Duke DQ GES-103 User Manual

H.C. Duke & Son, LLC. P/N 184560 January 2018 Printed In U.S.A.
OPERATOR’S MANUAL
with Illustrated Parts List
SOFT SERVE
TWIST FREEZER
Model
GES-103
184560 — 1/18

Duke DQ GES-103 Specifications

General

Brand	Duke
Model	DQ GES-103
Category	Freezer
Language	English

Summary

Operator's Manual

Soft Serve Twist Freezer Model GES-103

Manual for GES-103 soft serve twist freezer.

Safety First

Recognize Safety Information

Identifying safety alert symbols in the manual and on the freezer.

Understand Signal Words

Explaining the meaning of DANGER, WARNING, and CAUTION signal words.

Follow Safety Instructions

Reading and understanding all safety messages and decals on the freezer.

Definitions

Defining terms like Trained Person and Freezer Technician for safe operation.

Operate Safely

Guidelines for safe operation, including staff capabilities and cover security.

Caution

Important safety precautions for operating the freezer.

Safety Decal Locations

Identifying and maintaining safety decals on the freezer.

Introduction and Installation

Introduction

Overview of the manual's purpose and the freezer's design.

Technical Assistance Contact

Contact details for technical support and service assistance.

Note to Installer

Important information for those installing the freezer.

Installation and Warranty

Requirements for installation and warranty validation.

Uncrating and Inspection

Procedures for unpacking and inspecting the freezer.

Installing Legs or Casters

Procedure for installing mounting legs or casters on the freezer.

Installation

Guidelines for proper freezer placement and ventilation.

Water Cooled Unit Requirements

Specifications for water inlet, waste connection, and water pressure.

Leveling the Freezer

Adjusting legs or casters to level the machine properly.

Electrical Requirements

Ensuring correct supply voltage, phase balance, and proper grounding.

Power Disconnect

Requirement for an accessible main power disconnect for all poles.

Electrical Connections

Guidelines for making electrical connections to the freezer.

Grounding and Wiring

Importance of positive earth ground and checking data plate for specifications.

Voltage Switch Setting

Setting the voltage switch correctly to prevent component damage.

Beater Shaft Rotation

Ensuring correct clockwise rotation for beater shafts.

Specifications

Particulars

Key physical and operational specifications of the GES-103 freezer.

Dimensions

Detailed physical dimensions of the GES-103 freezer with diagrams.

Data Plate Information

Importance of the data plate for ordering parts and service requests.

Recording Freezer Details

Section to record model, serial, and electrical specifications for reference.

Installation Details

Recording installation date, installer, and contact information.

WEEE Disposal Guidelines

Instructions for proper disposal of electronic waste according to EU regulations.

Equipment Setup Videos

Link to videos for setting up and priming the GES freezer.

VQM Terminology

Beater Run and Demand Run Comp

Definitions for VQM timers related to beater and compressor operation.

Differential and Dual Differential

Explaining differential settings for temperature control.

Idle and Idle Run Comp

Definitions for idle mode and compressor delay during idle.

Lockouts and Main P.C. Board

Function of lockouts and description of the main control board.

Membrane Switch and Relay Board

Components related to user interface and system control.

Single Diff

Definition for single differential setting.

Slope/Demand Slope and Temp. Comp.

VQM functions for monitoring temperature change and compensation.

Temperature Offset and Transducer

Adjusting temperature and measuring cylinder pressure.

U.I./ User Interface

Description of the user interface board and its connection.

Part Names and Functions

Figure 5-1 Head Assembly

Diagram and listing of parts for the head assembly.

Head Assembly Components

Detailed descriptions of components within the head assembly.

Figure 5-2 Beater Shaft Assembly

Diagram and listing of parts for the beater shaft assembly.

Beater Shaft Assembly Components

Detailed descriptions of components within the beater shaft assembly.

Figure 5-3 Mix Transfer System (MTS)

Diagram of the Mix Transfer System with numbered parts.

Mix Transfer System Components

Detailed descriptions of Mix Transfer System components.

Operator Controls and Display Menus

Figure 6-1 Control Layout

Diagram of the operator control panel with numbered items.

Function Buttons

Description of the four function buttons and their operation.

OFF Key and Navigation Pad

Function of the OFF key and the navigation pad for menu control.

Freeze Symbol

Operation of the freeze symbol button for freeze or day mode.

Control Indicator and Mode of Operation

Explaining left/right indicators and OFF, FRZ, NIGHT modes.

Wash or Clean Mode

Activating the wash or clean mode function.

Information Window and Night Mode

Display window functions and night mode operation.

Hidden Operator Menu Key

Accessing the operator menu for settings adjustment.

Power Switch

Function of the power switch for operation and cleaning.

Operator Display Menus

Navigating and changing settings like product type and temperature offset.

Entering the Operator Menu

Steps to enter the operator menu using a hidden key.

Navigating and Changing Settings

How to navigate menus and change settings like product type and temperature offset.

Operator's Menu Options

List of available options within the operator's menu.

Basic Settings and Actual Temps

Details on product type, temperature offset, and cabinet/cylinder temps.

Event Log and Error Log

Accessing logged events and error logs for diagnostics.

Statistics

Viewing compressor, switch, and beater motor usage statistics.

Statistics Continued

Further details on statistics for spigot, compressor, and beater motor usage.

Lockouts and Screen Settings

Features for locking out functions and customizing screen display.

Date/Time and Last Clean

Setting date/time and viewing the last cleaning date.

Software Versions

Information on UI and main board software versions.

Night Mode Operation

How to activate and use the night mode for product preservation.

Disassembly and Cleaning

Safety Information

Crucial safety warnings for depressurizing and handling parts.

Depressurizing the Freezer

Steps to ensure the freezer is depressurized before proceeding with disassembly.

Cleaning with Mix Stored

Instructions for cleaning when mix is stored in drawers or a remote cooler.

Figure 8-1 Cleaning Accessories

Illustrated list of accessories required for cleaning and disassembly.

Figure 8-2 Spigot Assemblies

Diagram of spigot assemblies for disassembly reference.

Figure 8-3 Shaft Seal

Diagram of shaft seals for disassembly reference.

Disassembly Steps

Step-by-step instructions for disassembling the freezer components.

Figure 8-4 MTS

Diagram of the Mix Transfer System for disassembly.

Figure 8-5 MTS Hose Assembly

Diagram of MTS hose assembly for disassembly.

MTS Hose Removal Instructions

Detailed steps for removing MTS hose assemblies.

Figure 8-6 Air Curtain Installation

Illustration of air curtain installation for cleaning.

Figure 8-7 and 8-8

Diagrams of spigot parts and openings for cleaning.

Cleaning Procedures

General instructions for washing, rinsing, and sanitizing parts.

Figure 8-9 Scraper Blade Pin Holes

Illustration of scraper blade pin holes for cleaning.

Figure 8-10 Clean Cylinders

Illustration of cylinder cleaning process.

Figure 8-11 Cylinder Mix Feed Tubes

Illustration of cleaning mix feed tubes.

Sanitizing Parts

Steps for sanitizing washed and rinsed parts.

Figure 8-12 Clean Drain Tube

Illustration for cleaning the drain tube.

Figure 8-13 Slide Removal

Illustration for removing slides during cleaning.

Cleaning Drawers and Replacing Brushes

Specific instructions for cleaning drawers and replacing worn brushes.

Figure 8-14 MTS Assembly Lubrication

Diagram showing lubrication points for the MTS assembly.

MTS Assembly Cleaning and Lubrication

Steps for cleaning and lubricating the MTS assembly components.

Assembly

Figure 9-1 Shaft Seals

Diagram of shaft seals for assembly reference.

Figure 9-2 Beater Shaft Assemblies

Diagram of beater shaft assemblies for assembly.

Figure 9-3 Blade Installation

Illustration showing proper blade installation orientation.

Shaft Seal Installation

Steps for installing shaft seals and applying lubricant.

Figure 9-4 Head Assembly

Diagram of the head assembly for installation.

Beater Shaft and Bushing Installation

Steps for inserting beater shafts and installing cylinder bushings.

Spigot and Head Assembly

Installing spigots, o-rings, and the dispensing head assembly.

Figure 9-5 MTS Hose Assembly

Diagram of MTS hose assembly for installation.

MTS Hose Assembly Installation

Steps for assembling and installing MTS hose assemblies.

Figure 9-6 MTS

Diagram of the Mix Transfer System for final assembly checks.

Final MTS Assembly Checks

Ensuring proper alignment and securing of MTS components.

Start-up Instructions

10.1 Sanitizing

Procedures for washing, sanitizing, and preparing the freezer for use.

Sanitizing Solution and Hand Washing

Preparing sanitizing solution and personal hygiene before sanitizing.

Sanitizing with Mix Stored

Specific sanitizing steps for mix stored in drawers.

Sanitizing Procedures

Detailed steps for sanitizing the freezer and its components.

10.2 Priming

Removing air and sanitizer, setting overrun for initial product.

Priming Steps

Procedures for priming the freezer with mix and starting the freeze cycle.

10.3 Dispensing Product

How to dispense product correctly and safely.

Closing Procedures

11.1 Draining Product

Steps for draining product and preparing for cleaning.

Cleaning with Mix Stored

Procedures for cleaning with mix stored in drawers or remote cooler.

Cleaning with Mix Stored in Remote Cooler

Detailed cleaning steps for mix stored in a remote cooler.

Sanitizing Procedures

Final sanitizing steps after draining and cleaning.

11.2 Night Switch Operation

How to activate and use the night mode for product preservation.

General Information

12.1 Dairy Queen® Mix

Guidelines for using and storing Dairy Queen® mix.

Checking the Frozen DQ® Product

How to check product consistency, temperature, and overrun.

Product Temperature

Measuring and maintaining correct product temperature.

Overrun Calculation

Formula and explanation for calculating overrun percentage.

Overrun Adjustment

How to adjust overrun using air meters.

Rerun Policy

Information regarding the use and implications of product rerun.

Overrun Chart

Table showing net weight and corresponding overrun percentages.

Routine Maintenance

Daily Maintenance

Daily tasks for disassembly, cleaning, and inspection.

As Needed Maintenance

Maintenance tasks performed as required, such as cleaning the Mix Transfer System.

As Needed Maintenance (continued)

Further as-needed tasks including hose cavity cleaning and shoe cleaning.

Weekly Maintenance

Weekly inspection of parts for wear and replacement of blades.

Monthly Maintenance - Head Switch Test

Testing the head switch feature for proper operation.

Monthly Maintenance - Water Condenser

Checking water temperatures for water-cooled condensers.

Monthly Maintenance - MTS Cover Switch

Testing the MTS cover switch for accidental activation prevention.

Monthly Maintenance - Replace Mix Transfer Hose

Instructions for replacing the mix transfer hose.

Quarterly Maintenance

Air condenser and refrigeration system checks.

1500 Hours / 6 Months

Service for initial oil change of the gear reducer.

Semi-Annually

Checking condenser fan motor and adding oil as needed.

5000 Hours / 1 Year

Changing oil in the gear reducer.

Annually

Annual service for drive belts, fan motor, and internal cleaning.

Winter Storage

Procedures for proper storage of the freezer during winter shutdown.

Troubleshooting

Safety and Caution Notes

Important safety warnings and cautions for troubleshooting procedures.

Unit Does Not Operate

Troubleshooting common issues when the unit does not operate.

Mix or Water Leaking

Diagnosing and fixing leaks from the drain tube to the drip tray.

Mix Leaking at Dispensing Head

Troubleshooting mix leaks at the dispensing head.

Dispensed Product Too Soft

Addressing issues with soft product or high temperature.

Product Dispenses Slowly

Identifying causes for slow product dispensing from the head.

Dispensed Product Too Hard

Troubleshooting issues with dispensed product being too hard.

Freezer Runs Continually

Diagnosing why the freezer runs continuously and product gets colder.

Poor or Slow Product Recovery

Solutions for poor or slow product recovery from the freezer.

Compressor Does Not Operate

Troubleshooting compressor operational issues.

Compressor Operates Improperly

Addressing improper compressor operation.

Compressor and Beater Motor Operate Only When Dispensing

Diagnosing when motors run only during dispensing.

Cabinet Too Cold

Addressing issues where the cabinet temperature is too low.

Mix Sours in Cabinet

Troubleshooting reasons for mix souring in the cabinet.

Mix Leaks Out of MTS

Identifying and fixing leaks from the Mix Transfer System.

MTS Will Not Operate

Diagnosing why the Mix Transfer System is not operating.

MTS Cycles On and Off

Troubleshooting MTS cycling without dispensing.

MTS Will Not Prime

Addressing issues with the MTS failing to prime.

Mix Pickup Tube Loses Prime

Diagnosing why the mix pickup tube loses prime.

No Air (Overrun)

Troubleshooting lack of air or low overrun in the MTS.

Too Much Air / High Overrun

Addressing issues with too much air and high overrun, causing popping.

Mix Shoots Out Air Meter

Diagnosing why mix is shooting out of the air meter.

VQM Error Codes

MAIN COMM Error

Troubleshooting communication issues between Main P.C. board and UI.

NO COMM Error

Troubleshooting communication issues when UI is not receiving messages.

CYL RFG Error

Error for cylinder system run time exceeding 90 minutes.

CABINET RFG Error

Error for cabinet refrigeration system run time exceeding 90 minutes.

CABINET RFG Error (continued)

Further troubleshooting for cabinet refrigeration errors.

CABINET RFG Error (continued)

Additional causes and remedies for cabinet refrigeration errors.

CYL. TEMP Error

Error when cylinder thermistor is out of temperature limit.

CABINET TEMP. Error

Error when cabinet thermistor is out of temperature limit.

HEAD SW Error

Error related to the head switch not being installed or faulty.

MOTOR OVLD Error

Error indicating motor overload or internal overload open.

COMP. LO PSI Error

Error when low pressure control is activated.

COMP. HIGH PSI Error

Error when high pressure control is activated.

COMP. HIGH PSI Error (continued)

Further troubleshooting for high pressure control activation.

POWER FAIL Error

Error indicating main power failure to the system.

SPIGOT Error

Error when spigot switch is engaged for too long.

C SPIGOT Error

Error for center spigot switch engagement.

L PWR OFF Error

Error for left side power loss on dual power supply units.

PUMP HI PSI Error

Error when pump pressure exceeds limit.

PUMP ERROR

Error if pump runs continuously during freeze mode.

SHORT Error

Error indicating a thermistor has failed in a shorted state.

OPEN Error

Error when a thermistor has failed in an open state.

CYL T ALARM

Alarm when cylinder temperature exceeds limit.

CAB T ALARM

Alarm when cabinet temperature exceeds limit.

CLEAN FINISHED

Displayed when cleaning parameters are met.

PUMP COVER Error

Error if RMT pump cover is removed or open.

Main P.C. Board Heartbeat LED

Troubleshooting issues with the main PC board heartbeat LED.

Illustrations and Parts

Part II Replacement Parts Index

Index of replacement parts with corresponding figure numbers.

Figure 1 Head Assembly

Diagram and parts list for the Head Assembly.

Figure 2 Beater Shaft Assembly

Diagram and parts list for the Beater Shaft Assembly.

Figure 3 Cabinet Parts

Diagram and parts list for Cabinet Parts.

Figure 4 MTS—RMT Hose Assembly

Diagram and parts list for MTS—RMT Hose Assembly.

Figure 5 Mix Drawer

Diagram and parts list for the Mix Drawer.

Figure 6 Mix Transfer System — RMT

Breakdown diagram of the Mix Transfer System.

Figure 7 Switch Box

Breakdown diagram of the Switch Box.

Figure 8 Spigot Switch Assemblies

Diagram of Spigot Switch Assemblies.

Figure 9 Capacitor & Relay Box

Diagram of Capacitor & Relay Box.

Figure 10 AC Side/Back View

Diagram of AC Side/Back View.

Figure 11 WC Side/Back View

Diagram of WC Side/Back View.

Figure 12 Panel Breakdown

Diagram of Panel Breakdown.

Figure 13 Panel Hardware & Decals

Diagram of Panel Hardware & Decals.

Figure 14 Gear Reducer

Diagram of the Gear Reducer.

Figure 15 Evaporator Mix Tube Assembly

Diagram of Evaporator Mix Tube Assembly.

Figure 16 Air Cooled Remote Condenser

Diagram of Air Cooled Remote Condenser.

Accessories

List of available accessories for the freezer.

O-Ring Chart

Chart detailing O-ring part numbers and diagrams.