AFFINIS GROUP SanisServ 500 Series User manual

Operation Manual
500 Series
Soft Serve Twist Dispensers
SaniServ®
An AFFINIS GROUP Company
“Reliability from the team that Serves the Best”
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Distributor Name: _______________________________________________________
Address: ______________________________________________________________
Phone: _______________________________________________________________
Date of Installation: _____________________________________________________
Model Number: ________________________________________________________
Serial Number: _________________________________________________________
Installer/Service Technician: _____________________________________________
SERVICE: Always contact your SaniServ dealer or
distributor for service questions or service agency
referral. If your SaniServ dealer or distributor cannot
satisfy your service requirements, he is authorized to
contact the factory for resolution.
PARTS: Always order parts from your SaniServ dealer
or distributor. When ordering replacement parts, specify
the part numbers, give the description of the part, the
model number and the serial number of the machine.
WARRANTY: Remove the Check Test Start (CTS) form
and fill it out in its entirety. Return the original (white)
copy to SaniServ. The Dealer/Distributor retains the
second (yellow) copy and the Owner/Operator retains the
third (pink) copy.
The Manufacturer's Limited Warranty is printed on the
reverse side of the Owner/Operator copy.
TO VALIDATE THE WARRANTY, THE CTS FORM
MUST BE COMPLETED AND RETURNED TO THE
FACTORY WITHIN 30 DAYS OF INSTALLATION.
Note: The Check Test Start function must be performed
by a qualified technician.
WARRANTY INFORMATION
I
IMPORTANT
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Introduction........................................................................................................................................................................1
Installation..........................................................................................................................................................................1
Installer’s Preoperational Check........................................................................................................................................2
Disassembly and Cleaning................................................................................................................................................3
Assembly and Lubrication .................................................................................................................................................7
Sanitizing & Operation.....................................................................................................................................................10
Consistency Adjustment..................................................................................................................................................12
Routine Maintenance.......................................................................................................................................................13
Helpful Hints ....................................................................................................................................................................14
Troubleshooting...............................................................................................................................................................15
Service Record................................................................................................................................................................16
Fig. 1 Leg Installation...................................................................................................................................................1
Fig. 2 Control Switch....................................................................................................................................................2
Fig. 5 Carburetor Tube ................................................................................................................................................3
Fig. 6 Dispensing Product............................................................................................................................................3
Fig. 7 Front Plate Assembly.........................................................................................................................................4
Fig. 8 Front Plate Gasket Removal..............................................................................................................................4
Fig. 9 Spigot Plunger O-ring Removal..........................................................................................................................4
Fig. 10 Dasher Assemblies ............................................................................................................................................5
Fig. 11 Carburetor Tube ................................................................................................................................................5
Fig. 12 Mix Pan Reservoir Agitator.................................................................................................................................6
Fig. 13 Drip Tray Assembly............................................................................................................................................6
Fig. 14 Front Plate Assembly.........................................................................................................................................6
Fig. 15 Stator Rod and Dasher Lubrication....................................................................................................................7
Fig. 16 Stator Rod and Dasher Assemblies...................................................................................................................7
Fig. 17 Scraper Blade Assembly....................................................................................................................................8
Fig. 18 Dasher (Front View)...........................................................................................................................................8
Fig. 19 Spigot Plunger Lubrication.................................................................................................................................8
Fig. 20 Front Plate Assembly.........................................................................................................................................8
Fig. 21 Front Plate Gasket Installation...........................................................................................................................9
Fig. 22 Front Plate Assembly.........................................................................................................................................9
Fig. 23 Carburetor Tube ................................................................................................................................................9
Fig. 24 Mix Pan Components.........................................................................................................................................9
Fig. 25 Mix Pan Reservoir Mixout Probe.....................................................................................................................10
Fig. 26 Control Switch..................................................................................................................................................10
Fig. 27 Dispensing Product..........................................................................................................................................10
Fig. 29 Control Switch..................................................................................................................................................11
Fig. 30 Electronic Consistency Control Board..............................................................................................................12
Fig. 31 Spring Adjustment Mechanism.........................................................................................................................13
Fig. 32 Water-Cooled Condenser Flow Control Valve .................................................................................................14
Illustrations
Table of Contents
II
TABLE OF CONTENTS
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Introduction
ALWAYS CHECK ELECTRICAL SPECIFlCATIONS
ON THE DATA PLATE OF THE MACHINE. THE DATA
PLATE SPECIFICATIONS WILL ALWAYS
SUPERSEDE THE INFORMATION IN THIS MANUAL.
4. Electrical and refrigeration specifications are
located on the data plate on the rear panel of the
individual machines. Consult local authorities for
information regarding plumbing and electrical codes in
your area. Model 522 has two power hook-ups, 30
amps for single phase or 20 amps for three phase per
side. When operating only the right side on 522 models,
power must be applied to the left side for the cooling
fans to operate. Remove the left and right side panels
for power hook-up.
Note: All SaniServ machines should have their own
dedicated circuits to prevent low voltage conditions
caused by other operating equipment.
5. The water line connections on water-cooled
machines are located on the back side of the machine.
The IN/OUT lines are clearly marked and equipped
with 3/4” garden hose fittings.
Note: These water lines are installed on water-cooled
machines only.
FAILURE TO PROVIDE FOR PROPER EARTH
GROUND ACCORDING TO LOCAL ELECTRICAL
CODES COULD RESULT IN SERIOUS
ELECTRICAL SHOCK OR DEATH.
DO NOT USE EXTENSION CORDS
DO NOT TURN MACHINE ON
INTRODUCTION & INSTALLATION
This manual provides a general system description of the SaniServ Soft Serve Twist Dispensers. It has been prepared to
assist in the training of personnel on the proper installation, operation, and maintenance of the machines.
Please read and fully understand the instructions in this manual before attempting to install, operate, or perform routine
maintenance on the machines.
The following sections of the manual must be performed in sequence:
1. Installation 4. Assembly & Lubrication
2. Installer's Preoperational Check 5. Sanitizing & Operation
3. Disassembly & Cleaning 6. Consistency Adjustment
PAGE 1
IMPORTANT
WARNING
Installation
ALWAYS USE A SUFFICIENT NUMBER OF PEOPLE
OR MECHANICAL LIFTING EQUIPMENT TO
PROTECT ALL PERSONNEL FROM PERSONAL
INJURY DURING THE REMAINING STEPS.
1. Raise the machine to install the four legs packed in
the mix pan or the four casters packed in a box on the
skid or on the front mounted drip tray. Be certain all
four are tight! Thread lock is suggested.
2. Carefully lower the machine to the floor and place it
where it will be installed.
3. Level the unit by turning the bottom part of each leg
clockwise or counterclockwise (Fig. 2). The machine
MUST be level to operate properly.
THESE UNITS MUST NOT BE OPERATED WITHOUT
LEGS INSTALLED OTHERWISE BOTTOM AIRFLOW
TO THE CONDENSER WILL BE RESTRICTED.
A MINIMUM 6” (152 MM) CLEARANCE MUST BE
MAINTAINED AT THE REAR AND SIDES OF THE
MACHINE FOR ADEQUATE VENTILATION.
Fig. 1
Minimum
Clearance
4”(102 mm) for
WARNING
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Installer’s Preoperational Check
THE FOLLOWING ITEMS MUST BE PERFORMED BEFORE ATTEMPTING TO OPERATE THE EQUIPMENT.
INSTALLER’S PREOPERATIONAL CHECK PAGE 2
Fig. 2
Control Switch
1. Make certain that proper electrical connections have
been made. Plug power cord into power outlet.
2. Set each control switch (Fig. 2) to the “CLEANOUT”
position momentarily to verify the direction of rotation of
the dasher. It should rotate counter-clockwise.
3. Set each control switch to the “OFF” position.
In the event the dasher turns clockwise, STOP and
do not proceed any further. On three-phase units,
reverse the polarity.
WARNING
UNDER NO CIRCUMSTANCES SHOULD THE UNIT
BE OPERATED IN THE “AUTO” POSITION FOR MORE
THAN THREE MINUTES WITH EMPTY FREEZING
CYLINDERS . DOING SO WILL RESULT IN DAMAGE
TO THE MACHINE.
CAUTION
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Disassembly and Cleaning Procedure
1. Fill the machine with cold water and set the control
switches to the “CLEANOUT” position. DO NOT use
hot water which could damage the machine. Let the
machine agitate briefly and drain the water by pulling
downward on the spigot handle. Repeat the above
procedure as necessary to make certain all product is
removed from the machine. After the machine is
empty, set each control switch to the “OFF” position.
2. Prepare a suitable detergent and water solution at a
temperature of 125°F. to 130°F. DO NOT use an
abrasive detergent on any part of the dispenser.
DO NOT USE HOT WATER.
DOING SO MAY DAMAGE THE MACHINE.
3. Fill each mix pan with the cleaning solution. Make
certain that the machine is “OFF”. Clean the mix pans
thoroughly with a brush as the solution drains into the
freezing cylinders. Clean the mix inlet tubes and the
carburetor tube holes with the brush provided.
Emptying Machine
Prior to the disassembly and cleaning of parts, the
machine must be emptied of product. Use the following
procedures (Steps 1 through 3). If this is first time
operation, disregard these steps.
DO NOT INSERT ANY OBJECTS OR TOOLS INTO
THE MIX INLET HOLE, CARBURETOR TUBE HOLE,
OR FRONT PLATE DISPENSING HOLE WHILE THE
MACHINE IS RUNNING. DAMAGE TO THE MACHINE
OR PERSONAL INJURY MAY RESULT.
1. Remove the carburetor tubes (Fig. 5) from the mix inlet
holes and lay in the bottom of the mix pans.
2. Set each control switch (Fig. 2) to the “CLEANOUT”
position and dispense all product from the freezing cylinder
by pulling downward on the spigot handle (Fig. 6) to empty
the machine.
3. Set each control switch to the “OFF” (center) position.
Close the spigot handles before proceeding to cleaning.
CONSULT YOUR LOCAL HEALTH AGENCY FOR LOCAL CLEANING AND SANITIZING REQUIREMENTS.
This unit does not come pre-sanitized from the factory. Before serving product, the dispenser must be disassembled,
cleaned, lubricated, and sanitized. Please be aware that these instructions are general guidelines. Cleaning and sanitizing
procedures must conform to local Health Authority requirements.
DISASSEMBLY & CLEANING
PAGE 3
Fig. 6
Dispensing Product
CAUTION
CAUTION
Disassembly and Cleaning
Fig. 5
Carburetor Tube
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IMPORTANT
4. Set each control switch (Fig. 2) to the “CLEANOUT”
position and agitate for approximately 1 - 2 minutes and
then drain the water by opening the spigots (Fig. 6). After
the unit is empty, set the control switches to the “OFF”
position.
5. Remove the front plate by turning the four black plastic
knobs in a counterclockwise direction (Fig. 7).
6. Disassemble the front plate in the following manner:
a. Remove the pivot rod and spigot handles.
b. Push the spigot plungers out of the top of the front
plate assembly.
c. Remove both front plate gaskets by placing your
thumb and forefinger as shown in Fig. 8 and squeeze
until a loop is formed. Then roll each gasket out of its
groove.
d. Remove the o-rings from the spigot plungers by
grasping the part with one hand and with a dry
cloth in the other hand, squeeze each o-ring upward.
When a loop is formed, grasp the o-ring with the
other hand and roll it out of its groove and off of the
part (Fig. 9).
DO NOT USE ANY TOOLS OR SHARP OBJECTS TO
REMOVE ANY O-RINGS FROM THIS MACHINE.
SHARP OBJECTS WILL DAMAGE THE O-RINGS.
DISASSEMBLY & CLEANING
Fig. 8
Front Plate Gasket Removal
Fig. 9
Spigot Plunger O-ring Removal
PAGE 4
Fig. 7
Front Plate Assembly
Pivot Rod
Spigot Handles
Spigot Plungers
Spigot Plunger O-rings
Front Plate Gaskets
Knobs
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7. Remove the dasher assemblies (Fig. 10) being
careful not to damage the scraper blades.
a. For 501 and 527 models only: Remove the blades
and blade holders from the dasher assemblies -
Fig 10a - by rotating the blades downward, then
by pulling the short pins out of the rear supports.
Slide the scraper blades off of the scraper blade
holders.
b. For 522 models only: Remove the blades and blade
holders from the dasher assemblies -
Fig 10b - by rotating the front blades downward,
then by pulling the short pins out of the center
supports. To remove the rear blades, rotate the
blades downward, then pull the short pins out of
the rear supports. Slide the scraper blades off of
the scraper blade holders.
BLADES MUST BE REMOVED FOR CLEANING.
c. Remove and take apart the two piece rear seal
assemblies shown below.
d. Remove the stator rods from the dashers.
8. Remove the carburetor tubes (Fig. 11) from the mix
pans. Disassemble and clean in the following manner:
a. Remove the o-rings from the bottom of the insert
tube in the same manner as the spigot plunger
o-ring removal (Fig. 9).
b. Clean the inside of both tubes with the brush
provided.
DISASSEMBLY & CLEANING
Fig. 11
Carburetor Tube
PAGE 5
Fig. 10(a)
501 & 527 Dasher Assembly
Fig. 10(b)
522 Dasher Assembly
Scraper Blade
Long
Pin
Rear Seal
Short Pin
Rear Bearing
Flow
Plate
Stator Rod Auger
Short Pin
Rear Seal
Rear Bearing
AugerCenter SupportFlow Plate
Stator Rod
Scraper
Blade
Long
Pin
IMPORTANT
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11. Use the small diameter brush to clean all holes and
ports in the parts. DO NOT use an abrasive detergent.
12. After thoroughly washing the parts in the detergent
solution, rinse them in the rinse water. Place the parts in
the sanitizing solution for at least five (5) minutes or
whatever resident (contact) time is required by your local
Health Authority, and then air dry to prepare for
assembly and lubrication. DO NOT wipe dry.
13. The remainder of the machine including the mix
pans and freezing cylinders must be cleaned in place
using a mild detergent solution. Clean the exterior with a
damp cloth. DO NOT use an abrasive cleaner on
exterior panels.
WHEN CLEANING THE MACHINE, DO NOT ALLOW
EXCESSIVE AMOUNTS OF WATER AROUND ANY
ELECTRICALLY OPERATED COMPONENTS OF THE
MACHINE. ELECTRICAL SHOCK OR DAMAGE TO
THE MACHINE MAY RESULT.
9. Remove the mix pan lids, mix pan agitators (Fig. 12),
drip tray and drip tray insert (Fig. 13).
10. Place all loose parts including the front plate, all front
plate components (Fig. 14) and all dasher components in
a three partition sink filled with the following solutions:
a. In one partition, mild detergent solution.
b. In a second partition, clear rinse.
c. In a third partition, sanitizing rinse consisting of 200
parts per million (PPM) chlorine residual or what is
required by your local Health Authority.
DISASSEMBLY & CLEANING PAGE 6
Fig. 13
Drip Tray Assembly
Fig. 12
Mix Pan Agitator
Fig. 14
Front Plate Assembly
Pivot Rod
Spigot Handles
Spigot Plungers
Spigot Plunger O-rings
Front Plate Gaskets
Knobs
Drip Tray
Insert
Drip Tray
Drip Tray
Support
CAUTION
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c. Assemble and install the irreversible rear seals with
the rubber portions toward the rear of the freezing
cylinders as indicated in Fig. 16.
Note: The front plates cannot be installed if the rear
seal assemblies have been improperly put together
or slipped upon the shafts backwards.
DO NOT LUBRICATE THE REAR (RUBBER)
PORTION OF THE REAR SEAL ASSEMBLY
1. Lubricate and assemble the dasher assemblies in the
following manner:
a. Apply a generous amount of lubricant to the
shoulders of the dashers and the area of the shafts
where the white plastic portion of the assembled
rear seal contacts the shafts (Fig. 15). This is easily
performed by running a l/4” bead of lubricant around
the shoulder of each dasher.
b. Lubricate the two shaded areas of the stator rods
and slide the stator rods into the dashers. Make
certain that the ends of the stator rods are inserted
into the holes at the rear of the dashers.
Use only food approved lubricants. Haynes Lubri-Film (SaniServ part no. 1150) is recommended and is available from your
local authorized SaniServ dealer or distributor. Lubrication must be performed daily.
ASSEMBLY & LUBRICATION
PAGE 7
Fig. 15a
501 & 527 Stator Rod and Dasher Lubrication
Fig. 15b
522 Stator Rod and Dasher Lubrication
Fig. 16b
522 Stator Rod and Dasher Assembly
Fig. 16a
501 & 527 Stator Rod and Dasher Assembly
Lubricate
Shaded Areas
Lubricate
Shaded Areas
CAUTION
Assembly and Lubrication
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2. Lubricate and assemble the front plate assembly in
the following manner:
a. Install the two o-rings on each spigot plunger
(double o-ring on the plunger with vertical grooves)
by rolling them onto the plunger. Seat the o-rings in
the grooves making certain that they are not twisted.
Smooth the lubricant into the grooves and over the
sides of the plunger assemblies (Fig. 19).
b. Slide the lubricated spigot plungers into the front
plate (Fig. 20) making certain that the spigot handle
slots are aligned to the front of the front plate. The
spigot plunger with the double o-ring must be
installed in the center cylinder of the front plate.
C. Insert the spigot handles and secure them with the
pivot rod.
d. Place the scraper blades over the scraper blade
holders so the holder pins fit into the blade notches
as shown in Fig. 17.
e. With the front of
each dasher facing the installer, slide the scraper
blade holder (Long pin to front) forward into the
front of the dasher. Push the short pin back into the
mating hole in the rear of the dasher assembly. This
procedure must be performed with the blade in the
correct position - Fig. 18 Position A. Then rotate the
blade and lock it into place (Fig. 18 Position B).
On model 522 repeat this procedure to mount the
rear blades between the center and the rear of the
dasher assemblies.
f. Insert the dasher assemblies into the freezing
cylinders as far as possible being careful not to
damage the scraper blades.
g. While maintaining force against each dasher, rotate
it slowly until the tongue of the dasher engages the
groove in the drive system at the rear of each
freezing cylinder. The outermost portion of each
dasher should be recessed approximately 1/4” to
1/8” inside each freezing cylinder. No part of the
dashers should extend out side of the cylinders.
ASSEMBLY & LUBRICATION PAGE 8
Fig. 18
Dasher (Front View)
Fig. 17
Scraper Blade Assembly
Fig. 19
Spigot Plunger Lubrication
Pivot Rod
Spigot Handles
Spigot Plungers
Spigot Plunger O-rings
Front Plate Gaskets
Knobs
Position A Position B
Holder Pin
Notch
Blade Assembly
Scraper Blade
Holder
Scraper Blade
Lubricate
Shaded Area
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3. Install the o-ring on each carburetor tube (Fig. 23).
Apply a lubricant (SaniGel p/n 1150 recommended)
sparingly over the o-rings. Place the carburetor tubes in
the bottom of the mix pans for sanitizing. Be certain that
lubricant does not block the mix inlet hole on the
carburetor tube.
4. Apply a small amount of lubricant to the bottom of the
mix pan agitator. Place the lubricated mix pan agitator
into the right front corner of the mix pan. Position the mix
pan agitator until you feel the magnets of the agitator
engage the magnets of the drive system beneath the mix
pan. DO NOT apply lubrication to the Mixout probe
located in the mix pan.
d. Install the blue gaskets by slipping them into the
grooves in the front plate as shown in Fig. 21. Install
so that the thicker edge of the gasket is next to the
rear of the front plate. Then lubricate the outside
tapered edge of the gaskets.
e. Apply lubricant to the bottom of each mix pan
agitator and place the agitators in the mix pan
corners making certain the magnets engage the field
of the magnetic drive beneath each mix pan.
f. Install the front plate assembly with the four plastic
knobs. Turn the knobs in a clockwise direction and
be certain to tighten them evenly. DO NOT tighten
one knob all the way down and then another. Doing
so may result in front plate breakage. Only
moderate force is required. DO NOT overtighten.
Set all spigot plungers to the closed position as
shown in Fig. 22.
ASSEMBLY & LUBRICATION
Fig. 21
Front Plate Gasket Installation
Drip Tray Assembly
PAGE 9
Fig. 22
Front Plate Assembly
Drip Tray Insert
Drip Tray
Drip Tray Support
Fig. 23
Carburetor
Tube
Lubricate O-Ring
Mix Pan
Agitator
Carburetor
Tube
Carburetor
Tube O-ring
Fig. 24
Mix Pan Components
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1. First, wash hands with a suitable antibacterial soap.
2. Prepare approximately 2 - 3 gallons of sanitizing
solution equivalent to 200 ppm chlorine residual or what
is required by your local Health Authority.
3. Pour the solution into the mix pans.
4. Using a sanitary brush, wipe the solution onto the
undersides of the mix pan lids, the sides of the mix pans,
and over the mixout probes (Fig. 25).
5. Set each control switch (Fig. 26) to the bottom
“CLEANOUT” position and let the unit agitate for
approximately three to five minutes.
NOTE: DO NOT set the control switches to the top
“AUTO” position. Doing so would freeze the sanitizing
solution and may result in damage to the machine.
DO NOT INSERT ANY TOOLS OR OBJECTS INTO
THE MIX INLET HOLES, CARBURETOR TUBE
HOLES, OR THE DISPENSING HOLES IN THE
FRONT PLATE. DAMAGE TO THE MACHINE OR
PERSONAL INJURY MAY RESULT.
6. Set each control switch (Fig. 26) to the center “OFF”
position and drain the solution from the machine.
Proceed directly to the “Operation” section of this
manual.
DO NOT RINSE OUT THE MACHINE
Prior to operation, the machine must be sanitized. The unit must have already been cleaned and lubricated.
Note: Sanitize immediately before use, not several hours before or the previous evening.
Always start with a cleaned and sanitized dispenser as per previous instructions. Use only fresh mix when charging the
units. Following these instructions is critical to the maximum operating efficiency of the machine.
1. Remove the carburetor tubes from the bottom of the
mix pans and set aside in a sanitary location.
2. Place a 16 oz. Cup under the spigot and open the
spigot handle. Pour approximately one quart of fresh
product mix into the mix pan. (This will chase the
sanitizing solution from the mix pan and freezing
cylinder.) Close the spigot handle when the sanitizer is
purged from the system.
3. Close all spigot plungers and add mix until the
freezing cylinders stop bubbling.
SANITIZING & OPERATION PAGE 10
Mixout Probe
Fig. 26
Control Switch
Fig. 25
Mix Pan Reservoir Mixout Probe
CAUTION
Sanitizing
Operation
Fig. 27
Dispensing Product
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DO NOT INSTALL THE CARBURETOR TUBES UNTIL
THE MIXPAN IS FILLED WITH PRODUCT AND THE
BUBBLING HAS STOPPED.
4. Install the carburetor tubes into the holes in the mix
pans with a gentle twisting motion.
5. Be sure to keep mix in the mix pans at all times to
avoid starving the freezing cylinders. The machine will
not start without mix in the mix pans.
6. Start the machine by setting each control switch
(Fig. 29) to the top “AUTO” position. The dasher motors
and the compressor(s) will be activated.
Note: If a scraping sound is heard when you dispense
heavily from the unit, turn the unit off, remove the
carburetor tubes until the freezing cylinders stop
bubbling, replace the carburetor tubes and restart the
machine.
IF PRODUCT MIX IS RESTRICTED, THE PRODUCT
COULD FREEZE TOO HARD CAUSING DAMAGE TO
THE MACHINE. BE CERTAIN THE HOLE IN THE
CARBURETOR TUBE IS OPEN AT ALL TIMES.
NOTE: LUBRICANT BLOCKING THE CARBURETOR
TUBE HOLE WOULD CAUSE THE SAME RESULT.
7. Allow the compressor(s) to cycle 3-4 times dispensing
a sample of the product after each cycle to check for
consistency. If the machine is not dispensing the
product at the desired consistency after four full cycles,
refer to the Consistency Control Section of this manual.
Pulldown time will vary due to the nature of your product
and ambient conditions.
8. Replace the mix pan lids, and always operate the
machine with the lids on the mix pan reservoirs.
SANITIZING & OPERATION
PAGE 11
Fig. 29
Control Switch
CAUTION
WARNING
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Adjustments to the Electronic
Consistency Control System can be
made by the owner. Should any
problems arise when making
adjustments, SaniServ recommends
that a serviceman trained on SaniServ
equipment be contacted. DO NOT attempt to make
repairs on the machine.
Initial adjustments have been performed at the factory.
However, to satisfy individual preferences the following
adjustments may be required:
USE EXTREME CAUTION. ELECTRICAL SHOCK
HAZARD EXISTS EVEN WHEN THE UNIT IS IN THE
“OFF” POSITION. WHEN THE WIRING BOX COVER
IS REMOVED, DO NOT TOUCH ANYTHING IN THE
WIRING BOX EXCEPT THE POTENTIOMETER.
1. Remove the wiring box cover (Exploded View).
2. Set the control switch to the “AUTO” position.
Note: The unit will not operate if the mix pan is empty.
3. Locate the three LED’s - green, yellow, and red -
Fig. 29. These are used as a reference point to adjust
for proper consistency. Initially, all of the LED’s are off.
This indicates that the mix is too thin. The compressor
will now come on. As the product thickens, the green,
then the yellow, then the red LED illuminate. Two
seconds after the red LED is illuminated, the com-
pressor and dasher will shut off.
4. Using a small slotted and insulated screwdriver, turn
the potentiometer (Fig. 29) clockwise to make the
product harder or counterclockwise to make the
product softer. Note: The potentiometer is very
sensitive. Adjust in small increments
5. Let the compressor and dasher cycle off. Dispense
some product. If too thin, turn the potentiometer
clockwise.
6. If the product is too thick, turn the potentiometer
counterclockwise. Dispense 16 oz. from the barrel.
Let the compressor and dasher cycle off
7. Repeat procedure until proper consistency is
achieved.
Electronic Consistency Control Operation
1. “CLEANOUT” Position: The dasher motor
operates continuously, the compressor will not come
on. The mix out probe activates the mix out light but
will not activate the buzzer.
2. “AUTO” Position: When product is dispensed, the
dasher motor will automatically come on and the
compressor will run as required by the consistency of
the product. The machine will remain running until the
product has reached proper consistency, at which time
the dasher motor and compressor will stop running. If
product has not been dispensed for approximately 10
minutes, the dasher motor will come on and the control
board will sense the product consistency. The
compressor will come on if required to maintain product
consistency. If the product is correct, the dasher motor
will stop.
When product mix is low in the mix pan, the “mix out”
light will flash and the buzzer will beep for three
minutes or until the mix pan is filled. If the pan has not
been filled by the end of the three minute period, the
mix out light will glow continuously, the beeping will
become a continuous tone, and the machine will not
dispense product until mix is added.
NOTE: If product does not freeze to a hard enough
consistency, the problem may not be that of the
machine. To verify, use a standard thermometer to
obtain the temperature of the product.
The problem is not in your machine if the product
temperature is between 17°and 22°F. Check to
see that the product was prepared to the
manufacturer’s recommendations.
Electronic Consistency Control System
WARNING
IMPORTANT
CONSISTENCY ADJUSTMENT
Consistency
Control Board
Consistency LED’s
(Green, Yellow, Red)
Potentiometer
PAGE 13
Fig. 30
Electronic Consistency Control
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Routine Maintenance (Owner-Operator)
DISCONNECT THE MACHINE FROM ITS POWER
SOURCE(S) BEFORE PERFORMING ANY ROUTINE
MAINTENANCE. PERSONAL INJURY OR DAMAGE
TO THE MACHINE COULD RESULT IF THIS
PRACTICE IS NOT OBSERVED.
Daily: Inspect the machine for signs of product leaks
past seals and gaskets. If proper assembly does not
HAZARDOUS MOVING PARTS
2. Remove both side panels first, then remove the rear
panel of the machine.
3. On the side of the spring adjustment mechanism
use a pencil to mark the position of the nut (Fig 31).
Relieve the tension on the yellow spring by turning the
adjustment screw near the label which warns: DO NOT
ADJUST. Disconnect the spring from the belt idler arm
by placing needle nose pliers on one end of the spring
and pulling the end out of the retainer.
4. Remove the nut from the pivot point of the idler arm
assembly.
5. Remove the idler arm and inspect the pivot point
sleeve. These areas should be free of rust, debris, or
dried lubricant. If any of these substances are found,
they must be removed.
6. Clean and polish the sleeve surface with a fine
grade of emery cloth.
7. Reinstall the idler arm.
8. Install the belt making certain that there is no grease
on the belt or pulleys. Step to the side of the unit and
view the belt to determine whether or not it is properly
aligned (straight from top to bottom).
9. Install the yellow spring and turn the adjustment
screw returning the adjustment nut to the pencil mark
you placed on the side of the adjustment mechanism in
step 3 above.
10. Repeat steps 3 - 9 for the other side and then place
the unit back into operation. Check the product for
proper consistency and adjust as required. When the
consistency is right, replace the rear and both side
panels.
CONDENSER FINS ARE VERY SHARP
USE EXTREME CAUTION WHEN CLEANING
Quarterly: Thoroughly clean the condenser fins on all
air-cooled machines. Remove all lint and dust with a
vacuum cleaner or compressed air to clean fins. A dirty
condenser greatly reduces refrigeration capacity and
efficiency. When using compressed air, place a damp
cloth on the opposite side of the condenser to catch the
flying dirt or lint.
Annually: Check the belts for signs of wear or cracking.
Remove panels and clean all parts inside of the machine
including the base, side panels, fan blades, condensers,
etc.
Semiannually: It is advisable to clean and lubricate the
idler arms (Fig. 31) to ensure their smooth operation. Use
the following procedures:
Note: Twist units have two separate idler arm assemblies
(one for each side). For convenience and simplicity,
complete the following maintenance on one side of the
system before proceeding to the other.
1. Make certain that ALL power to the dispenser is off.
ROUTINE MAINTENANCE
stop leaks around gaskets or seals, check for improper
lubrication and worn or damaged parts. Replace parts as
needed.
Periodically: Inspect the scraper blades to see that they
are straight and sharp. If worn, damaged or warped, the
blades will not scrape the cylinder walls correctly and the
freezing capacity will be reduced.
The drip chute assembly which catches seepage from
around the rear seal should be cleaned with warm water
and detergent solution (Fig. 31).
Fig. 31
Spring Adjustment Mechanism
Drip Chute
Mark
Nut Position
With Pencil
Idler Arm Pivot
PAGE 13
WARNING WARNING
WARNING
Routine Maintenance (Trained Service Technician)
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Helpful Hints
Front Plate: This component is the plastic device from
which the product is dispensed. It is designed and
manufactured for strength and durability. However,
through improper use, the front plate can be damaged.
Use the following information for proper care:
a. Do not over tighten the knobs.
b. Always tighten knobs evenly. Do not attempt to
turn one knob all the way down and then one of
the other three knobs. Doing so will bind the front
plate and could result in breakage.
c. Improper installation of the stator rods can cause
breakage. The stator rods must be properly
seated in the dasher before installing the front
plate. If the stator rods are improperly installed,
subsequent tightening of the knobs will break the
front plate.
d. DO NOT attempt to wash the front plate or any
other components in a dishwasher.
Mix Out Light: When the mix out light comes on, the
mix pan is low on mix. The mix pan must be filled with
fresh product mix immediately to prevent air from
entering the freezing cylinder starving the machine and
causing freeze-up and vibration. If this condition occurs,
set the selector switch to the “OFF” position. Remove
the carburetor tube and add mix to the low mix pan until
the freezing cylinder stops bubbling. Replace the
carburetor tube with a gentle twist, then return the control
switch to the “AUTO” position.
Filling: Always fill the machine with fresh product at the
start of each day.
Drip Tray: This should be removed daily and cleaned to
remove residue.
Mix Pan Lid: Be certain to leave the lid in place on top
of the machine to prevent any foreign materials from
contaminating the mix.
Mixing: Make certain that the product mix is prepared
according to label instructions.
Sanitizing: Do not soak plastic parts in sanitizer
overnight. Doing so can cause the plastic parts to
become brittle and lead to premature failure.
Mix Pan Agitator: If the mix pan agitator stops turning
during operation of the machine, turn off the machine,
reposition the agitator with a sanitized utensil, and follow
the instructions for starting the machine.
DO NOT POUR SOFT SERVE MIX DIRECTLY ONTO
THE AGITATOR WHEN YOU FILL THE MACHINE.
Treat the mix pan agitators as any other small parts such
as the scraper blades. Follow the same cleaning and
sanitizing instructions.
Winter Storage: To protect the unit during seasonal
shut-down, it is important that the dispenser be stored in
the proper manner. Use the following procedures:
1. Turn off ALL power to the machine.
2. Wash all parts that come in contact with the mix with
a warm mild detergent solution. Rinse in clear water
and dry parts thoroughly.
3. Store the loose parts such as the mix pan
components, front plate parts, and the dasher
assembly parts outside of the machine.
4. Do not lay heavy objects on the plastic or rubber
parts.
5. Cover the machine and all loose parts to protect
them from dust or other contaminants while in
storage. Place the machine in a dry location.
6. On water-cooled units, disconnect the water lines.
Use compressed air to blow out all remaining water
in the condenser. Insert a screwdriver (Fig. 32) to
open the water valve. Note: Failure to purge the
machine of water can result in severe damage to the
cooling system.
HELPFUL HINTS PAGE 14
Fig. 32
Water-Cooled
Condenser Valve
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PAGE 15 TROUBLESHOOTING GUIDE
Please make these simple checks prior to contacting you service provider. Because adjustments to the machine are not covered
under the terms of warranty, these tips can save you time and money. If you feel you are not comfortable performing trouble-shooting
su
gg
estions
,
p
lease contact
y
our local certified service
p
rovider.
Machine will
not start  Make sure electrical cord is correctly seated in the electrical receptacle.
 Check circuit breaker in electrical panel.
Product is
Soft
 Do not make a consistency adjustment at this point. Always check product temperature first. Should be
between 18-21 degrees soft serve, 17-20 degree’s yogurt, 25-28 degrees shake. If using a soft serve
product and temperature is lower than listed, product is broken down. See Product Breakdown in
glossary section. Replace with fresh product.
 Check for properly mixed product. Replace as necessary
 If using Re-run product, remove product and add fresh mix.
 Confirm that the carbtube has been installed. Product will not thicken without carbtube.
 Check for dull scraper blades. Blades should be sharp. Replace every 6 months.
 Check Condenser for dirt or obstructions. See Quarterly Maintenance
 Confirm that the condenser fan is running.
 Confirm 6” of airflow on all both sides and back of machine.
 High ambient temperature. Recommended machine ambient temperature not to exceed 82 degrees.
Product is too
Thick
 Check for properly mixed product.
 Confirm freezing cylinder is not starved of product. See glossary (Starved Cylinder)
 Check product temperature. Should be between 18-21 degrees soft serve, 17-20 degree’s yogurt, 25-28
degrees shake.
 Check for missing scraper blade or stator rod. Check dasher assemblies.
 Check for sticking spigot lever and or switch. If stuck in the up position, will cause unit to run continually.
Front Plate
Leaking
 Confirm front plate o-ring is not ripped or torn. Replace if necessary. Replace seals and o-rings every six
months.
 Do not lubricate front plate o-ring.
 Confirm spigot plunger o-rings are not ripped or torn. Replace if necessary. Replace every six months.
 Confirm spigot plunger o-rings are lubricated daily.
 Tighten front plate knobs evenly.
 Confirm stator rod is not worn or grooved.
Product
leaking from
the drip chute
and or drip
tube.
 Rear Seal is worn. Replace. Note: Replace seals, o-rings and gaskets every six months.
 Do Not Lubricate the rubber portion of the rear seal
 The shaft of the dasher where the rear seal is installed must be lubricated daily.
 Confirm stator rod is not worn or grooved.
 Front plate knobs loose.
Squeaking ,
chirping
noises and or
vibration
heard.
 Use properly mixed product. Replace as necessary.
 Confirm freezing cylinder is not starved of product. See glossary (Starved Cylinder)
 Check lubrication
 Confirm all panel screws are installed and tightened
 Adjust width of drip tray bracket.
 Check for dull scraper blades. Blades should be sharp. Replace every 6 months.
Product in
mix-pan too
warm. (soft
serve /shake
machines)
 Refrigerate product prior to use.
 Confirm storage source of product at 40 degrees or below.
 Maintain product level of ½ to ¾ full in mix-pan reservoir.
 Confirm magnetic agitator is installed and turning.
 Mix-pan lid must be installed at all times to prevent foreign materials contaminating product and to insulate
product in the mix-pan .
Who to
contact for
service and
parts
 If you do not have a local service and parts provider, contact your SaniServ Dealer/Distributor. Visit
www.saniserv.com to locate a Distributor (Sales Section) or a Service Agent (Technical Support Section).
Note: Refer to
g
lossar
y
for those items selected in bold.
Standard Units
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PAGE 16
TROUBLESHOOTING GLOSSARY
Trouble Shooting Glossary
Ambient Temperature. The temperature of the air in the immediate vicinity of the operating machine. High ambi-
ent temperature can reduce the capacity with an air-cooled condenser.
Capacity. The total capacity of frozen product that a freezer can produce in a given period usually stated in gal-
lons per hour (G.P.H.).
Carbtube. Flow control device that allows product and air to be blended together. The air added to the product is
labeled as over-run. The over-run helps provide a thick and rich product. If the carbtube is not used the product
will be heavy, wet, grainy, will not thicken and product temperatures will be lower than the specified 18-21 degrees
soft serve and 25-28 degrees shake.
Condenser. The part of the refrigeration mechanism that receives hot, high-pressure refrigeration gas from the
compressor and cools gaseous refrigerant until it returns to a liquid state.
Consistency. The viscosity or thickness of the product in the freezing cylinder.
Consistency Control. A control that senses the thickness or viscosity of the product in the freezing cylinder.
Dasher. The part of the freezer that scrapes frozen product off the inside of the freezing cylinder and blends the
product. In a gravity freezer, this assembly also moves the product forward to be dispensed.
Front Plate. Seals the front of the freezing cylinder and provides a means for dispensing the product. On gravity
fed freezers, the front plate indirectly holds the dasher in place via the stator rod. It also provides compression for
the rear seal.
Freezing Cylinder. The part of the refrigeration mechanism in which the refrigerant vaporizes and absorbs heat.
This is the part of the freezer where the liquid product is frozen.
Magnetic Agitator. Installed in the mix-pan reservoir and used to maintain product temperatures and prevent
product separation. The bottom of the agitator must be lubricated.
Mix-pan. Is the top container that product is poured into. It is used as storage until product is needed for the
freezing cylinder. Soft Serve and Shake machines have refrigerated mix-pans to prevent bacteria from forming.
Mixing Product / Product Temperatures. If your using a product that has to be mixed with water or other ingredi-
ents, it is imperative the product is mixed consistently everyday. If not, the machine will not run consistent and
could possibly damage components. This is very important with frozen (slush) beverages. Always mix to the
product manufactures recommendations. The machine is designed to operate with a frozen product that falls
within these temperatures (soft serve 18-21 degrees, yogurt 17-20 degrees, shake 25-28 degrees).
Overrun. The volumetric increase of product from the liquid to the solid state due to the incorporation of air into
the frozen product. Overrun is states as a percentage.
Product Breakdown. The decline in frozen product quality resulting from excess agitation or temperature varia-
tions of product that has been in the freezing cylinder too long. Product, which has broken down, may be grainy, wet and or
heavy. Product breakdown is easily detected by taking the temperature of the dispensed product. Temperatures will always
be lower than recommended product temperatures.
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PAGE 17 TROUBLESHOOTING GLOSSARY
Trouble Shooting Glossary
Rear Seal. This part is stationary during operation and must not move. When installed and lubed properly, seals
mix in cylinder. When installed and lubed improperly, it causes main shafted bearing failure.
Regulator. Used to control the rate of water or CO2 P.S.I..
Rerun. The reuse of previously frozen product after it has melted to a liquid. Rerun is obtained when emptying a
freezer for periodic cleaning. Use caution when using rerun as it may contain high bacteria or Coli count, which
could contaminate the fresh mix with which it is combined. Freezers should never be started with rerun. If used at
all, it should be blended with fresh mix at a ratio of seven parts new mix with three parts old mix, after initial
freeze-down with fresh mix.
Scraper Blades. The component that scrapes the frozen product from the freezing cylinder surface. Blades must
be sharp, as dull blades will leave product on the freezing cylinder, insulating the mix from the refrigerant.
Spinner Assembly. An externally installed or internally installed component used to blend a base product with
flavoring or other particulate.
Spigot Plunger. The mechanism on the front plate through which the product is dispensed.
Starved Cylinder. A starved cylinder is often mistaken for a freeze up or product too thick. A starved cylinder
(starving) is created when a larger percentage of frozen product is dispensed from the freezing cylinder than the
percentage of liquid product entering the freezing cylinder from the mix-pan. There are several causes of starving.
1. Overdrawing: Dispensing more product from the machine than it’s designed to do. This would occur if a ma-
chine were undersized for its application.
2. Inserting the carbtube prior to pouring the initial product into the mix-pan at the start of each day. This forms a
vacuum and traps a large percentage of air in the cylinder; therefore the cylinder will not fill with product.
3. When carbtube hole setting is not set on the correct hole size for the amount of product being drawn. Exam-
ple, if several customer dispense product from the machine with the carbtube set on the small hole, it will not
allow the freezing cylinder to be replenished with product in a timely manner. Change carbtube setting to a
larger hole.
4. Carbtube not being cleaned, thus allowing product build-up in the carbtube holes. This restricts product from
entering the freezing cylinder.
5. Mix out light not working therefore not alerting operator the need to add product.
6. Pouring frozen or semi frozen product into the mix-pan reservoir. This will form a blockage in the carbtube
hole and not allow liquid product to flow into the cylinder.
7. Mix-pan too cold, allowing product to freeze in mix-pan and restricting product flow.
Stator Rod. Acts as a bearing surface. Helps enfold air for overrun. Transmits compression to the rear seal.
Helps mechanical torque system sense torque. Be sure to lubricate.
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