ELECTRO FREEZE cs5 Operator's Manual

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H. C. Duke & Son, Inc. P/N 184627 July 2002 Printed in U.S.A.

OPERATOR'S MANUAL

with Illustrated Parts List

COMPACT SERIES

SOFT SERVE FREEZER

Model CS5

184627 - 7/02

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ELECTRO FREEZE Model CS5

Operator’s Manual

for the

Electro Freeze Model CS5

Compact Series

Soft Serve Freezer

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Follow these four steps to safety ....

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1. Recognize Safety Information ....Look for this safety

alert symbol throughout this manual.

2. Understand Signal Words ....

WARNING

CAUTION

SAFETY FIRST!

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.

The signal words — DANGER, WARNING and

DANGER

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 identifies the most serious hazard. Decals with the words DANGER or WARNING are typically near specific hazards on the freezer . General precautions are listed on CAUTION safety decals.

In this manual, CAUTION messages with the safety alert symbol

ii

call attention to safety messages.

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ELECTRO FREEZE Model CS5

SAFETY FIRST!

3. Follow Safety Instructions ....

Read and understand all safety messages in this manual. Read and understand the decal safety messages 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 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, Inc.

DO NOT attempt to operate the CS5 freezer until you read and understand all safety messages and the operating instructions in this manual.

4. Operate Safely ....

DO NOT allow untrained personnel to maintain or service this machine. Failure to follow this instruction may result in severe personal injury. DO NOT operate the freezer unless all service panels and access doors are secured with screws. DO NOT attempt to maintain or rep air the freezer until the main power supply has been disconnected. Contact your local Electro Freeze Distributor for authorized service.

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Safety Decal Locations

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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 figure to the right. 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 your local authorized Electro Freeze Distributor or H. C. Duke & Son. 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.

No. Part No. Description (Qty)

1 P/N 165126 Decal — Panel Removal Warning (3) 2 P/N 165025 Decal — Beater Warning (1)

You may contact your local authorized Electro Freeze Distributor, as follows:

Name: Address:

Phone: or —for factory service assistance —

contact H. C. Duke & Son, Electro Freeze Service Department by phone or FAX:



Phone: (309) 755-4553 FAX: (309) 755-985

8

(The decals on the next page are numbered 1 through 7. Those numbers correspond to the numbers in the table below. The table provides the part number, description, and quantity for each decal.)

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Safety Decal Locations

Hazardous rotating beater shaft. Do not

2

operate unit with dispense head removed.

ELECTRO FREEZE Model CS5

!

1

Before removing dispense head:

1. Turn all control switches to "OFF".

2. Disconnect main power supply-unit may have more than one power supply.

v

Hazardou s m ovi ng parts. Machine starts automatically. Do not op e r ate with pa nel removed.

WARNING

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SECTION DESCRIPTION PAGE

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1. INTRODUCTION

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2. NOTE TO INSTALLER

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3. ELECTRICAL REQUIREMENTS

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4. SPECIFICATIONS

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5. PART NAMES AND FUNCTIONS

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6. OPERATOR CONTROLS & INDICATORS

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7. DISASSEMBLY AND CLEANING

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8. ASSEMBLY

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9. START-UP INSTRUCTIONS

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SAFETY

............................................................................................. ii

4.1 Particulars. ....................................................................................... 2

4.2 Data Plate ......................................................................................... 3

4.3 Reference Information ...................................................................... 3

4.4 Installation Date................................................................................ 3

4.5 Dimensions. ....................................................................................... 4

6.1 Selector Switch ................................................................................ 7

6.2 Day-Night Switch .............................................................................. 7

6.3 "ADD MIX" Indicator Light ................................................................. 7

6.4 Mix Float ........................................................................................... 8

6.5 Mix Feed Tube & Regulator ............................................................... 8

7.1 Accessories...................................................................................... 9

7.2 Disassembly Instructions ................................................................ 10

7.3 Cleaning Instructions ...................................................................... 10

9.1 Sanitizing........................................................................................ 15

9.2 Priming ........................................................................................... 16

1 Introduction

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2 Note to Installer

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The CS5 Freezer is designed to produce soft serve ice cream, ice milk, yogurt, and similar frozen dairy products, with a product serving temperature range of 15 to 25ºF. If such products are prepared from powdered concentrate, they should be precooled to 40ºF 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 you in the proper operation and general maintenance of the Electro Freeze Model CS5 Freezer.

Make sure all personnel responsible for equipment operation completely read and understand this manual before operating the freezer. When properly operated and maintained the freezer will produce a consistent quality product.

This freezer must be installed and serviced by an Electro Freeze Distributor or authorized service technician in accordance with the installation instructions.

Verify the weight of the freezer. Ensure a counter or table of sufficient strength is used to hold this weight and prevent excessive vibration.

Air cooled models require a minimum of 6-inches (15.2 cm) air space on both sides and back of the freezer for adequate ventilation.

If this freezer is to be used in a selfservice application, it is recommended that the machine be fitted with a selfservice kit. Contact your Electro Freeze Distributor or H. C. Duke for this kit.

If you require technical assistance, please contact your local authorized Electro Freeze Distributor, as follows:

Name: Address:

Phone:

For factory service assistance —contact H.C. Duke, Electro Freeze Service Department as follows.

Phone: (309) 755-4553







FAX: (309) 755-9858

Test the operation of the head switch prior to placing the freezer in service. See Section 12, Routine Maintenance, Monthly.

After installation the warranty registration card must be completed and returned to validate the warranty.

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3 Electrical Requirements

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4 Specifications

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4.1 Particulars

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Figure 2-3 Plug

Plug Rating: 15A, 125VAC (For use with a NEMA “5-15R” Receptacle)

Width (in/cm) 16.3/41.4 Height (in/cm) 29.25/75 Depth (in/cm) 23.25/59 Weight (lbs/kg) 175/79 Voltage* 115/60/1 Min.Circuit Ampacity 15.0 Compressor 3/4 HP/3600 (BTUH)

CAUTION All materials and connections must conform to local requirements and be in compliance with the National Electric Code (NEC).

CAUTION To prevent accidental electrical shock, a receptacle with a positive earth ground is required.

.56 kw (Motor)

1.1 kw (Cooling)

1. Always verify electrical specifications on the data plate (figure 4-1) of each individual freezer. Data plate specifications will always supersede the information in this manual.

2. This freezer requires a protected 15 amp 120 volt circuit. Connect the freezer to a circuit separate from any other electrical equipment.

3. Always check and verify voltage and amperage on the data plate (figure 4-1) located on the back panel of each freezer.

4. All 115 volt 15 amp freezers are supplied with a factory power cord (Figure 2-3) that requires a NEMA “5-15R” type receptacle to accomodate the plug. All freezers should be connected to a circuit separate from any other electrical equipment.

Beater Motor 1/2 HP/.37 kw Refrigerant R-404a Charge 20.0 oz/.57 kg Cooling Air Hopper 10 qts/9.5 liters Cylinder 1.8 pts/.85 liter

*Contact factory for other voltages.

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4.2 Data Plate

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4.3 Reference Information

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4.4 Installation Date

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Figure 4-1

Write in Reference Information HERE!

(

Fill in the date of installation, and the name, address, and phone number of the installer in the space provided below. This information will be needed when ordering parts or service for the CS5 Freezer.

Date of installation: _________________________________________

Installed by: _________________________________________

Address: _________________________________________

_________________________________________

Phone: _________________________________________

The data plate provides important information that the operator should record and have available for parts ordering, warranty inquiries and service requests.

Fill in the following information as soon as you receive the Electro Freeze CS5. (The item numbers — encircled, below — correspond with the callout numbers in figure 4-1.)

1 Model Number: _________________ 2 Serial Number:__________________ 3 Electrical Spec: Voltage ________

Phase _______ Hertz _________

4 Total Amps:_____________________

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4.5 Dimensions

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Figure 4-2 Electro Freeze Model CS5 Dimensions

The dimensions of the CS5 Freezer are provided in figure 4-2, below.

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5 Part Names and Functions

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Figure 5-1 Head Assembly

1 HEAD.

Encloses the freezing cylinder and provides an opening for product to be dispensed.

2 O-RING - HEAD

head to the freezing cylinder. Must be lubricated.

3 O-RING - PLUNGER. Seals the plunger in the head. Must be lubricated to seal and slide freely.

4 ROD - PLUNGER.

freezer when dispensing. Must be in place before freezer will operate.

.

Seals the

Starts the

5 PLUNGER.

Seals the product opening in the head when closed. Allows product to flow when open.

6 HANDLE - DISPENSE.

and closes the plunger to start and stop the flow of product from the freezer.

7 PIN - HANDLE. Secures

handle to the head.

8 KNOB - HAND.

Secures the

head to the freezing cylinder.

9 NOZZLE.

Shapes the frozen

product being served.

Opens

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5 Part Names and Functions

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Figure 5-2 Beater Shaft Assembly

Figure 5-3 Mix Feed Tube Assembly

10 SHAFT - BEATER.

Rotates in the freezing cylinder blending air and mix and ejecting product.

11 BAR - BREAKER. Keeps product blended in the center of the beater shaft.

12 SEAL - SHAFT.

Seals the opening between the freezing cylinder and the beater shaft.

13 BUSHING - BEATER.

Supports

front portion of beater on breaker bar.

14 TUBE - MIX FEED. Meters the correct amount of mix and air into the freezing cylinder from the hopper.

15 O-RING - TUBE.

Seals the opening between the hopper and mix feed tube. (O-rings do not need lubrication.)

16 REGULATOR. Provides a positive shut off of mix flow to the freezing cylinder.

17 O-RING - REGULATOR. Holds the regulator in place in the mix tube. Must be lubricated.

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6 Operator Controls

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6.1 Selector Switch 1

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6.2 Day– Night Switch 2

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6.3 “ADD MIX” Indicator Light 3

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The following paragraphs describe the operator controls and indicators. Refer to figure 6-1 for location of these controls and indicators on the Model CS5 freezer.

NOTE: The plunger rod must be in place before the freezer will operate in “DAY”, “NIGHT”, or “CLEAN” position.

CAUTION Test operation of the head switch prior to placing the freezer in service. See Section 12, Routine Maintenance, Monthly.

This three-position switch selects the mode of operation of the freezer.

a. “CLEAN” (left) — This position operates the beater only (no refrigeration). Always use this mode when performing cleaning and sanitizing operations.

b. “OFF” (center) — In this position the beater motor and refrigeration system will not operate.

a. “DAY” (left) — The low tempera- ture thermostat controls the system cycles to maintain the product serving temperature between 18°–21°F. This is the normal operating position.

b. “NIGHT” (right) — This energy saving mode will reduce product agita-

Important: If proper mix level is not maintained, a freeze-up may occur and damage the freezer.

Figure 6-1

Important: Do not use the automatic position with water or sanitizer in the cylinder or hopper — the freezer will be damaged.

c. “AUTO” (right) — This position activates both the beater motor and refrigeration unit. This is the normal operating position.

tion. The freezer will automatically cycle to maintain temperatures below 41ºF (5 C). This position should be used when the freezer will not be in use for periods of more than an hour.

This light indicates the mix in the hopper is at a low level and should be refilled as soon as possible. Always maintain at least 2 inches (5.1 cm) of mix in the hopper. For best operating results keep hopper full.

º

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6 Operator Controls – continued

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6.4 Mix Float

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6.5 Mix Feed Tube & Regulator

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Figure 6-2

Figure 6-3

Figure 6-4

The float must be installed on the sensor tube for the “ADD MIX” indicator light to work.

This two-position regulating device (figure 6-3) meters the correct amount of mix and air into the freezing cylinder.

a. “OPEN” - This position must be used whenever product is being dispensed. (See figure 6-4. When OPEN you can see clear through the hole in the top of mix feed tube.)

Important: If product is dispensed when the regulator is in the “CLOSED” position, a freeze-up will occur and may damage the freezer.

b. “CLOSED” - This position should be used when the freezer is in the “NIGHT” mode, and when product will not be dispensed for a long period of time. (See figure 6-4. When CLOSED you cannot see through the hole in the top of the mix feed tube — the white plastic regulator tube inside will block the hole.)

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7 Disassembly and Cleaning

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7.1 Cleaning Accessories

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It is important that the freezer be disassembled, washed, lubricated and sanitized before operation.

The cleaning and sanitizing instructions explained in this manual are required to maintain a clean, sanitary freezer. The freezer should be disassembled,

The following are accessories necessary for cleaning, sanitizing and disassembly/ assembly.

a. BRUSH, Cylinder. 2-9/16 inch diameter with 10-inch handle, used for cleaning the cylinder.

b. BRUSH, Double end. 1-1/8 inch diameter and 7/16-inch diameter, used for cleaning the drain tube, mix inlet tube and mix feed tube.

c. BRUSH, General parts cleaning. 1-inch diameter with 12-inch handle, used for cleaning the head.

d. BRUSH, Mix feed assembly. 1/4inch diameter with 18-1/2 inch handle used for cleaning the mix feed tube and regulator.

Figure 7-1 Cleaning Accessories

cleaned, reassembled, lubricated and sanitized daily to ensure the best possible product and freezer operation.

Persons assembling, cleaning or sanitizing the freezer must wash and sanitize hands and forearms with an approved sanitizer.

e. KIT, O-ring. This kit contains all O-rings and seal needing replacement on a regular basis.

f. LUBRICANT, Petrol Gel. Approved lubricant for moving parts and Orings. See assembly instructions for lubricating points.

g. SANITIZER, Sample. Approved sanitizer Stera-Sheen, also available in 4 lb. jar.

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7.2 Disassembly Instructions

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Figure 7-2

Figure 7-3

Figure 7-4

Figure 7-5

It is important that the freezer be disassembled, washed, lubricated and sanitized before operation.

NOTE: If there is product in the freezer, refer to Section 10, Closing Procedures, 10.1 Draining Product.

1. Remove plunger rod (4, figure 7-

2) by lifting it up and pulling the bottom out and down. Remove the hand knobs (8) and pull the dispensing head (1) straight out.

2. Remove the handle pin (7),

plunger (5) and nozzle (9) from head (1).

3. Remove the beater shaft (1, figure 7-3) from the cylinder. Then remove breaker bar (2), beater bushing (4) and shaft seal (3) from the beater shaft.

4. Remove hopper cover. Remove drip tray and drip tray insert.

5. Remove the mix feed tube (figure 7-4) and mix float from the hopper.

6. Remove O-rings (2) from mix feed tube (1).

7. Remove regulator (3) from mix feed tube. Remove O-ring (4) from regulator.

8. Remove O-ring (2, figure 7-2) from head (1). Remove O-rings (3) from plunger (5). Remove the seals from the washer on the shaft seal assembly (3, figure 7-3). Disassemble the shaft seal assembly (figure 7-5).

CAUTION To avoid electrical shock or contact with moving parts, make sure all switches are in the “OFF” position and that the main power supply is disconnected.

CAUTION To prevent bacteria growth, remove all O-rings when cleaning. Failure to do so could create a health hazard.

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7.3 Cleaning Instructions

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Figure 7-6 Brush the mix feed tube

Figure 7-7 Brush the head ports

The cleaning instructions explained in this section are procedures to remove bacteria and maintain a clean sanitary freezer. The soft serve freezer must be disassembled, washed and sanitized according to the instructions in this manual before start-up to ensure the best possible cleanliness.

CAUTION Electric shock hazard. Do not splash water on switches or allow water to flow onto electrical components inside the machine.

CAUTION To prevent bacteria growth, use only approved sanitizers to sanitize the machine. Failure to do so could create a health hazard.

Important: Do not use unapproved sanitizers or laundry bleach. These materials may contain high concentrations of chlorine and will chemically attack freezer components.

NOTE: It is your responsibility to be aware of the requirements for meeting federal, state, and local laws concerning the frequency of cleaning and sanitizing the freezer.

1. Prepare a three-compartment sink for washing, rinsing, and sanitizing parts removed from the freezer per applicable health codes. Also, prepare a clean surface to air-dry all parts.

NOTE: The sanitizer should be mixed according to the manufacturer’s instructions to yield 100 parts per million (PPM) available chlorine solution. (example: Stera Sheen Green Label). Use warm water (100º-110ºF or 38º - 43ºC) to wash, rinse, and sanitize.

Important: Do not leave parts in sanitizer for more than 15 minutes.

2. Wash all parts removed from the freezer thoroughly with dish detergent. Clean the following parts with the appropriate brush provided:

a. The mix feed tube and regula-

tor main bore and cross holes (figure 7-

6).

b. The head plunger openings, center plunger ports, breaker bar cavities, O-ring grooves, dispense nozzle mounting rings and mix ports (figure 7-

7).

— continued

ELECTRO FREEZE cs5 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

OPERATOR'S MANUAL

Safety Decal Locations

Table of Contents

1 Introduction

2 Note to Installer

3 Electrical Requirements

4 Specifications

4.1 Particulars

4.2 Data Plate

4.3 Reference Information

4.4 Installation Date

4.5 Dimensions

5 Part Names and Functions

Figure 5-1 Head Assembly

Figure 5-2 Beater Shaft Assembly

Figure 5-3 Mix Feed Tube Assembly

6 Operator Controls

7 Disassembly and Cleaning

7.1 Cleaning Accessories