Donper

Model: BH7480

Soft Serve Freezer

Technical Service Manual

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 Technical Service Manual

For Donper BH7480 Soft Serve Machine

Gravity-Fed, Air-cooled, Floor Model

This manual provides detailed technical information about the machine. Instructions and suggestions are
provided for basic operation, maintenance, and care.

The illustrations and specifications are not binding in detail. We reserve the right to make changes to the
machine without notice, and without incurring any obligation to modify or provide new parts for the machines
built prior to date of change.

The following information provided within this Technical Service Manual is intended for qualified commercial
refrigeration repair technicians and service providers. Work should only be performed by qualified commercial
refrigeration repair personnel.

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 Symbol Convention

Informational Notice. General information or tip.

Warning. General warning regarding the safety of the operator and the machine.

Warning. Warning regarding the safety of the operator. Failure to follow this warning may result in
injury.

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 Table of Contents

Section Description Page

1 Description and Specification
1.1 Description
1.2 Specification
2 Installation Instructions
2.1 Safety Precautions
2.2 Shipment and Transit
2.3 Machine Installation
3 Maintenance and Adjustments
3.1 Product Temperature Adjustment
3.2 Drive Belt Tension Adjustment
3.2 Preventative Maintenance
3.3 Extended Storage
4 Refrigeration System
4.1 Refrigeration System
4.2 Refrigerant Recovery and Evacuation
4.3 Refrigerant Charging
4.4 Compressor
4.5 Condenser
4.6 High Pressure Cutout Switch
4.7 Capillary Tube
4.8 Filter Drier
5 Electrical System
5.1 Main Control Board
5.2 AC Contactor
5.3 Limit Switch
5.4 Capacitors
5.5 Proximity Switch

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5.6 Control Panel Circuit Board
5.7 Condenser Fans Motors
6 Mechanical System
6.1 Drive Motor
6.2 Gearbox Speed Reducer
7 Troubleshooting
7.1 Symbol Description
8 Appendix
8.1 Electrical Schematic
8.2 Refrigeration Schematic

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Section 1 Description and Specification

1.1 Description
The Donper BH7480 soft serve machine is an air-cooled, gravity-fed soft serve machine. The BH7480 model is
compatible for ice cream, frozen yogurt, sorbet, and custard. This manual is designed to help qualified service
personnel and technicians with installation, operation, service, and maintenance.
1.2 Specification
Model BH7480
Dimensions Machine
height 56.5 (1435 mm)
width 21.3 (540 mm)
depth 25.6 (650 mm)
Weight 397 lbs (180 kg)
Electrical 230V, 1 Phase, 60Hz
Breaker Type 20A, Double Pole
Connection NEMA L6-20P power cord provided
Compressor 6,452 Btu/hr
Drive Motor 1 HP, TEFC, 1 Phase, 1720 RPM, Start-Run Capacitors
Air Flow Air-cooled units require a minimum of 5 (127 mm) of clearance
around all sides of the machine.
Hopper Volume Two-9.5 quarts (9 liters)
Freezing Cylinder Volume Two-2 quarts (1.9 liters)

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Section 2 Installation Instructions

2.1 Safety Precautions

Failure to adhere to the following safety precautions may result in severe personal injury or
death. Failure to comply with these warnings may damage the machine and its components.
Component damage will result in part replacement expense and service repair expense.

Do not operate the soft serve machine without reading this Users Guide. Failure to follow this
instruction may result in equipment damage, poor freezing performance, health hazards, or
personal injury.

Do not operate the freezer unless it is properly grounded. Failure to follow this instruction may
result in electrocution.

Do not attempt any repairs unless the main power supply to the soft serve machine has been
disconnected. Failure to follow this instruction may result in electrocution.

Do not operate the soft serve machine with larger fuses than specified on your specification
sheet. Failure to follow this instruction may result in electrocution or damage to the machine.
Consult your electrician.

Do not allow untrained personnel to operate this machine. Failure to follow this instruction
may result in severe personal injury to fingers or hands from moving parts.

Do not operate the machine while the stainless steel panels are removed from the unit. Loose
garments and/or long hair can get caught in the moving parts resulting in serious personal
injury.

Do not obstruct the air intake and discharge openings on all sides of the machine. Failure to
follow this instruction may cause poor performance and damage to the machine.

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2.2 Shipment and Transit
The machine has been assembled, operated, and inspected at the factory. Upon arrival at the final
destination, the entire machine must be checked for any damage which may have occurred during
transit.

2.3 Machine Installation

Installation of the machine involves moving the machine close to its permanent location, removing all
crating, setting in place, assembling parts, and cleaning.

A) Uncrate the machine. Using a 13mm ratchet, carefully remove the four (4) brackets that secure the
machine to the bottom of the crate. Use caution when removing the machine from the base.
Assistance will be needed.
B) Accurate leveling is necessary for correct drainage and overrun. Place a bubble level on top of the
machine at each corner to check for level condition.
C) Correct ventilation is required. Allow 8 (203 mm) clearance around all sides to allow for adequate
air flow.
D) Connect the power cord to the proper power supply. The plug on the BH7480 is designed for 230
volt / 20 amp duty. The unit must be connected to a properly grounded receptacle. The electrical
cord furnished with your unit has a three prong grounding type plug. The use of an extension cord
is not recommended. Do not use an adapter to circumvent the grounding requirement.

Do not alter or deform the electrical plug in any way. Altering the plug to fit into an outlet of
different configuration may cause fire, risk of electrical shock, product damage, and will void
warranty.

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Section 3 Maintenance and Adjustments

3.1 Product Firmness Adjustment

5 Second Setting
The up() and down() buttons on the control panel are used to adjust the product firmness level. With the
control panel powered ON, press and hold the up and down buttons simultaneously for 5 seconds for the side
you wish to adjust. The LCD display will flash a numerical value from 1 to 10. You can now use the up and down
buttons to adjust the level of firmness. This value can be adjusted from 1 to 10 (10 being a very firm
consistency and 1 being a very soft consistency). The control panel will automatically return back to 00 after
the numerical value is set.

15 Second Setting
With Press and hold the up() and down() buttons simultaneously for 15 seconds for the corresponding
side. The LCD will now flash -1, -2, -3, or -4. Select the appropriate number based on the type of product you
are using from the table below.

As a guide to determine the appropriate firmness level setting, the LCD should display a value
between 84 to 87 when the Auto button is first pressed when the product inside the freezing
cylinder is in a liquid state.

5 Second Setting 15 Second Setting

Softer Firmer Firmer Softer
1 2 3 4 5 6 7 8 9 10 -1 -2 -3 -4

Recommended Default Settings: 9 and -3

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 3.2 Drive Belt Tension Adjustment

To check belt tension, refer to Figure 3-2 and follow the steps below:
Remove the side panel by unscrewing the six (6) screws with a Phillips head screw driver
Now that both panels are removed you will need the following tools to adjust the belt tension.
13mm socket
13mm wrench
Use a Burroughs Belt Tension Gauge to set the tension for the drive belt. Set the belt tension to 2 lbs.

Figure 3.2

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3.2 Preventative Maintenance

A. Daily
The exterior should be kept clean at all times to preserve the luster of the stainless steel. A mild
stainless steel cleaner is recommended. Use a soft cloth or sponge to apply the cleaner.
Check the o-rings, seals, and scraper blades during the cleaning process for excessive wear and replace
them if necessary.
Remove the drip tray by gently lifting it up and pulling it out. Clean behind the drip tray and front of the
machine with a soap solution.

B. Annual

Air-Cooled Condenser
The air-cooled condenser is a copper tube and aluminum fin type. Condensing is totally dependent
upon airflow. A dirty condenser or restrictions in the shroud panel will restrict airflow. This will lower
the refrigeration capacity of the system and damage the compressor. The condenser must be kept clean
of dirt and grease. The BH7480 must have a minimum of 8 (203 mm) of ventilation around the side
panels of the unit for proper flow of air. Make sure the air entering the machine is under 85F (29 C).
The condensers require annual cleaning. To clean, refer to the following procedures.

Drive Belt Replacement

Disconnect the machine from the power source.

Remove the side panels from the machine by unscrewing the six (6) Phillips head screws from each
panel.
Using a 13mm socket and 13mm wrench, loosen the two (2) tension bolts from the motor base
platform. Once the belts are loose, remove both belts and replace with new.
Be sure both belts are properly inserted in the pulley sheaves before tightening.
Using the 13mm ratchet and 13mm wrench, tighten the tension bolts to apply tension to the new belts.
Use a Browning Belt Tension Gauge to set the tension for the drive belts to 2 lbs max.

3.3 Extended Storage

Refer to the following steps for storage of the machine over any long period of shutdown time:
Place the CLEAN-OFF-ON switch in the OFF (middle) position.
Disconnect (unplug) from the electrical supply source.
With warm detergent water, thoroughly clean all parts that come in contact with mix. Rinse the parts in
clean water and dry them. Do not sanitize.
NOTE: Do not let the cleaning solution stand in the hopper or in the freezing cylinder during the
shutdown period.
Remove, disassemble, and clean the front door and beater parts.

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Section 4 Refrigeration System

4.1 Refrigeration System

The Donper BH7480 soft serve machine contains two (2) refrigeration systems that have separate functions:
Medium Temperature R134a system for maintaining proper product temperature in the hopper.
Low Temperature R404A system for producing and maintaining high quality product in the freezing
cylinder.

Table 4.1
Refrigerant Charge Amount Low Side Pressure Amb
R404A 31.7 oz/ 900 g 15-20 psig (2 min. with 75 degrees
no load)
R134a 4.6 oz/ 130 g 22 psig (5 min. with 2/3 75 degrees
water in the hopper)

Refrigerant Recovery and Evacuation

Refer to the following procedures to properly recover and evacuate the refrigeration system. Do not
purge refrigerant into the atmosphere.

The unit must be disconnected from electrical supply before removing any access panel. Failure to
disconnect power before servicing could result in death or serious injury.

Disconnect the machine from electrical supply before removing any panels for servicing.
Remove theside panels.
If evacuating the system, connect a vacuum gauge to the Schrader valve next to the hopper evaporator.
Perform the recovery. For recovery, operate the recovery unit per manufacturers instructions.

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 4.2 Recovery

For Evacuation of 404A/134A Systems

Evacuate the system until the gauge reads 500 microns of mercury (500 Hg). Turn off evacuation unit and wait
5 minutes.
If the gauge stays below 500 Hg, the system is properly evacuated.
If the gauge slowly rises to 1500-2000 Hg, there is still moisture in the system and further evacuation
is required.
If the gauge rises to atmosphere, the system has a leak which must be resolved before continuing.
Remove evacuation or recovery unit and gauge.

4.3 Recovery Procedure

1. Disconnect machine from power supply.

2. Remove electrical panel to access circuit board
3. Locate -FJ- and -DCF- terminals on main circuit board
4. Label/tag wires to ensure proper reconnection to correct terminals
5. Remove -FJ- and -DCF- wires. Attach jumper wires to terminals
6. Locate terminal -A- label and remove wire
7. Attach loose ends of jumper wires to terminal -A-
8. Connect recovery machine and gage manifold and hoses properly
9. Connect hoses to recovery bottle on scale
10. Start recovery machine
11. Turn both power and keep fresh switches off
12. Plug unit into power supply
13. The solenoids are now energized to access all the 404A refrigerant in system
14. Check the solenoids periodically to be sure they dont overheat
15. If warm unplug the unit till cool then plug in again
16. Continue recovery till all refrigerant is removed
17. Once recovery is complete unplug the unit
18. Remove jumper wires, reconnect wires to -A- -FJ- and -DCF- terminals
19. Reinstall circuit panel cover

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Refrigerant Charging

Refer to the following procedures to properly charge the refrigeration system.

Per manufacturer's recommendation, charging system must be done with liquid refrigerant only.

For qualified service personnel only: Anybody working with refrigerants must be certified as a Technician
TYPE I as required by 40 CFR 82 Sub part F and hold all State and/or local refrigerant handling certifications.
In addition, all handling, storage, and disposal of refrigerants must be in accordance with Environmental
Protection Agency (EPA) guidelines and standards and all State and local guidelines and standards.

Ensure the electrical supply has been removed before continuing.

If the system has been opened or if there was a leak, refer to Section 4.2 - Refrigerant Recovery and
Evacuation to evacuate the system prior to charging.
Refer to machines information plate for total charge requirements.
For liquid refrigerant charging, connect refrigerant cylinder to the discharge Schrader valve of the
compressor.
Add the proper amount of refrigerant according to the unit's information plate.

The refrigeration system of the Donper BH7480 is critically charged. Be sure to charge the system
to the weight listed on the machines information plate.

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4.4 Compressor
The BH7480 has a Reciprocating Welded Hermetic compressor (Fig. 4-2). This compressor type uses two spiral
shaped scrolls to compress gas. One scroll rotates around an identical stationary scroll. Gas is drawn into the
compression chamber by the rotating scroll and is compressed as it moves towards the center of the chamber.
Operation of this compressor is continuous because, during each rotation, several gas pockets are
compressed simultaneously. Details of the compressors starting components are in Section 5.

Winding Test
To test the compressor motor windings for possible problems, perform the following steps:
1. Disconnect the machine from electrical supply before removing any panels for servicing.
2. Remove the front panel.
3. Pull the compressor connector plug off of the compressor. The compressor has three terminals; C (common), R
(run), and S (start). (Fig. 4-3)
4. Connect an ohmmeter to the C and R terminals. Resistance through the run winding should be 1.81 10%.
5. Connect an ohmmeter to terminals C and S. Resistance through the start winding should be 2.27 10%.
6. Connect an ohmmeter to the R and S terminals. Resistance through the start winding should be 4.08 10%.
7. To check if windings are shorted to ground, connect one ohmmeter lead to a bare metal part on the compressor
(such as any copper line leading to or from the compressor) and check terminals C, R, and S.

Compressor Removal
1. Disconnect the machine from electrical supply before removing any panels for servicing.
2. Disconnect the electrical plug from the compressor.
3. Recover refrigerant charge per the instructions in Section 4.2.
4. Remove six inches of insulating tubing on the suction line going to the compressor and unsweat the
suction and discharge line from the compressor.
5. Remove the four nuts and washers from the base of the compressor.
6. Remove the compressor.
7. Remove the four rubber compressor mounts from the compressor.
8. Plug all open ports of the old compressor.

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Compressor Installation
1. Make sure the machine is disconnected from the electrical supply before servicing.
2. Install the four rubber mounts on the compressor.
3. Install the new compressor into the machine, fitting the base over the four bolt holes.
4. Install the four washers and nuts onto the bolts and tighten securely.
5. Remove all tubing plugs from the replacement compressor.

The compressor plugs protect the compressor from moisture in the air. Do not remove the plugs
until you are ready to install. The compressor must not be opened to the atmosphere for more
than 10 minutes.

6. Leave a port open to prevent pressure buildup. Braze the suction and discharge line to the compressor.
7. Connect the wires to the compressor terminals.
8. Replace the liquid line drier per the instructions in Section 4.8.
9. Evacuate the system per the instructions in Section 4.2
10. Recharge the system per the instructions in Section 4.3.
11. Replace the insulation on the suction line.

4.5 Condenser

The BH7480 has an air-cooled condenser. The capacity of the machine is directly related to keeping the
condenser clean and free of debris, regardless of cooling type. The air-cooled condenser is a copper tube and
aluminum fin type. There must be a minimum of 3 of clearance at the front and back of the machine. The
water-cooled condenser is a tube and shell type. This condenser requires cool, clean water to function
properly. Inlet and discharge lines must be 3/8 ID minimum.

CONDENSER TESTING
The condenser can be checked for leaks using the bubble test or using an electronic leak detector.

Condenser Cleaning
Disconnect (unplug) the machine from the electrical supply source.
Remove the side panels by unscrewing the sic (6) Phillips head screws. Next, slide the panel down and
away.
Remove the R404A condenser fan by unscrewing the four (4) 10mm bolts that secure the fan to the
shroud assembly. Carefully remove the condenser fan to gain access to the condenser.
Carefully clean the condenser fins from the inside and outside of the machine. A stiff bristled brush
may help in releasing debris from between the condenser coils. Be sure not to bend the aluminum fins
on the condenser. Brush in the direction of the fins up and down, not side to side.
Remove the accumulated dust and debris with a vacuum cleaner or damp rag.

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4.6 High Pressure Cutout Switch
The high pressure cutout (Fig. 4-6) will stop the compressor if the high side pressure reaches 47 mpa.
Figure 4-6 High Pressure Cutout

On: 2.8 mpa = 406 psig

Off: 3.3 mpa = 479 psig

High Pressure Cutout Test

Connect a gauge to the Schrader valve on the discharge line.
Disconnect condenser fan.
High pressure cutout switch should trip when pressure reaches 47 mpa. When the high pressure switch
is activated, the front control panel will display HH on the LCD screen and beep continuously.

High Pressure Cutout Removal

1. Remove the side panels.
2. Disconnect terminals from high pressure cutout.
3. Recover refrigerant charge per instructions in Section 5.2.
4. Leave a port open to prevent pressure buildup during removal.
5. Apply a heat sink (i.e. wet cloth) to the cutout switch.
6. Unsweat cutout from discharge line.

High Pressure Cutout Replacement

1. Apply a heat sink (i.e. wet cloth) to the new cutout switch.
2. With an open port, braze the cutout to the discharge line.
3. Replace the drier per the instructions in Section 4.9.
4. Evacuate the system per the instructions in Section 4.2.
5. Recharge the system per the instructions in Section 4.3.
6. Connect the wire terminals for the high pressure cutout switch

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4.7 Capillary Tube
The capillary tube meters refrigerant flow in the evaporators (Fig. 4-9). The amount of flow is dependent on
the length and ID of the capillary tube as well as the refrigerant charge.
Inner Diameter Length Flow Rate
R404A System 0.047 33.46 15.54 ounces/min
R134a System 0.0236 32.3 1.69 ounces/min

Figure 4-9 Capillary Tube

Capillary Tube Removal

Recover refrigerant charge per instructions in Section 4.2.
Leave a port open to prevent pressure buildup during capillary tube removal.
Remove foam insulation from the capillary tube at the evaporator inlet.
Unsweat the capillary tube and remove.

Capillary Tube Replacement

Position the capillary tube in place.
Apply a heat removing gel to the capillary tube and drier assembly.
With an open port, braze the capillary tube into the system using appropriate brazing material.
Replace foam insulation to the capillary tube at the evaporator inlet.
Evacuate the system per instructions in Section 4.2.
Recharge the system per instructions in Section 4.3.

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4.8 Liquid Line Drier
The liquid line drier must be replaced every time the refrigeration system is opened for service. A new filter
drier improves operation of the entire refrigeration system by stopping the circulation of moisture and by
removing harmful contaminants (Fig. 4-10).
Part Description
R404A System Emerson EK-083S
R134a System Emerson EK-032S

Figure 4-10

Filter Drier Removal

Recover refrigerant charge per instructions in Section 4.2.
Cut the refrigeration line as close to the filter drier as possible and remove drier.
Cap the ends of the drier using the plugs from the new drier to prevent moisture from entering.

Filter drier replacement

Position the filter drier so the arrow is pointing towards the evaporators (pointing away from the
condenser).
Apply a heat removing gel or wet cloth to the filter drier.
With an open port, braze the filter drier into the system using appropriate brazing material.
Evacuate the system per instructions in Section 4.2.
Recharge the system per instructions in Section 4.3

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Section 5 Electrical System

5.1 Main Control Board

The control board uses a microprocessor to control all timing and mode operations. It processes
information from the motor and spigot and sends signals to the compressor and motor.

Main Control Board Test

1. The following test will show if the control board has proper voltage.
2. Remove the header panel.
3. When the CLEAN-OFF-ON switch is in the ON position, read voltage on the control board. Voltage
should be near line voltage.

Service on the machine must be performed by a qualified electrician/refrigeration specialist. Any

tests or work done on the machine must be done by a qualified technician. Service to the
machine done by an unqualified person, could result in serious personal injury.

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5.2 AC Contactor
The AC contactor is located inside the electrical box behind the right side panel. The control board
sends electronic signals to trigger the AC contactor and start the compressor.

A. Contactor Test
The following test will show if the control board is sending a voltage signal to the AC contactor.
Remove the header panel.
When the CLEAN-OFF-ON switch is in the ON position, read voltage on the control board across the L1
terminal and one of the neutral terminals (P2, P3, P4 or P5). Voltage should be near line voltage (208-
240VAC).
Read voltage on the control board across the L1 terminal and the Compressor Contactor terminal
during a freezing cycle. Voltage should be 0V.
The following test will show if a Contactor is receiving a voltage signal from the control board.
Remove the header panel.
Read voltage across the coils of the AC contactor during a freezing cycle. Voltage should be near line
voltage (230V). If there is no voltage reading, refer to Section 7 Troubleshooting.

Figure 5-2 Contactor

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5.3 Limit Switch

Figure 5-3 Limit Switch

Amp Voltage
7.5 A 250 V

Installation:
1. Disconnect machine from electrical supply before removing any panels for servicing.
2. Remove the handles, dispenser door assembly, and beaters from the machine.
3. Unscrew two (2) screws underneath the plastic, front control panel. Carefully remove the plastic
control panel by sliding it downwards. See picture below.
4. Unscrew the two (2) Philips screws that secure the Limit Switch to panel. See picture below.
5. Label the four (4) wires that connect to the limit switches. This is to ensure that the wires are
reconnected to the proper terminals during reassembly.

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5.4 Capacitors
The R404A compressor start and run capacitors are located in the electrical box behind the left side panel. See
Figure 5-4a. The capacitor for the Lafert drive motors are mounted directly on top of the motor inside the
electrical housing compartment. See Figure 5-4b.

Figure 5-4a Compressor Capacitors

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Capacitor Test
1. Place the Power switch in the OFF position.
2. Remove a lead from one of the capacitor terminals.
3. Using insulated pliers, create a short across the capacitor terminals with a 20K 5W resistor to
discharge the capacitor.

NOTE: Create the short even if there is a bleeder resistor across the terminals. There may be an open in the
bleeder resistor preventing it from working properly.

Disconnect the bleeder resistor from the circuit.

Measure capacitance across the terminals. The results should be as follows:
Capacitor F Voltage
Lafert Drive Motor Model: LME80L4
Lafert Drive Motor Start 80 280
Lafert Drive Motor Run 20 400
R404A Compressor Make: Tecumseh Model: CAJ2464Z
R404A Compressor Start 125 280
R404A Compressor Run 20 400
R134a Compressor Make: Donper Model: L65DZ
Start 75 300

B. Capacitors Replacement
Place the Power switch in the OFF position.
Remove leads from the capacitor terminals.
Using insulated pliers, create a short across the capacitor terminals with a 20K 5W resistor to
discharge the capacitor.
Pull the capacitor out of its holder and replace.
Connect the leads to the terminals.

Create the short even if there is a bleeder resistor across the terminals. There may be an open
in the bleeder resistor preventing it from working properly.

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5.5 Rotational Sensor
1. Disconnect machine from electrical supply before removing any panels for servicing.
2. Remove the left or Right side panel depending on which rotational switch you are replacing.
3. The rotational sensor is located next to the gearbox reducer. See Figure 5-5 below.
4. Remove the two (2) 10mm bolts attaching the rotational sensor bracket to the machine frame.
5. Remove the 14mm nut that is securing the rotational switch to the bracket.
6. Follow the wiring from the rotational sensor to the circuit board and replace.

Figure 5-5 Rotational Switch

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5.6 Control Panel Circuit Board
1. Disconnect machine from electrical supply before removing any panels for servicing.
2. Remove the handles, dispenser door assembly, and beaters from the machine.
3. Unscrew two (2) screws underneath the plastic control panel. Carefully remove the plastic control
panel by sliding it downwards.
4. Unscrew the four (4) screws that secure the Control Panel Circuit Board to the plastic control panel as
shown in Figure 5-6

Figure 5-6a Control Panel Circuit Board (Back)

Figure 5-6b Control Panel Circuit Board (Front)

5. After removing the circuit board follow the wire harness from the control panel to the main PCB circuit
board located on the left of the machine as shown in the picture below:
6. Remove the left side panel (point of view: front) from the machine.
7. Remove the four (4) screws from the main circuit board housing cover. This will give you access to the
main circuit board.

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Code Description
ZC9 Control Panel Circuit Board Harness

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5.7 Condenser Fan Motor

A. Fan Motor Removal

Disconnect machine from electrical supply before removing any panels for servicing.
Remove the side panels.
Trace and disconnect the wires AC contactor.
Remove the four (4) 10mm bolts that secure the fan to the condenser. Be careful to not damage the
aluminum fins of the condenser with the fan blades.
Cut the wiring from the fan

B. Fan Motor Installation

Attach fan with the four bolts.
Route the wires to the AC contactor.
Reconnect the wiring.

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Section 6 Mechanical System

6.1 Driver Motor

Drive Motor
The drive motor is used to rotate the auger assembly. An internal, normally closed, centrifugal switch
starts the drive motor. The motor has an internal thermal overload.

A. Drive Motor Voltage Test

The following test will show if the relay on the control board is working properly and sending a voltage signal
to the drive motor.
1. Remove the header panel.
2. When the OFF-ON switch is in the OFF position, read voltage on the control board across the L1
terminal and one of the neutral terminals (P2, P3, P4 or P5). Voltage should be near line voltage (208-
240VAC).
3. Read voltage across the L1 terminal and the AUGER terminal. Voltage should be 0V.

B. Drive Motor Removal

1. Disconnect machine from electrical supply before removing any panels for servicing.
2. Remove the back panel and also the left and right side panel of the machine.
3. Remove the ground wire from the machine frame.
4. Loosen the motor adjustment bolts at the front and back of the motor.
5. Rotate the motor so that the electrical cover plate can be removed. Remove the cover plate from the
back of the motor.
6. Identify (mark) wires and remove them from the motor.
7. Remove the belt tension adjustment nut and remove the belt.
8. Remove the two bolts from the bushing clamp at the rear of the machine and pull the motor out
through the back of the machine.
9. Remove the bolts that connect the motor to the mounting plate.
10. Loosen the two allen head screws from the pulley.
11. Remove the pulley and key from the motor shaft.

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C. Drive Motor Installation
1. Place the drive motor on the mounting plate and install the four mounting bolts.
2. Place the pulley and key on the motor shaft.
NOTE: Do not tighten the pulley screws until after the belt tension has been properly adjusted.
3. Install the motor and mounting plate in the machine to the bushing clamp using the mounting bolts.
4. Install the belt and the tension bolt. Tighten the tension bolt.
5. Test for proper belt tension using a Burroughs Belt Tension Gauge to set the tension for the drive
belt. Set the tension to 15-25 lbs.
6. Using a straightedge, align the drive motor pulley with the gearbox pulley. Tighten the two Allen
head screws on the drive motor pulley.
7. Loosen the motor cradle clamps at the front and back of the motor.
8. Rotate the motor so that the electrical cover plate can be removed. Remove the cover plate from the
back of the motor
9. Install wiring according to the wiring diagram. Install electrical cover plate.
10. Tighten the motor cradle clamps.
11. Install back and side panels.

6.2 Gearbox
A. GEARBOX REMOVAL
1. Disconnect machine from electrical supply before removing any panels for servicing.
2. Remove the back panel and the side panels.
3. Remove protective shield from side of machine.
4. Remove the belts.
5. Remove the pulley by loosening the set screws.
6. Remove the three bolts holding the gearbox to the barrel.
7. Remove the two bolts holding the gearbox to the mounting bracket and remove the gear box
through the rear of the machine.

B. GEARBOX INSTALLATION
1. Place the gear box in position from the rear of the machine. Fasten the three bolts through the gear
box to the rear of the barrel.
2. Fasten the gearbox to the mounting bracket using the two bolts.
3. Mount the pulley on the gear box shaft and align with the motor pulley, then tighten the Allen head
screws.
4. Install the belt.
5. Test for proper belt tension using a Browning Belt Tension Gauge to set the tension for the drive belt.
Set the tension to 2 lbs max.

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Section 7 Troubleshooting

Displayed Signal Meaning

1 NL Problem:
Problem with drive motor's rotational speed
Belt is slipping on the pulley.
Solution:
Visually inspection the drive belts by removing the rear panel
of the machine. Be sure the machine is powered OFF and
unplugged before inspecting. Look for signs of cracking, tears,
uneven wear, or excessive belt looseness. If signs do exist,
replace drive belt(s) with new.
Make sure rear breaker switches are in the ON position.
If problems persist, contact a food service equipment repair
technician.
2 -- Problem:
Problem with beater electric motor. Check for overheating or
faulty capacitor(s).
Faulty rotational sensor(s).
Rotational sensor(s) disconnected on main circuit board.
Breaker(s) on rear panel in the downward position.
Frozen product in the freezing cylinder or object restricting
the rotational of the beater(s).
Solution:
With the unit powered OFF and unplugged, carefully inspect
beater motors with rear panel removed. Check for
overheating, loose wiring, or any signs of obstruction. If
motor(s) seems excessively hot, turn machine OFF and allow
time to cool down before restarting. If problems persist, call a
food service equipment repair technician.
Inspect the rotational sensors.
Inspect the main circuit board for proper connection.
Switch breaker(s) to the upright position.
Be sure product is not completely frozen solid inside the
freezing cylinder before restarting. Check freezing cylinders of
any foreign matter that may impede the rotational movement
of the beater.
If problems persist, contact a food service equipment repair
technician.

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3 Cb Problem:
Dispensing handle has been left open for over one (1) minute.

Solution:
Return handle(s) back to upright position. If beeping
continues, turn power switch OFF and restart as normal.
Lubricate torsion spring assembly.
If problem still exists, inspect limit switch located behind the
control panel for any malfunction.
4 HH Problem:
High pressure switch has been activated.

Solution:
While the machine is in Auto Run Mode, if the high pressure
switch is activated, the unit will repeatedly beep, control
panel lights will turn off, and the control panel will stop
working. This is caused by high pressure being detected at the
condenser inlet point. Caused by:
High ambient temperature
Poor cooling from the condenser
Poor air circulation around the machine
Faulty R404A condenser fan
Dirty condenser coils

Contact a commercial refrigeration technician to inspect the

refrigeration system.
5 AL Problem:
The temperature inside the freezing cylinder has dropped
below 10F(-12C)
Temperature sensor(s) are disconnected from the main circuit
board.

Solution:
Check the freezing cylinder to make sure product has not
frozen solid. If the product is frozen solid, turn machine off
and allow time to defrost before restarting. Adjust the Product
Firmness Level as needed.
Contact a commercial refrigeration technician to inspect the
refrigeration system and electronic instrumentation.

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6 AH Problem: The temperature inside the freezing cylinder has risen
above 140F (60C) or the temperature sensor circuit is short.

Solution: Make sure machine has enough space on all sides for
proper ventilation. Open rear panel and visually inspect condenser for
dust or debris. If dirty, clean with a soft brush or moist towel. Be
careful not to damage the heat fins. Do NOT spray with compressed
air. If problems persists, contact a commercial refrigeration technician
to inspect the refrigeration system and electronic instrumentation.
7 bb Unit has entered Keep Fresh mode
8 CL Problem:
Product level in hopper is low. Unit will beep three (3) times
while CL flashes in the display.
Solution:
Refill hopper with more product. After the hopper has been
refilled, the display will no longer flash.
9 LL Problem:
1.Machine has entered Low Temperature Protection. When the
temperature of the freezing cylinders has dropped below 10F (-
12C), the compressor will cycle off and go into Discharge Mode.

Solution:
1. In Auto Mode, the temperature sensors detect the temperature of
the product in the freezing cylinders. This Low Temperature
Protection is to prevent the product from over freezing. If over
freezing occurs, adjust the product firmness level (See Section 5).

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