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Model SU444 / U444A SERVICE MANUAL Manual No. 513640 Rev.1...
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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.
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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.
TABLE OF CONTENTS Section Description Page Introduction Description ....................1 Specifi cations ..................... 2 Right Side Control Operation ..............3 Initial Status......................3 Serve Mode ......................3 Standby Mode ...................... 3 Sleep 1 Mode ....................... 4 Sleep 2 Mode ....................... 4 IntelliTec Restart ....................
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Section Description Page Initial Set-Up and Operation Operator’s Safety Precautions ..............13 Operating Controls and Indicators .............. 13 Important Information Regarding Cleaning and Sanitizing ......14 Disassembly of Left Side ................16 Disassembly of Right Side ................17 Cleaning Disassembled Parts ..............18 Sanitizing Parts ...................
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Section Description Page Refrigeration System Refrigeration System .................. 33 Refrigerant Recovery And Evacuation ............33 Refrigerant Recovery ................... 34 Evacuating the Refrigeration System ..............34 Refrigerant Charging .................. 34 Compressor ....................35 Condenser ....................36 Evaporator ....................36 Valves ......................37 Thermostatic Expansion Valve (TXV) ..............
SECTION 1 DESCRIPTION AND SPECIFICATIONS DESCRIPTION The Stoelting SU444 and U444A fl oor model machines are pressure fed. They are equipped with fully automatic controls to provide a uniform product. The SU444 and U444A are designed to dispense soft serve product from the left side and shake product from the right side.
1.3 RIGHT SIDE CONTROL OPERATION Following are details of the operational modes on the right side of the SU444 and U444A. NOTE: The preset amounts, times, and temperatures listed below are references to actual settings on the IntelliTec control. Refer to Table 1-1 on page 6 for details on each setting.
The “Standby Mode” maintains product quality during slow times, while minimizing reactivation time. This mode lasts for a preset time (Stb Time). Once this time has been reached without user interruption, the control moves into the “Sleep 1 Mode”. Refer to Figure 1-4 for a graphical representation of the “Standby Mode”.
H. CLEAN MODE A. SERVE AND STANDBY MODE When the CLEAN button is pressed, freezing cylinder In the event of a temperature sensor failure on a freezing refrigeration stops, the drive motor starts and will run for cylinder, the IntelliTec control will function in two modes, 20 minutes, and a 5 minute countdown timer is displayed.
IntellITec Control Setting Specifi cations Basic Menu DISPLAY Value MODE DEFINITION CutOut Serve Amp draw setting for cut out Cut In T 28.5°F Serve Temperature setting for cut in Cycles Serve Freezing cycles before going into Standby Mode Stir On 15 sec Serve Stir-only on time...
1.8 LEFT SIDE CONTROL OPERATION NOTE The soft serve side is run by a temperature control. Fol- If the sensor resistance is below the HI relay cutout, lowing are details of the operational modes on the left the yellow LED will also light. The yellow LED will side of the SU444 and U444A.
SECTION 2 INSTALLATION INSTRUCTIONS Install the four casters. Turn the threaded end 2.1 SAFETY PRECAUTIONS into the machine until no threads are showing. To Do not attempt to operate the machine until the safety level, turn out casters no more than 1/4” maximum, precautions and operating instructions in this manual are then tighten all jam nuts.
6” (15cm) Figure 2-2 Mix Hose Installation 2.5 CHECK COMPRESSOR FOR PROPER WARNING POWER (3 PHASE ONLY) After connecting the electrical, check that the compressor Hazardous Moving Parts is operating in the proper direction. Blender shaft and agitator can grab and cause injury.
Figure 2-3 Mix Pump Connections for Standard Mix Container Allow the hose to feed itself through the pump B. MIX PICKUP HOSE INSTALLATION until about 6” (15cm) remains on the entering The machine may be connected to the standard mix side.
Slide the hose clip over free end of 3/8” (9,5mm) secure with a retaining clip. ID plastic food grade tubing. Attach the free end Place the mix bag(s) into the mix container. of the tubing to a manifold adapter. Secure with Connect the bag adapter attached to the left side a large hose clamp or equivalent.
SECTION 3 INITIAL SET-UP AND OPERATION 3.1 OPERATOR’S SAFETY PRECAUTIONS 3.2 OPERATING CONTROLS AND INDICATORS SAFE OPERATION IS NO ACCIDENT; observe these Before operating the machine, it is required that the op- rules: erator know the function of each operating control. Refer to Figure 3-1 for the location of the operating controls on Know the machine.
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C. FRONT DOOR SAFETY SWITCH (BOTH SIDES) K. FREEZING CYLINDER OFF/ON SWITCH (RIGHT SIDE) The front door safety switch prevents the auger from turn- ing when the front door is removed. The switch is open The Freezing Cylinder OFF/ON switch is a two position when the door is removed and closed when the door is toggle switch used to supply power to the right freezing properly installed.
Push to Freeze SOIL MATERIALS ASSOCIATED WITH FROZEN DESSERT MACHINES Green LED MILKFAT/BUTTERFAT – As components of ice-cream/ frozen custard mix, these soils will accumulate on the Amber LED interior surfaces of the machine and its parts. Fats are diffi cult to remove and help attribute to milkstone buildup. Purge/Clean Button MILKSTONE –...
DO NOT USE BLEACH PROPER DAILY MAINTENANCE: The Only Way to Assure Food Safety and Product Quality · BLEACH HAS ABSOLUTELY NO CLEANING PROPERTIES. Proper daily maintenance can involve a wide variety of products and procedures. Overall, the products and ·...
Before using the machine for the fi rst time, complete A. REMOVE FRONT DOOR AND AUGER machine disassembly, cleaning and sanitizing proce- Make sure the Clean/Off/Serve switch is in the dures need to be followed. Routine cleaning intervals OFF position and procedures must comply with the local and state Remove the knobs on the front door and remove health codes.
Remove the air bleed valve by unscrewing the 3.7 SANITIZING PARTS knob while holding the valve stem from behind. Use a sanitizer, mixed according to manufacturer’s Remove the compression spring and push the instructions, to provide a 100 parts per million air bleed valve through the rear of the front door.
Secure the front door to the machine by placing Petrol-Gel the knobs on the studs and tightening until fi nger tight. Do not overtighten. Proper o-ring seal can be observed through the transparent front door. 3.10 ASSEMBLING THE RIGHT SIDE Refer to the following steps for assembling the right freezing cylinder: Hex Drive...
Place the front door assembly on the mounting Place the CLEAN-OFF-SERVE toggle switch in studs and the push front door against the machine the CLEAN position. carefully. Check for leaks when the machine barrel is fi rst On the SU444, place the blender assembly onto pressurized with sanitizing solution.
When the solution has drained, press the CLEAN After entering 8.0, press SET to save this value. button to stop the auger and place the Main The LCD will read “CutOut Set — OK”. Freezer Power OFF/ON and Freezing Cylinder Press the SEL button.
Press the SEL button. The LCD will read “CutOut Place a container under the spigot and open it to amps” along with the programmed value from the allow the mix to fl ush out about 8 ounces (0.23 previous step. liters) of sanitizing solution and liquid mix.
3.14 MIX INFORMATION NOTE Mix can vary considerably from one manufacturer to The mix pump motor is equipped with an internal another. Differences in the amount of butterfat content overload that will “trip”, disabling the pump when and quantity and quality of other ingredients have a the motor is overloaded.
Pump 2 gallons (7.5 liters) of 90° to 110°F (32°C CAUTION to 43°C) detergent solution through the machine. System Under Pressure The use of soft water is recommended, along with dishwashing detergents such as “Joy,” “Dawn,” Never disconnect hoses from the machine or the or equivalent.
SECTION 4 MAINTENANCE AND ADJUSTMENTS control may be set from 1 to 9. The value increases MACHINE ADJUSTMENT by 1 each time the up arrow button is pressed. This section is intended to provide maintenance personnel After the value reaches 9, numbering restarts at with a general understanding of machine adjustments.
IntelliTec Control Readings READINGS (SERVICE PERSONNEL ONLY) (RIGHT SIDE) To obtain machine readings, locate the value on the ma- chine’s menu settings sheet and follow the steps below. The IntelliTec control continuously monitors and records temperatures, voltages, amps, and error code details. Press and hold the SEL button for 8 seconds.
VAC and Mode Stor Max (°F) A calculated input voltage and mode at which The highest average cabinet temperature is the error occurred are recorded. Following are recorded. descriptions of each mode: Power On (hrs) Mode Description This value is a record of the time the machine Start of freezing cycle has been in service.
OTHER SETTINGS (SERVICE Refriger PERSONNEL ONLY) (RIGHT SIDE) This setting changes how the control handles the storage refrigeration cycle. The correct setting for Changing any setting on the IntelliTec control will alter the SU444 and U444A is Cabinet. machine operation and affect the product temperature, consistency, or life.
The mix pump has been preset at the factory to produce Tighten the allen screw, then place the wrench a product with approximately 40% overrun. Because of back in its clip. Replace the lower back panel and differences in mix formulation, temperatures and baro- secure with the four screws.
Connect the free end of the mix pump hose to the 4.11 MIX PUMP HOSE REPLACEMENT 3-way Tee. When all connections are complete, Mix pump hose must be replaced when tubing cannot be the 3-way Tee must be lower than the black pump further repositioned (every four to eight weeks).
Using a straightedge, check that the drive motor 4.13 DRIVE BELT TENSION ADJUSTMENT pully is aligned with the speed reducer pulley. To check belt tension, follow the steps below: Align the pulley if necessary. Remove a side panel and the back panel. NOTE Belt life will be increased if new drive belts are tightened after two or three weeks of operation.
4.16 EXTENDED STORAGE Refer to the following steps for winterizing the machine or for storing the machine over any long period. Clean all of the parts that come in contact with mix thoroughly with warm detergent . Rinse in clear water and dry all parts. Do not sanitize. NOTE Do not let cleaning solution stand in machine barrel or mix pump during the shutdown period.
SECTION 5 REFRIGERATION SYSTEM 5.1 REFRIGERATION SYSTEM NOTE The machine has three separate refrigeration systems; For qualifi ed service personnel only. Anybody work- one for each freezing cylinder and one for the cabinet. ing with refrigerants must be certifi ed as a Techni- cian TYPE I as required by 40 CFR 82 Subpart F The freezing cylinder systems are designed for use with and hold all State and/or local refrigerant handling...
A. REFRIGERANT RECOVERY B. EVACUATING THE REFRIGERATION SYSTEM Close any open ports in the refrigeration system. Connect a vacuum gauge to one of the Schrader WARNING valves next to an evaporator. Hazardous voltage Connect the evacuation unit to the suction and The Main Freezer Power switch and the Clean/Off/ discharge service valves of the compressor.
Ensure the electrical supply has been removed scroll compressor type uses two spiral shaped scrolls before continuing. to compress gas. One scroll rotates around an identi- cal stationary scroll. Gas is drawn into the compression If the system has been opened or if there was a chamber by the rotating scroll and is compressed as it leak, refer to Section 5.2 - Refrigerant Recovery moves towards the center of the chamber.
B. COMPRESSOR REMOVAL NOTE Disconnect the machine from electrical supply The compressor plugs protect the compressor from before removing any panels for servicing. moisture in the air. Do not remove the plugs until you are ready to install. The compressor must not be opened to the atmosphere for more than 10 WARNING minutes.
The TXV can be adjusted after the steps above are 5.7 VALVES completed. When adjusting, do not turn the valve A. THERMOSTATIC EXPANSION VALVE (TXV) over 1/4 turn (90°). Turn the valve stem clockwise The Thermostatic Expansion Valve (TXV) is used to meter to increase the superheat or counterclockwise to the refrigerant to the freezing cylinder evaporator.
Evacuate the system per the instructions in Section B. CHECK VALVE 5.2. The machine has 2 magnetic check valves (Refer to Figure 5-6). Each valve is positioned in the suction line Recharge the system per the instructions in and prevents backfl ow of refrigerant into the evapora- Section 5.3.
Unsweat the capillary tube from the discharge ACTIVATING A SOLENOID VALVE line. Disconnect the machine from electrical supply Remove the clamps from the water lines at the before removing any panels for servicing. valve. Remove the two screws holding the water valve WARNING to the frame and remove the valve.
Attach a gauge to the access fi tting before Replace insulation around valve. the solenoid and monitor refrigerant pressure. Replace the fi lter drier. Refer to Section 5.8 for Excessively high pressure indicates a details. malfunctioning solenoid. Evacuate and recharge system per instructions Disconnect the machine from the elextrical supply.
5.10 CAPILLARY TUBE 5.11 ACCUMULATOR There are two capillary tubes. The capillary tubes meter The accumulator is located on the suction line of the left refrigerant fl ow in the cabinet evaporator and the mix line side. It protects the compressor by storing any liquid re- evaporator (Refer to Figure 5-15).
SECTION 6 ELECTRICAL AND MECHANICAL CONTROL SYSTEMS NOTE The wiring diagram is available in Section 8. CONTROLS A. INTELLITEC CONTROL The IntelliTec control operates the shake side and the cabinet of the machine. The IntelliTec control consists of three main components; the control board (Figure 6-1), the membrane switch (Figure 6-2), and the display panel module (Figure 6-3).
Check to ensure contactor is receiving signal. B. DRIVE MOTOR REMOVAL Read voltage across the coils of the contactor Disconnect machine from electrical supply before during a freezing cycle. Voltage should be about removing any panels for servicing. 24VAC for the left side and about 115VAC for the Remove the back panel and a side panel.
Using insulated pliers, discharge the capacitor CAPACITORS by connecting a 20K Ohm 5W resistor across the The compressor start and run capacitors are mounted terminals. behind the side panels on 1 phase machines. The start and run capacitors for the drive motors are mounted NOTE directly onto the motor body.
Install the gearbox and evaporator supports to Press the up arrow () button to navigate to the the evaporator. Supply V screen. On the left side (soft serve), fasten the bolts NOTE throught the gearbox to the rear of the evaporator. The buck-boost transformer is only for the fan Then fasten the bolts holding the evaporator motor.
CAB CONDENSER FAN MOTOR SWITCHES A. FAN MOTOR REPLACEMENT A. SPIGOT SWITCH Shut the machine down and remove mix from the The spigot switch is a normally closed switch held open freezing barrel and cab. by the spigot handle. When a spigot is pulled, the spigot switch sends a signal to the control.
Check resistance readings across the common SPIGOT SWITCH REPLACEMENT (COM) and normally closed (NC) terminals. When Remove the header panel. the spigot is closed, the resistance should show Remove the dispense rate adjuster knob located an open. When the spigot is opened, the switch below the header panel.
Remove the switch bracket and unscrew the TEMPERATURE CONTROL SENSOR switch from the bracket. The temperature control sensor is a thermistor used to Remove the old switch from the machine. sense the temperature of the suction line. As the suction line temperature increases, the internal resistance of the Route the wires of the new switch through the thermistor will decrease.
SECTION 7 TROUBLESHOOTING freezing cylinder. Check the mix in the cabinet. If 7.1 ERROR CODES (RIGHT SIDE) the level mix is low, add mix. If there is a possibility When the right side experiences a problem, one of the that the mix is broken down, clean and sanitize the following error codes will be displayed on the IntelliTec machine, and replace the mix with fresh product.
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If continuity is found, replace the sensor. Place a SHAKE SENSOR RESISTANCE thermocouple in the cabinet evaporator discharge 180,000 airstream (outlet air fl ow). Compare temperature 160,000 to sensor resistance using the table as reference. If CutIn/CutOut values do not coincide with the 140,000 values on the table, replace the sensor.
7.3 TROUBLESHOOTING - FREEZER PROBLEM POSSIBLE CAUSE REMEDY 1 Power to machine is off. 1 Check power to machine. Drive motor (auger) 2 Low line voltage. 2 Check, must be ±10% of nameplate voltage. “kicks-out”, or 3 Product too hard. 3 Increase overrun.
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PROBLEM POSSIBLE CAUSE REMEDY 1 Drive belt tension not correct. 1 Adjust belt tension. (See Section 4.13) Drive belts slipping 2 Worn belt(s). 2 Replace belts. or squealing. 3 Low overrun. 3 Check for air leak. 1 Temperature control set too warm. 1 Decrease CabCtOut and CabCutIn (See Mix temperature Section 4.12)
7.4 TROUBLESHOOTING - MIX PUMP PROBLEM POSSIBLE CAUSE REMEDY 1 Power to pump is off. 1 Supply power to pump. 2 Low voltage. 2 Check for low voltage. 3 Mix pump hose jammed inside black 3 Disconnect pump from power source. Remove cover/clamp.
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PROBLEM POSSIBLE CAUSE REMEDY 1 Mix pump hose service life is 1 Reposition/replace mix pump hose. exceeded. 2 Out of mix. 2 Replenish mix supply. Overrun too high. 3 Overrun setting too high. 3 Decrease overrun setting. 4 Pick-up leg of mix pump hose is 4 Reposition hose.
SECTION 8 REPLACEMENT PARTS BRUSHES, DECALS AND LUBRICATION Part Number Description Quantity 208135 Brush - 4” X 8” X 16” (Barrel) 208380 Brush - 1/4” X 3” X 14” 208387 Brush - 1/2” X 5” X 24” 208465 Brush - 1” X 3-1/2” X 18” 208467 Brush - 3/8”...
LEFT SIDE AUGER SHAFT AND FRONT DOOR PARTS 667868 624678 381804 1151859 694255 2104552 4151178 2183106 625133 149003 624520 2187696 482004 2187680 624598 694200 Part Number Description Quantity 149003 Bushing - Front Auger Support 381804 Auger Flight 482004 Knob (Air Bleed Valve & Blender Motor) 624520 O-Ring - Air Bleed Valve - Black 624598...
RIGHT SIDE AUGER SHAFT AND FRONT DOOR PARTS 667868 624678 2183751 2187880 2183106 2187877 336548-SV 625314 Install O-Ring 2187941 Into Groove 694200 482004 624520 2187878 482019 624614 Part Number Description Quantity 336548-SV Front Door 482004 Knob (Air Bleed Valve) 482019 Knob - Front Door (Black) 624520 O-Ring - Air Bleed Valve - Black...
8.12 PUMP PARTS Part Number Description Quantity 150809 Belt (Shake) (Cab) 369037 Fitting - Flared - Air Inlet (Cab) 376035 Tee Connector - Air Pressure Switch (Cab) 432003-SV Valve Head Only w/Tubes (Pump) (Cab) 522229 Motor - Pump (Cab) 598025 Pulley - Large (Shake) (Cab) 650146 Set Screw - Pulley (Cab)
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