Duke SUBWAY Series User manual

Service Manual
SUBWAY FRONT COUNTERS
Please read this manual completely before attempting
to install, operate or service this equipment
This document is prepared for trained Duke service technicians. It is not to be used by anyone not
properly qualified to perform these procedures.
This Service Manual is not all encompassing. If you have not been trained on servicing this product,
be sure to read the manual completely before attempting servicing. Be sure all necessary tools, test
equipment, and skills are available. Those procedures for which you do not have the proper skills
and test equipment must be performed only by a qualified Duke trained service technician.
This manual is Copyright © 2007 Duke Manufacturing Co. All rights reserved.
Reproduction without written permission is prohibited. Duke is a registered
trademark of the Duke Manufacturing Co.
Duke Manufacturing Co.
2305 N. Broadway
St. Louis, MO 63102
Phone: [phone]
Toll Free: 1-800-735-3853
Fax: [phone]
www.dukemfg.com
P/N 219206A

Service Manual for Subway Front Counters
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IMPORTANT WARNING AND SAFETY INFORMATION
WARNING
READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR
PERFORMING MAINTENANCE ON THE EQUIPMENT.
WARNING
FAILURE TO FOLLOW INSTRUCTIONS IN THIS MANUAL CAN CAUSE PROPERTY
DAMAGE, INJURY OR DEATH.
WARNING
DO NOT USE OR STORE GASOLINE OR OTHER FLAMMABLE VAPORS OR
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WARNING
DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPERLY PLACING AND
SECURING ALL COVER AND ACCESS PANELS.
CAUTION
Observe the following:
• Provide and maintain adequate minimum clearances from all walls and combustible materials.
• Provide and maintain adequate clearance for air openings.
• Keep the equipment area free and clear of combustible material.
• Operate equipment only on the type of electricity indicated on the specification plate.
• Retain this manual for future reference.

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Service Manual for Subway Front Counters
TABLE OF CONTENTS
GENERAL ...........................................................................................................................5
SPECIFICATIONS...........................................................................................................5
INSTALLATION ..............................................................................................................5
Location.......................................................................................................................5
Leveling .......................................................................................................................5
Stabilizing ....................................................................................................................6
Electrical Connection ................................................................................................6
PARTS REPLACEMENT ....................................................................................................7
TRI-CHANNEL COLD PAN ............................................................................................7
Thermostat .................................................................................................................7
Digital Thermostat ......................................................................................................9
Capillary Tube ............................................................................................................9
Capacitor ....................................................................................................................11
Evaporator ..................................................................................................................12
Condenser Cooling Fan .............................................................................................12
Refrigeration System ..................................................................................................13
Recharging the Refrigeration System ........................................................................14
HOT FOOD UNIT ...........................................................................................................15
Infinite Switch .............................................................................................................15
Indicator Lamp ...........................................................................................................16
Heat Element .............................................................................................................16
Capacitor ....................................................................................................................17
PURSE RAIL REPLACEMENT ......................................................................................17
DAYCOVER....................................................................................................................19
Daycover Bulb Gasket................................................................................................19
Gas Damper and Gas Shock Replacement ...............................................................20
End Glass – Tri-Channel unit .....................................................................................21
End Glass – Hot Food Unit.........................................................................................22
Daycover Door ...........................................................................................................23
Daycover Light ...........................................................................................................24
Daycover Light Clip ....................................................................................................25
Daycover Damage Repair ..........................................................................................25
Daycover Replacement – Cold Pan Unit ....................................................................26
Daycover Retrofit Replacement – Cold Pan Unit .......................................................27
Daycover Replacement – Hot Food Unit ....................................................................29
Daycover Retrofit Replacement – Hot Food Unit .......................................................29
MAINTENANCE .................................................................................................................31
Stainless Steel Care and Cleaning.................................................................................31
Cleaning the Condenser Coil .........................................................................................32

Service Manual for Subway Front Counters
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TABLE OF CONTENTS (CONTINUED)
SERVICE INFORMATION ..................................................................................................33
Duke Service Bulletin 26 ...............................................................................................33
Refrigeration System Evacuation Process ....................................................................33
TROUBLESHOOTING PROCEDURES..............................................................................34
Troubleshooting Guide ..................................................................................................34
Tri-Channel Step One Troubleshooting Guide .............................................................35
Leak Testing .................................................................................................................37
SCHEMATIC DIAGRAMS ...................................................................................................38
Tri-Channel.....................................................................................................................38
Hot Food........................................................................................................................38

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Service Manual for Subway Front Counters
SPECIFICATIONS
ELECTRICAL DATA:
GENERAL
INSTALLATION
Location
The unit represented in this manual is intended
for indoor use only. Be sure the chosen location
has a floor strong enough to support the total
weight of the unit. Reinforce the floor if necessary
to provide for maximum loading. For the most
efficient operation, be sure to provide good air
circulation inside and out.
The outline drawing for the unit is shown below.
Provide adequate space along the front and back
taking care to not block airflow to the fan. Be sure
that the unit has access to ample air; avoid hot
corners and locations near stoves and ovens.
MODEL DESCRIPTION VOLTAGE AMPS PHASE
SUB-GP-L Left to Right Tri-Channel
Cold Pan
120 VAC (60 Hz)
220 VAC (50 Hz)
7.9
4.4
1
1
SUB-GP-R Right to Left Tri-Channel
Cold Pan
120 VAC (60 Hz)
220 VAC (50 Hz)
7.9
4.4
1
1
SUB-HF-L Left to Right Hot Food Unit (500 Watts) 120 VAC (60 Hz) 4.2 1
SUB-HF-R Right to Left Hot Food Unit (500 Watts) 120 VAC (60 Hz) 4.2 1
Leveling
Be sure that the units are placed on a firm, flat
surface/floor. Check for cracks in flooring or tile
and avoid these areas if possible. If necessary
place support pads, properly rated for the weight
of the unit, to “bridge” uneven or cracked flooring.
Level unit accordingly.
The units are provided with adjustable feet. All
three units (Tri Channel, Hot Food and Cashier
Counter) must be adjusted to the same height.
First level the Tri-Channel unit. Adjust the feet
on the Hot Food Unit and Cash Unit to meet the
height of the Tri-Channel.
Subway Front Counter

Service Manual for Subway Front Counters
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Stabilizing
Use the leg adjustments to insure that the unit is
solid to the floor surface at all four contact points.
Insure that the unit does not “rock” when pressure
is applied to the top corners.
Electrical Connection
The unit is designed to be operated on one 15AMP
dedicated circuit. The unit must be grounded. The
receptacle, wired circuit and protection must meet
all required local codes for proper operation. All
electrical connections should be performed by a
certified electrician and should comply with local
electrical codes for your municipality.
The Tri-Channel Cold Pan is pre-wired with a
NEMA 5-15 cord.
The Hot Food Unit is also pre-wired with a NEMA
5-15 cord.
WARNING
REFER TO THE AMPERAGE DATA
LIST IN THE SPECIFICATIONS OR
THE SERIAL TAG DATA AND YOUR
LOCAL CODE OR THE NATIONAL
ELECTRICAL CODE TO BE SURE
UNIT IS CONNECTED TO THE
PROPER POWER SOURCE. A
PROTECTED CIRCUIT OF THE
CORRECT VOLTAGE AND AMPERAGE
MUST BE RUN FOR CONNECTION
OF THE SUPPLY CORD OR
PERMANENT CONNECTION TO
THE UNIT. THE POWER MUST BE
TURNED OFF AND DISCONNECTED
WHENEVER PERFORMING
MAINTENANCE OR REPAIR
FUNCTIONS.

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Service Manual for Subway Front Counters
PARTS REPLACEMENT
TRI-CHANNEL COLD PAN
Thermostat
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Location of Thermostat
Service may be performed from the front or back
of the counter. It may be easier to access the
compressor from the front of the counter. This
can only be done on counters with Duke Décor
Panels installed.
1. Disconnect the unit from its power source.
2. Unplug the Purse Rail Lights from the duplex
box located on the compressor cage inside
the unit.
3. Loosen the screws in the stainless steel top
that hold the Décor Panel in place.
CAUTION: For front counters with curved
glass, these screws fasten the
glass extrusion to the top of the
front counter. Loosen the screws
above only one panel at a time.
4. Lift up on the Décor Panel and pull the bottom
of the panel away from the front of the unit.
4. Remove the Décor Panel from the unit.
5. Move to the Operator’s side of the counter
and remove the Lower Functionality Shelf.
NOTICE: On older versions of the counter, the
Louvered Front Vent Panel is held in place with
four Phillips screws. On newer versions, the
Louvered Front Vent Panel lifts off.
6. Remove the Louvered Front Vent Panel.
Condensing Unit Slide Plate Bolt
7. Remove the slide plate bolt.
8. Slide the Condensing unit forward enough to
expose the Manifold area.
NOTICE: If the unit has a thermostat with ¼″ copper
capillary mounted on the manifold, simply change
out the thermostat. If not continue to step 9.
9. Tag and disconnect the Thermostat wiring.

Service Manual for Subway Front Counters
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10. Cut away the foam insulation from the manifold
and pull the Thermostat wire from copper
tube.
11. Remove and discard the old thermostat.
Manifold Prepared with 1/4″ Copper Tube
12. Prepare the Manifold for ¼″ copper tube.
Secure the copper tube to the Manifold with
four zip ties. Make sure the copper tube
extends 1″ beyond the 90º bend in the Manifold
closest to the Condenser Coil.
NOTICE: Trim the excess ends off the zip ties.
13. Cover the manifold and copper tube with foil
tape.
14. Install split insulation onto the manifold; make
sure the copper tube is exposed where it
extends beyond the manifold to allow for new
Thermostat Bulb insertion.
Thermostat Bulb Inserted into Copper Tube
15. Insert the new Thermostat Capillary Bulb into
the copper tube and secure with cork tape.
NOTE: Do not kink thermostat probe.
16. Reverse steps 1 through 8 to complete this
procedure.
17. Connect unit to its power source and test for
proper operation.
NOTICE: Technical support may request a filled
out checklist. A copy of the check list can be
found in the SUBWAY TRI-CHANNEL STEP
ONE TROUBLESHOOTING GUIDE section of
this manual.

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Service Manual for Subway Front Counters
Digital Thermostat
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Digital Thermostat
1. Disconnect the Tri-Channel unit from its power
source.
2. Remove the Louvered Panel and the Control
Panel.
3. Tag and disconnect the Digital Thermostat
wiring.
4. Remove the Digital Thermostat Probes from
the Evaporator Coil, which is located above
the Refrigeration Assembly.
5. Remove the Digital Thermostat from the
Control Panel by pushing in the tabs on the
mounting brackets.
6. Install the replacement Digital Thermostat.
NOTICE: Do not kink Digital Thermostat
probes.
7. Install the Digital Thermostat probes onto the
Evaporator Coil.
8. Refer to the tags to reconnect the Digital
Thermostat wiring.
9. Install the Control Panel and Louvered
Panel.
10. Connect the Tri-Channel unit to its power
source and check for proper operation.
Additional adjustment to the Digital Thermostat
may be required.
Capillary Tube
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
1. Disconnect the Tri-Channel unit from its power
source.
Tap Valve Installation
2. To properly recover refrigerant, install a Line
Tap Valve on High Process side tube, see the
illustration above.

Service Manual for Subway Front Counters
10
NOTICE: Using a Refrigeration-Charging Unit,
evacuate refrigerant from the system according
to Duke Manufacturing Service Bulletin Number
26. Refrigerant must be recovered in accordance
with Federal, State and Local regulations.
3. Removal of the Lower Shelf if necessary to pull
the Condensing unit out from under the unit.
4. Remove the insulation from the Suction Line at
the Compressor. Be careful, as theAccumulator
Insulation will be reused.
Un-brazed Drier – Condenser Side
NOTICE: Note the position of the Drier; the new
Drier must be installed in the same position. See
the illustration above.
5. Un-braze the Drier from the Condenser Outlet,
see the illustration above.
Un-brazed Suction Line
6. Un-brazetheSuctionLinefromtheCompressor,
see the illustration above.
NOTICE: Care should be given to support the
Condensing unit once out of the cage.
7. Slide the Condensing unit out of the cage as
far as possible.
8. Remove the insulation from each of the
Evaporator Inlets and the Suction Line at the
Manifold.
9. Cut each Evaporator Inlet Tube 1″ from the end
of the Capillary Tube. Cut the Suction Line 4″
from the Manifold.
10. Install the new Capillary Tube Assembly onto
Condensing unit.
CAUTION: A heat sink must be used
when brazing the suction line
at the manifold to ensure that
the thermostat bulb does not
overheat.
11. Reinstall the Condensing unit; braze the
Suction Line to the Compressor and the Drier
connection to the Condenser Outlet.
12. Leak check the system.
13. Re-insulate the Evaporator Inlets, Suction Line
and Accumulator.