Duke DQ GEN-102 Operator’S Manual With Illustrated Parts List Download

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185232

April 2018

Printed in U.S.A.

OPERATOR’S MANUAL

with Illustrated Parts List

H. C. DUKE & SON, LLC

2116 - 8th Avenue

•

East Moline, Illinois 61244

Twin Twist
Soft Serve Freezer
Model

GEN-102

5232

— 4/18

Summary of Contents for DQ GEN-102

Page 1: ...185232 April 2018 Printed in U S A OPERATOR S MANUAL with Illustrated Parts List H C DUKE SON LLC 2116 8th Avenue East Moline Illinois 61244 Twin Twist Soft Serve Freezer Model GEN 102 185232 4 18...

Page 2: ......

Page 4: ...ghout this manual When you see this symbol on your freezer or in this manual be alert to the potential for personal injury Follow recommended precautions and safe operating practices 2 Understand Sign...

Page 5: ...ir the freezer until the main power supply has been disconnected Some freezers have more than one disconnect switch Contact your IDQ authorized service representative or H C Duke Son LLC Service Depar...

Page 6: ...nstruction and information decals or labels on the freezer as shown in the figure on the next page The labels have been put there to help maintain a safe working environment The labels have been desig...

Page 7: ...and 2 Disconnect all power supplies Unit may have more than one power supply P N HC165025 1 Hazardous moving parts Machine starts automatically Do not operate with panel removed P N HC165126 3 P N HC...

Page 8: ...M Terminology 8 5 Part Names and Functions 10 6 Operator Controls 16 7 Operator Display Menus 18 8 Disassembly and Cleaning 22 8 1 Cleaning Accessories 23 8 2 Disassembly Instructions 24 8 3 Cleaning...

Page 9: ...sembly 2 Figure 3 MTS RMT Hose Assembly 3 Figure 4 1PH Mix Transfer System RMT 4 Figure 5 3PH Mix Transfer System RMT 6 Figure 6 Cabinet Parts 8 Figure 7 Spigot Switch Assembly 9 Figure 8 Capacitor Re...

Page 10: ......

Page 11: ...t to follow the assembly and priming procedures detailed in this manual Be sure all personnel responsible for equipment operation completely read and understand this manual before operating the freeze...

Page 12: ...f the SHOCKWATCH label indicates red and or the carton is broken torn or punctured note the damage on the carrier s freight bill and notify the carrier s local agent immediately also note on the freig...

Page 13: ...any two voltage measurements at 208 230 volts indicates a possible imbalance Request your local power company to correct any voltage problem 3 An easily accessible main power disconnect must be provi...

Page 14: ...ta plate for fuse size wire ampacity and electrical specifications See Figure 3 2 3 Refer to the wiring diagram provided for proper power connections 4 Electrical connections are made in the junction...

Page 15: ...Refrigerant 404a Charge 3 75 lb 1 7 kg Compressor Cabinet 1 1 6HP 650BTUH 125w Motor 190w Cooling Beater Motor 2 2 H P 1 5 kw Refrigerant 134a Charge 6oz 0 37lb 17kg Mix Container 2 24 Qts 22 7 Liter...

Page 16: ...3 2 Dimensions LEFT RIGHT OFF OFF Model Ser No Volts Ph HZ Wire ASSEMBLED IN USA SINGLE UNIT Cyl Compressor RLA LRA Beater Motor FLA HP Pump Motor FLA HP Cabinet Compressor FLA PH Flavor Blender Moto...

Page 17: ...reference 1 Model Number ___________________ 2 Serial Number ___________________ 3 Electrical Spec _ Voltage____________ Phase _______ Hertz______________ 4 Minimum Circuit Ampacity __________ 5 Maxi...

Page 18: ...or the unit housed behind the trim strip panel This board has many connectors on it and is responsible for the main operations of the unit Membrane Switch The black Electro Freeze decal visible on the...

Page 19: ...r than 5 colder and greater than 5 warmer Transducer An electronic control used to measure the cylinder pressure for mix pump operation U I User Interface The board that lies directly behind the membr...

Page 20: ...185232 10 Soft Serve Freezer Model GEN 102 5 Part Names and Functions Figure 5 1 Head Assembly...

Page 21: ...plug in the head 5 ROD SPIGOT Starts the freezer when dispensing 6 SPIGOT ASSEMBLY SIDE WITH HANDLE Stainless Steel Seals the product opening in the head when closed Allows product to flow when open...

Page 22: ...185232 12 Soft Serve Freezer Model GEN 102 5 Part Names and Functions continued Figure 5 2 Beater Shaft Assembly...

Page 23: ...tates in the freezing cylinder blending air and mix as it ejects product 3 BLADE SCRAPER Scrapes the frozen product from the freezing cylinder wall 4 O RING SHAFT SEAL Seals the beater shaft to the sh...

Page 24: ...AIR AIR METER AIR METER RETAINER CLAMP SOFT HOSE HOSE MIX BRAIDED HOSE TRANSFER RED LINE SUPPORT ROLLER BEARING ROLLER ASSY COMPLETE SHOE ROLLER COVER MTS PORT AIR MIX CLAMP SOFT TUBE DUCKBILL INLET B...

Page 25: ...h tubing to freezing cylinder 20 COVER MTS Protection against moving parts Cover must be in place for the MTS to operate 1 DUCKBILL A rubber check valve that prevents mix from falling back into the mi...

Page 26: ...ead must be in place before the freezer will operate 1 Function Buttons Four Pressing any of these buttons will activate the icon directly above in the display screen Left side L1 L2 Right Side R1 R2...

Page 27: ...gy saving feature will activate and reduce product refrigeration The freezer will automatically cycle to maintain temperatures in the cylinder and cabinet below 41 F and keep product from deterioratin...

Page 28: ...menu is highlighted in this example we will use Basic Settings press the select button to enter the sub menu Product Type and Temperature Offset will be shown for left and right barrel Use the Arrow...

Page 29: ...e power switch cycle low mix etc The log will display the last 50 events with the newest event at the top Error Log Allows the operator to look at logged errors i e Barrel refrigeration timeout low hi...

Page 30: ...tings Operator can turn on or off the following functions Display Cabinet Temperature Y or N Will or will not display Cabinet temp on home screen Alternate Moon Y or N Beep Function Y or N unit will o...

Page 31: ...on As pictured below the Soft Key located below the image of the Moon will allow the machine to be switched into NIGHT refrigeration mode This feature is used at the closing of the day s business to h...

Page 32: ...Draining Product 5 Remove the spigot switch rods and open the spigots completely 6 Inside the refrigerated cabinet remove the MTS cover loosen the shoe clamp hand knob swing back the shoe clamp and s...

Page 33: ...bushing 5 HC158037 BRUSH 1 4 inch diameter 18 1 2 inches overall length used to clean the air meter hose the small hole in the back of the dispense head and small parts 6 HC169374 TOOL O RING REMOVAL...

Page 34: ...mbly Instructions CUP SEAL WASHER O RING PORT AIR MIX ASSEMBLY CORDSET MIX LEVEL AIR METER AIR METER TUBE SWING CLOSED ROLLER SHOE ROLLER SHOE MIX TRANSFER HOSE NO TWIST NOTE RED LINE BRAIDED HOSE ASS...

Page 35: ...s 6 and pull the dispensing head 1 straight out 3 Remove the cylinder bushings and beater shafts from the cylinders 4 Remove the scraper blades and shaft seals from the beater shafts Remove the drip t...

Page 36: ...to yield 100 PPM available chlorine solution example Stera Sheen Green Label Use warm water 100 110 F or 38 43 C to wash rinse and sanitize 4 Wash all the parts removed from the freezer thoroughly wit...

Page 37: ...air dry after sanitizing 6 The following must be thoroughly brushed first with a warm dish detergent solution then rinsed with clear water followed by the sanitizing solution a mix feed tubes from th...

Page 38: ...place in sanitizing solution for 5 minutes 8 Wash the outside of the freezer and inside of the cabinet with a warm dish detergent solution Rinse with clear water Replace worn brushes Use only original...

Page 39: ...of the clamp arm See figure 8 11 2 Carry to the sink wash in mild detergent with the brush provided and dry thoroughly 3 Brush in between rollers Flush clean with water bottle Important Do not let sh...

Page 40: ...e 9 6 Apply a light amount of approved sanitary lubricant such as Lubri Film Plus to the o ring and the face of the plastic washer opposite the bell portion of the seal Do not allow any lubricant to c...

Page 41: ...bushings and place on the end of the beater shaft assemblies The bushings will slide on only one way Important Dispensing head must be installed for beater motor s to operate Do not interchange heads...

Page 42: ...nsfer hose when assembling or installing Important Replace transfer hose every 30 days 13 Assemble the MTS hose assembly as shown in figures 9 5 and 9 6 The transfer hose has a red locating line Hold...

Page 43: ...se clamps should be exposed Tighten cover knob Hand tighten only 22 Loop the braided hose towards you and slide the hose over the cylinder inlet tube Tighten the clamp Make sure the braided hose is no...

Page 44: ...mix tank walls the underside of the tank covers and low mix probes with sanitizer liquid and the appropriate brush provided 4 Place the mix tank in the refrigerated cabinet Fill with sanitizing soluti...

Page 45: ...After the cylinders are pressurized and the MTS has cycled off approximately 30 seconds Press the left and right Freeze keys 14 Allow the freezer to cycle for 15 20 minutes The product is now ready t...

Page 46: ...the product requires a firm base then dispense a small amount of mix in the spigot into a separate container 1 NOTE For shakes large sundaes floats and other similar products this practice of drawing...

Page 47: ...be handled according to local health codes 6 Place a clean sanitized container under the dispensing head 7 Very slowly open the side spigots and dispense the semi frozen product until it quits dispen...

Page 48: ...from the sanitizing solution 20 Refer to Disassembly and Cleaning Instructions 11 2 Night Switch Operation 1 In areas where health codes will allow the freezer may be switched to night mode operation...

Page 49: ...e and overrun to see if they fall into normal operating ranges 12 2 Checking the Frozen DQ Product 12 1 Dairy Queen Mix 1 Standard approved Dairy Queen mix weight is approximately 9 25 lbs per gallon...

Page 50: ...part HC158049 that is graduated in overrun percentage Section 12 7 is an overrun chart which shows the net weight of one measure pint of frozen Dairy Queen product in grams ounces and their correspond...

Page 51: ...ll step change will result in a 8 10 change in overrun The orifice or hole in this air meter must be open at all times It is the only source of air into the freezing cylinder Check this daily The mix...

Page 52: ...Pint of Frozen Dairy Queen In Grams Percentage of Overrun 13 7 388 4 35 13 6 385 5 36 13 5 382 7 37 13 4 379 9 38 13 3 377 39 13 2 374 2 40 13 1 371 4 41 13 0 368 5 42 12 9 365 7 43 12 8 362 9 44 12 7...

Page 53: ...ransfer System Important If the transfer hose is assembled improperly or replacement has been neglected it may be necessary to clean mix from the MTS due to hose failure If this happens frequently the...

Page 54: ...ed flush the hose cavity and roller assembly e Use a brush supplied to clean in between rollers Flush with sanitizer f Wipe all surfaces with a clean dry cloth g Remove and clean roller shoe and shoe...

Page 55: ...the display does not read HEAD SWITCH Freezer has a head switch or software problem Turn the power switch OFF DO NOT place the freezer in service until the problem has been corrected The head switch f...

Page 56: ...and listen for the gear motor to turn on The cover should be almost completely closed when the gear motor turns on DO NOT insert fingers or objects into roller cavity during this test If the MTS does...

Page 57: ...sits if necessary SEMI ANNUALLY 1 Have the condenser fan motor checked by your service technician Add oil as needed 5000 HOURS OF OPERATION OR 1 YEAR 1 Contact your service technician to have the oil...

Page 58: ...m while in storage Place the freezer in a dry location 6 On air cooled freezers have condenser fins cleaned by authorized service technician 7 On water cooled freezers disconnect the water supply Use...

Page 59: ...environment use a refrigerant recovery recycling unit when removing refrigerant from the system This safety alert symbol identifies important personal safety messages in this manual When you see this...

Page 60: ...tact your Your local service company 7 Faulty selector switch 7 Contact your Your local service company 8 Disconnected or broken wire in electrical circuit 8 Contact your Your local service company Mi...

Page 61: ...our local service company 3 Spigot switch electrically or mechanically stuck closed Unit runs all the time 3 Contact your Your local service company 4 Component failure 4 Contact your Your local servi...

Page 62: ...ot operate 1 Head assembly is not installed 1 Install head assembly 2 Magnetic head switch defective 2 Contact your Your local service company 3 Component failure 3 Contact your Your local service com...

Page 63: ...act your Your local service company 2 Cabinet solenoid defective does not open 2 Contact your Your local service company 3 Cabinet switch defective 3 Contact your Your local service company 4 Door swi...

Page 64: ...Contact your Your local service company 7 Motor defective or internal overload tripped 7 Contact your Your local service company MTS will not shut off 1 Hose broken 1 Replace hose 2 Pressure switch s...

Page 65: ...between pickup tube and hose 2 Replace as needed 3 Air line hose cracked sucking air 3 Replace air line hose 4 Defective or missing duckbill valve 4 Replace valve Mix shoots out air meter 1 Swing Cla...

Page 66: ...ompatible and using the test cable does not resolve the issue then the main control board is not functioning properly and needs to be replaced Contact H C Duke Son Factory Tech Support NO COMM The U I...

Page 67: ...ce of refrigerant leak and repair 3 Locate faulty connection Wire rubbed through cut and repair as needed 4 Check Compressor Starting components and replace as needed 5 Check contactor coil for proper...

Page 68: ...check for a short and proper winding resistance check compressor starting components for failure allow compressor protector to reset and check for proper amp draw 13 Recover refrigerant change filter...

Page 69: ...aulty replace if thermistor tests o k check wire harness connections If all connections are sound possibility of control board issue Contact H C Duke Son Factory Tech Support 8 Check to see if Relay i...

Page 70: ...unit is in cabinet only mode Cabinet is in time cycle mode and both cylinders remain off 1 Faulty wire connection 2 Faulty Thermistor 3 Program Issue 1 Locate faulty connection Wire rubbed through cut...

Page 71: ...re Too cold low overrun and gear reducer operation 2 Locate Faulty wire connection and repair as needed 3 Check contactor coil for proper resistance check for voltage drop across contact points Replac...

Page 72: ...trol as needed 4 Locate and remove restriction i e restricted drier AXV closed down Solenoid valve not opening etc 5 Repair connection as needed i e faulty connection on LPCO etc 6 Locate failed compo...

Page 73: ...nection on HPCO etc 6 Fully recover refrigerant from system change the refrigerant filter drier evacuate system to at least 200 microns and weigh in Factory refrigerant charge Contact H C Duke Son in...

Page 74: ...been rectified 1 Spigot Push rod not installed 2 Spigot switch has failed in the closed position 3 Spigot Switch is out of adjustment 4 Plunger is sticking open 1 Install Spigot Push Rod and start sys...

Page 75: ...main control board Check continuity through relay contacts to ensure proper operation Repair any connections as needed 4 Contact H C Duke Son Technical Support PUMP HI PSI Displays Pump Hi PSI if the...

Page 76: ...eset the machine to return it to normal operation Please Note If the mix bag is not checked when the machine shows a mix out condition the Pump Error will occur frequently 2 Install the Duck bill chec...

Page 77: ...s are connected fully and that no wiring from the control board to the sensor has been severed 2 Change Thermistor CYL T ALARM Displays CYL T ALARM when the cylinder temperature has reached 36 degrees...

Page 78: ...has to see a mix out condition PUMP COVER Occurs if the RMT pump cover is removed or the cover switch is open Action If unit is in Freeze the affected side will be turned to standby and the affected p...

Page 79: ...munication cable are working properly and the problem lies with the U I Board 4 If 5 96 VDC is read on the black wires but the U I Board does not light up the issue might lie with the communication ca...

Page 80: ...Distributor for instructions prior to warranty compressor replacement Keep your freezer in excellent condition always contact your H C Duke Son LLC Distributor for replacement parts and maintenance sc...

Page 81: ...REPLACEMENT PARTS MANUAL with Illustrations P N 185232 01 November 2018 Printed in U S A SOFT SERVE FREEZER Model GEN 102 185232 01 11 18...

Page 82: ......

Page 83: ...h H C Duke Son LLC 2116 8th Avenue East Moline Illinois 61244 Telephone 309 755 4553 or 800 755 4545 Fax 309 755 9858 E mail service hcduke com Figure 1 Dispense Head Assembly 1 Figure 2 Beater Shaft...

Page 84: ......

Page 85: ...1 Head only 2 HC160583 O ring Head 3 HC115129 Bleeder Assy 4 HC160562 O ring Bleeder Assembly 5 HC136126 Rod Spigot Switch 6 HC134921 Spigot Long Single less extension 6A HC162624 Handle Black Tapered...

Page 86: ...oved parts will void warranty Figure 2 Beater Shaft Assembly Item Part No Description 1 HC113438 Shaft Assy Beater 2 HC196079 Bushing Cylinder 3 HC137334 Blade Scraper Soft Serve 4 HC160500 O ring Sea...

Page 87: ...HC138170 02 Tube Air 9 HC162324 Clip Tube Retainer 10 Meter Air Order by meter number 11 HC121638 Hose Assy Mix Braided Item Part No Description 1 2 3 4 5 6 7 8 9 10 11 AIR METERS Meter No Part No 9 H...

Page 88: ...y original or authorized replacement parts with this freezer Use of unapproved parts will void warranty Figure 4 1PH Mix Transfer System RMT Breakdown 4 8 5 32 33 13 17 23 24 22 20 21 34 31 27 11 30 9...

Page 89: ...oller 13 HC138799 Arm Swing Clamp 14 HC138797 Arm Shoe Pivot 15 HC116009 Roller Assy Complete 16 HC138800 Spacer Swing Arm 17 HC160338 Pin Dowel 1 4 Dia X 3 4 SST 18 HC160093 Screw TRPS 1 4 28x2 1 4 S...

Page 90: ...only original or authorized replacement parts with this freezer Use of unapproved parts will void warranty Figure 5 3PH Mix Transfer System RMT Breakdown 24 33 16 4 3 2 25 23 7 8 21 22 34 31 32 29 30...

Page 91: ...HC140706 Knob Fluted 1 4 20 Custom 10 HC160612 O Ring 11 HC160628 O Ring 12 HC139751 Shoe Roller 13 HC138799 Arm Swing Clamp 14 HC138797 Arm Shoe Pivot 15 HC116009 Roller Assy Bearing 16 HC160338 Pin...

Page 92: ...Part No Description 1 HC161313 Switch Proximity Reed NC 2 HC140706 Knob Fluted 1 4 20 Custom 3 HC162330 Spring Compression 3 HC140711 Washer Spring End 4 HC138799 Arm Swing Clamp 5 HC121798 Cover Ass...

Page 93: ...ng Spigot Switch 6 HC136124 Button Spigot Switch 7 HC160303 Ring Retaining 1 2 External 8 HC113902 Bracket Assy Spigot Switch Mtg 9 HC113901 Bracket Assy Adjusting 10 HC160267 Screw RDHM 8 32 x 7 8 Br...

Page 94: ...GEN 102 Use only original or authorized replacement parts with this freezer Use of unapproved parts will void warranty Figure 9 Switch Box Breakdown 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 12 19...

Page 95: ...2 5 8 7 HC150927 Support 5 8 Circuit Board 8 HC150999 Anchor Din Rail 9 HC150098 Socket Miniature Relay DPDT 10 HC150166 Clip Miniature Relay Retaining 11 HC150044 Relay Miniature DPDT 230V Au Contact...

Page 96: ...10 Panel Assembly Breakdown Hardware for Panels Panel Screw Nut Speed Spacer Nut Speed on Frame Channel Rear HC160048 HC160117 n a n a Dispense HC160076 HC159132 HC138456 n a Front HC160076 HC159132...

Page 97: ...ell 26 In 12 HC141353 Trimstrip Lower 26In 13 HC121375 Trimstrip Assy W DQ Decal 14 HC141323 Cover Electric Box 15 HC140133 02 Panel Dispense AC Air Cooled WC Water Cooled ACR Air Cooled Remote LH Lef...

Page 98: ...185232 14 Soft Serve Freezer Model GEN 102 Use only original or authorized replacement parts with this freezer Use of unapproved parts will void warranty Figure 11 Side Rear View AC...

Page 99: ...heave 7 8 Bore 3 25 OD 3 00PD 18 HC120810 04 Box Assy Caps 2Hp BF 2Hp COPZS 19 HC155405 Cut Out High Pressure 20 HC155701 Cut Out Low Pressure 21 HC154948 Compressor Scroll ZS19KAE TF5 22 HC121027 Gea...

Page 100: ...185232 16 Soft Serve Freezer Model GEN 102 Figure 12 Side Rear View WC...

Page 101: ...3 00PD 16 HC120810 04 Box Assy Caps 2Hp BF 2Hp COPZS 17 HC155702 Cut Out High Pressure 375PSI 18 HC155701 Cut Out Low Pressure 19 HC154948 Compressor Scroll ZS19KAE TF5 20 HC121027 Gearmotor 1 6 Hp 11...

Page 102: ...y Item Part No Description 1 HC160320 Screw SKHC 10 24 x 1 3 4 SST 2 HC160166 Washer Lock 10 SST 3 HC160556 Gasket Mix Joint 4 HC139351 Collar Alignment 5 HC139349 Tube Mix Feed Clamp 6 HC139352 Clamp...

Page 103: ...HC153420 Coupling Refr 3 8 MQC 3 8 SW 7A HC191538 Plate Coupling Mtg 8 HC153418 Coupling Refr 1 2MQC 1 2 SW 8A HC153502 Flange Refr Coupling Mount 8B HC153503 Cap Dust Refr Coupling 9 HC139017 Shield...

Page 104: ...ter 1 1 4 ST PT w Brake HC162106 Caster 1 1 4 ST PT w o Brake HC184238 Chart O ring Ivory Laminated HC158051 Cup Overrun Measuring One Pint HC136567 Hose Spigot Drain HC115538 Kit O ring Head HC112978...

Page 105: ...185232 21 Soft Serve Freezer Model GEN 102 O Ring Chart...

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Duke DQ GEN-102, Operator’S Manual With Illustrated Parts List

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