Donper USA User Manual

Introduction

Thank you for your purchase of a Donper Soft Serve Machine. It is important to read the entire User Manual before operating the machine, as there are several safety issues you must know and understand to safely operate the machine.

If you have any questions about the material in this manual, please call Donper USA at 1-844-366-7371 or email us at Sales@DonperUSA.com. Do not operate the machine until you have read and understood the material in this manual.

Thank you again for your purchase and enjoy your machine!

Introduction to the Machine

The Donper Model 800(H)/900(H) soft serve machine, when properly operated and maintained, is designed to produce a smooth and creamy product to be enjoyed by all. However, it is important to understand that the machine, like ALL machines, will require regular cleaning and maintenance to ensure proper and safe operation.

Failure to clean and maintain the machine as described in this manual will reduce the performance and operational life of the machine, as well as voiding the machine warranty provided by Donper USA.

The following symbols are used throughout this manual:

• General Information: Indicated by a yellow diamond symbol.
• Cautionary Information: Indicated by a yellow triangle with an exclamation mark [!].
• Important Safety Issue: Indicated by a red triangle with an exclamation mark [!], requiring careful attention to avoid injury.
• Electrical Shock Hazard: Indicated by a yellow triangle with a lightning bolt [⚡], requiring careful attention to avoid injury.

To avoid physical injury, this User Manual must be read and understood completely before operating or performing any installation or maintenance on the machine.

Call 1-844-366-7371 before operating the machine if you have any questions about the instructions in this manual.

Machine Specifications

Electrical Requirements (D800(H), D900(H))

Size and Capacity (D800(H), D900(H))

A dedicated 30 amp circuit is required to operate the machine. Using a shared circuit may damage the machine and will void the machine warranty.

The machine uses an air cooled refrigeration system which requires a minimum of 6-8 inches of clearance on the left and right sides of the machine and at least 8 inches of clearance behind the machine.

Dimensional Views

Right Side View: The overall dimensions are approximately 27.50 inches (698.5 mm) wide, with a depth of 19.00 inches (482.6 mm) and a height of 56.5 inches (1435 mm). The unit features air intake vents and a NEMA L6-30P power plug.

Front View: The overall dimensions are approximately 21.25 inches (539.8 mm) wide, with a depth of 16.00 inches (406.4 mm) and a height of 53.88 inches (1368.4 mm). It shows the dispensing handles, digital control panel, internal drip tray, and air intake vents. The power plug is NEMA L6-30P.

Top View: The top view shows the two refrigerated hoppers, with dimensions of approximately 21.25 inches (539.8 mm) wide and 27.50 inches (698.5 mm) deep.

Clearance Diagram: Illustrates the required clearances around the machine. It shows walls on the left and right, with 8 inches of space indicated between the machine and each wall. It also implies 8 inches of clearance behind the machine.

Machine Parts Identification

The following are key components of the Donper soft serve machine:

• Beater Assembly with Scraper Blades & Shaft Seal
• Outer Draw Valve with O-Rings
• Feed Tube with O-Rings
• Middle Draw Valve with H-Seal
• Donper Dispenser Head Knob (Item #: DNP13583374)
• Donper Door Bearing (Item #: DNP68045043)
• Donper Scraper Blade (Item #: DNP91592407)
• Donper Shaft Seal (Item #: DNP95019531)
• Donper Drip Tray Liner (Item #: DNP38058471)
• Donper Drip Tray Splash Shield (Item #: DNP84671020)
• Donper Drive Belts (Item #: DNP40228271)
• Donper Feed Tube O-Ring (Item #: DNP62991333)
• Donper Draw Valve O-Ring (Item #: DNP87539672)
• Donper Middle Draw Valve H-Seal (Item #: DNP92935180)
• Donper Dispenser Door (Item #: DNP24810791)
• Donper Dispenser Door O-Ring (Item #: DNP25063449)

Installation

The machine is shipped on a pallet and secured/bolted to prevent shipping damage. To install, remove the bolts connecting the pallet bracket to the base of the machine. Once removed, the machine can be carefully taken off the pallet.

USE EXTREME CAUTION REMOVING THE MACHINE FROM THE PALLET. Professional unpacking and installation is recommended due to the machine's weight and the potential for bodily injury from improper handling.

Models/Machines use air-cooled refrigeration systems and require a minimum of 6-8 inches of clearance around the sides of the machine and 8 inches around the back panel to allow for adequate airflow. Failure to allow proper clearance will restrict airflow, reduce refrigeration capability, and may cause overheating and/or damage to the cooling system.

Electrical Installation: This equipment must be installed in accordance with the National Electrical Code (NEC), NFPA 70. A licensed electrician must install the electrical connections to ensure safe operation. The machine must be properly grounded. Failure to properly ground the machine can result in severe bodily injury from electrical shock.

Beater Rotation: When making electrical connections, note that the beater rotation must be counter-clockwise when viewed looking into the freezing cylinder from the front of the machine. If the rotation direction is incorrect, it may be necessary to change the position of the hot wires in the machine plug to allow the motors to rotate correctly.

Operating the Machine

Controls Overview

The machine features several controls for operation:

• Main Power Switch: Located on the front panel, labeled "POWER ON" / "OFF".
• Dispense Valve Handles: Three handles are present. The left and right handles dispense pure product, while the middle handle dispenses a mix or a twist of the two pure products.
• Hopper Refrigeration Power Switch: This switch turns on the secondary compressor that cools the product in the two hoppers.
• Digital Control Panel: Features buttons for UP, DOWN, AUTO, WASH, and KEEP FRESH (ON/OFF). It also displays numerical values related to the freezing process.

Machine Controls (cont'd)

Key components are identified as:

1. Dispensing Handles
2. Main Power Switch
3. Valve Body Thumb Screws
4. Drip Tray Cover
5. Hopper Cooling Switch
6. Valve Body
7. Drip Tray

Additional components include:

• A) Level Switch
• B) Air Cap
• C) Feed Tube

Front Control Panel: Shows digital readouts and operational mode buttons (UP, DOWN, AUTO, WASH).

Refrigerated Hoppers with Feed Tubes Installed: Shows the two hoppers where the product mix is stored, with feed tubes inserted.

Operating Modes

The machine has three primary operating modes:

1. Wash Mode: The refrigeration system is turned off, but the mixing motors run. This mode is used to circulate cleaning or sanitizing solution through the machine's hoppers and barrels. During Wash Mode, the refrigeration for the freezing cylinders is OFF. Wash Mode only rotates the beaters without freezing, used to drain mix or rinse components.
2. Auto Mode: The normal operating mode where the refrigeration system and mixing motors are active, allowing the machine to freeze and prepare soft serve product. The digital display shows a cycle from 0 to 99, reaching 00 when the product is ready. An indicator light above the AUTO button flashes when the product reaches the desired firmness. The hopper cooling switch should be ON during Auto Mode. NEVER RUN THE MACHINE IN AUTO MODE WITH WATER IN THE FREEZING CYLINDERS, AS DAMAGE WILL OCCUR.
3. Standby Mode: The machine is configured to keep the product in the barrels refrigerated for extended periods (e.g., during slow sales or overnight).

Operating in Wash Mode

Press the "Wash" button; the "Wash" indicator light will turn on. Both left and right mixing motors will run. Press the "Wash" button again to stop. Wash Mode does not freeze; it only rotates the beaters.

Operating in Auto Mode

Press the Auto button on the control panel for the desired barrel to begin freezing. The indicator light will turn on along with the beater motor. The display will show numbers increasing from 0 to 99, then stop at 00 when the product is ready. The hopper cooling switch should also be ON.

Adjusting Product Firmness Level

With the Power Switch ON and both Auto buttons OFF, press and hold the UP and DOWN buttons simultaneously for 5 seconds (the machine will beep 5 times). A numerical value from 1 to 10 will flash on the screen, representing the firmness setting (1 being softer, 10 being firmer). Use the UP/DOWN buttons to adjust. The control panel will return to "00" after 10 seconds of inactivity.

The recommended starting setting is 5. Monitor the display during the AUTO feature's cycle (0 to 99, then 00). Dispense product to check consistency. If firmer product is desired, increase the setting by 1-2 and allow the machine to recycle. A guide for firmness: numbers should rise from 0 to about 84-87 when the product is liquid. If numbers rise above 87, increase firmness; if they slow before 84, increase firmness.

Operating in Standby Mode

To enter Standby Mode, with the machine in Auto Mode on both sides, press and hold the Wash button for 5 seconds (machine beeps 5 times). The LCD displays will alternate between "00" and "bb". Both mixer motors turn off, and the refrigeration system keeps the product in the cylinders refrigerated. Ensure the hopper cooling system switch is ON.

Feed Tube Position for Standby: To enter standby mode, remove the feed tubes from the hoppers and reverse their position. Remove air caps, insert feed tubes into the bottom end, and reinsert them into the hopper. The hole-side of the feed tube should now be at the top. This prevents product from entering the freezing cylinder.

It is also advised to remove valve caps, drip tray, and drip tray cover. Sanitize and dry these parts. Clean the machine exterior and valve body.

Exiting Standby Mode: To return to normal operation (Auto Mode), press and hold the Wash button for 5 seconds. The machine will return to Auto Mode when the button is released, resuming auger rotation and refrigeration. When exiting Standby Mode, reverse the feed tubes back to their normal operating position (holes nearer the bottom) so product mix can flow into the freezing cylinder. Failure to do so may result in machine damage.

Cleaning the Machine

Draining Product from the Machine

1. Turn Auto Mode OFF for both freezing cylinders. Place the hopper cooling switch in the OFF position.
2. Remove hopper lids and feed tubes. Remove all star caps from dispenser valves.
3. Unscrew Adjustable Flow Rate Screws in handles to fully open draw valves.
4. Place a large bucket beneath the dispenser door. Press the Wash button. Pull and hold all three handles down until all product is removed. Press Wash button to turn Wash Mode off.
5. Pour water/cleaning solution into hoppers and repeat step 4 until drained water is clean.

Cleaning the Machine (Quick Rinse & Sanitize)

The machine should be shut down and fully cleaned every 2-3 days, or as instructed by local health codes. For mix changes or sanitization, follow these steps:

1. Pour a gallon of room-temperature water into each hopper. Allow water to flow into freezing cylinders. Use a tube brush to clean inside hoppers, including L-shaped level probes.
2. Press the Wash button and run in Wash Mode for 1-2 minutes.
3. While in Wash Mode, place a large bucket beneath the dispenser door. Pull and hold all three handles down until all water is removed. Press Wash button to turn Wash Mode off and discard water.
4. Repeat rinse process 2-3 more times until discarded water is clear.
5. Repeat steps 1-3 using water with approved sanitizing solution, then rinse with plain water.
6. If running with new product immediately: Pour 1-2 cups of product into hoppers, activate Wash mode, and dispense product until water is pushed out.
7. If not running immediately: Remove dispensing door and beater bars. Dry freezing cylinder and beater bar components to prevent corrosion. Clean disassembled parts in warm soapy water before reassembly.

Complete Cleaning of the Machine

1. Conduct the quick cleaning and sanitization steps noted above.
2. Remove valve body components by first removing the valve body retaining pin. (Image shows a pin being removed from the valve body assembly).
3. With the handle pin removed, remove valve assemblies (handles and plungers) from the valve body.
4. Unscrew the 4 thumb screws and remove the valve body from the machine.
5. Remove the beater bar from the freezing cylinder. Use caution as scraper blade edges are sharp and may cause injury.
6. Prepare a sink with sanitizer solution and warm water. Use a brush kit to clean disassembled parts. Use a small pipe brush for valve body channels. Remove scraper blades and seals from beater bar and clean all components thoroughly.
7. Clean freezing cylinder and hopper with sanitizing solution using a large tube brush.
8. Dry all cleaned components. Dry the inside of the freezing cylinder and hopper.

Reassembly after Cleaning

1. Ensure the Power switch is OFF. Lubricate the inside surface of the shaft seal and slide it down onto the beater bar shaft, with the flared end pointing away from the beater bar. Apply additional lubricant to the inside of the flared end.
2. Re-attach the four scraper blades to both beaters. Ensure blades slide completely under the stainless steel tabs at the end of each blade.
3. Slide beater assemblies into the freezing cylinder, shaft side first. Ensure the shaft end engages the back of the freezing cylinder. Push the beater bar toward the back of the machine and rotate it until the square end of the shaft fits into the corresponding socket.
4. Reattach door bearings and screw rods onto the back of the dispenser door. Use the handle pin to gently tighten.
5. Place dispenser door O-rings into grooves and lubricate them to help them stick to the door during mounting.
6. Slide the door flush onto the freezing cylinder, ensuring O-rings stay in grooves. Tighten door knobs equally in a criss-cross pattern for a snug fit. Longer knobs go into the top two sockets, shorter knobs into the bottom two. Ensure O-rings are secure before moving. Do not overtighten knobs, as this can cause seals to fail and leaks.
7. Lubricate the O-rings on the three draw valves. Slide draw valves into the dispenser door from the bottom until the slot is visible through the handle insertion hole. Ensure the draw valve slot faces forward. Wipe away excess lubricant.
8. Snap star caps onto dispenser door spouts. Install the three handles and slide the handle pin into place.
9. Install the air cap onto the feed tubes. Ensure the hole in the air orifice is not clogged. If clogged, use soap, water, and a brush to clear it. Do not enlarge the hole in the cap. (Image shows a feed tube with an air cap).

Adding Mix Into the Machine

1. With feed tubes removed, pour about 2 cups of mix into one hopper. As product fills the freezing cylinder, push down the corresponding handle. Sanitizer should flow out ahead of the mix. Once only mix dispenses, return the handle to closed. This ensures all excess sanitizer is removed.
2. Pour the rest of the mix into the desired hoppers.
3. Once bubbles stop rising from hopper openings, insert feed tubes with the hole closest to the bottom and attach air caps. Place covers on hoppers and turn on the Hopper Cooling Power Switch.
4. Press the Auto button to begin freezing. The Auto indicator light will turn on, and the mix will be frozen and ready to dispense in about 7-10 minutes.

Firmness Setting Guidance: When Auto mode is selected, the display numbers should rise from 0 to about 84-87 when the machine starts freezing from a liquid state. If numbers slow before 84 or pass 87 without slowing, adjust the consistency or firmness setting and restart Auto mode. If numbers go past 87 quickly, decrease firmness. If numbers slow before 84, increase firmness.

Error Codes

The following error codes may appear on the control panel. Follow the troubleshooting recommendations and contact your service provider if problems persist.

Error Code: ΠL

Problem:

1. Beater motor rotational speed is low according to the sensor.
2. Belt is slipping on the pulley.

Solution:

1. Inspect drive belts by removing the rear panel (ensure machine is OFF and unplugged). Look for cracking, tears, uneven wear, or excessive looseness. Replace worn belts.
2. If belts are good, check tightness. Belts should not move more than 1-2 inches horizontally when tightened. Tighten if necessary.

If problems persist, contact an authorized repair technician.

Error Code: bb

Problem: Unit is in standby mode.

Solution: To exit standby mode, press and hold the Wash button for 5 seconds.

Error Code: AL

Problem:

1. The temperature inside the freezing cylinder has dropped below 10°F (-12°C) when the machine is in Standby mode.
2. Temperature sensor(s) are disconnected from the main circuit board or are not operating properly.

Solution:

1. Check the freezing cylinder to ensure the product has not frozen solid. If frozen, turn the machine off for 45 minutes to defrost before restarting. Adjust the Product Firmness Level to a lower number (e.g., 7 to 4).

If problems persist, contact an authorized service technician.

Error Code: AH

Problem:

1. The temperature inside the freezing cylinder has risen above 140°F (60°C) or the temperature sensor circuit is short.

Solution:

1. Inspect the R404A refrigeration system to ensure high side and low side pressures are correct.

If problems persist, contact an authorized service technician.

Error Code: CL

Problem: Product level in hopper is low. Unit will beep three (3) times while "CL" flashes.

Solution: Refill the hopper with more product. The display will stop flashing once refilled. If problems persist, contact an authorized service technician.

Error Code: LL

Problem: Machine has entered Low Temperature Protection. When the temperature of the freezing cylinders has dropped below 10°F (-12°C) while in Auto Mode, the compressor will turn off and go into Discharge Mode.

Solution: In Auto Mode, the machine detects product temperature via probes. This protection prevents over-freezing. If over-freezing occurs, turn the machine off for 10 minutes, decrease the firmness setting to a lower number (e.g., 7 to 4), and restart. If problems persist, contact an authorized service technician.

Error Code: -- (Double Dash)

Problem:

1. Breaker in the side panel access door is tripped.
2. Frozen product in the freezing cylinder or object restricting beater rotation. Check for loose wiring, overheating, or faulty starting components.
3. Faulty rotational movement sensor(s).
4. Rotation sensor(s) disconnected from the main circuit board.

Solution:

1. Switch breaker(s) to the upright position.
2. Set Auto Mode OFF and decrease the temperature setting to soften product. Ensure product is not frozen solid before restarting.
3. With the unit powered OFF and UNPLUGGED, inspect beater motors (rear panel removed) for overheating, loose wiring, or obstructions. If motors are hot, allow them to cool before restarting. If problems persist, call an authorized service technician.
4. Inspect the rotational sensors.
5. Inspect the main circuit board for proper connection.

Error Code: C6

Problem:

1. Dispensing handle has been left open for over 60 seconds.
2. Dry torsion spring assembly.

Solution:

1. Return handle(s) to upright position. Turn power switch OFF and restart. Draw valves may not return properly if O-rings or H-rings are not adequately lubricated. Ensure sufficient lubricant on each draw valve during assembly.
2. Lubricate torsion spring assembly.

If problems persist, inspect the limit switch behind the control panel for malfunction and contact an authorized service technician.

Error Code: HH

Problem: High pressure switch has been activated.

Solution: If the high pressure switch is activated, the unit will beep and display "HH". This is caused by high pressure in the main compressor refrigeration system. Possible causes include high ambient temperature, poor condenser cooling, poor air circulation, faulty condenser fan, or dirty condenser coils. Contact an authorized commercial refrigeration technician to inspect the refrigeration system.

Routine Maintenance

Dispensing Handle Flow Rate

The dispensing handles have adjustable flow rate screws to control dispense speed. To increase flow rate, turn the screw counter-clockwise (loosen). To decrease flow rate, turn clockwise (tighten). Once set, tighten the nut against the handle to secure the position. During sanitizing and rinsing, unscrew flow rate screws to a "wide open" position to allow free flow of water and sanitizer.

Maintenance Schedule

General Maintenance Advice

• Drain and thoroughly clean/sanitize the unit every 2-3 days (or per local health codes). Proper cleaning ensures creamier product consistency, increases reliability and efficiency, and prevents costly repairs. Do not run the machine empty, as this can damage internal parts.
• Be familiar with all operational modes and their features for safe and reliable operation.
• Use a recommended soft serve machine cleaner and sanitizer. Regular dish soap, chemicals, and detergents can degrade seals and leave residues.

Things to Make Sure You DO with Your Machine

• ALWAYS unplug the machine before any maintenance, disassembly, or service. NEVER remove side or back panels without unplugging first. Serious bodily injury can occur.
• Drain, clean, and sanitize the unit every 2-3 days. Proper cleaning and preventative maintenance lead to better product consistency, reliability, and efficiency, preventing future costly repairs.
• Understand all operational modes for safe and reliable use.
• Use recommended cleaners/sanitizers. Avoid dish soap, chemicals, and detergents that can degrade seals.
• Visually inspect wearable parts regularly (drive belts, O-rings, shaft seals, dispensing head O-rings, door bearings). Replace parts that are torn, cracking, hardened, or unevenly worn.
• Lubricate seals and O-rings with a food-grade lubricant.

Things to Make Sure You DON'T DO with Your Machine

• Do not run the machine while empty, as this can severely damage internal parts.
• Do not pour water, product, or any fluid into the hopper while beaters are removed from the freezing cylinder, as fluid will be discharged from the machine.
• Do not add candies, jellies, or other particles into the hopper, as they may clog the passageway and damage the unit.
• Do not operate the machine with side panels removed. Loose garments or long hair can get caught in moving parts, causing serious injury. ALWAYS unplug the machine before removing any side or rear panel.
• Do not run the machine with water in Auto Mode. Water will solidify into ice, expand, and severely damage the machine internally, potentially beyond repair.

Troubleshooting

Warranty Information

Donper USA is committed to providing quality products and excellent after-sale service and warranty support. Every Donper USA soft serve machine comes with a full 2-year non-consumable parts warranty for manufacturer's defects. A 3-year warranty is offered on the compressors. These warranties do not cover abuse, failure to maintain, or failure to conduct preventative maintenance as noted in this manual.

These warranties are provided by Donper USA in Houston, Texas, not the manufacturer. Donper USA stocks all warranty parts, and their technical support team is available Monday-Friday, 9 AM to 4 PM CST at 1-844-366-7371 for technical service issues and to dispatch warranty parts via overnight delivery. They aim to resolve issues quickly to minimize downtime.

Donper USA soft serve machines have an optional 1-year labor warranty available. Inquire with your sales representative at the time of purchase.

Thank you for your purchase. Donper USA hopes you will enjoy several years of reliable operation from your machine.