FREEZER MODEL FREEZER width 15 38 1 cm width 15 38 1 cm width 15 38 1 cm depth 29 5 74 8 cm depth 19 25 48 9 cm depth 19 25 48 9 cm height 34 75 88 3 cm height 61 38 156 cm height 61 38 156 cm WEIGHT 130 Ibs 58 9 kg 140 lbs 63 5 kg 140 Ibs 63 5 kg ELECTRICAL 1 Phase 115 VAC 1 Phase 115 VAC 1 Phase 115 VAC 1 12 HP Drive Motor 1 12 HP
46. out push to reset E SPIGOT ASSEMBLY Dispensing of frozen mix is done by the SPIGOT ASSEMBLY By pulling the spigot plunger out mix in the form of ice crystals is dispensed through the port on the bottom of the SPIGOT ASSEMBLY To stop dispensing push the spigot plunger in F FLAVORBOTTLES The FLAVOR BOTTLES are operated by a spring loaded push button pump By pushing down 1 4 ounce 7 39 ml of flavor is dispensed 3 3 DRAINING THE FREEZER FOR DISASSEMBLING AND CLEANING After installation and initial set up the freezer exterior must be cleaned and the freezer parts must be disas sembled cleaned and sanitized Cleaning and sanitizing MUST be done before the initial freeze down and operation Subsequent cleaning and sanitizing afterthe freezer has been operated and product has been dispensed will require the freezerto be completely drained of all unused mix Perform the following steps to drain the freezer of any unused mix A Setthe STIRRING ONLY OFF STIRRING amp FREEZING switch to the STIRRING ONLY position well in advance of cleaning and sanitizing to assure complete defrosting and draining of the product cylinder B While the freezer is inthe STIRRING ONLY mode remove the unused flavoring from the flavor bottles All unused flavoring should be poured into the containers from which they came C Remove the Sani tray and cover by gently pushing up to disengage from the support pins and pulling out and down
47. rant if necessary Replace compressor Saget Fix leak add refrigerant Check and replace torque control m Refrigerant mix before adding to hopper Spring length should be 3 1 8 long Adjust if necessary M Determine location and remove T Louvered panels require 6 15 2 cm clearance for air intake and 10 25 4 cm clearance for discharge sheeted Clean or replace filter Check fan and replace if necessary Clean condenser m Take Brix reading Fill with properly mixed product Gre Check locking pin inside of drive shaft and slot in agitator for excessive wear and replace if necessary Find tighten Lubricate agitator drive shaft Reform to be free of contact Fill product cylinder with properly mixed neutral base m Replace fan Replace motor Realign replace agitator and stationary fingers sapa ys Replace compressor ii Install lower bushing Close start or disconnect switch Will reset after cooling E Check and replace torque control ET Replace contactor D Check wiring against diagram Pet Reset timer 34 8 7 COMPRESSOR WILL NOT START HUMS BUT TRIPS ON OVERLOAD PROTECTOR Improperly CTT Check wiring against diagram Low voltage vekse ti keyi tect ai Determine reason and correct Start capacitor defective Replace start capacitor Relay failing
48. re 37 Filter Drier Replacement 26 SECTION 6 ELECTRICAL SYSTEM OPERATION AND ADJUSTMENTS 6 1 24HOUR TIMER The 24 hr timer is used to eliminate refrigeration during non use hours When properly setitwillpreventbuild up of large ice crystals and or build up ofice on the agitator The timer is located behind the lower front panel To program thetimer rotate program discinthe direction ofthe arrows to align the correct time with the time of day Then pull out for OFF time or push in for ON time Each actuator is equivalent to 15 minutes Check for AM PM centered between 12 and 12 on rotating disc At a 6 00 setting the indicator will point to AM or PM 6 2 ELECTRONIC TORQUE CONTROL The electronic torque control is a time delay that controls the operation of the compressor The electronic torque control operates in unison with two micro switches ON and OFF and the agitator drive motor If the control is viewed from the back of the freezer while the freezer is operating the following conditions of normal operation will be evident WARNING VIEWING THE FREEZER WITH ANY SIDE PANEL RE MOVED DURING OPERATION IS NOT RECOM MENDED AS THE POSSIBILITY OF ELECTRICAL SHOCK HAZARD IS GREATLY INCREASED THIS PRO CEDURE HAS BEEN ADDED ONLY TO CLARIFY THE THEORY OF OPERATION 1 Whenthe righthand arm ofthe control bracket contacts the right hand micro switch the compressor will start As the compressor continues to run ice crystals
49. reezer from the left side fitting the base over the four mounting studs 6 Installthefour washers and four nuts onto the mounting studs and tighten securely Figure 44 Compressor Removal 5 Remove the four nuts and four washers from the base 7 Leavingaportopento prevent pressure build up braze ofthe compressor the suction line and discharge line to the compressor Fig 45 6 Remove compressor through left side of the freezer NOTE 7 Removethe four rubber compressor mounts from the Cap and valve must be removed old compressor NOTE Rubber mounts are not always furnished with re placement compressors 8 Unsweat the access fitting line from the compressor 9 Checkthe compressorfor a burn out condition using an acid test kit If acid is found clean out the system perthe compressor manufacturer s instructions 10 Sweat shut all open ports of the old compressor Figure 45 Install Compressor NOTE 8 Connectthe lead wires to the compressor Replace the A compressor returned to the company with any terminal cover and retaining clip open ports will void the warranty ALWAYS plug any open ports on a compressor that has been removed 9 Evacuate the refrigeration system to 50 microns of mercury for approximately 30 minutes 30 10 Break the vacuum 0 P S 1 G through the Schrader valve with the dry nitrogen 11 Leaving a port opento prevent pressure build up remove the filter drier and install a new filter dr
50. ring Slide bearing down and off 3 Slide new bearing on and replace snap ring Bearing must turn freely when assembled 1 Remove the necessary panels Model E257 back and 74 COMPRESSORREMOVAL side panels Montsides and bonom panels Toremove a defective compressor perform the following procedures 29 WARNING 7 5 COMPRESSOR INSTALLATION DISCONNECT FREEZER FROM ELECTRICAL To install a serviceable compressor perform the following SUPPLY SOURCE BEFORE SERVICING procedures 1 Remove the necessary panels Model E257 back and WARNING side panels Model E157 back panel and back shroud DISCONNECT FREEZER FROM ELECTRICAL SUPPLY SOURCE BEFORE SERVICING 2 Disconnect lead wires at the compressor ASSUMING THE SIDE AND BACK PANELS HAVE 3 Recover refrigerant charge then leave a port open to BEEN REMOVED FOR COMPRESSOR REMOVAL prevent pressure build up during compressor removal AND THE ENTIRE REFRIGERATION SYSTEM PURGED THOROUGHLY YOU CAN BEGIN IN 4 Unsweat the suction line and discharge line from the STALLING A NEW COMPRESSOR compressor Fig 44 WARNING IF ACID IS FOUND IN THE SYSTEM CLEAN OUT PER COMPRESSOR MANUFACTURER S IN STRUCTIONS 2 Install the four rubber compressor mounts on the replacement compressor 3 Remove all plugs from the replacement compressor 4 Brazethe access fitting line to the correct compressor port using the appropriate brazing material 5 Install the compressor into the f
51. tes Drain the solution in the same manner as draining the product F Pour approximately one pint 1 2 liter of mixed neutral base into the product cylinder Wait one minute then drain the neutral base and remaining sanitizing solution through the drain spigot Sanitizing mustbe done afterthe freezeris clean and just before the product cylinder is filled with mixed neutral base Sanitizing the nightbefore is not effective However you should always clean the freezer and parts after use WARNING THE UNITED STATES DEPARTMENT OF AGRICULTURE AND THE FOOD AND DRUG ADMINIS TRATIONREQUIRE THAT ALL CLEANING AND SANI TIZING 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 disinfecting products and procedures The frequency of sanitizing must comply with local health regulations CAUTION PROLONGED CONTACT OF SANITIZING SOLUTION WITH FREEZER MAY CAUSE CORROSION OF STAIN LESS STEEL PARTS 3 6 ASSEMBLY OF FREEZER To assemble the freezer and freezer parts refer to the following steps NOTE Petro Gel sanitary lubricant or equivalent must be used when lubrication of parts is specified The United States Department of Agriculture and the Food and Drug Administration require that lubricants used on food processing equipment be certified for this use Use lubricants only in accordance with manufacturers instr
52. the product cylinder Fig 26 Figure 26 Proper Installation of Sealer Ring 9 Rollthe agitator tube O Ring completely down the agitator tube until it seals tightly to the divider plate 10 Rotate the agitator tube clockwise until the guide hole atthe top of the agitator tube forms a complete circle with the hole at the top of the vertical center post Fig 27 CORRECT INCORRECT 00 Figure 27 Correct and Incorrect Alignment of Vertical Center Post Guide Hole 11 Assemblethe drive cap onto the agitatortube aligning the guide pin in the drive cap with the guide hole in the vertical center post and pressing down 16 B Assemble O rings onto the spigot plungers without lubricant Then apply a thin film of sanitary lubricant to the exposed surfaces of the O rings 1 Insert the spigot assembly into the product outlet 2 Slide the spigot retaining clip into position C Assemble the flavor bottles as follows 1 Replace the bottles in the flavor rack D Install sani tray and cover E Replace the cup dispensers on the side of the freezer by positioning the bracket on the dispenser abovethe bracket on the side ofthe freezer and sliding down 3 7 MIXINFORMATION It is essential to follow the mixing instructions on the neutral base container carefully The concentration of ingredients in the product which determines the Brix sugar level is very important to the operation of the freezer and the q
53. uality of the drink When the proper amountofneutral base is mixed with the proper amount of water the mixture should have a Brix reading between 1 1 and 13 CAUTION DO NOT POUR THEINDIVIDUAL INGREDIENTS WA TERORNEUTRAL BASE DIRECTLY INTO THEFREEZER AND DEPEND ON THE AGITATOR TO DO THE MIXING THIS DOES NOT PROVIDE FOR ADEQUATE MIXING AND MAY CAUSE DAMAGE TO THE FREEZER Refer to the following steps for filling the freezer A Follow instructions on neutral base containers to mix neutral base with water Then pour into the freezer B The product cylinder has a 10 gallon capacity when filled approximately 1 2 54 cm from the top of the cylinder When filling the cylinder it is necessary to remove all trapped air from below the divider plate Fill the product cylinder with mix to within 1 2 54 cm from the top Place a sanitary container under the serving spigot and dispense small amounts of liquid by pulling out and pushing in the spigot in a series of short bursts Each time the spigot is closed bubbles will rise to the top of the liquid in the product cylinder When no more bubbles rise to the top the air trapped under the divider plate has been removed Pourthe contents ofthe container back into the product cylinder 3 8 FREEZE DOWN AND OPERATION A With mixed neutral base in the product cylinder start the freezing process by setting the STIRRING ONLY OFF STIRRING amp FREEZING switch in the STIRRING amp FREEZING pos
54. uctions A Assemble the divider plate and agitator assembly as follows 1 Before installing the drive shaft lubricate the bottom with Petro Gel or any other type of sanitary lubricant Enough lubricant must be applied to create approximately a 1 8 inch bulge at the bottom of the drive shaft Fig 24 PETRO GEL Figure 24 Lubricating Drive Shaft 15 2 Install the drive shaft into the center post by rotating and pressing down lightly on the shaft until the shaft drops down and engages with the gear box shaft 3 Replace the plastic lower bushing to the bottom of the vertical center post 4 Assemble the divider plate to the stationary fingers 5 Assemble the anti lift disc onto the agitator See Fig 23 6 Slide the divider plate down from the top of the agitator tube until it is seated properly allowing the agitator fingers clearance for rotation 7 Assemble the divider plate and agitator assembly onto the vertical center post making sure the indicator arrow on the divider plate is in position to line up with the upper spigot Grasp the agitator tube and slide the assembly down the vertical center post and lock Fig 25 Figure 25 Installing Divider Plate and Agitator Assembly 8 Install the sealer ring by squeezing the looped section and sliding down into the product cylinder NOTE For proper operation of the freezer the looped Section of the sealer ring MUST be positioned to the back of
55. ut 31 7 7 Condenser Fan Installation uuu uuu uuu u sees nnne nnns 31 SECTION8 TROUBLESHOOTING U L sw a L een en aan 33 8 1 Compressor Run Capacitor Open Shorted or BIOWN 2 34 8 2 Compressor Relay Defective or Burned Out 34 8 3 Compressor Starts and Runs But Short Cycles on Overload Protector 34 8 4 Compressor Runs Continuously r 34 8 5 Bhd 34 8 6 Compressor Will NOE Start cti teet reete te ee na 34 TABLE OF CONTENTS 8 7 Compressor Will Not Start Hums But Trips On overload Protector 35 8 8 Compressor Starts But Does Not Switch Off Of Start Windings 35 8 9 Compressor Start Capacitor Open Shorted or Blown 35 8 10 Freezer Will NOt Start sn u al 35 8 11 Drive Motor Overload Trips Freezer Shuts Down When Running 35 8 12 Compressor Will Not Run But Drive Motor uns 35 8 13 Product Dispenses Incorrectly eene 35 8 14 Produetis Too TAIN e inch 36 8 15 Agitator Does 36 8 16 No Ice Crystals On Initial Freeze DOWN 40000 aaa a 36 8 17 Excessive Ice Crystals Above Divider Plate 36 8 18 Spigot Leaking or StUCK ss iiit icti nl 36 SECTIONS
56. val and installation of the condenser fan drive motor and compressor Itis extremely Disconnectthe wire leading from the drive motor to the important to follow each step accurately and completely reset switch on the front of the freezer Fig 42 Failure to do so could result in further problems later 4 Remove the three socket head cap screws securing the 7 2 CONDENSERFAN REMOVAL mounting flange to the bearing Fig 43 Remove the To remove a condenser fan which has been found to be drive motor from either side defective refer to the following procedures WARNING DISCONNECT FREEZER FROM ELECTRICAL SUPPLY SOURCE BEFORE SERVICING 1 Remove the necessary panels Model E257 back and side panels Model E157 back panel and back shroud 2 Disconnect the condenser fan lead wires 3 Using a5 16 nutdriver or a phillips screwdriver remove the four fastening screws from the fan mounting brack ets Fig 41 Figure 41 Fan Removal e Figure 43 Drive Motor Removal 4 Removethe fan andits supports through the side ofthe freezer taking care not to damage the fan blade Ifthe drive motor failure is due to a defective drive motor mount bearing replace the bearing assembly as follows 7 3 DRIVEMOTORREMOVAL To remove a defective drive motor perform the following procedures 2 WARNING DISCONNECT FREZER FROM ELECTRICAL SOURCE BEFORE SERVICING 1 Remove snap
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