SaniServ

®

An AFFINIS GROUP Company

“Reliability from the team that Serves the Best”

Frozen Beverage Dispensers

Operation Manual

SaniServ P.O. Box 1089 Mooresville, Indiana 46158

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.

Note: It is the Owner’s responsibility to maintain the

Service Record located on the inside rear cover of this manual. An accurate record of service performed can greatly expedite troubleshooting of problems and significantly reduce repair costs.

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.

IMPORTANT

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

STATEMENT OF INTENDED USE

All SaniServ Machines covered in this manual are designed for one specific end use - to freeze and dispense frozen beverages.

PICTOGRAM LEGEND

ELECTRICAL

SHOCK HAZARD

TIP AND CRUSH

HAZARD

PROTECT EYES

SPLASH HAZARD

HAND PINCH OR

ENTRAPMENT HAZARD

SHARP MACHINE

PARTS HAZARD

CLEANOUT

OPERATION

FROZEN

PRODUCT

USE MECHANICAL

LIFT EQUIPMENT

READ AND

UNDERSTAND

WASH HANDS

BEFORE PROCEEDING ii

Width

Inches (mm)

Height

Inches (mm)

Depth

Inches (mm)

Machine Weight

lb (kg)

Circuit Amps -

Minimum

Circuit Amps -

Maximum

704

20.4

(518)

32.8

(832)

33.6

(854)

310

(141)

25

30

SPECIFICATIONS

707

14

(356)

31

(787)

24

(610)

159

(72)

15

15

709

17.0

(432)

32.5

(826)

28.6

(726)

207

(94)

20

25 15

*Amps per side - this machine has two independent refrigeration systems

714

17.0

(432)

58.1

(1477)

24.8

(629)

305

(139)

15

SPECIFICATIONS

724

26.0

(660)

55.9

(1419)

30.8

(781)

501

(228)

15*

15*

Table of Contents

Introduction and Installation .............................................................................................................. 1

Installer’s Preoperational Check ....................................................................................................... 3

Disassembly and Cleaning ............................................................................................................... 3

Assembly and Lubrication ................................................................................................................. 8

Sanitizing ....................................................................................................................................... 12

Operation (Filling and Starting) ....................................................................................................... 13

Helpful Hints ................................................................................................................................... 14

Consistency Adjustment ................................................................................................................. 15

Routine Maintenance ...................................................................................................................... 17

Troubleshooting .............................................................................................................................. 19

Troubleshooting Glossary ............................................................................................................... 20

Service Record ............................................................................................................................... 21

TABLE OF CONTENTS iii

iv

Illustrations

Fig. 2 Control Switch ...................................................................................................................2

Fig. 3 Front Plates.......................................................................................................................2

Fig. 5 Do Not Insert Objects!.......................................................................................................3

Fig. 6 Restrictor Tube..................................................................................................................3

Fig. 7 Control Switch ...................................................................................................................3

Fig. 8 Dispensing Product ...........................................................................................................3

Fig. 9 Control Switch ...................................................................................................................4

Fig. 10 Dispensing Product ...........................................................................................................4

Fig. 11 Front Plate Assembly ........................................................................................................4

Fig. 12 O-Ring Removal................................................................................................................4

Fig. 13 High Capacity Machine Front Plate Assembly ..................................................................5

Fig. 14 Large Barrel Machine Front Plate Assembly .....................................................................5

Fig. 15 Restrictor Tube..................................................................................................................5

Fig. 16 Dasher Assembly ..............................................................................................................6

Fig. 17 Scraper Blade Removal ....................................................................................................6

Fig. 18 Large Barrel Machine Dasher Assembly...........................................................................6

Fig. 19 High Capacity Machine Dasher Assembly ........................................................................6

Fig. 20 Drip Tray Assembly...........................................................................................................6

Fig. 21 Cleaning ALL Ports and Holes ..........................................................................................7

Fig. 22 Dasher Lubrication ............................................................................................................8

Fig. 23 Dasher Assembly ..............................................................................................................8

Fig. 24 Scraper Blade Installation .................................................................................................9

Fig. 25 Scraper Blade Installation .................................................................................................9

Fig. 26 Scraper Blade Wear Mark.................................................................................................9

Fig. 27 Dasher Installation ............................................................................................................9

Fig. 28 Dasher Installation ............................................................................................................9

Fig. 29 Dasher with Blade (Front View).......................................................................................10

Fig. 30 Spigot Plunger Lubrication ..............................................................................................10

Fig. 31 Front Plate Assembly ......................................................................................................10

Fig. 32 Large Barrel Machine Front Plate Assembly ...................................................................10

Fig. 33 Large Barrel Machine Front Plate Assembly ...................................................................11

Fig. 34 Drip Tray Assembly.........................................................................................................11

Fig. 35 Restrictor Tube Lubrication .............................................................................................11

Fig. 36 Do Not Insert Objects!.....................................................................................................12

Fig. 37 Dispensing Product .........................................................................................................13

Fig. 38 MIXOUT Light .................................................................................................................13

Fig. 39 Mechanical Consistency Control .....................................................................................15

Fig. 40 Electronic Consistency Control .......................................................................................16

Fig. 41 Scraper Blade Wear Mark...............................................................................................17

Fig. 42 Drip Chute .......................................................................................................................17

Fig. 43 Clean Sharp Condenser Fins ..........................................................................................17

Fig. 54 Spring Adjustment Mechanism .......................................................................................18

ILLUSTRATIONS

Introduction

This manual provides a general system description of the SaniServ Frozen Beverage Dispensers. It has been prepared to assist in the training of personnel on the proper installation, operation, and maintenance of the machines.

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

3. Disassembly & Cleaning

5. Sanitizing & Operation

6. Consistency Adjustment

Installation

WARNING

IMPORTANT

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. 1). The machine

MUST be level to operate properly.

Minimum

Clearance

4”(102 mm) for

Fig. 1

A MINIMUM 6” (152 MM) CLEARANCE MUST BE

MAINTAINED AT THE REAR AND SIDES OF THE

MACHINE FOR ADEQUATE VENTILATION.

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. 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 is located on the back side of the machine. The IN/OUT lines are clearly marked and equipped with 3/4” garden hose fittings.

WARNING

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. INSTALL THE PROPER SIZE WIRE FOR

THE REQUIRED MACHINE AMPS. BE CERTAIN TO

OBSERVE LOCAL CODES IN SELECTING WIRE OR

CORD SIZE AND TYPE.

DO NOT TURN MACHINE

ON UNTIL THE

INSTALLER’S PRE-

OPERATIONAL

CHECK SECTION IS

COMPLETE.

INTRODUCTION and INSTALLATION

PAGE 1

Installer’s Preoperational Check

THE FOLLOWING ITEMS MUST BE PERFORMED BEFORE ATTEMPTING TO OPERATE THE EQUIPMENT:

WARNING

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. Looking at the front of the machine, the dasher 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.

Fig. 2

Control Switch

O

F

F

AUTO

O

F

F

CLEANOUT

Fig. 3a

High Capacity

Machine Front

Plate

CAUTION

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.

Fig. 3b

Large Barrel

Machine Front

Plate

Fig. 3c

Machine Front

Plate 5” (127 mm)

Barrel

PAGE 2

INSTALLERS PREOPERATIONAL CHECK

Disassembly and 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.

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.

CAUTION

DO NOT INSERT ANY OBJECTS OR TOOLS (FIG. 5)

INTO THE MIX INLET HOLE, RESTRICTOR TUBE

HOLE, OR FRONT PLATE DISPENSING HOLE WHILE

THE MACHINE IS RUNNING. DAMAGE TO THE

MACHINE OR PERSONAL INJURY MAY RESULT

1. For Models 108 & 704, remove the restrictor tube (Fig.

6) from the mix inlet holes and lay in the bottom of the mix pans. Note: Some units have these tubes welded in place

2. Set each control switch (Fig. 7) to the “CLEANOUT” position and dispense all product from the freezing cylinder by pulling downward on the spigot handle

(Fig. 10) to empty the machine.

3. Set each control switch to the “OFF” (center) position.

Close the spigot handle(s) (Fig. 8) before proceeding to cleaning.

Fig. 6

Model 108 & 704

Restrictor Tube

O

F

F

AUTO

O

F

F

CLEANOUT

Fig. 7

Control Switch

Fig. 8

Dispensing Product

Fig. 5

Do Not Insert Objects or Tools

DISASSEMBLY and CLEANING

PAGE 3

Disassembly and Cleaning Procedure

1. Fill the machine with cold water and set each control switch (Fig. 9) to the “CLEANOUT” position. DO NOT use hot water which could damage the machine. Let the machine agitate 1 to 2 minutes, then drain the water by pulling downward on the spigot handle (Fig. 10). 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 approximately 125

°

F. (52

°

C.) to 130

°

F.

(55

°

C.). For best cleaning results select a concentrated anti-bacterial dishwashing detergent containing biodegradable anionic and nonionic surfactants. Avoid detergents containing phosphates. DO NOT use an abrasive detergent on any part of the dispenser.

CAUTION

DO NOT USE HOT WATER.

DOING SO MAY DAMAGE THE MACHINE.

3. Make certain that the machine is “OFF”. Fill the mix pan(s) with the cleaning solution. Clean the mix pan(s) thoroughly with a brush as the solution drains into the freezing cylinder(s). Clean the mix inlet tube(s) and the restrictor tube holes with the brush provided.

4. Set the control switch to the “CLEANOUT” position and agitate for approximately 1 to 2 minutes and then drain the water by pulling down on the spigot handle.

After the unit is empty, set each control switch to the

“OFF” position.

AUTO

CAUTION

DO NOT USE ANY TOOLS OR SHARP OBJECTS TO

REMOVE ANY O-RINGS FROM THIS MACHINE.

SHARP OBJECTS WILL DAMAGE THE O-RINGS.

5. Remove the front plate by turning the black plastic knobs in a counterclockwise direction (Fig. 11).

Disassemble the front plate in the following manner: a. Remove the faspin and spigot handle. b. Remove the front plate o-ring. c. With the spigot handle removed, push the spigot plunger out the top of the front plate and remove all lubricant from the spigot plunger. d. Remove the o-rings from the spigot plunger by grasping the part with one hand and with a dry cloth in the other hand, squeeze the 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 the

spigot plunger (Fig. 12).

Fig. 11

Front Plate Assembly

Spigot Plunger

Spigot Plunger

O-rings

Front Plate O-ring

DO NOT LUBRICATE

Spigot

Handle

Faspin

Front Plate

Knobs Front Plate

O

F

F

O

F

F

CLEANOUT

Fig. 9

Control Switch

Fig. 10

Dispensing Product

Fig. 12

O-Ring Removal

PAGE 4

DISASSEMBLY and CLEANING

6. The front plate for the high capacity series machines

(Fig. 13) is disassembled in the same manner as the front plate shown in Fig. 11.

Fig. 13

High Capacity Machine

Front Plate Assembly

Spigot Plunger

Spigot Plunger

O-rings

Front Plate

O-ring

Front Plate

Knob x 4

Spigot

Assembly

Spigot Handle

Knob

O-Ring

Fig. 14

Large Barrel Machine

Front Plate Assembly

Front Plate

FasPin

7. Disassemble the large barrel machine front plate

(Fig. 14) in the following manner: a. Remove the four front plate knobs. b. Remove front plate from machine c. Remove front plate O-Ring d. Open spigot handle. e. Clean spigot openings with the cleaning brush.

(Fig. 15)

8. Remove the restrictor tube from the mix pan and remove the o-ring in the same manner used to remove the o-rings from the spigot plunger. Clean the inside of the tube with the brush provided.

Front Plate

O-ring

Spigot Nut

Fig. 15

Cleaning Large Barrel

Front Plate Assembly

DISASSEMBLY and CLEANING

PAGE 5

9. Remove the dasher assembly (Fig. 16) being careful not to damage the scraper blades, then disassemble in the following manner: a. Remove and take apart the rear seal assembly. b. Remove the stator rod from the dasher. c.

Remove the blades from the dasher (Fig. 16) by first rotating blade upward (Fig. 17) and then

Rear Bearing

Dashers in the high capacity and large barrel machines have no stator rods, but both have front bushings (Fig. 18 and Fig. 19).

Scraper Blade

Dasher Rear Seal

Rear Bearing

Scraper Blade

Dasher

Front Bushing

Fig. 18

Large Barrel Machine

Dasher Assembly

Front Bushing

Scraper Blade

Rear Seal

Rear Bearing

Rear Seal

Stator Rod

Fig. 16

Dasher Assembly

Dasher Front

View

Scraper Blade

Support

Rod

Dasher

Fig. 19

High Capacity Machine

Dasher Assembly

10. Remove the mix pan lid, drip tray and drip tray insert (Fig. 20).

Drip Tray Insert

Blade Support

Tab

Scraper Blade

Dasher Front

View

Support

Rod

Drip Tray

PAGE 6

Blade Support

Tab

Fig. 17

Scraper Blade Removal

DISASSEMBLY and CLEANING

Fig. 20

Drip Tray Assembly

Drip Tray Support

Remains Attached

To Machine Front

11. For best cleaning results select a concentrated anti-bacterial dishwashing detergent containing biodegradable anionic and nonionic surfactants.

NOTE: Avoid detergents containing phosphates.

CAUTION

WEAR SAFETY GLASSES

- DO NOT SPLASH

DETERGENT SOLUTION

IN EYES

Be certain to follow the manufacturer’s mixing instructions when adding the dishwashing detergent concentrate to water.

Fig. 21

Clean ALL Holes and Ports with Brushes

12. Place all parts in a three partition sink filled with the following solutions: a. In one partition, detergent solution diluted to the manufacturer’s suggested concentration for use.

b. In a second partition, clear rinse water. c. In a third partition, sanitizing rinse solution which will produce a 200 parts per million (PPM) Chlorine residual or whatever Chlorine residual is required by your Local Health Authority.

13. Use the brushes to clean all holes and ports in the parts (Fig. 21).

CAUTION

DO NOT use an abrasive detergent

14. After thoroughly washing the parts in the detergent solution, rinse them in the clear rinse water. Place the parts in the sanitizing solution for at least five minutes or whatever your Local Health Authority requires, and then air dry the parts before for assembly and lubrication.

DO NOT ALLOW THE PARTS TO SOAK IN

CAUTION

SANITIZER FOR SEVERAL HOURS.

DO NOT WIPE THE PARTS DRY - AIR DRY ONLY.

15. The remainder of the machine including the mix pan and freezing cylinder must be cleaned in place using a mild detergent solution followed by a clear rinse. Clean the exterior with a damp cloth.

DO NOT use an abrasive cleaner on the exterior of the

CAUTION machine or on any of the panels (guards).

WARNING

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.

DISASSEMBLY and CLEANING

PAGE 7

Assembly and Lubrication

Use a food grade lubricant* ONLY. Haynes Lubri-Film (SaniServ part number 1150) is recommended and is available from the factory or your local authorized SaniServ dealer or distributor. Lubrication must be performed daily.

* The SaniServ recommended product is a colorless to white, odorless, tasteless food contact lubricant accepted by the

United States Food and Drug Administration (FDA) with a USDA rating of H1 and certified for food contact by NSF

International.

1.

Lubricate and assemble the dasher assembly in the following manner: a. Apply a generous amount of lubricant to the shoulder of the dasher and the area of the shaft where the white plastic portion of the assembled rear seal contacts the shaft (Fig. 22). This is easily performed by running a 1/4” (6 mm) bead of lubricant around the shoulder of the dasher. b. Lubricate the two areas of the stator rod (Fig. 22a) and slide the stator rod into the dasher (Fig. 23).

Make certain that the end of the stator rod is inserted into the hole at the rear of the dasher.

CAUTION c.

Assemble and install the rear seal with the rubber portion toward the rear of the freezing cylinder as indicated in Fig. 23.

DO NOT LUBRICATE THE RUBBER PORTION OF

THE REAR SEAL. LUBRICATION ON THE REAR

SEAL WILL DAMAGE THE MACHINE. d. Install the o-ring on the rear of the dasher shaft.

DO NOT LUBRICATE DASHER O-RINGS e. Install the front bearing on the dasher of the large barrel and the high capacity machines.

Lubricate Shaded

Areas Including

Rear of Shoulder

Lubricate

Shaded

Areas

Fig. 22a

Stator Rod and Dasher Lubrication

Fig. 22b

High Capacity Machine

Dasher Assembly

Fig. 22c

Large Barrel Machine

Dasher Assembly

Scraper

Blade

Fig. 23

Dasher Assembly

Dasher

Lubricate Shaded

Areas Including

Rear of Shoulder

Rear Seal

Rear Bearing

Stator Rod

PAGE 8

ASSEMBLY and LUBRICATION

f. Install the scraper blades onto the dasher assembly by holding the blades perpendicular to the tabs (Fig. 24) and then snapping them over the flat area of the support rod. Then rotate the blades downward in a counterclockwise direction as viewed from the front of the dasher (Fig. 25). BE

CERTAIN THAT THE SCRAPER BLADES REST

UPON THE DASHER TABS ON ALL DASHERS

EXCEPT HIGH CAPACITY MACHINE DASHERS.

THOSE BLADES REST UPON PINS.

Note: Reverse the blades at each cleaning to maintain sharpness. In addition, the blades are equipped with a wear mark (Fig. 26). When the blade is worn to this wear mark, it must be replaced.

Dasher Front View

Scraper Blade

Support Rod g. Insert the dasher assembly into the freezing cylinder as far as possible (Fig. 27) being careful not to damage the scraper blades. Damage will occur to the scraper blades and the dispenser will not operate properly if the scraper blades are installed facing in a clockwise direction (Fig. 28).

Blade Support

Tab

Fig. 24

Scraper Blade Installation

Scraper Blade

Dasher Front

View

Rotate Down

Counter

Clockwise

Blades

Resting On Tabs

Blades Pointing In A

Counterclockwise

Direction

CORRECT

Fig. 27

Dasher Installation

Blade Support

Tab

Fig. 25

Scraper Blade Installation

Support Rod

Scraper Blade Wear Mark

End

View

Side

View

Fig. 26

Scraper Blade Wear Mark

INCORRECT

Blades Should

Rest On Tabs

Blades Should Not Point

In A Clockwise Direction

Fig. 28

Dasher Installation

Note: The stator rod has been deleted from Fig. 29 and

Fig. 30 for clarity only. The stator rod must be installed for proper machine operation. h. While maintaining force against the dasher, rotate it slowly until the tongue of the dasher engages the groove in the drive system at the rear of the cylinder. The outer most portion of the dasher should be recessed approximately 1/4” (6 mm) to

3/8” (10 mm) inside the freezing cylinder. No part of the dasher should extend outside the cylinder.

Scraper blades should be visible, extending approximately 1/8” (3 mm) beyond the dasher

ASSEMBLY and LUBRICATION

PAGE 9

Fig. 29

Approximately 1/8 inch

Exposed

Dasher with Blade (Front View)

2. Lubricate and assemble the front plate assembly in the following manner: a. Install the two o-rings on the spigot plunger by rolling them onto the plunger. Seat the o-rings in the grooves. Be certain that they are not twisted.

Smooth the lubricant into the grooves and over the sides of the plunger assembly (Fig. 30).

Spigot Plunger

Fig. 31

Front Plate

Assembly

Spigot Plunger

O-rings

Front Plate O-ring

DO NOT LUBRICATE

Spigot

Handle

Faspin

Front Plate

Knobs

Front Plate

3. The high capacity machine front plate is lubricated and assembles in the same manner.

4. Assemble the large barrel machine front plate in the following manner:

Fig. 30

Spigot Plunger Lubrication

Front Plate

Lubricate Shaded Area

Spigot

Assembly b. Slide the lubricated spigot plunger into the front plate (Fig. 31) making certain that the spigot handle slot is aligned to the front.

C. Insert the spigot handle and secure with the faspin. d. Install the front plate o-ring.

DO NOT LUBRICATE THE FRONT PLATE O-RING e. Secure the front plate assembly with the two plastic knobs. Simultaneously, turn the knobs in a clockwise direction. Tighten the knobs evenly.

DO NOT tighten one knob all the way down and then the other. Doing so may result in front plate breakage. Only moderate force is required.

DO NOT over tighten. Close the spigot plunger.

PAGE 10

O-Ring

Fig. 32

Large Barrel Machine

Front Plate Assembly

ASSEMBLY and LUBRICATION

Front Plate

O-ring

Spigot Nut

Lubricate flat side of nut with Sani-Gel.

Install flat side of nut toward spigot.

Front Plate

Front Plate

O-ring

5. Install the drip tray and drip tray insert (Fig. 34).

6. Install the o-ring on the restrictor tube (Fig. 35) if removable . Apply lubricant sparingly over the oring. Place the restrictor tube in the bottom of the mix pan for sanitizing. Make certain that lubricant does not block the mix inlet hole on the restrictor tube.

7. Proceed to the “Sanitizing” section of this manual.

Spigot

Assembly

Assemble gasket on spigot side.

Warning: Machine damage possible if nut installed incorrectly!

Fig. 33

Large Barrel Machine

Spigot Assembly

Fig. 34

Drip Tray

Assembly

Drip Tray Insert

Drip Tray

Drip Tray Support

Remains Attached

To Machine Front

Fig. 35

Restrictor Tube

Lubrication

Lubricate Shaded

Area Including

O-ring

ASSEMBLY and LUBRICATION

PAGE 11

Sanitizing

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.

1. First, wash hands with a suitable antibacterial hand soap.

For best results select a concentrated anti-bacterial hand soap containing biodegradable anionic and nonionic surfactants.

2. Prepare approximately 2 to 3 gallons (8 to 12 liters) of sanitizing solution equivalent to 200 ppm chlorine residual or the residual required by your local health agency.

3. Carefully pour the solution into the mix pan.

4. Using a sanitary brush, wipe the solution onto the sides of the mix pan, over the mixout probe in the bottom of the mix pan, and the underside of the mix pan lid.

5. Set the control switch

(Fig. 39) to the “CLEANOUT” position and let the unit agitate for approximately three to five minutes.

NOTE: DO NOT set the control switch to the “AUTO” position. Doing so would freeze the sanitizing solution and may result in damage to the machine.

WARNING

DO NOT INSERT ANY TOOLS OR OBJECTS INTO

THE MIX INLET HOLE, RESTRICTOR TUBE HOLE,

OR THE DISPENSING HOLE IN THE FRONT PLATE.

DAMAGE TO THE MACHINE OR PERSONAL

INJURY MAY RESULT (FIG. 36)

6. Set the control switch to the “OFF” position and drain the solution from the machine. Proceed directly to the “Operation” section of this manual.

WARNING

DO NOT RINSE OUT THE MACHINE

DO NOT ALLOW SANITIZING SOLUTION TO

REMAIN IN THE MACHINE FOR SEVERAL HOURS.

DOING SO COULD DAMAGE THE MACHINE.

PAGE 12

Fig. 36

Do Not Insert Objects or Tools

SANITIZING

Operation (Filling and Starting)

Always start with a cleaned and sanitized dispenser as per previous instructions. Following these instructions is critical to the maximum operating efficiency of the machine.

1. Remove the restrictor tube from the bottom of the mix pan 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. Fill the freezing cylinder until the mix comes out of the recirculation hole on units with two mix inlet

Fig. 37

Dispensing Product holes or until the freezing cylinder stops bubbling on units with only one mix inlet hole.

4. Install the removable restrictor tube with a gentle twisting motion into the front hole if the mix pan has two mix inlet holes. For units with only one hole, simply insert the restrictor tube in the only mix inlet hole.

5. Fill the mix pan with chilled, properly mixed product.

Keep the mix level in the mix pan at least one inch

(25 mm) deep at all times to avoid starving the freezing

Fig. 38

MIXOUT Light cylinder. A MIXOUT light (Fig. 38) located on the front of the machine (one per freezing cylinder) is activated when the mix solution drops to a potentially damaging level.

6. Set the control switch to the “AUTO” position to start the machine.

7. Allow the compressor to cycle 3 or 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. Initial pull-down time may vary due to model, product and ambient conditions.

8. Replace the mix pan lid and always operate the machine with the lid on the mix pan reservoir.

Note: SaniServ dispensers are designed to run frozen beverage products having a Brix (sugar content) range of 12.5 to 14 with a dispense temperature of 26

°

F to 28

°

F (-3.3

°

C to -2.2

°

C).

Brix reading is taken by placing a small sample of normally diluted concentrate on the viewer of a refractometer. If a refractometer is not available, contact the mix supplier.

Do not use a mix with a Brix reading of less than

12.5. Doing so may result in serious damage to the machine.

If the Brix reading is above 14.0 or the alcohol content is too high, the freezing point of the solution may be too low to form slush.

DO NOT ATTEMPT TO MAKE FROZEN BEVERAGE

USING ARTIFICIALLY SWEETENED PRODUCT.

MACHINE OPERATIONS WITH ELECTRONIC CONSISTENCY CONTROL

Control Switch Positions

“CLEANOUT” Position: The dasher motor operates continuously and the compressor will not come on.

The mix out level sensor will turn on the “MIXOUT” light but will not activate the beeper.

“AUTO” Position: The dasher motor operates continuously. Upon machine start up the compressor will run until proper product consistency is reached.

Then the compressor will shut off.

If the liquid level sensor detects a low level condition, it will flash the “MIXOUT” light and activate the beeper for three minutes or until the mix pan is filled to satisfy the mix level probe. If the beeper is activated for more than three minutes, the light will begin to glow continuously, the beeping tone will slow down, and the machine will no longer dispense product.

OPERATION

PAGE 13

Helpful Hints

Closed Hours/Shut-Down: If the machine is turned off during closed hours, to resume operation:

1. Set the control switch to the "CLEANOUT" position.

2. Dispense two quarts (2 liters) of product into a sanitized pitcher and pour it back into the mix pan.

Doing so serves as a mixing process to eliminate any overnight separation.

NOTE: NEVER POUR FROZEN PRODUCT INTO

THE MIX PAN. LET IT MELT FIRST.

3. Set the control switch to the "AUTO" position and resume operation.

Mixing: Make certain that the product is prepared per label instructions. The machine is designed to operate with frozen product base having a brix range of 12.5 to

14.0. To ensure consistency and quality, use a mixing container large enough to hold 5 gallons (20 liters) with

1 gallon (4 liter) markings to allow accurate mixing of the frozen beverage base. Stir well before adding to the mix solution to the mix pan. Refrigerate the base after diluting. Keep the empty gallon bottles with their lids or caps installed and refill them with diluted base for easy access during busy operating periods.

Filling: Always fill the machine at the start of each day. Fresh prechilled mix will produce the best results.

Mix Pan Lid: Be sure to leave the lid in place on top of the machine to prevent any foreign materials from contaminating the mix.

Drip Tray: This should be removed daily and cleaned to remove residue (Fig. 37).

Front Plate: This component (Fig. 33) is the plastic device from which the product is dispensed. It is designed and made for strength and durability.

However, through improper use, it can be damaged.

Use the following information for proper care.

1. Do not lubricate the large o-ring on the rear of the front plate. If lubricated, it will not seal properly and product will leak from the front plate (Fig. 33).

2. Do not over tighten the knobs.

3. Always tighten the front plate knobs evenly. Do not attempt to turn one knob all the way down and then the other(s). Doing so will bind the front plate and result in breakage.

4. Improper installation of the stator rod can cause breakage. The stator rod must be properly seated in the dasher before installing the front plate. If the stator rod is improperly installed, subsequent tightening of the knobs will break the front plate.

5. Do not attempt to wash the front plate or any other machine components in a dishwasher.

Mix Out Light: When the mix out light comes on, fill the mix pan. The mix pan must be filled immediately to prevent air from entering the freezing cylinder. If air enters the freezing cylinder, it will create the condition known as “starving the machine”, causing freeze-up and vibration. If this condition occurs, set the control switch to the "OFF" position and add mix to the mix pan. Allow the freezing cylinder to refill and return the control switch to the "AUTO" position.

PAGE 14

HELPFUL HINTS

Consistency Adjustment

WARNING: Adjustments to mechanical and electronic consistency control systems should be made ONLY by trained service personnel

. Power must be removed from the machine before panels

(guards) or protective covers are removed. Once the panels (guards) are removed, an adjustment is made, protective panels (guards) are replaced, power is restored to the machine, and the consistency setting is tested.

This process is repeated as necessary until the desired product consistency is obtained.

The mechanical control system is a very simple method of controlling the consistency of the finished product. The machine operates without a temperature control. Refrigeration is controlled by measuring the torque on the dasher motor and the consistency of the product. The tension of a spring against the torque idler determines how long the unit will run by activating a limit switch which turns the compressor on and off. The longer the compressor runs, the harder the product. The less it runs, the softer the product. Run time and belt tension directly relate to product temperature.

Initial adjustments have been performed at the factory.

However, to satisfy individual product preferences, the following adjustments may be required:

1. Remove power, then remove the right side panel

(guard) as viewed from the front of the machine.

2. Using a regular straight flat blade screwdriver, turn the mechanical consistency (torque adjustment) screw

(Fig. 39) clockwise to make the product harder or counterclockwise to make the product softer. Do not adjust more than one turn each time.

CAUTION

Do not attempt to adjust the belt idler screw (s) marked “Do Not Adjust”.

WARNING

EXTREME CARE SHOULD BE EXERCISED TO

KEEP HANDS AND TOOLS AWAY FROM MOVING

PARTS. PERSONAL INJURY COULD RESULT.

3. Replace the side panel (guard), restore power, and start the machine. Wait 10 - 15 minutes or until the compressor cycles off, then check the consistency of the product.

4. Repeat steps 1, 2 and 3 until the desired product consistency is obtained.

IMPORTANT

NOTE: If product does not freeze to a hard enough consistency, the problem may not be in the machine.

To verify, use a thermometer to measure the product temperature. The problem is NOT in the machine if the temperature of non-alcoholic product is between 26

°

F. and 28

°

F. (-3.3

°

C. and -2.2

°

C.). Product with alcohol is usually 19

°

F. to 22

°

F. (-7.2

°

C. to -5.6

°

C.). Make certain the product mix was prepared to the manufacturer’s recommendation.

Fig. 39

Mechanical Consistency

Control

CONSISTENCY ADJUSTMENT

PAGE 15

Consistency Adjustment

FOR MODEL 704 WITH ELECTRONIC CONSISTENCY CONTROL

Consistency

Control Board

Consistency LED’s

(Green, Yellow, Red)

Potentiometer

Fig. 40

Electronic Consistency Control

CAUTION

1. DISCONNECT THE POWER.

2. Remove the right side panel as viewed from the front of the machine.

3. Use a small slotted and insulated screwdriver to turn the potentiometer clockwise for thicker product or turn it counterclockwise for thinner product. (Fig. 40)

3. Restore power to the unit and set the control switch

(Fig. 44) to the “AUTO” position. Note: The unit will not operate if the mix pan is empty.

4. The three LED’s (green, yellow, and red) are used as reference points 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.

5. Repeat as necessary until desired product consistency is achieved.

PAGE 16

CONSISTENCY ADJUSTMENT

Routine Maintenance (Owner-Operator)

WARNING

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 stop leaks around gaskets or seals, check for improper lubrication and worn or damaged parts. Replace parts as needed.

Periodically: Inspect the scraper blades (Fig. 41) 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.

Clean the drip chute assembly (Fig. 42) with warm water and detergent solution.

Scraper Blade Wear Mark

Fig. 42

Drip Chute

End

View

Side

View

Fig. 41

Scraper Blade Wear Mark

Routine Maintenance (Trained Service Technician)

WARNING

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 (Fig. 43) 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.

ROUTINE MAINTENANCE

Fig. 43

Clean Sharp Condenser Fins

PAGE 17

Routine Maintenance (Trained Service Technician)

WARNING

HAZARDOUS MOVING PARTS

Semiannually: It is advisable to clean and lubricate the idler arms to ensure their smooth operation. Use the following procedures:

1. Make certain that ALL power to the dispenser is off.

2. Remove both side panels first, then remove the rear panel of the machine.

3. Use a pencil to mark the position of the nut (Fig 44) on the side of the belt idler arm spring adjustment mechanism. Relieve the tension on the 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. Note the color of the springs for reassembly.

4. Remove the nut from the pivot point of the belt idler arm assembly.

5. Remove the belt 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 belt idler arm.

Rotation

NOTE: BE CERTAIN NOT TO OVERTIGHTEN THE

LOCKING NUT. ON SOME UNITS IT IS POSSIBLE TO

OVERTIGHTEN THE LOCKING NUT AND CAUSE

THE IDLER ARMS TO BIND. THE ARMS SHOULD

MOVE FREELY.

8. Repeat the process for the torque idler arm.

Mark Nut

Position

With Pencil

Rotation

Mark Nut

Position

With Pencil

Belt Idler

Arm Pivot

Torque

Adjustment

9. 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).

10. Reinstall the torque idler arm spring and the belt idler arm spring and turn the adjustment screws

Torque Idler Arm Pivot returning the adjustment nuts to the pencil marks you placed on the side of each adjustment mechanism in step 3 above.

11. Repeat steps 3 - 9 for the other side if your machine has two freezing cylinders 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.

PAGE 18

ROUTINE MAINTENANCE

Fig. 44

Spring Adjustment Mechanism

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 suggestions, please contact your local certified service provider.

Machine will not start

Product is

Soft

9 Make sure electrical cord is correctly seated in the electrical receptacle.

9

Check circuit breaker in electrical panel.

9

Do not make a consistency adjustment at this point. Always check product temperature first. Should be between 25-28 degrees non-alcoholic frozen beverage and 18-22 degrees alcoholic frozen beverage. If using a frozen beverage product and temperature is lower than listed, product has too much sugar, alcohol or combination. Correct ingredients and start with freshly mixed product.

9 Check for properly mixed product . Replace as necessary

9 Check for dull scraper blades . Blades should be sharp. Replace every 6 months.

9

Condenser for dirt or obstructions. See Quarterly Maintenance

9 Confirm that the condenser fan is running.

9

Confirm 6” of airflow on all both sides and back of machine.

9 High . Recommended machine ambient temperature not to exceed 82 degrees.

Product is too

Thick

Front Plate

Leaking

Product leaking from the drip chute and or drip tube.

Squeaking , chirping noises and or vibration heard.

Who to contact for service and parts

9 Check for properly mixed product .

9 Confirm is not starved of product. See glossary (Starved Cylinder)

9 Check product temperature. Should be between 25-28 degrees non-alcoholic frozen beverage and 18-22 degrees alcoholic frozen beverage.

9

Check for missing scraper blade or stator rod. Check dasher assemblies.

9 Check for sticking spigot lever and or switch. If stuck in the up position, will cause unit to run continually.

9 Restrictor tube installed in rear hole. Install in front hole of mix-pan reservoir.

9 Confirm o-ring is not ripped or torn. Replace if necessary. Replace seals and o-rings every six months.

9

Do lubricate o-ring.

9 Confirm o-rings are not ripped or torn. Replace if necessary. Replace every six months.

9

Confirm spigot plunger o-rings are lubricated daily.

9 Tighten knobs evenly.

9

Confirm is not worn or grooved.

9 Rear Seal is worn. Replace. Note: Replace seals, o-rings and gaskets every six months.

9 Do Not Lubricate the rubber portion of the rear seal

9

The shaft of the dasher where the rear seal is installed must be lubricated daily.

9 Confirm is not worn or grooved.

9

Front plate knobs loose.

9

Use mixed product . Replace as necessary.

9 Confirm is not starved of product. See glossary (Starved Cylinder)

9 Check

9

Confirm all panel screws are installed and tightened

9 Adjust width of drip tray bracket.

9 Check for dull scraper blades . Blades should be sharp. Replace every 6 months.

9 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).

TROUBLESHOOTING GUIDE PAGE 19

PAGE 20

Trouble Shooting Glossary

Ambient Temperature. The temperature of the air in the immediate vicinity of the operating machine. High ambient 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 gallons per hour (G.P.H.).

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.

Front Plate Pressure Relief Valve. Spring-loaded button located on the front plate when depressed will allow air to escape from the cylinder. Used only on specific frozen beverage machines.

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.

Mix-pan. Is the top container that product is poured into. It is used as storage until product is needed for the freezing cylinder.

Mixing Product / Product Temperatures. If your using a product that has to be mixed with water or other ingredients, it is imperative the product is mixed consistently everyday. If not, the machine will not run consistent and could possibly damage components. Always mix to the product manufactures recommendations. The machine is designed to operate with a frozen product that falls within these temperatures (non-alcoholic frozen beverage 25-

28 degrees and alcoholic frozen beverage 18-22 degrees).

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.

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.

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 machine were undersized for its application.

2. Mix out light not working therefore not alerting operator the need to add product.

3. Pouring frozen or semi frozen product into the mix-pan reservoir. This will form a blockage in the restrictor tube and not allow liquid product to flow into the cylinder.

4. Mix-pan too cold, allowing product to freeze in mix-pan and restricting product flow.

5. Restrictor tube installed into the rear hole, should be installed in the front hole of the mix-pan reservoir.

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.

TROUBLESHOOTING GLOSSARY

Service Record

Date Service Performed Serviceman’s Signature

SERVICE RECORD

PAGE 21

SaniServ

®

An AFFINIS GROUP Company

451 E. County Line Road

P.O. Box 1089

Mooresville, Indiana 46158-5089

We are on the web... www.saniserv.com

Proudly made in the U.S.A.

Technical Publication

Publ. No. 105504

Updated 05/06