Model U421. OWNER'S MANUAL Manual No Mar., 2003 Rev. 1

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Model U421 OWNER'S MANUAL Manual No Mar., 2003 Rev. 1 Need Parts or Service? We stock the parts you need. Our Technicians are factory trained and are certified in the Stoelting Technicare program.
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Model U421 OWNER'S MANUAL Manual No Mar., 2003 Rev. 1 Need Parts or Service? We stock the parts you need. Our Technicians are factory trained and are certified in the Stoelting Technicare program. CALL Distributor: Phone No.: (fill in or affix label) Model No.: Serial No.: Purchase Date: Start-Up Date: STOELTING OWNER'S MANUAL FOR MODEL U421 CAB MODEL SOFT-SERVE PRESSURIZED FREEZER This manual provides basic information about the freezer. Instructions and suggestions are given covering its basic operation and care. The illustrations and specifications are not binding in detail. We reserve the right to make changes at any time without notice, to the freezer and its components, without incurring any obligation to modify or provide new parts for freezers built prior to date of change. DO NOT ATTEMPT to operate the freezer until instructions and safety precautions in this manual are read completely and are thoroughly understood. If problems develop or questions arise in connection with installation, operation or servicing of the freezer, contact the company at the location listed below. STOELTING, LLC Tele: Hwy 67 Kiel, WI Fax: TABLE OF CONTENTS Section Description Specifications... 1 Section Safety Precautions Shipment & Transit Freezer Installation Installing Permanent Wiring Mix Pump... 5 Section Safety Precautions Operating Controls and Indicators Sanitizing Initial Freeze Down and Operation Mix Information Operation of Mix Pump Removing Mix from the Freezer Cleaning the Freezer Disassembly of Freezer Parts Routine Cleaning Mix Pump Cleaning Sanitize Freezer Parts Assembly of Freezer Section Freezer Adjustment Product Temperature Adjustment Overrun Adjustment Mix Pump Hose Reposition Mix Pump Hose Replacement Cab Temp. Adjustment Drive Belt Tension Adjustment Condenser Cleaning (Air Cooled Freezers) Preventative Maintenance Extended Storage Troubleshooting Section How to Order Replacement Parts Parts Lists and Reference Drawings... 27 ILLUSTRATIONS Figure 1 Model U421 Freezer...1 Figure 2a Air-Cooled Specifications...2 Figure 2b Water-Cooled Specifications...2 Figure 3 Decal Locations...3 Figure 4 Water/Electrical Connections...4 Figure 5 Auger Rotation...5 Figure 6 Mix Hose Installation...5 Figure 7 Mix Pump...6 Figure 8 4 Way Tee...7 Figure 9 Mix Inlet Tube & Probe Assy. Clip...7 Figure 10 Hose Holder...7 Figure 11 Operating Controls...9 Figure 12 Air Bleed Valves...10 Figure 13 Draining Sanitizer...11 Figure 14 Mix Container...11 Figure 15 Mix Pumps...12 Figure 16 Auger Flight Wear & Front Auger Support Bushing Wear...13 Figure 17 Front Door Disassembly...14 Figure 18 Auger Flight Removal...14 Figure 19 Rear Seal Removal...14 Figure 20 Cleaning Feed Tube...16 Figure 21 Cleaning Air Tube...17 Figure 22 Removable Parts...17 Figure 23 Rear Seal Lubrication...17 Figure 24 Spring Installation...18 Figure 25 Front Door Assembly...18 Figure 26 Potentiometer...19 Figure 27 Overrun Adjustment...19 Figure 28 Temperature Control Cab...20 Figure 29 Belt Adjustment...21 SECTION 1 INTRODUCTION 1.1 DESCRIPTION The Stoelting U421 floor model freezer is pressure fed. The freezer is equipped with fully automatic controls to provide a uniform product. The freezer is designed to operate with almost any type of commercial soft-serve or non-dairy mixes available, including ice milk, ice cream, yogurt, and frozen dietary desserts. This manual is designed to assist qualified personnel and operators in the installation, operation and maintenance of the Stoelting Model U421 pressure freezer. Figure 1. Model U421 Freezer 1.2 SPECIFICATIONS MODEL U421 DIMENSIONS Width: 26-3/4 (68cm) Depth: 39-3/4 (101cm) Height: 65-3/4 (167cm) WEIGHT 925lbs. (419,5 kg) 975lbs. w/crate (442 kg) ELECTRICAL COOLING 208/230 volt, 1 Ph or 3 Ph, Two 2 H.P. drive and Two BTUH Compressors motors Water or air cooled. req's 3 (7,6cm) all around clearance and 10 (25cm) top clearance. Water cooled req's 1/2 (1,3cm) NPT water and drain fittings. 1 Figure 2a. Air-Cooled Specification Figure 2b. Water Cooled Specification 2 SECTION 2 INSTALLATION INSTRUCTIONS 2.1 SAFETY PRECAUTIONS Do not attempt to operate the freezer until the safety precautions and operating instructions in this manual are read completely and are thoroughly understood. Take notice of all warning labels on the freezer. The labels have been put there to 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 address and mail to: STOELTING, LLC ATTENTION: Customer Service 502 Hwy. 67 Kiel, Wisconsin Figure 3. Decal Locations Decal Mix Low Decal 2 x 1-1/4 Blk on White Decal Clean-Off-Serve Switch Tag, Caution - Supply Voltage Decal Caution - Rotating Blades Decal GM Header (Stoelting Logo) Tag Read Manual & All Decals Decal GM Header (Stoelting Swirl) Decal Stoelting Swirl Logo Decal DQ Header (DQ Logo) Decal Cab ON/OFF Decal Caution Hazard.Moving Pump On/Off Decal Standby/Serve Decal Refrig. Leak Check Decal Temperature Control Decal Caution - Rotating Shaft Decal Manual Reset Decal Danger Automatic Start Decal Arrow Decal Caution Moving Parts Decal Freezing Decal Elect.Shock Hazard Water Cooled Only Decal Field Connections A Decal Water Inlet Decal Attention Installer B Tag Winterizing Disconnect Line Bag, Envelope Front Loading C Tag, W/C Tower Instructions Decal Adequate Ventilation D Decal Caution Moving Parts Decal Copper Conductors Only Air Cooled Only Decal Caution Wiring Mat'l E Decal Hazardous Moving Parts Decal Wired According To F Decal Caution Moving Parts 3 2.2 SHIPMENT AND TRANSIT The freezer has been assembled, operated, and inspected at the factory. Upon arrival at the final destination, the freezer must be checked for any damage which may have occurred during final transit. With the method of packaging used, the equipment should arrive in excellent condition. THE CARRIER IS RESPON- SIBLE FOR ALL DAMAGE IN TRANSIT, WHETHER VIS- IBLE OR CONCEALED. Do not pay the freight bill until the freezer has been checked for damage. Have the carrier note any visible damage on the freight bill. If concealed damage and/or shortage is found later advise the carrier within ten days and request inspection. The customer must place claim for damage and/or shortages in shipment with the carrier. Stoelting, LLC. cannot make any claims against the carrier. 2.3 FREEZER INSTALLATION D. The freezer must have a minimum of 3 (7,5cm) -6 (15cm) high ambient conditions- of space on all sides and 10 (25cm) at the top for proper circulation. CAUTION Risk of product damage Air cooled condenser requires proper ventilation. Failure to provide adequate ventilation will void factory warranties. E. Water-cooled freezers need an adequate water supply. Install 1/2 (12,7mm) pipe or 1/2 (12,7mm) inside diameter copper water line to the freezer. Connect water outlet to a drain using a 1/2 (12,7mm) inside diameter line. Automatic washer hoses work well for final connections. All water connections must comply with local codes. Fig. 4. WARNING Installation must be performed by a qualified electrician/refrigeration specialist. Incorrect installation may cause personal injury, severe damage to the machine and will void factory warranties. WARNING Lifting hazard Do not attempt to lift freezer manually. Use proper lifting equipment such as a forklift, lift table, or pallet jack, with lifting device positioned beneath the freezer s base. Ensure that personnel remain clear of suspended load. Failure to do so may result in personal injury and/or damage to the freezer that will void any factory warranties. 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. Install the four casters. Turn the threaded end into the freezer until zero threads are showing. To level, turn out casters no more than 1/4 maximum, then tighten all jam nuts. C. The freezer must be placed in a solid level position. NOTE Accurate leveling is necessary for correct drainage of freezer barrel and to insure correct overrun. Figure 4. Water/Electrical Connections CAUTION Flush all water lines before installation. In stores with sediment in water, add suitable filter or strainer to water inlet. F. Place the CLEAN-OFF-SERVE switches in the OFF position before continuing. Figure INSTALLING PERMANENT WIRING Permanent wiring is required by local codes, the following procedure must be performed: WARNING Hazardous voltage High voltage will shock, burn or cause death. Turn off and lock out main power disconnect before installing wiring. Do not operate machine with cabinet panels removed. 4 A. Refer to the nameplate at the rear of the freezer for specific electrical requirements. Make sure the power source in the building matches the freezer nameplate requirements. Bring the wires into the junction boxes through the access holes in the bottom rear of the freezer. Figure 4. Auger shaft rotation is clockwise as viewed through the clear plastic front door. If the rotation is not clockwise, turn main electrical power OFF. Then reverse L1 and L3 electrical power lines to the junction box (three phase only). Re-check auger shaft rotation. Figure 5. NOTICE Three phase freezers in areas of unbalanced electrical loads require special attention when connecting input electrical power. The unbalanced leg of power (called wild or high) must be connected to L2 in the junction box. NOTICE Verify actual voltage. Machine is equipped with a transformer to supply a control circuit. You will need to check voltage on terminal C1 and C2 on EACH control board. (Located behind decorative header panel on front of machine.) Transformers are located behind electrical panel enclosing control boards. Access these by removing top panel of machine. Actual transformer voltage should read V.A.C. B. Remove the lower back panel and the two junction box covers located at the bottom of the freezer. C. lnstall permanent wiring according to local code. D. Check the auger shaft rotation by placing the MAIN DRIVE switch in the CLEAN position. 2.5 MIX PUMP A. Mix Pump Hose Installation Follow the steps below to install the mix pump hose. 1. Turn pump on. Figure 5. Auger Rotation 2. Feed one end of mix pump hose into the entering or pick-up hose side (left) of black cover. 3. Gently push the hose into the black cover until it begins to feed. 4. Allow the hose to feed itself thru the pump until 6 (15cm) remains on the entering side. 6 (15cm) Figure 6. Mix Hose Installation 5 5.Turn pump off. 6.Connect mix pump hose to pickup hose adapter using small hose clamp. CAUTION DO NOT TWIST MIX PUMP HOSE. 7.Turn pump off. 8.Allow remaining 6 (15cm) of tubing to feed hru pump until hose adapter prevents further feeding. 9.Turn pump off. 10.Connect free end of mix pump hose to 4 way Tee B. Connect 1/2 inch (12,7mm) I.D. plastic food grade tubing to check valve and then to the mix container. Observe check valve flow arrow. Secure with hose clamps. Then place assembly thru hole in cover and install retainer clip. Figure 9. C. Connect 1/2 inch (12,7mm) I.D. plastic food grade tubing between the large port of air/mix tee and refrigerated mix transfer line. Secure with large hose clamp or equivalent. Figure 9. CAUTION Air/Mix tee must remain below the black cover/ clamp. If the tee is above the pump mix will drain to the air compressor resulting in pump damage. D. Connect mix low cords. Figure 9. Figure 7. Mix Pump / STAINLESS 4-WAY TEE 6 Refrigerated Mix Transfer Line 4 Way Tee Large Port Air/Mix Tee Figure 8. 4 Way Tee Low Mix Cord Cover Mix Container Retainer Clip Figure 9. Mix Inlet Tube & Probe Assy. Clip Hose Holder Figure 10. Hose Holder 7 8 SECTION 3 INITIAL SET-UP AND OPERATION 3.1 SAFETY PRECAUTIONS SAFE OPERATION IS NO ACCIDENT; observe these rules: A. Know the freezer. Read and understand the operating instructions. B. Notice all warning labels on the freezer. C. Wear proper clothing. Avoid loose fitting garments, and remove watches, rings or jewelry which could cause a serious accident. D. Maintain a clean work area. Avoid accidents by cleaning the area and keeping it clean. E. Stay alert at all times. Know which switch, push button or control you are about to use and what effect it is going to have. F. Disconnect electrical power 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 this freezer if unusual or excessive noise or vibration occurs. 3.2 OPERATING CONTROLS AND INDICATORS Before operating the freezer, it is required that the operator know the function of each operating control. Refer to Fig.11 for the location of the operating controls on the freezer. WARNING Hazardous voltage The CLEAN-OFF-ON switch must be placed in the OFF position when disassembling for cleaning or servicing. The freezer must be disconnected from electrical supply before removing any access panel. Failure to disconnect power before servicing could result in death or serious injury. A. Spigot Switch When the spigot handle is opened the SPIGOT switch will start the auger drive and refrigeration systems. When the spigot handle is closed, the drive motor and compressor will remain on until the product in the barrel reaches the proper temperature. B. Clean-Off-Serve Switch The CLEAN-OFF-SERVE switch is a three position toggle switch used to control the operation of the refrigeration system and auger. When the switch is placed in the CLEAN position, the refrigeration system will be off and auger will rotate for cleaning. Figure 11. Operating Controls 9 When the switch is placed in the OFF position, the refrigeration system and auger will not operate. When the switch is placed in the SERVE position, the refrigeration system and auger will operate automatically. The switch should be placed in the SERVE position for normal operation. C. Cabinet-Off-On Switch The CABINET-OFF-ON switch is a two position toggle switch. When the switch is placed in the OFF position, the lower cabinet refrigeration system will not run. When the switch is placed in the ON position, the lower cabinet refrigeration system will run until the preset temperature is reached; then cycle ON and OFF to maintain that temperature. D. Cab Indicator Light A flashing light indicates the cab OFF-ON switch is in the OFF position, no refrigeration. Place the OFF- ON switch in the ON position for cab refrigeration. E. Pump Switch The pump motor switch is a two position toggle switch. When the switch is placed in the OFF position, the pump will not run. When the switch is placed in the ON position, the pump will run until the preset pressure is reached, then cycle ON and OFF as product is drawn to maintain that pressure. F. Standby/Serve Switch The standby/serve switch is a two position toggle switch. When the switch is placed in the standby position the freezer will cycle to maintain a temperature below 41 F (-15 C). When the switch is in the Serve position the freezer will cycle to maintain a servable product. G. Freezing Switch The freezing switch is a two position toggle switch. When the switch is placed in the MAXIMUM position the freezer will be forced to run 30 seconds after the temperature control is satisfied. H. High Head Pressure Cut Out If the head pressure exceeds 445 psig (28 bar) air cooled and water cooled, the high head pressure cutout will trip. The reset button can be accessed from the side of the freezer. 3.3 SANITIZING Sanitizing must be done after the freezer is clean and just before the freezer is filled with mix. Sanitizing the night before is not effective. However, you should always clean the freezer and parts after using it. WARNING The United States Department of Agriculture and the Food and Drug Administration require that all cleaning and sanitizing solutions used with food processing equipment be certified for this use. When sanitizing the freezer, refer to local sanitary regulations for applicable codes and recommended sanitizing products and procedures. The frequency of sanitizing must comply with local health regulations. Mix sanitizer according to manufacturer s instructions to provide a 100 parts per million strength solution. Mix sanitizer in quantities of no less than 2 gallons (7.5 liters) of 120 F (49 C) water. Allow sanitizer to contact the surfaces to be sanitized for 5 minutes. Any sanitizer must be used only in accordance with the manufacturer s instructions. Air Bleed Valves Figure 12. Air Bleed Valves CAUTION Avoid prolonged contact of sanitizer with freezer parts. Prolonged contact of sanitizer with freezer may cause corrosion of stainless steel parts. In general, sanitizing may be conducted as follows: A. Clean and lubricate parts. I. Low Mix Light The low mix light will illuminate when the liquid level in the mix container drops below two gallons. J. Front Door Safety Switch The front door safety switch prevents the auger from turning when the front door is removed. The switch is open when the door is removed and closed when the door is properly installed. 10 B. Prepare 3 gallons (11 liters) of sanitizing solution following manufacturer's instructions, and pour into storage container. C. Place the mix pump switch in the ON position and open air bleed valve on the front door by pushing valve in and holding. Figure 12. D. Let sanitizing solution fill the freezer barrel to air bleed valve, then close the valve by pulling out to lock in place. E. Place the CLEAN-OFF-SERVE switch in the CLEAN position. F. Check for leaks when the freezer barrel is first pressurized with sanitizing solution. 1. Check for leaks at the plastic front door, the 0-rings may not be sealed. 2. Check the drain tray located at the right or left side of the freezer for leaks. 3. Check inside cab unit for leaks at hose connections and manifolds. 3.4 INITIAL FREEZE DOWN AND OPERATION This section covers the recommended operating procedures to be followed for the safe operation of the freezer. A. Sanitize just prior to use according to instructions. B. Prepare the desired amount of mix and then fill storage container with approximately 3 gallons (11 liters) or more of mix. Place a container(s) of mix in the cooler. If drawing from a storage container, place the draw tube through the cover to the bottom of the container. If drawing from a bag in a box, remove the cap, push out all of the air, and insert the adaptor. G. Using a sanitized soft bristle brush or equivalent, dipped in sanitizing solution, clean mix container. H. After five minutes, open spigot to expel sanitizing solution. Drain all solution from freezer. Figure 13. I. Close the spigot and place the mix pump switch and the CLEAN-OFF-SERVE switch in the OFF position. The freezer is now sanitized and ready for adding mix. Mix Low Sensor Figure 14. Mix Containers C. Place the mix pump switch, located on the front of the freezer, in the ON position. Immediately open the spigot and let approximately 8 ounces (236 milliliters) of liquid mix with sanitizing solution drain out of the spigot. D. Close the spigot and open the air bleed valve on the front door by pushing the valve in and holding. Allow the barrel to fill until the mix level is 1/2 inch (12,7 mm) below air bleed valve, then release valve and pull closed to lock in place. Figure 13. Draining Sanitizer E. Start the compressor and drive by placing the CLEAN-OFF-SERVE switch in the SERVE position. F. The product will be ready to serve after approximately 20 minutes. 11 G. The refrigeration is automatically actuated when the spigot i
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