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H.C Duke & Son 959R User Manual

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H.C. Duke & Son, Inc. P/N 184981 February 2007 Printed in U.S.A.
OPERATOR'S MANUAL
with ILLUSTRATED PARTS LIST
TWIN TWIST
SOFT SERVE FREEZER
MODEL 959R
184981 - 2/07

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the H.C Duke & Son 959R and is the answer not in the manual?

H.C Duke & Son 959R Specifications

General IconGeneral
BrandH.C Duke & Son
Model959R
CategoryFreezer
LanguageEnglish

Summary

SAFETY FIRST!

Recognize Safety Information

Explains the importance and usage of the safety alert symbol in the manual.

Understand Signal Words

Defines signal words like DANGER, WARNING, and CAUTION used with safety symbols.

SAFETY FIRST! - Continued

Follow Safety Instructions

Instructs users to read all safety messages and keep decals in good condition.

Operate Safely

Warns against untrained personnel, operating with covers removed, or servicing before power disconnect.

Safety Decal Locations

1 Introduction

2 Note to Installer

2.1 Uncrating and Inspection

2.2 Installation

2.3 Electrical Requirements

2.4 Electrical Connections

3 Specifications

3.1 Particulars

Lists specific technical details like dimensions, compressor, and motor specs.

3.2 Dimensions

Provides physical dimensions of the freezer unit.

3.3 Data Plate

3.4 Reference Information

3.5 Installation Date

4 Part Names and Functions

Figure 4-1 Head Assembly

Diagram and list of parts for the head assembly of the freezer.

4 Part Names and Functions – Continued

HEAD

Encloses the freezing cylinder and provides an opening for product dispensing.

SPIGOT - ASSEMBLY

Seals the product opening in the head when closed, allows flow when open.

ROD - SPIGOT

Starts the freezer when dispensing; must be in place for operation.

PLUG - AIR BLEED

Seals the air bleed opening, allows excess air removal during priming.

4 Part Names and Functions – Continued (Beater Shaft)

Figure 4-2 Beater Shaft Assembly

Diagram and list of parts for the beater shaft assembly.

SHAFT - BEATER

Rotates in the freezing cylinder, blending mix as it ejects product.

BLADE - SCRAPER

Scrapes the frozen product from the freezing cylinder wall.

SEAL(CUP) - BEATER SHAFT

Seals the opening between the cylinder and beater shaft.

4 Part Names and Functions – Continued (Accessories)

Accessory

Describes optional accessories available for the freezer.

Figure 4-3 Duke Remote Mix Transfer System (RMT)

Diagram and description of the optional RMT system.

5 Operator Controls

5.1 Selector Switch

Explains the three positions (CLEAN, OFF, AUTO) of the selector switch.

5 Operator Controls – Continued

5.2 Pump Switch

Describes the ON/OFF positions of the mix pump switch.

5.3 Reset - Overload

Details the function and reset procedure for the overload protection.

5.4 Timer

Explains the function of the timer for quick start-ups or fast recovery.

5 Operator Controls – Continued (Lights & Outlets)

5.5 Pilot Lights

Explains the meaning of the amber and red pilot lights.

5.6 Outlet

Describes the purpose and limitations of the 115v receptacle outlets.

6 Disassembly and Cleaning

Safety Information

Emphasizes depressurizing the freezer before disassembly, cleaning, or servicing.

6.1 Cleaning Accessories

6.2 Disassembly Instructions

6.3 Cleaning Instructions

7 Assembly

Figure 7-1 Shaft Seal Assembly

Diagram illustrating the assembly of the shaft seal components.

Figure 7-2 Beater Shaft Assembly

Diagram showing the assembly of the beater shaft components.

Figure 7-3 Blade Installation

Illustration detailing the correct installation method for beater blades.

7 Assembly – Continued

8 Start-up Instructions

8.1 Sanitizing

Provides instructions for sanitizing the freezer before initial start-up.

8.1 Sanitizing – Continued

8.2 Priming

8.2 Priming – Continued

8.3 Dispensing Product

9 Closing Procedures

9.1 Draining Product

Provides daily procedures for rinsing, disassembling, and cleaning the freezer parts.

10 General Information

10.1 Dairy Queen® Mix

Provides guidelines and specifications for using Dairy Queen® mix.

10.2 Checking the Frozen DQ® Product

Explains how to assess product consistency through temperature and overrun.

10.3 Product Temperature

Details how to measure and maintain the correct product temperature.

10.4 Overrun

Explains the concept of overrun and its importance for product quality.

10.5 Overrun Measurement

Provides a step-by-step guide and formula for measuring product overrun.

10 General Information – Continued

10.6 Overrun Chart

Presents a chart correlating product weight to overrun percentage.

10.7 Overrun Adjustment

Guides on adjusting pump settings to correct overrun variations.

10.8 Rerun

Addresses the policy and issues related to reprocessing melted product.

11 Routine Maintenance

DAILY

Outlines daily tasks for cleaning, sanitizing, and inspecting parts.

WEEKLY

Details weekly checks for wear on seals, O-rings, blades, and beater shank.

11 Routine Maintenance – Continued

MONTHLY

Instructions for testing the head switch function monthly.

MONTHLY – Continued

Instructions for checking water condenser performance monthly.

11 Routine Maintenance – Continued (Schedules)

QUARTERLY

Recommends professional checks of the refrigeration system quarterly.

SEMIANNUALLY

Advises changing gear reducer oil every six months or 2500 hours.

ANNUALLY

Lists annual tasks like replacing drive belts and cleaning the freezer interior.

11 Routine Maintenance – Continued (Storage)

WINTER STORAGE

Provides procedures for proper storage of the freezer during off-season.

12 Troubleshooting Charts

Unit does not operate.

Lists probable causes and remedies for the unit failing to operate.

Leakage of mix or water from drain tube to drip tray.

Identifies causes and solutions for leaks in the drain tray system.

Mix leaking at dispensing head.

Addresses issues related to mix leakage from the dispensing head.

Dispensed product too soft.

Lists causes and remedies for product dispensing too soft.

12 Troubleshooting Charts – Continued

Product dispenses slowly out of dispensing head.

Lists causes and remedies for slow product dispensing.

Dispensed product too hard.

Lists causes and remedies for product dispensing too hard.

Freezer runs continually and product continues to get colder.

Addresses issues where the freezer runs continuously and product gets too cold.

12 Troubleshooting Charts – Continued (Motor & Compressor)

Poor or slow product recovery.

Lists causes and remedies for poor or slow product recovery.

Beater motor does not operate.

Lists causes and remedies for the beater motor not operating.

Compressor does not operate or operates improperly.

Addresses issues with compressor operation or lack thereof.

Compressor and beater motor do not operate when dispensing.

Lists causes and remedies for compressor/beater motor not operating during dispensing.

Compressor and beater motor operates only when dispensing or turning timer knob.

Addresses compressor/beater motor operation tied to dispensing or timer.

Capacitor failures. (Single phase only)

Lists causes and remedies for capacitor failures in single-phase units.

Discharge pressure too low.

Addresses causes and remedies for low discharge pressure.

Compressor starts, but remains in start windings (single phase only)

Diagnoses issues with single-phase compressors starting but not running.

Compressor does not start – hums intermittently (cycling on overload).

Addresses intermittent compressor start issues or overload cycling.

Unit operates long or continuously.

Lists causes and remedies for the unit running continuously.

Discharge pressure too high.

Addresses causes and remedies for excessively high discharge pressure.

Noisy compressor

Lists causes and remedies for a noisy compressor.

Replacement Parts Orders

ILLUSTRATIONS

Figure 1 Head Assembly

Detailed diagram and part list for the head assembly.

Figure 2 Beater Shaft Assembly

Diagram and part list for the beater shaft assembly.

Figure 3 Contactor Box

Diagram and part list for the contactor box components.

Figure 4 Switch Assemblies

Diagrams and part lists for side and center switch assemblies.

Figure 5 Electrical Box (Sheet 1 of 2)

Diagram of the electrical box components, top and front views.

Figure 6 Panels (Sheet 1 of 2)

Exploded view and part list for the freezer panels and decals.

Figure 7 959R Freezer Breakdown (Sheet 1 of 2)

Exploded view of major freezer components with numbered parts.

Figure 7 959R Freezer Breakdown (Sheet 2 of 2)

Continued exploded view and comprehensive part list for the freezer.

Figure 8 Gear Reducer

Diagram and part list for the gear reducer assembly.

Figure 9 Air Cooled Remote Condenser

Diagram and part list for the remote air-cooled condenser unit.

Accessories

SOFT SERVE DISPENSING HEADS

O-RING CHART

Illustrates O-ring sizes and part numbers for the dispensing heads.

Alphabetized Parts List for Model 959R

3 Service "FIRST"

3.1 Installation, Start-up, and Instruction Checklist

Instructs to complete a checklist for proper installation and start-up.

4 Uncrating and Inspecting the Freezer

4.1 Uncrating the Freezer

Provides instructions for uncrating the freezer and inspecting for shipping damage.

4.2 Inspecting the Freezer

Details checks for cabinet exterior damage, tubing, pulleys, and condenser fan.

5 Installation Procedures

5.1 Placement of the Freezer

Guides on selecting a suitable location and ensuring proper ventilation and leveling.

5.2 Water and Drain Connections

Provides instructions for making water and drain connections for water-cooled models.

5.3 Electrical Requirements

Outlines critical electrical specifications, grounding, and voltage requirements.

5.4 Data Plate

Explains the importance of the data plate for operator reference.

5.5 Reference Information

Provides fields to record freezer installation details for future reference.

6 Remote Air Condenser

6.1 Placement of the Remote Air Condenser

Guides on selecting an optimal location for the remote condenser unit.

6.2 Remote Air Condenser Installation

Details procedures for connecting the pre-charged refrigerant line sets.

6.2.1 Connecting Condenser Line Couplings

Explains how to properly connect refrigerant line couplings, including torque values.

6.2.2 Condenser Electrical Wiring

Provides instructions for wiring the condenser fan motor and electrical disconnects.

7 Tests of Installation

7.1 Head Switch Operation

Details how to test the head switch to ensure it prevents accidental beater activation.

7.2 Cylinder Frost Pattern

Explains how to check the refrigeration system's performance via frost pattern.

7.3 Spigot Switch Operation

Describes how to test and adjust the spigot switch for proper operation.

7.4 Beater Rotation

Explains how to check the beater shaft rotation direction, especially for three-phase models.

8 Operating Adjustments

8.1 Thermostat

Guides on setting the cylinder thermostat for optimal product temperature and cycle times.

8.2 Refrigeration Settings - Bristol Compressors

Provides pressure settings for water-cooled and air-cooled refrigeration systems.

8.3 Operational Checks

Outlines checks for refrigeration pressure, mix leaks, product temperature, and pump operation.

9 Equipment Operation

9.1 The Refrigeration System

Explains the basic principles of the refrigeration system in the freezer.

9.2 The Electrical Circuit

Explains how the selector switch and spigot switch control electrical operations.

10 Maintenance and Adjustments

10.1 Gear Reducer Lubrication Instructions

Provides instructions for lubricating the gear reducer, including oil type and changing frequency.

10.2 Condenser Cleaning

Details cleaning procedures for air-cooled and water-cooled condensers, and fan motor inspection.

10.3 Pulley Alignment and Belt Tension

Explains how to check and adjust pulley alignment and belt tension.

10.4 Beater Drive Coupling Replacement and End Play Setting

Guides on replacing the beater drive coupling and adjusting end play.

11 Service Troubleshooting Charts

Unit does not operate.

Lists probable causes and remedies for the unit failing to operate.

Leakage of mix or water from drain tube to drip tray.

Identifies causes and solutions for leaks in the drain tray system.

Mix leaking at dispensing head.

Addresses issues related to mix leakage from the dispensing head.

Dispensed product too soft.

Lists causes and remedies for product dispensing too soft.

Product dispenses slowly out of dispensing head.

Lists causes and remedies for slow product dispensing.

Dispensed product too hard.

Lists causes and remedies for product dispensing too hard.

Freezer runs continually and product continues to get colder.

Addresses issues where the freezer runs continuously and product gets too cold.

Poor or slow product recovery.

Lists causes and remedies for poor or slow product recovery.

Beater motor does not operate.

Lists causes and remedies for the beater motor not operating.

Compressor does not operate or operates improperly.

Addresses issues with compressor operation or lack thereof.

Compressor and beater motor do not operate when dispensing.

Lists causes and remedies for compressor/beater motor not operating during dispensing.

Compressor and beater motor operates only when dispensing or turning timer knob.

Addresses compressor/beater motor operation tied to dispensing or timer.

Capacitor failures. (Single phase only)

Lists causes and remedies for capacitor failures in single-phase units.

Discharge pressure too low.

Addresses causes and remedies for low discharge pressure.

Compressor starts, but remains in start windings (single phase only)

Diagnoses issues with single-phase compressors starting but not running.

Compressor does not start – hums intermittently (cycling on overload).

Addresses intermittent compressor start issues or overload cycling.

Unit operates long or continuously.

Lists causes and remedies for the unit running continuously.

Discharge pressure too high.

Addresses causes and remedies for excessively high discharge pressure.

Noisy compressor

Lists causes and remedies for a noisy compressor.

Replacement Parts Orders

ILLUSTRATIONS

Figure 1 Head Assembly

Detailed diagram and part list for the head assembly.

Figure 2 Beater Shaft Assembly

Diagram and part list for the beater shaft assembly.

Figure 3 Contactor Box

Diagram and part list for the contactor box components.

Figure 4 Switch Assemblies

Diagrams and part lists for side and center switch assemblies.

Figure 5 Electrical Box (Sheet 1 of 2)

Diagram of the electrical box components, top and front views.

Figure 6 Panels (Sheet 1 of 2)

Exploded view and part list for the freezer panels and decals.

Figure 7 959R Freezer Breakdown (Sheet 1 of 2)

Exploded view of major freezer components with numbered parts.

Figure 7 959R Freezer Breakdown (Sheet 2 of 2)

Continued exploded view and comprehensive part list for the freezer.

Figure 8 Gear Reducer

Diagram and part list for the gear reducer assembly.

Figure 9 Air Cooled Remote Condenser

Diagram and part list for the remote air-cooled condenser unit.

Accessories

SOFT SERVE DISPENSING HEADS

O-RING CHART

Illustrates O-ring sizes and part numbers for the dispensing heads.

Alphabetized Parts List for Model 959R

3 Service “FIRST”

3.1 Installation, Start-up, and Instruction Checklist

Instructs to complete a checklist for proper installation and start-up.

4 Uncrating and Inspecting the Freezer

4.1 Uncrating the Freezer

Provides instructions for uncrating the freezer and inspecting for shipping damage.

4.2 Inspecting the Freezer

Details checks for cabinet exterior damage, tubing, pulleys, and condenser fan.

5 Installation Procedures

5.1 Placement of the Freezer

Guides on selecting a suitable location and ensuring proper ventilation and leveling.

5.2 Water and Drain Connections

Provides instructions for making water and drain connections for water-cooled models.

5.3 Electrical Requirements

Outlines critical electrical specifications, grounding, and voltage requirements.

5.4 Data Plate

Explains the importance of the data plate for operator reference.

5.5 Reference Information

Provides fields to record freezer installation details for future reference.

6 Remote Air Condenser

6.1 Placement of the Remote Air Condenser

Guides on selecting an optimal location for the remote condenser unit.

6.2 Remote Air Condenser Installation

Details procedures for connecting the pre-charged refrigerant line sets.

6.2.1 Connecting Condenser Line Couplings

Explains how to properly connect refrigerant line couplings, including torque values.

6.2.2 Condenser Electrical Wiring

Provides instructions for wiring the condenser fan motor and electrical disconnects.

7 Tests of Installation

7.1 Head Switch Operation

Details how to test the head switch to ensure it prevents accidental beater activation.

7.2 Cylinder Frost Pattern

Explains how to check the refrigeration system's performance via frost pattern.

7.3 Spigot Switch Operation

Describes how to test and adjust the spigot switch for proper operation.

7.4 Beater Rotation

Explains how to check the beater shaft rotation direction, especially for three-phase models.

8 Operating Adjustments

8.1 Thermostat

Guides on setting the cylinder thermostat for optimal product temperature and cycle times.

8.2 Refrigeration Settings - Bristol Compressors

Provides pressure settings for water-cooled and air-cooled refrigeration systems.

8.3 Operational Checks

Outlines checks for refrigeration pressure, mix leaks, product temperature, and pump operation.

9 Equipment Operation

9.1 The Refrigeration System

Explains the basic principles of the refrigeration system in the freezer.

9.2 The Electrical Circuit

Explains how the selector switch and spigot switch control electrical operations.

10 Maintenance and Adjustments

10.1 Gear Reducer Lubrication Instructions

Provides instructions for lubricating the gear reducer, including oil type and changing frequency.

10.2 Condenser Cleaning

Details cleaning procedures for air-cooled and water-cooled condensers, and fan motor inspection.

10.3 Pulley Alignment and Belt Tension

Explains how to check and adjust pulley alignment and belt tension.

10.4 Beater Drive Coupling Replacement and End Play Setting

Guides on replacing the beater drive coupling and adjusting end play.

11 Service Troubleshooting Charts

Unit does not operate.

Lists probable causes and remedies for the unit failing to operate.

Leakage of mix or water from drain tube to drip tray.

Identifies causes and solutions for leaks in the drain tray system.

Mix leaking at dispensing head.

Addresses issues related to mix leakage from the dispensing head.

Dispensed product too soft.

Lists causes and remedies for product dispensing too soft.

Product dispenses slowly out of dispensing head.

Lists causes and remedies for slow product dispensing.

Dispensed product too hard.

Lists causes and remedies for product dispensing too hard.

Freezer runs continually and product continues to get colder.

Addresses issues where the freezer runs continuously and product gets too cold.

Poor or slow product recovery.

Lists causes and remedies for poor or slow product recovery.

Beater motor does not operate.

Lists causes and remedies for the beater motor not operating.

Compressor does not operate or operates improperly.

Addresses issues with compressor operation or lack thereof.

Compressor and beater motor do not operate when dispensing.

Lists causes and remedies for compressor/beater motor not operating during dispensing.

Compressor and beater motor operates only when dispensing or turning timer knob.

Addresses compressor/beater motor operation tied to dispensing or timer.

Capacitor failures. (Single phase only)

Lists causes and remedies for capacitor failures in single-phase units.

Discharge pressure too low.

Addresses causes and remedies for low discharge pressure.

Compressor starts, but remains in start windings (single phase only)

Diagnoses issues with single-phase compressors starting but not running.

Compressor does not start – hums intermittently (cycling on overload).

Addresses intermittent compressor start issues or overload cycling.

Unit operates long or continuously.

Lists causes and remedies for the unit running continuously.

Discharge pressure too high.

Addresses causes and remedies for excessively high discharge pressure.

Noisy compressor

Lists causes and remedies for a noisy compressor.

Replacement Parts Orders

ILLUSTRATIONS

Figure 1 Head Assembly

Detailed diagram and part list for the head assembly.

Figure 2 Beater Shaft Assembly

Diagram and part list for the beater shaft assembly.

Figure 3 Contactor Box

Diagram and part list for the contactor box components.

Figure 4 Switch Assemblies

Diagrams and part lists for side and center switch assemblies.

Figure 5 Electrical Box (Sheet 1 of 2)

Diagram of the electrical box components, top and front views.

Figure 6 Panels (Sheet 1 of 2)

Exploded view and part list for the freezer panels and decals.

Figure 7 959R Freezer Breakdown (Sheet 1 of 2)

Exploded view of major freezer components with numbered parts.

Figure 7 959R Freezer Breakdown (Sheet 2 of 2)

Continued exploded view and comprehensive part list for the freezer.

Figure 8 Gear Reducer

Diagram and part list for the gear reducer assembly.

Figure 9 Air Cooled Remote Condenser

Diagram and part list for the remote air-cooled condenser unit.

Accessories

SOFT SERVE DISPENSING HEADS

O-RING CHART

Illustrates O-ring sizes and part numbers for the dispensing heads.

Alphabetized Parts List for Model 959R

3 Service “FIRST”

3.1 Installation, Start-up, and Instruction Checklist

Instructs to complete a checklist for proper installation and start-up.

4 Uncrating and Inspecting the Freezer

4.1 Uncrating the Freezer

Provides instructions for uncrating the freezer and inspecting for shipping damage.

4.2 Inspecting the Freezer

Details checks for cabinet exterior damage, tubing, pulleys, and condenser fan.

5 Installation Procedures

5.1 Placement of the Freezer

Guides on selecting a suitable location and ensuring proper ventilation and leveling.

5.2 Water and Drain Connections

Provides instructions for making water and drain connections for water-cooled models.

5.3 Electrical Requirements

Outlines critical electrical specifications, grounding, and voltage requirements.

5.4 Data Plate

Explains the importance of the data plate for operator reference.

5.5 Reference Information

Provides fields to record freezer installation details for future reference.

6 Remote Air Condenser

6.1 Placement of the Remote Air Condenser

Guides on selecting an optimal location for the remote condenser unit.

6.2 Remote Air Condenser Installation

Details procedures for connecting the pre-charged refrigerant line sets.

6.2.1 Connecting Condenser Line Couplings

Explains how to properly connect refrigerant line couplings, including torque values.

6.2.2 Condenser Electrical Wiring

Provides instructions for wiring the condenser fan motor and electrical disconnects.

7 Tests of Installation

7.1 Head Switch Operation

Details how to test the head switch to ensure it prevents accidental beater activation.

7.2 Cylinder Frost Pattern

Explains how to check the refrigeration system's performance via frost pattern.

7.3 Spigot Switch Operation

Describes how to test and adjust the spigot switch for proper operation.

7.4 Beater Rotation

Explains how to check the beater shaft rotation direction, especially for three-phase models.

8 Operating Adjustments

8.1 Thermostat

Guides on setting the cylinder thermostat for optimal product temperature and cycle times.

8.2 Refrigeration Settings - Bristol Compressors

Provides pressure settings for water-cooled and air-cooled refrigeration systems.

8.3 Operational Checks

Outlines checks for refrigeration pressure, mix leaks, product temperature, and pump operation.

9 Equipment Operation

9.1 The Refrigeration System

Explains the basic principles of the refrigeration system in the freezer.

9.2 The Electrical Circuit

Explains how the selector switch and spigot switch control electrical operations.

10 Maintenance and Adjustments

10.1 Gear Reducer Lubrication Instructions

Provides instructions for lubricating the gear reducer, including oil type and changing frequency.

10.2 Condenser Cleaning

Details cleaning procedures for air-cooled and water-cooled condensers, and fan motor inspection.

10.3 Pulley Alignment and Belt Tension

Explains how to check and adjust pulley alignment and belt tension.

10.4 Beater Drive Coupling Replacement and End Play Setting

Guides on replacing the beater drive coupling and adjusting end play.

11 Service Troubleshooting Charts

Unit does not operate.

Lists probable causes and remedies for the unit failing to operate.

Leakage of mix or water from drain tube to drip tray.

Identifies causes and solutions for leaks in the drain tray system.

Mix leaking at dispensing head.

Addresses issues related to mix leakage from the dispensing head.

Dispensed product too soft.

Lists causes and remedies for product dispensing too soft.

Product dispenses slowly out of dispensing head.

Lists causes and remedies for slow product dispensing.

Dispensed product too hard.

Lists causes and remedies for product dispensing too hard.

Freezer runs continually and product continues to get colder.

Addresses issues where the freezer runs continuously and product gets too cold.

Poor or slow product recovery.

Lists causes and remedies for poor or slow product recovery.

Beater motor does not operate.

Lists causes and remedies for the beater motor not operating.

Compressor does not operate or operates improperly.

Addresses issues with compressor operation or lack thereof.

Compressor and beater motor do not operate when dispensing.

Lists causes and remedies for compressor/beater motor not operating during dispensing.

Compressor and beater motor operates only when dispensing or turning timer knob.

Addresses compressor/beater motor operation tied to dispensing or timer.

Capacitor failures. (Single phase only)

Lists causes and remedies for capacitor failures in single-phase units.

Discharge pressure too low.

Addresses causes and remedies for low discharge pressure.

Compressor starts, but remains in start windings (single phase only)

Diagnoses issues with single-phase compressors starting but not running.

Compressor does not start – hums intermittently (cycling on overload).

Addresses intermittent compressor start issues or overload cycling.

Unit operates long or continuously.

Lists causes and remedies for the unit running continuously.

Discharge pressure too high.

Addresses causes and remedies for excessively high discharge pressure.

Noisy compressor

Lists causes and remedies for a noisy compressor.

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