Duke DQ GES-103 Setup guide

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

Operator’s Manual
for the
Soft Serve Twist Freezer
Model GES-103
All contents © Copyright 2018 H.C. Duke & Son, LCC, 2116 Eighth Avenue, East Moline, Illinois 61244

Twin Twist Soft Serve Freezer Model GES-103
ii 184560
Follow these four steps to safety ....
WARNING
SAFETY FIRST!
The signal words — DANGER, WARNING and
CAUTION — are used with the safety alert symbol
(DANGER decals on the freezer may or may not
have the safety alert symbol, but the message is the
same). Decals with the words DANGER, WARNING,
or CAUTION appear on the freezer. DANGER
identies the most serious hazard. Decals with the
words DANGER or WARNING are typically near
specic hazards on the freezer. General precautions
are listed on CAUTION safety decals.
In this manual, CAUTION messages with the safety
alert symbol call attention to safety messages.
DANGER
CAUTION
1. Recognize Safety Information ....Look for this
safety alert symbol throughout this manual.
When you see this symbol on your freezer or in this
manual, be alert to the potential for personal injury. Follow
recommended precautions and safe operating practices.
2. Understand Signal Words ....
Read and understand all safety messages in this
manual and on your freezer. Take notice of the location
of all decals on the freezer and keep the safety decals
in good condition. Check them periodically and replace
missing, damaged, or illegible safety decals. The
safety decals must remain in place and be legible for
the life of the freezer. If you need new decals, use the
information and illustrations on pages iv and v of this
manual to identify the decal and call or write to H.C.
Duke & Son, LLC.
DO NOT attempt to operate the GES-103 Twin Twist
Soft Serve Freezer until you read and understand all
safety messages and the operating instructions in this
manual.
Safety
First!
3. Follow Safety Instructions ....

Twin Twist Soft Serve Freezer Model GES-103
184560 iii
SAFETY FIRST!
Trained person (or Operator): A person who has been trained in the basic operation of
the freezer. This person is knowledged in operation of machine startup, stopping, lling,
and basic cleaning, disassembly, washing, and sanitation of the freezer.
Freezer Technician: A person who has been trained by a factory representative, or
an experienced and qualied service person, to perform more complicated operations
such as freezer installation, maintenance repairs, component replacement , is aware of
hazards associated with electricity, moving parts, and takes necessary steps to protect
against injury to themselves and other people.
4. Definitions ....
5. Operate Safely ....
DO NOT allow untrained personnel to maintain or
service this freezer. Failure to follow this instruction
may result in severe personal injury. DO NOT operate
the freezer until all service and access covers are
secured with screws. DO NOT attempt to repair
the freezer until the main power supply has been
disconnected. Some freezers have more than one
disconnect switch. Contact your IDQ authorized
service representative or H.C. Duke & Son, LLC
Service Department for original equipment parts.
6. Caution ....
• This Freezer is to be operated by trained persons. The Dispense
feature, if used by public in self-serve applications, shall be monitored
by trained persons able to assist people with physical, sensory or mental
impaired capabilities.
• Children should not be allowed to play around this equipment.
• Do not store explosive substances such as aerosol cans with a ammable propellant
in freezer.
• This appliance is not designed for outdoor weather conditions and shall not be
exposed to rain.
• Do not wash machine with power sprayer. Do not install machine next to a power
sprayer where splash of freezer can occur.
• Machine is designed for use in areas of normal atmosphere. It is not to be used in
areas subject to explosion-proof standards.
IMPORTANT: Store Managers,owners, and supervisors must be aware of staff
capabilities and that they do not perform freezer operations outside their level of
knowledge or responsibility.

Twin Twist Soft Serve Freezer Model GES-103
iv 184560
Safety Decal Locations
For factory service assistance, contact H.
C. Duke & Son, LLC, Service Department
by phone or FAX:
Phone: [phone]
[phone]
FAX: [phone]
E-mail: [email protected]
(The decals on the next page are
numbered 1, 2, 3, and 4. Those numbers
correspond to the numbers in the table
below. The table provides the part
number, description, and quantity for each
decal.)
Do not attempt to operate the freezer
until all safety precautions and operating
instructions in this manual are read and
understood.
Take notice of all warning, caution,
instruction and information decals (or
labels) on the freezer as shown in the
gure on the next page. The labels have
been put there to help maintain a safe
working environment.
The labels have been designed to
withstand washing and cleaning. All labels
must remain legible for the life of the
freezer. Check labels periodically to be
sure they can be recognized as warning
labels.
If it is necessary to replace any label,
please contact H.C. Duke & Son, LLC
When ready to order you will need to
determine the (1) part number, (2) type of
label, (3) location of label, and (4) quantity
required, and include a return shipping
address.
1 ..................... HC165025 ...................Decal-Beater Warning (1)
2 ..................... HC165246 ..................Decal-Pressurized System (3)
3 ..................... HC165126 ...................Decal-Panel Removal Warning (1)
4 ..................... HC165048 ...................Decal-Warning Rotating Parts (2)
No. Part No. Description


Twin Twist Soft Serve Freezer Model GES-103
184560 v
Safety Decal Locations
Hazardous rotating beater shaft. Do not operate
unit with dispense head removed.
Before removing dispense head:
1. Turn all control switches to "OFF", and
2. Disconnect all power supplies. Unit may
have more than one power supply.
P/N HC165025
1
P/N HC165126
3
P/N HC165246
2
Pressurized system.
Depressurize unit
before dismantling
mix transfer system.
Do not
operate
with cover
removed!
165048
Do not
operate
with cover
removed!
165048
Do not
operate
with cover
removed!
165048
P/N HC165048
4

Twin Twist Soft Serve Freezer Model GES-103
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Table of Contents
Safety Decal Locations .....................................................iv
1 Introduction ............................................................... 1
2 Note to Installer .......................................................... 1
2.1 Uncrating and Inspection ...............................................2
2.2 Installation .....................................................................3
2.3 Electrical Requirements .................................................3
2.4 Electrical Connections ...................................................4
3 Specifications ............................................................ 5
3.1 Particulars .....................................................................5
3.2 Dimensions ....................................................................6
3.3 Data Plate ......................................................................6
3.4 Reference Information ...................................................7
3.5 Installation Date .............................................................7
3.6 WEEE (Waste Electrical and Electronic Equipment) .......7
3.7 Equipment Videos ..........................................................7
4 Virtual Quality Management System ........................... 8
5 Part Names and Functions ........................................ 10
6 Operator Controls .................................................... 16
7 Operator Display Menus ........................................... 18
8 Disassembly and Cleaning ........................................ 22
8.1 Cleaning Accessories ....................................................23
8.2 Disassembly Instructions ...............................................24
8.3 Cleaning Instructions .....................................................26
8.3.1 Cleaning and Lubricating - MTS Assembly ..........29
9 Assembly ................................................................. 30
10 Start-up Instructions ................................................ 34
10.1 Sanitizing .....................................................................34
10.2 Priming ........................................................................35
10.3 Dispensing Product ...................................................... 36
11 Closing Procedures .................................................. 37
11.1 Draining Product ..........................................................37
12 General Information ................................................. 40
12.1 Dairy Queen® Mix .........................................................40
12.2 Checking the Frozen DQ® Product ...............................40
12.3 Product Temperature ...................................................40
12.4 Overrun .......................................................................41
12.5 Overrun Adjustment .....................................................41
12.6 Rerun ...........................................................................42
12.7 Overrun Chart ..............................................................42
13 Routine Maintenance ................................................ 43
14 Troubleshooting ....................................................... 49
14.1 MTS Troubleshooting Tables ........................................54
15 VQM Error Codes ..................................................... 56

Twin Twist Soft Serve Freezer Model GES-103
184560 vii
Part II
Replacement Parts
Figure 1 Head Assembly ............................................1
Figure 2 Beater Shaft Assembly .................................2
Figure 3 Cabinet Parts ...............................................3
Figure 4 MTS—RMT Hose Assembly ...........................4
Figure 5 Mix Drawer ...................................................5
Figure 6 Mix Transfer System — RMT .........................6
Figure 7 Switch Box ...................................................8
Figure 8 Spigot Switch Assemblies ............................10
Figure 9 Capacitor & Relay Box ..................................10
Figure 10 AC Side/Back View .....................................11
Figure 11 WC Side/Back View ....................................12
Figure 12 Panel Breakdown .......................................13
Figure 13 Panel Hardware & Decals ...........................14
Figure 14 Gear Reducer• ...........................................15
Figure 15 Evaporator Mix Tube Assembly ...................16
Figure 16 Air Cooled Remote Condenser ...................17
Accessories ..............................................................18
O-Ring Chart .............................................................19

Twin Twist Soft Serve Freezer Model GES-103
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2 Note to Installer
The GES-103 Freezer is designed to
produce DQ frozen soft serve ice cream
or DQ yogurt, with a product serving
temperature of 18 to 19ºF (-8 to -7ºC).
If such products are prepared from
powdered concentrate, they should
be precooled to 40°F (4°C) prior to
introduction to the freezer. Use of other
products in this machine is considered
misuse (see Warranty.)
This manual has been prepared to assist
in the training of personnel on the proper
operation and general maintenance of
your Duke freezer.
Your freezer will not compensate for or
correct any assembly or priming errors
made during the initial start-up. Therefore
it is extremely important to follow the
assembly and priming procedures
detailed in this manual.
Be sure all personnel responsible for
equipment operation completely read and
understand this manual before operating
the freezer. When properly operated and
maintained, your freezer will produce a
consistent quality product.
If you require technical assistance, please
contact your local authorized H.C. Duke &
Son, LLC service company:
1 Introduction
Name ______________________
Address_____________________
____________________________
Phone_______________________
or H.C. Duke & Son, LLC Service Dept.
for factory service assistance.
Phone: [phone]
[phone]
Fax number: [phone]
E-mail: [email protected]
This freezer must be installed and serviced by a service technician in
accordance with the installation instructions.
After installation the warranty registration card must be completed and
returned to validate warranty.


Twin Twist Soft Serve Freezer Model GES-103
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— continued
Figure 2-1 Machine bolted to Shipping Base
Figure 2-2 Installing Mounting Legs or Casters
CAUTION
Be sure to properly support
the machine when removing
bolts and installing legs or
casters.
When the unit is received and while
the carrier is still present, inspect the
shipping carton for any damage that
may have occurred in transit. If the
SHOCKWATCH® label indicates red and/
or the carton is broken, torn, or punctured
note the damage on the carrier’s freight
bill and notify the carrier’s local agent
immediately. Also note on the freight bill
1. Remove the carton from the pallet,
and move the machine as close as
possible to the permanent location.
2. Remove the shipping bolts on the
bottom of the freezer (gure 2-1) and
install either the legs or casters (gure
2-2).
NOTE: Screw casters or
legs all the way in coupling,
then adjust out to level side
to side with 1/4 inc (6mm)
slope to the front.
2.1 Uncrating and Inspection
REAR
OF UNIT
CASTER
WITHOUT
BRAKE
CASTER
WITH BRAKE

Twin Twist Soft Serve Freezer Model GES-103
184560 3
not subjected to hot exhaust air from
other equipment. Anything blocking
ventilation, (e.g. cone dispenser), will
reduce the efciency of the freezer.
4. Water cooled double models will
require a 1/2” MPT water inlet and
water waste connection. Both water
condensers are tied together so that
one water inlet and one water waste
is all that is required. The connections
are found on the bottom under the
compressor mounting area and are
clearly tagged - “Water Inlet” and
“Water Waste”. A manual shut-off
valve should be installed in the water
inlet line at the time of installation.
The water pressure must be between
35-140 psig (241-965kPa) for proper
operation.
5. Place the freezer in the nal location
and level the machine by adjusting
the legs or casters so that the unit
is level side-to-side, and the front
is approximately ¼” lower than the
rear, to allow proper drainage of the
freezing cylinder.
6. Water Cooled Do not allow freezer to
be in ambient where air temperature
goes below 0°C (32°F),the freezing
temperature of water.
7. Water consumption increases if
temperature of entering water is
above 20°C (65°F)
CAUTION
To prevent accidental
electrical shock, a positive
earth ground is required.
2. Supply voltage must be within + 10%
of voltage indicated on the nameplate.
Also, on three-phase systems,
voltage between phases must be
balanced within 2%. (More than a
6 volt difference between any two
voltage measurements at 208-230
volts indicates a possible imbalance.)
Request your local power company to
correct any voltage problem.
3. An easily accessible main power
disconnect must be provided for all
poles of the wiring to the freezer.
2.3 Electrical Requirements
1. Always verify electrical specications
on the data plate of each individual
freezer. Data plate specications will
always supersede the information in
this manual. (See Figure 3-2)
2.2 Installation
1. This freezer is designed for indoor use
and must be protected from outdoor
weather conditions.
2. Where codes permit, we recommend
that the freezer be installed on casters
and have exible water and electrical
connections for service and cleaning
ability.
IMPORTANT:
Unit requires air ventilation. The
minimum air space at the sides must
be 6 inches (15.2cm) and 1 in.(2.5cm)
in the rear or 6 inches in the rear and
1 inch on the sides. Top must have
29 inches clearance. Failure to follow
minimum air clearances will void
warranty.
3. All models require 6 inches (15.3 cm)
minimum air space at rear, 1in(2.54
cm) on sides or 6 inch (15.3 cm) on
each side and 1inch (2.54cm) at rear.
Space above freezer is to be 29 inch
(79.7 cm) and is to be provided with
an 6 in (15.3 cm) air deector at rear
if boxed on 3 sides. Insure freezer is
CAUTION
All materials and connections
must conform to local
requirements and be in
compliance with the National
Electrical Code (NEC).

Twin Twist Soft Serve Freezer Model GES-103
4 184560
CAUTION
To prevent accidental
electrical shock, a positive
earth ground is required.
2.4 Electrical Connections
Important!
A positive earth ground is required
for electronic VQM system to operate
correctly.
1. Double freezers with two compressors
require one power supply for each
side of the freezer. Each side of the
freezer operates independently.
2. Check the data plate for fuse
size, wire ampacity, and electrical
specications. (See Figure 3-2)
3. Refer to the wiring diagram provided
for proper power connections.
4. Electrical connections are made in
the junction boxes located mid-level
behind the right side panel.
Important
Set switch next to the connection
box “UP” for 220-230v or “DOWN”
for 208-219V. Failure to set switch to
proper voltage will cause damage to
the electrical components and will void
all warranties.
5. Use a exible connection when
permissible.
6. Beater Shaft Rotation Freezers are
designed for clockwise rotation when
viewed from front of freezer. 1ph
machines are prewired for proper
rotation. On 3 phase machines,
phase wires to freezer should be
connected to produce proper beater
rotation. This is to be done by a
freezer technician.
WARNING
Warning: When installing the machine,
insert an all pole disconnect, adequately
sized according to freezer nameplate
marking with electrical contact spacing of
3mm minimum. This should be within sight
of the freezer.

Twin Twist Soft Serve Freezer Model GES-103
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3 Specifications
3.1 Particulars
Always check and verify voltage and amperage on the data plate
located on the back panel of each freezer.
GES-103
Width-in./cm 26.125/66.36
Height-in./cm 69.875/177.48
Depth-in./cm 38.25/97.16
Weight-lbs./kg 850/386
Compressor (2) 2.5 H.P. /19000 BTUH
2.2 kw (Motor)
3.2 kw (Cooling)
Compressor Cabinet (1) 1/6HP/1000BTUH
125w (Motor)
190w (Cooling)
Beater Motor (2) 2 H.P/1.5 kw
Refrigerant 404a
Charge* 3.75 lb/1.7 kg
Mix Capacity 6 - 5gal. Bags
Cylinder (2) 5 Qts./4.7 Liters
ACR
Noise: The Steady acoustic pressure level, for both air cooled
and water cooled freezers, is less than 70dB(A).
Water Cooled units: Water consumption increases if
temperature of entering water is above 20°C (65°F)
*Approximate for each side. See nameplate for actual charge.

Twin Twist Soft Serve Freezer Model GES-103
6 184560
3.3 Data Plate
The data plate provides important
information that the operator should
record and have available for parts
ordering, warranty inquiries, and
service requests.
Figure 3-2 Data Plate
The dimensions of the GES-103 are provided in Figure 3-1, below.
Figure 3-1
3.2 Dimensions
AIR IN
THROUGH BOTTOM OF FREEZER
ELECTRICAL
SERVICE
CONNECTION
ALL CONNECTIONS ARE MADE
AIR OUT
AIR IN
CLEAR TO ALLOW AIR EXHAUST
TOP OF UNIT MUST BE KEPT
AIR IN
26.125"
66.36 cm
1/2 FPT WATER IN/OUT
(WATER COOLED ONLY)
IN OUT
65.5"
166.37 cm
4.3125"
10.95 cm
69.875"
177.48 cm
38.25"
97.16 cm
1 2 3
4
5

Twin Twist Soft Serve Freezer Model GES-103
184560 7

Write in
Reference
Information HERE!
3.4 Reference Information
Fill in the following information below
as soon as you receive the GES-103.
(The item numbers—encircled, below—
correspond with the callout numbers
above.)
IMPORTANT: Complete for reference:
1.) Model Number: ________________
2.) Serial Number: ________________
3.) Electrical Spec: Voltage __________
Phase _______ Hertz ___________
4.) Maximum Fuse Size: ____________
5.) Minimum Circuit Ampacity: ________
Installation Date_______________________
Installed by ___________________________
Address ___________________________
___________________________
Phone ___________________________
3.5 Installation Date
3.6 WEEE (Waste Electrical and Electronic Equipment)
In conformity with EU 2002/96/EC,
this freezer, at the end of life cycle,
is not to be discarded with normal
urban waste. Instead, it is the user’s
responsibility to dispose of this product
by returning it to a collection point
designated for the recycling of electrical,
electronic components and separation
of reclaimable, recyclable materials.
Contact your local distributor or authority
for correct disposal.
3.7 Equipment Videos
To view videos on setting up and priming
the GES freezer visit:
http://www.electrofreeze.com/GES_Videos.aspx

Twin Twist Soft Serve Freezer Model GES-103
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4 Virtual Quality Management System
(VQM) Terminology
Beater Run: ...................... This D.O.B. timer used to delay the beater motor after
the refrigeration shuts down. Beater Run Range: 0 to 10
seconds
Demand Run Comp: ......... The D.O.B. timer used to delay the compressor when
product is being drawn. Demand Run Comp. Range: 0 to
12 seconds
Differential/ Hyst: .............. Symbolizes the differential setting. Differential range: 7 to
20°F i.e. if your cut in is at 18°F and your Differential is
at 10°F your unit will cut out at 8°F
Dual Diff: ........................... The differential used when product is being drawn out of
the center spigot. Dual Differential range: 7 to 20°F
Idle: ................................... When the unit is cycling on temperature and no product
is being dispensed
Idle Run Comp:................. Delay on break (D.O.B.) timer used for the compressor
when the unit is in idle mode/no product being drawn.
Idle Run Comp. Range: 0 to 20 seconds
Lock outs: ......................... Allows the function of a specic feature/button to be
temporarily disabled to deter un-necessary usage of that
feature.
Main P.C. Board: ............... Main Control board for the unit, housed behind the trim
strip panel. This board has many connectors on it and is
responsible for the main operations of the unit.
Membrane Switch: ............ The black Electro Freeze decal visible on the front of the
unit, which houses the hidden operator, technician, soft,
and hard keys used to navigate the menus
Relay Board ...................... A control board located in the main electrical control box.
This Board contains no software, only solid state control
relays to operate system components.
Single Diff: ....................... The differential used when product is being drawn out of
one barrel. Single Hysteresis range: 7 to 20°F

Twin Twist Soft Serve Freezer Model GES-103
184560 9
4 Virtual Quality Management System
(VQM) Terminology (continued)
Slope/Demand Slope: ...... Utilizes a function within the system to watch the
temperature change as the unit freezes a barrel. If utilizing
the slope feature and the unit sees a lack of temperature
change during freeze down, the unit will cycle off. This
will prevent a freeze up condition due to a long run time.
Demand Slope range: 0 to -0.2
Temp. Comp.: ................... Temperature compensation, utilized when the slope feature
is turned on. It prevents the system from seeing the
slope temperature curve until a determined temperature
is reached. Once that temperature has been reached
then the system will examine the curve and shut down if
necessary. Temp. Comp. Range: -10
to 22°F
Temperature Offset: .......... A function that allows temperature adjustment to the
operator. Adjustable from 1-9 and 5 being neutral/no
change, Lower than 5= colder and greater than 5=warmer
Transducer: ...................... An electronic control used to measure the cylinder
pressure for mix pump operation.
U.I./ User Interface: .......... The board that lies directly behind the membrane switch
on the front panel. This board houses the LED screen that
displays the menus and operations. The membrane switch
is connected to this board via a ribbon cable. This board
also has its own software.

Twin Twist Soft Serve Freezer Model GES-103
10 184560
5 Part Names and Functions
Figure 5-1 Head Assembly