Cornelius FCB 3 H.P. POST-MIX DISPENSER Installation & Service Manual

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IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234 Telephone (800) 238-3600 Facsimile (612) 422-3246

Installation/Service

Manual

FCB 3 H.P. POST-MIX DISPENSER

TWO-FLAVOR W/HOT-GAS DEFROST AND V3+ FEATURES

IMPORTANT:

TO THE INSTALLER. It is the responsibility of the Installer

to ensure that the water supply to the dispensing equipment is provided with protection against backflow by an air gap as defined in ANSI/ASME A112. 1.2-1979; or an approved vacuum breaker or other such method as proved effective by test.

Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed, and maintained according to Federal, State, and Local laws.

Part No. 312026000 March 14, 1995 Revised: February 3, 1998 Control Code A–B–C

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment

IMI CORNELIUS INC; 1995–98

PRINTED IN U.S.A

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TABLE OF CONTENTS

GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT DESCRIPTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFRIGERATION SYSTEMS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“AIR-COOLED” 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“WATER-COOLED” 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THEORY OF OPERATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEFROST SYSTEMS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL DEFROST SYSTEM 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTOMATIC DEFROST SYSTEM 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘SLEEP’’ (SLEEP TIME) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘WAKE UP’’ (WAKE UP TIME) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNPACKING AND INSPECTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION OF LOOSE-SHIPPED PARTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL POWER REQUIREMENTS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SELECTING LOCATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING UNIT 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLACING UNIT IN OPERATING LOCATION 7. . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING SOUND BAFFLE/DRIP TRAY ASS’Y ON UNIT 8. . . . . . . . . . . .

INSTALLING PRIMARY CO2 REGULATOR ASSEMBLY ON CO2

CYLINDER 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING SOFT DRINK TANKS CO2 LINES TO PRIMARY CO2

REGULATOR ASSEMBLY 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT

DRINK TANKS 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING CITY PLAIN WATER SOURCE LINE (S) TO UNIT 9. . . . . .

CONNECTING ELECTRICAL POWER CIRCUIT TO UNIT 10. . . . . . . . . . . . .

PREPARATION FOR OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TURNING ON ELECTRICAL POWER TO UNIT 10. . . . . . . . . . . . . . . . . . . . . . .

TURNING ON CO2 SUPPLY TO UNIT 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TURNING ON CITY PLAIN WATER SOURCE LINE TO UNIT 11. . . . . . . . . . .

CONNECTING SOFT DRINK TANKS TO UNIT SYRUP SYSTEMS 11. . . . . .

ADJUSTING BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ OF DISPENSED

PRODUCT 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FILLING FREEZE CYLINDERS WITH PRODUCT 12. . . . . . . . . . . . . . . . . . . . .

ADJUSTING “WATER-COOLED” UNIT REFRIGERATION SYSTEM

VARIABLE WATER REGULATOR 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE) 13. . . . . . . . . . . .

PROGRAMMING MAIN MENU SELECTIONS ONTO THE MESSAGE

DISPLAY 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO THE UNIT 13

PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO THE UNIT 13. . . . . . . . . . . .

PROGRAMMING ‘‘WAKE UP’’ (WAKE UP) TIME INTO THE UNIT 13. . . . . . .

PROGRAMMING POINT OF SALE MESSAGE DISPLAY 13. . . . . . . . . . . . . . .

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TABLE OF CONTENTS (cont’d)

ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED

PRODUCT 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“VIS READ” (ACTUAL VISCOSITY READOUT) OF PRODUCT IN

FREEZE CYLINDERS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON

OUTLET SENSORS TEMPERATURES 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) 14. . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE)

INTO THE UNIT 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYING ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS)

ONTO THE MESSAGE DISPLAY 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT

ELECTRONICS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT

ELECTRONICS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED ERROR CONDITIONS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING CONTROL BOX COVER AND BACK, SIDES LOWER ACCESS,

AND TOP PANELS ON UNIT 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATORS INSTRUCTIONS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

CONTROL PANEL SWITCHES AND DISPLAYED MESSAGES 17. . . . . . . . . . . . . .

CONTROL PANEL SWITCHES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL DISPLAY MESSAGES 18. . . . . . . . . . . . . . . . . . . . . . . . . . . .

FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS 19.

MANUAL DEFROST SYSTEM 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTOMATIC DEFROST SYSTEM 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘SLEEP’’ (SLEEP TIME) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘WAKE UP’’ (WAKE UP TIME) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FACEPLATE RELIEF VALVES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT SAMPLE VALVES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT SHUTOFF VALVES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMARY CO2 REGULATOR 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY CO2 REGULATORS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATED WATER FLOW REGULATORS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP FLOW REGULATORS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSING VALVES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT CONDITIONS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘OVERRUN’’, AS APPLIED TO FROZEN CARBONATED BEVERAGES 20. .

OPERATING CHARACTERISTICS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING UNIT 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING SYRUP SUPPLY 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT FLAVOR CHANGE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING CO2 SUPPLY 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CONDENSER COIL 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS (cont’d)

LUBRICATION 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATED WATER FLOW RATE 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CO2 REGULATORS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING BEATERS MOTORS CURRENTS 24. . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY 24

SETTING ‘‘CLOCK’’ (TIME OF DAY) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT 24. .

PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT 24. . . . . . . . . . . . . . . . .

PROGRAMMING ‘‘WAKE UP’’ (WAKE UP) TIME INTO UNIT 24. . . . . . . . . . . .

PROGRAMMING POINT OF SALE MESSAGE DISPLAY 24. . . . . . . . . . . . . . .

ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED

PRODUCT 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“VIS READ” (ACTUAL VISCOSITY READOUT) OF PRODUCT IN

FREEZE CYLINDERS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND

COMMON OUTLET SENSORS TEMPERATURES 25. . . . . . . . . . . . . . . . . . . .

‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) 25. . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE)

INTO UNIT 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYING ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS)

ONTO MESSAGE DISPLAY 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT

ELECTRONICS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT

ELECTRONICS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED ERROR CONDITIONS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP DOUBLE LIQUID CHECK VALVE MAINTENANCE 26. . . . . . . . . . .

CLEANING CO2 GAS CHECK VALVES 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND MAINTENANCE 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING 27. . . . . . . . . .

PERIODIC INSPECTION 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL OF DRIP TRAY, AND BACK, SIDES, TOP, LOWER FRONT ACCESS,

AND CONDENSER COIL ACCESS PANELS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIP TRAY 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BACK PANEL 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIDE PANELS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOP PANEL 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOWER FRONT ACCESS PANEL 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSER COIL ACCESS PANEL 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATOR WATER PUMP MOTOR 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE

CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES 28. . . . . . . . . . . . . . . . . . . . .

CLEANING CONDENSER COIL 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT WITH AIR-COOLED REFRIGERATION SYSTEM 35. . . . . . . . . . . . . . . .

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TABLE OF CONTENTS (cont’d)

Page

UNIT WITH WATER-COOLED REFRIGERATION SYSTEM 36. . . . . . . . . . . . .

ADJUSTMENTS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING PLAIN WATER PRESSURE REGULATOR 36. . . . . . . . . . . . . . . .

ADJUSTING CARBONATED WATER FLOW RATE 36. . . . . . . . . . . . . . . . . . . .

ADJUSTING CO2 REGULATORS 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING BRIX (WATER-TO-SYRUP) “RATIO” OF DISPENSED

PRODUCT 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT CARBONATION ADJUSTMENT 38. . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE) 39. . . . . . . . . . . . .

ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS INTO UNIT 40

PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY 40

SETTING CLOCK (TIME OF DAY) 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT 41. . .

PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT 41. . . . . . . . . . . . . . . . .

PROGRAMMING ‘‘WAKE UP’’ (WAKE UP TIME) INTO UNIT 43. . . . . . . . . . . .

PROGRAMMING POINT OF SALE MESSAGE DISPLAY 43. . . . . . . . . . . . . . .

ADJUSTING “VIS SET” (PRODUCT VISCOSITY) OF DISPENSED

PRODUCT 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘VIS READ’’ (ACTUAL VISCOSITY READOUT) OF PRODUCT IN

FREEZE CYLINDERS 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND

COMMON OUTLET SENSORS TEMPERATURES. 44. . . . . . . . . . . . . . . . . . . .

‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) 44. . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE)

INTO UNIT 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYING ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS)

ONTO MESSAGE DISPLAY 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO

UNIT ELECTRONICS 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT

ELECTRONICS 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED ERROR CONDITIONS 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING OF UNIT 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING SYRUP SYSTEMS 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YEARLY OR AFTER WATER SYSTEM DISRUPTION) 52. . . . . . . . . . . . . . . . . . . . .

SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK

VALVE 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING SYRUP SUPPLY 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP FLAVOR CHANGE 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CO2 GAS CHECK VALVES 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR 56. . . . . . . . . . . . . . . .

ADJUSTING CARBONATED WATER TANKS LIQUID LEVEL 58. . . . . . . . . . . . . . .

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TABLE OF CONTENTS (cont’d)

TROUBLESHOOTING 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT

MESSAGES 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING. 63. . . . .

ALL CONTROL PANEL SWITCHES NOT OPERATING. 63. . . . . . . . . . . . . . . .

ALL CONTROL PANEL SWITCHES NOT OPERATING. (COND’T) 64. . . . . .

CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED. 64. . . . . . . . . .

PARTIAL MESSAGE OR DULL (POORLY ILLUMINATED) DISPLAY. 64. . . . .

ONE OR MORE FAULT MESSAGES NOT OPERATING. 64. . . . . . . . . . . . . . .

ALL FAULT MESSAGES NOT OPERATING. 64. . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘CO2 OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. 65. . . . . . .

‘‘H2O OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. 65. . . . . . .

‘‘SYRUP 1’’ OR ‘‘SYRUP 2’’ FAULT MESSAGE GOES ON DURING

OPERATION. 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘ERROR 1’’ OR ‘‘ERROR 2’’ FAULT MESSAGE GOES ON DURING

OPERATION. 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT

OPERATE. 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE. 65. . . . . . . . . . .

MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN ‘‘DEFROST’’

SWITCH IS PRESSED. 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING ‘‘CANCEL

DEFROST ’’ SWITCH. 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATORS 66. .

CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE. 66. . . . . . . . .

CARBONATOR WATER PUMP WILL NOT SHUT OFF. 66. . . . . . . . . . . . . . . . .

ERRATIC CARBONATOR WATER PUMP CYCLING. 66. . . . . . . . . . . . . . . . . .

TROUBLESHOOTING DISPENSED PRODUCT 67. . . . . . . . . . . . . . . . . . . . . . . . . . .

BRIX (WATER–TO–SYRUP) ‘‘RATIO’’ TOO LOW. 67. . . . . . . . . . . . . . . . . . . . .

BRIX (WATER–TO–SYRUP) ‘‘RATIO’’ TOO HIGH. 67. . . . . . . . . . . . . . . . . . . . .

IMPROPER PRODUCT DISPENSED. 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE, IN ONLY

SMALL AMOUNTS, OR ONLY LIQUID. 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN

DISPENSING. 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY. 67. . . . . . . . .

CYLINDER FREEZE–UP. 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING REFRIGERATION SYSTEM 68. . . . . . . . . . . . . . . . . . . . . . . .

UNIT EQUIPPED WITH AIR-COOLED REFRIGERATION SYSTEM 68. . . . .

UNIT EQUIPPED WITH WATER-COOLED REFRIGERATION SYSTEM 68. .

ACCESSORIES AND TOOLS 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERIC FLAVOR TABS 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE TOOLS 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

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TABLE OF CONTENTS (cont’d)

LIST OF FIGURES

FIGURE 1. FCB DISPENSER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 2. FLOW DIAGRAM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 3. SELF-CLOSING DISPENSING VALVE 28. . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 4. OPERATING CONTROLS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 5. UNIT INTERNAL COMPONENTS 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. FREEZE CYLINDER CUTAWAY VIEW 32. . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 7. SERVICING BEATER MOTOR DRIVE SHAFT/SEAL ASSEMBLY 33.

FIGURE 8. BEATERS AND SCRAPER BLADES INSTALLATION 34. . . . . . . . . . . .

FIGURE 9. CONTROL PANEL 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 10. MASTER AND RELAY CIRCUIT BOARD 45. . . . . . . . . . . . . . . . . . . . . .

FIGURE 11. LIQUID CHECK VALVE ASSEMBLY 54. . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 12. CO2 GAS CHECK VALVE 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 13. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK

VALVE 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 14. CARBONATOR LIQUID LEVEL CONTROL SWITCH

ADJUSTMENT 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 15. REFRIGERATION FLOW DIAGRAM (AIR-COOLED

REFRIGERATION SYSTEM) 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 16. REFRIGERATION FLOW DIAGRAM (WATER-COOLED

REFRIGERATION SYSTEM) 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 17. WIRING DIAGRAM 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

LIST OF TABLES

TABLE 1. DESIGN DATA 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 2. LOOSE-SHIPPED PARTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 3. MAIN MENU SELECTIONS 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 4. DIP SWITCH SETTINGS 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 5. MOTOR SELECT 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 6. POINT OF SALE DISPLAY MESSAGES 42. . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 7. “TOTALS” (DISPLAYED CYCLES AND HOURS TOTALS) MENU 47. . .

TABLE 8 DISPLAYED ERROR CONDITIONS 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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GENERAL INFORMATION

IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, and maintaining this equipment. Refer to Table of Contents for page location of information pertaining to questions that arise during installation, operation, service and maintenance, or troubleshooting this equipment.

Warranty Registration Date

(to be filled out by customer) Model Number: Serial Number: Install Date: Local Authorized

Service Center:

GENERAL DESCRIPTION

This section gives the description, theory of operation, and design data for the FCB 3 H.P. Two-Flavor Post-Mix Dispenser with Hot-Gas Defrost and V3+ Features (hereafter referred to as a Unit).

UNIT DESCRIPTION

The Two-Flavor FCB Dispenser (see Figure 1) consists basically of two freeze cylinders each containing an internal beater driven by an electric motor, one refrigeration system with a 3-horsepower compressor, two carbonated water tanks which feed both carbonator-blender tanks, a timer-controlled automatic hot-gas defrost system to defrost the freeze cylinders, and interconnecting tubing, components, and fittings necessary to regulate, transfer, and dispense product.

The components are attached to a steel frame and are enclosed in a steel cabinet. The cabinet panels are easily removed to facilitate installation and service and maintenance. A transparent faceplate, with an integral relief valve and a removable self-closing dispensing valve, is mounted on front of each freeze cylinder. A removable drip tray, with cup rest, is located directly below the dispensing valves.

FIGURE 1. FCB DISPENSER

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CAUTION: Before shipping, storing, or relocating Unit, syrup systems must be sanitized and all sanitizing solution must be purged from syrup systems. All water must also be

purged from plain and carbonated water systems. A freezing ambient environment will cause residual sanitizing solution or water remaining inside Unit to freeze resulting in damage to internal components.

Table 1. Design Data

Unit Part Number:

Two-Flavor 3 H.P. (Air--Cooled) 4166200000 Two-Flavor 3 H.P. (Water-Cooled) 4166220000

Overall Dimensions:

Height Width Depth (W/O Drip Tray) Depth W/Drip Tray

Shipping Weight (approx) 466 pounds

Compressor Horsepower 3 H.P.

Refrigeration System:

Refrigerant Type and Charge See Unit

60-1/2 inches 19-1/4 inches 32-1/2 inches

38 inches

Nameplate

Ambient Operating Temp. 40° F to 100° F

Electrical Requirements:

Operating Voltage See Unit Nameplate Current Draw See Unit Nameplate

REFRIGERATION SYSTEMS

NOTE: The FCB Dispenser (depending upon the model number) refrigeration system is either

“air-cooled” or “water-cooled”.

“AIR-COOLED”

The “air-cooled” FCB Dispenser refrigeration system is equipped with a condenser coil that is cooled by a condenser coil fan.

“WATER-COOLED”

The “water-cooled” Two-Flavor FCB Dispenser refrigeration system is equipped with a Refrigeration Cooling Coil Assembly that contains both refrigerant and plain water cooling coils. Circulating cool plain water through the cooling coil cools the refrigerant also inside the coil. During installation, City cold plain water is connected to the FCB Dispenser Refrigeration Cooling Coil water inlet line labeled “COOLING WATER IN”. The water drain line labeled “COOLING WATER OUT” must be routed to and be connected to a permanent drain.

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THEORY OF OPERATION

(see Figure 2)

IMPORTANT: Before connecting electrical power to Unit, refer to nameplate and note if Unit is to be operated with 50 or 60 Hz power source.

Note: The following paragraph describes the theory of operation for the Two-Flavor FCB Dispenser (see Figure 2).

A CO2 cylinder delivers carbon dioxide (CO2) gas to an adjustable primary CO2 regulator assembly attached to the cylinder. The primary CO2 regulator assembly in turn delivers CO2 gas to an adjustable secondary CO2 regulators inside the Unit and also to the soft drink tanks. CO2 is delivered from the adjustable secondary CO2 regulators to the two carbonated water tanks and also to the product-blender tanks inside the Unit. CO2 gas pressure pushes syrup out of the soft drink tanks through the syrup sold-out switches, through adjustable syrup flow regulators, through electrically-operated syrup solenoid valves, and on to the product blender tanks. At the same time, plain water passes through the water pressure regulator and is pumped into the carbonated water tanks by the water pump and is carbonated by CO2 gas pressure also entering the tank. Carbonated water is pushed by CO2 gas pressure from the carbonated water tanks, through adjustable carbonated water flow regulators, through electrically operated carbonated water solenoid valves, and on to the product blender tanks. Carbonated water and syrup enter the tanks properly proportioned (blended) for desired BRIX of dispensed product by adjustment of the syrup flow regulators. From product blender tanks, product is pushed by the CO2 gas into the freeze cylinders. The beater in each freeze cylinder is driven by an electric motor. Scraper blades, attached to the beaters, scrapes product from the cylinder walls as product enters the freeze cylinders and is frozen. Transparent faceplate, attached to the front of each freeze cylinder, includes a self-closing dispensing valve and a spring-loaded relief valve that protects freeze cylinder from accidental over pressure. The relief valve is also used to bleed CO2 gas pressure from the freeze cylinder to atmosphere when filling the cylinder with product. Electronic sensing on each freeze cylinder motor provides a means of adjusting viscosity (consistency) of the dispensed product to suit customer preference.

DEFROST SYSTEMS

The Unit is equipped with both manual and automatic hot-gas defrost systems. The automatic defrost system may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours between defrost time settings or the system may be completely turned off.

MANUAL DEFROST SYSTEM

The Manual hot-gas defrost system may be activated at any time by pressing the ‘‘DEFROST’’ switch on front of the Unit. Refrigeration compressor will operate for a short time, then both freeze cylinders will go into defrost and defrost for approximately 60-seconds. At the end of the manual defrost cycle, the Unit will return to normal operation. Manual defrost may be cancelled at any time by pressing the ‘‘CANCEL DEFROST’’ switch.

AUTOMATIC DEFROST SYSTEM

The automatic hot-gas defrost system may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours between defrost settings. At the start of each automatic defrost cycle, refrigeration compressor will operate for 30-seconds to pump freon out of the freeze cylinders evaporator coils. After freon has been pumped out of the freeze cylinders evaporator coils, No. 1 freeze cylinder only will go into defrost cycle and defrost for approximately 7-minutes, then will return to normal operation. This ends the automatic defrost cycle of No. 1 freeze cylinder. No. 2 freeze cylinder will defrost 30-minutes after the start of No. 1 freeze cylinder. The next automatic defrost cycle will occur according to the time programmed into the Unit. Automatic defrost may be cancelled at any time by pressing the ‘‘CANCEL DEFROST’’ switch.

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‘‘SLEEP’’ (SLEEP TIME)

‘‘SLEEP’’ (SLEEP TIME) may be programmed into Unit to allow Unit to go into sleep time (Unit shut down, freeze cylinders beaters and refrigeration systems not operating). At start of sleep time, refrigeration compressor will operate for 30-seconds to pump freon out of freeze cylinders evaporator coils, then No. 1 freeze cylinder will go into defrost and defrost for 60-seconds. After No. 1 freeze cylinder has defrosted, No. 2 freeze cylinder will go into defrost and defrost for 60-seconds. At end of No. 2 freeze cylinder defrost, Unit will shut down and go into sleep time.

‘‘WAKE UP’’ (WAKE UP TIME)

‘‘WAKE UP’’ (WAKE UP TIME) may be programmed into the Unit to allow Unit to resume normal operation at a desired time. When programmed wake up time is reached, an alarm will sound for a short duration, then Unit will resume normal operation.

NOTE: Automatic defrost, sleep time, and wake up time may be used in any combination together or separately.

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*WATER PRESSURE REGULATOR IS FACT ORY ADJUSTED TO 45–PSI AND SHOULD NOT BE READJUSTED.

**SYRUP SOLD–OUT SWITCHES ARE FACTORY ADJUSTED AND SHOULD NOT BE READJUSTED.

LINE LEGEND CO

PLAIN WATER CARB WATER SYRUP PRODUCT

CARBONATOR

TANK

PRODUCT BLENDER

TANK(2)

PRODUCT SHUTOFF

VALVE(2)

FREEZE

CYLINDER(2)

FREEZE CYLINDER

OVERFLOW TUBE

PRODUCT SAMPLE

VALVE(2)

CARBONATED WATER

VOLUME SAMPLE VALVE

CARBONATED WATER

SOLENOID VALVE(2)

CARBONATED WATER

FLOW REGULATOR(2)

SYRUP SOLENOID

VALVE(2)

PRIMARY CO

REGULATOR ASS’Y

CYLINDER

SYRUP SOLD–OUT

FLOAT SWITCH(2)

**SYRUP SOLD–OUT

SWITCH

CHECK

VALVE

SYRUP FLOW

REGULATOR(2)

LIQUID CHECK

VALVE(2)

DOUBLE

LIQUID

CHECK

VALVE

PRESSURE

SWITCH

CHECK

VALVE(3)

SOFT DRINK

TANK(2)

SECONDARY CO2 REGULATORS

TO PRODUCT BLENDER

TANKS (60–PSI GAGE) (2)

SECONDARY CO2 REGULATOR

TO CARBONATOR TANK

(100–PSI GAGE)

FIGURE 2. FLOW DIAGRAM

CARBONATOR

WATER PUMP

*WATER PRESSURE

REGULATOR

WATER

PRESSURE

SWITCH

PLAIN WATER

SOURCE

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INSTALLATION

This section covers unpacking and inspection, installing LOOSE-SHIPPED PARTS, selecting location, installing Unit, preparing for operation, and operation.

UNPACKING AND INSPECTION

(see Figure 4)

NOTE: The Unit was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it. Any damage or irregularities should be noted at time of delivery (or not later than 15 days from date of delivery) and immediately reported to the delivering carrier. Request a written inspection report from Claims Inspector to substantiate any necessary claim. File claim with the delivering carrier, not with IMI Cornelius Inc.

1. After Unit has been unpacked, remove shipping tape and other packing material.

2. Remove Unit sides, top and back panels as instructed.

3. Unpack LOOSE-SHIPPED PARTS. Make sure all items are present and in good condition.

IDENTIFICATION OF LOOSE-SHIPPED PARTS

1. TAPERED GASKETS, WHITE (item 1) are used to seal connections when connecting Unit product inlet lines to product tanks and connecting Unit CO2 inlet line to CO2 source.

2. SPANNER WRENCH, DISPENSING VALVE (item 2) is used to remove shank nuts securing dispensing valves to faceplates.

3. CLEANING BRUSH (item 3) is used to clean faceplate relief valves passages.

Table 2. Loose-Shipped Parts

Item No. Part No. Name Qty.

1 178025100 Tapered Gasket, White 4 2 322859000 Spanner Wrench, Dispensing Valve 1 3 325216000 Cleaning Brush 1 4 311304000 Tapered Gasket, Black 3 5 2899 Wrench, Rear Seal Housing 1 6 3810 Tool, Drive/Coupler Adjustment Gauge 1 7 325018000 Caster Kit, 4-inch diameter Casters 1 8 XXXX Sound Baffle/Drip Tray Ass’y (see NOTE) 1

Note: All parts for the Sound Baffle/Drip Tray Assembly are shipped with the Dispenser in a separate box and must be installed on the Dispenser. Refer to Installation Instructions provided with the Sound Baffle/Drip Tray Assembly for installation procedure.

4. TAPERED GASKET, BLACK (item 4) is used to seal connection when connecting plain water source line to Unit water inlet line.

5. WRENCH, REAR SEAL HOUSING (item 5) used to remove the drive shaft/seal assembly from inside the freeze cylinder.

6. TOOL, DRIVE/COUPLER ADJUSTMENT GAUGE (item 6) is used for servicing the beater motor drive shaft/seal assembly (see Figure 7).

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7. CASTER KIT (item 7) to be installed on the Unit as instructed in Instructions provided in the Kit.

8. All parts for the SOUND BAFFLE/DRIP TRAY ASS’Y (item 8) are shipped with the Dispenser in a separate box and must be installed on the Dispenser during Dispenser installation.

ELECTRICAL POWER REQUIREMENTS

IMPORTANT: Before connecting electrical power to Unit, refer to nameplate and Note if Unit is to be operated with 50 or 60 Hz power source.

A properly grounded 198-253 VAC, 60Hz single-phase electrical circuit with a 30-amp minimum-rated disconnect switch (not provided) fused at 30 amps (slow-blow) or circuit connected through an equivalent HACR circuit breaker must be available to the Unit. ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES. MAKE SURE UNIT IS PROPERLY GROUNDED.

SELECTING LOCATION

CAUTION: This Unit is intended for indoor installation only. Do not install this Unit in an outdoor environment which would expose it to the outside elements.

IMPORTANT: Unit operating ambient temperature MUST NOT EXCEED 100° F. Operating ambient in excess of 100° F will automatically void the factory warranty and will eventually result in Unit failure. Several means are available to achieve proper ambient temperature and air circulation around the Unit which are wall air intake grilles and ceiling exhaust fans, air conditioning, etc. Consult local codes.

Locate Unit so the following requirements are satisfied.

1. Close to a plain water inlet supply line with a minimum pressure of 12-psig.

NOTE: “AIR-COOLED FCB DISPENSER The “air-cooled” FCB Dispenser refrigeration system is equipped with a condenser coil that is cooled

by a condenser coil fan. Circulating air, required to cool the refrigeration system’s condenser coil, is drawn in through the grille on front and exhausted out through the sides and back of Unit. Restricting air circulation through the Unit will decrease its cooling efficiency.

2. When installing Unit, do not allow obstruction to block grille on front which will block off air intake to inside of Unit. If installation dictates only one side or back being unobstructed, allow 18-inches clearance between Unit and obstruction. If both sides or one side and back are unobstructed, allow 12-inches clearance. If both sides and back are unobstructed, allow 6-inches clearance.

CAUTION: Do not place or store anything on top of the Unit.

INSTALLING UNIT

PLACING UNIT IN OPERATING LOCATION

1. Place Unit in operating location meeting requirements of SELECTING LOCATION.

The FCB Dispensers manufactured prior to the model documented in this manual were elevated in the front (dispensing valve side) 1/4 to 3/8-inch higher than the back when placing the Unit in operating position to eliminate gas pockets being trapped inside the freeze cylinders. Due to a redesign of the foam pack in the models documented in this manual, elevating the front of the Dispenser is no longer required. The Dispenser must be leveled at time of placing in operating location.

IMPORTANT NOTICE

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Note: An alternate to sealing the Unit base to the floor would be to install the available 4-inch Caster Kit (P/N 309570000).

2. After Unit has been placed in operating location, make sure it is sitting in a level position.

3. To comply with National Sanitation Foundation (NSF) requirements, Unit installed with base contacting floor must have base sealed to floor with Dow Corning RTV 731 or equivalent.

INSTALLING SOUND BAFFLE/DRIP TRAY ASS’Y ON UNIT

All parts for the SOUND BAFFLE/DRIP TRAY ASS’Y (item 8) are shipped with the Dispenser in a separate box. Refer to Installation Instructions provided with the Sound Baffle/Drip Tray Assembly and install as instructed.

INSTALLING PRIMARY CO2 REGULATOR ASSEMBLY ON CO2 CYLINDER

(see Figure 2)

WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder in upright position with a safety chain to prevent it from falling over. Should the valve become accidentally damaged or broken off, CO2 cylinder can cause serious personal injury.

WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is

suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO2 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation.

1. Unscrew protector cap (with chain attached) from CO2 cylinder valve. Open CO2 cylinder valve slightly counterclockwise to blow any dirt or dust from outlet fitting before installing primary CO2 regulator, then close valve.

2. Remove shipping plug from primary CO2 regulator assembly coupling nut and make sure gasket is in place inside nut. Install regulator assembly on CO2 cylinder so gages can be easily read, then tighten coupling nut. DO NOT OPEN CO2 CYLINDER VALVE AT THIS TIME.

CONNECTING SOFT DRINK TANKS CO2 LINES TO PRIMARY CO2 REGULATOR ASSEMBLY

(see Figure 2)

1. Connect soft drink tanks CO2 lines to primary CO2 regulator manifold assembly as shown in Figure 2.

2. Install gas quick disconnects on ends of soft drink tanks CO2 lines. DO NOT CONNECT CO2 LINES TO TANKS AT THIS TIME.

PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT DRINK TANKS

(see Figure 2)

1. Route Unit syrup inlet lines, labeled No. 1 and No. 2, out through hole provided in the Unit base to the soft drink tanks location.

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2. Install liquid disconnects on ends of Unit syrup inlet lines. DO NOT CONNECT SYRUP LINES TO TANKS AT THIS TIME.

CONNECTING CITY PLAIN WATER SOURCE LINE (S) TO UNIT

NOTE: All of the Units require connection to a city plain water source line with a minimum water pressure of 12-psig to be connected to the Unit plain water inlet line, which provides plain water to the Unit post-mix system. The Unit equipped with a water-cooled refrigeration system also requires a city plain water source line be connected to the refrigeration cooling coil assembly plain water inlet line. Proceed as follows to connect a city plain water source line to the Unit.

Connecting City Plain Water Source Line to Unit Post-Mix System.

(see Figure 2)

NOTE: IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the city plain water source line (see applicable Figure NO TAG) that provides plain water to the Dispenser post-mix system. A Cornelius Water Filter (P/N 313860000) and Quick Disconnect Set (P/N 313867000) are recommended.

1. Before connecting the city plain water source line to the Unit that provides plain water to the post-mix system, open shutoff valve in city plain water source line for a period of time to flush out any metal shavings.

2. Route Unit plain water inlet line out through hole in bottom of Unit base.

NOTE: The carbonator plain water inlet adjustable water pressure regulator (see Figure 2) is factory adjusted to 45-psi and should not be readjusted.

3. Connect Unit plain water inlet line to the city plain water source line (12-psi minimum pressure). Seal connection with TAPERED GASKET, BLACK (item 4). DO NOT OPEN THE CITY PLAIN WATER SOURCE LINE SHUTOFF VALVE AT THIS TIME.

Connecting City Plain Water Source Line to Unit With Water-Cooled Refrigeration System.

(See Figure 16)

NOTE: The water-cooled Two-Flavor FCB Post-Mix Dispenser has one water-cooled refrigeration system that requires connection of a City plain water source line to its refrigeration cooling coil plain water inlet line. THE CITY PLAIN WATER SOURCE LINE MUST INCLUDE A WATER SHUTOFF VALVE. Proceed as follows to connect the City plain water source line to the Dispenser refrigeration cooling coil plain water inlet line.

1. Route the refrigeration cooling coil plain water inlet line labeled “COOLING WATER IN” and line labeled “ COOLING WATER OUT” out through hole in bottom of the Unit base.

2. Connect the refrigeration cooling coil plain water inlet line labeled “COOLING WATER IN” to the City plain water inlet line. Seal connection with TAPERED GASKET, BLACK (item 4).

3. Route the line labeled “COOLING WATER OUT” to a permanent drain and connect. Seal connection with a black TAPERED GASKET, BLACK (item 4).

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CONNECTING ELECTRICAL POWER CIRCUIT TO UNIT

(see Figure 17)

WARNING: Make sure disconnect switch (not provided) or equivalent HACR circuit breaker is in ‘‘OFF’’ position.

IMPORTANT: Power circuit voltage across L1 and L2 terminals on the contactor inside the lower control box, with refrigeration compressor operating, must be in the range of 198-253 VAC, 60Hz single-phase for proper operation. Use No. 10 AWG copper wire, or larger, depending upon line length, in suitable conduit or BX sheath. POWER CIRCUIT TO UNIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES.

1. Remove lower control box (located on lower-right side facing front of Unit) cover for access to contactor L1 and L

2. Connect electrical power from a 30-amp minimum-rated disconnect switch (not provided) fused at 30-amps slow-blow or through an equivalent HACR circuit breaker to L1 and L2 terminals on the contactor inside the control box. MAKE SURE GROUND WIRE IS CONNECTED TO GREEN GROUND SCREW INSIDE CONTROL BOX.

terminals.

WARNING: This Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator. A green screw, with lock washer, is provided inside control box to connect power circuit ground wire electrically grounding the Unit.

3. Install lower control box cover and secure with screws.

PREPARATION FOR OPERATION

TURNING ON ELECTRICAL POWER TO UNIT

Turn on electrical power to Unit. Operational status of Unit is now being displayed as fault messages on control panel message display. The following fault messages will be continuously displayed at 2-second intervals until necessary operation requirements are satisfied.

‘‘OFF 1’’ (Beater Motor No. 1 not operating) ‘‘OFF 2’’ (Beater Motor No. 2 not operating) ‘‘H2O OUT’’ (No water supply to Unit) ‘‘CO2 OUT’’ (No CO2 gas supply to Unit) ‘‘SYRUP 1’’ (No syrup supply to Unit No. 1 syrup

system) ‘‘SYRUP 2’’ (No syrup supply to Unit No. 2 syrup system)

TURNING ON CO2 SUPPLY TO UNIT

1. Open CO2 cylinder valve slightly to allow lines to slowly fill with gas, then open valve fully to back seat valve. Back-seating valve prevents leakage around valve shaft.

IMPORTANT: If bag-in-box syrup supply system will be connected to the Unit instead of soft drink tanks, the primary CO2 regulator (see figure 2) must be adjusted to no less than 80-PSI.

2. For soft drink tanks installation (see Figure 2), adjust primary CO2 regulator by turning regulator adjusting screw to the right (clockwise) until regulator pressure reads 80 to 100-psig. OUT OF CO2 warning light on control panel message display should have gone out.

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3. Pull up on product blender tanks relief valves to purge air from tanks.

4. Remove Unit lower stainless steel access panel as instructed for access to carbonator secondary CO regulators (see Figure 4).

5. Check product blender tanks secondary CO2 regulators with 60-psi gages for pressure setting which should be set at 25 to 30-psi for best textured product. If further adjustment is necessary, adjust as instructed.

IMPORTANT: The carbonated water tanks secondary CO2 regulators must be adjusted 25-psi higher or more above product blender tanks secondary CO2 regulators pressure settings. Carbonated water and syrup pressures must be able to overcome and vent product blender tanks head pressures while tanks are filling with carbonated water and syrup. Carbonated water tanks secondary CO2 regulators not adjusted high enough will cause decreased flow of carbonated water into the product blender tanks which will increase brix of the dispensed product.

6. Adjust carbonated water tanks secondary CO2 regulators, with 100-psi gages, by turning regulators adjusting screws to the right (clockwise) until gages reads 50 to 60-psi.

7. Pull up on carbonated water tanks relief valves plastic covers to purge air from the tanks.

TURNING ON CITY PLAIN WATER SOURCE LINE TO UNIT

City Plain Water Source Line Connected to Unit Post-Mix System (Water-Cooled and Air-Cooled Refrigeration Units).

Open shutoff valve in City plain water line connected to the Unit Post-mix system. Check for water leaks and tighten or repair if evident. ‘‘H2O OUT’’ fault message should have gone out but ‘‘SYRUP 1’’, and ‘‘SYRUP 2’’ fault messages will continue to be displayed.

City Plain Water Source Line Connected to Unit With Water-Cooled Refrigeration System.

Open shutoff valve in City water line connected to the refrigeration cooling coil assembly. Check for water leaks and tighten or repair if evident.

CONNECTING SOFT DRINK TANKS TO UNIT SYRUP SYSTEMS

IMPORTANT: Product shutoff valves, located in lines leading from product blender tanks to freeze cylinders (see Figure 2 and 5), must be closed at this time. Closing valves prevents product from filling freeze cylinders while checking BRIX of product in product blender tanks.

1. Close product shutoff valves, located in lines leading from product blender tanks to freeze cylinders, to prevent product from entering cylinders.

IMPORTANT: The following CO2 and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows:

To disconnect soft drink tank from Unit syrup system. A. Disconnect liquid disconnect from soft drink tank. NOTE - Disconnecting liquid quick disconnect

from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment.

B. Second, disconnect CO2 quick disconnect from soft drink tank.

2. Pressurize soft drink tanks containing syrup, then connect tanks to Unit syrup systems. ‘‘OFF 1’’, ‘‘OFF 2’’, ‘‘SYRUP 1’’, and ‘‘SYRUP 2’’ fault messages will continue to be displayed.

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ADJUSTING BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ OF DISPENSED PRODUCT

NOTE: The Unit is equipped with one control panel (see Figure 4) which controls operation of the two freeze cylinders. The Unit control panel is equipped with a hidden ‘‘SECURITY SWITCH’’ located between ‘‘FILL 1’’ and ‘‘ERROR RESET’’ control switches (see Figure 4). Pressing in and holding the ‘‘SECURITY SWITCH’’ for 10-seconds deactivates the control switches preventing tampering with the Unit normal operation. To reactivate the control switches, press in and hold the ‘‘SECURITY SWITCH’’ for 10-seconds.

The following steps 1 through 9 are instructions for adjusting Brix (Water-to-Syrup ‘‘Ratio’’ (mixture) of dispensed product on one of the two systems.

Note: The adjustable carbonated water flow regulators (see Figure 2 and 13 ) located in their respective systems, control carbonated water flow rate to the product blender tanks. The water flow regulators are factory adjusted at 1.3  0.05 oz/sec and should not normally require adjustment. If adjustment is necessary, adjust as instructed.

1. Press ‘‘FILL 1’’ switch to fill No. 1 syrup system sold-out float. ‘‘SYRUP 1’’ fault message will go out and ‘‘FILL 1’’ fault message will come on. ‘‘OFF 1’’, ‘‘OFF 2’’, and ‘‘SYRUP 2’’ fault messages will continue to be

displayed.

2. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 system product blender tank with product. ‘‘FILL 1’’ fault message will go out when ‘‘AUTO BLEND 1’’ switch is pressed. When product blender tank is full, press

‘‘FILL 1’’ switch to prevent more product from entering tank. ‘‘OFF 1’’, ‘‘OFF 2’’, and ‘‘SYRUP 2’’ fault messages will continue to be displayed.

3. Open No. 1 product blender tank product sample valve (see Figure 2) and take sample (approximately 6-ounces) of product in a cup or glass.

NOTE: Temperature compensated hand-type refractometers (P/N 511004000) are available from The Cornelius Company.

4. Check product BRIX with a temperature compensated hand-type refractometer. BRIX should read 13 ± 1. If BRIX is not within tolerance, adjust white syrup flow regulator for No. 1 syrup system as follows:

Turn regulator adjusting screw to the left (counterclockwise) no more than 1/8-turn at a time to reduce syrup flow rate or turn screw to the right (clockwise) no more than 1/8-turn to increase flow rate.

5. Place container under No. 1 product sample valve. Open valve to purge product out of product blender tank, line, and valve, then close valve. ‘‘OFF 1’’, ‘‘OFF 2’’, and ‘‘SYRUP 2’’ will continue to be displayed.

6. Press ‘‘AUTO BLEND 1’’ switch to run new batch of product into product blender tank. When product blender tank is full, press

‘‘FILL 1’’ switch to prevent more product from entering product blender tank. ‘‘OFF 1’’, ‘‘OFF 2’’, and ‘‘SYRUP 2’’ fault messages will continue to be displayed.

7. Repeat steps 3 and 4 preceding to check product sample for BRIX.

8. Repeat steps 5 through 7 preceding until proper BRIX adjustment is achieved.

9. Repeat steps 1 through 8 preceding to adjust BRIX of dispensed product on No. 2 system. After completing BRIX adjustment on No. 2 system, only the ‘‘OFF 1’’ and ‘‘OFF 2’’ fault messages should continue to be displayed.

NOTE: Syrup systems may be sanitized at this time as instructed.

FILLING FREEZE CYLINDERS WITH PRODUCT

1. Open product shutoff valves, located in lines leading from product blender tanks to freeze cylinders.

2. Press ‘‘AUTO BLEND 1’’ and ‘‘AUTO BLEND 2’’ switches to begin filling freeze cylinders. Open freeze cylinders faceplates relief valves to bleed air from cylinders while filling with product, then close valves. Do not relieve freeze cylinder pressure too fast or product will foam excessively in cylinder and lose carbonation.

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ADJUSTING “WATER-COOLED” UNIT REFRIGERATION SYSTEM VARIABLE WATER REGULATOR

IMPORTANT NOTICE

Water-Cooled Refrigeration System Dispenser. Water flow rate through the refrigeration cooling coil varies due to pressure change on the high side

of the refrigeration compressor which influences opening and closing of the variable water regulator (see Figure 16). The variable water regulator must be adjusted to maintain 240-psi refrigeration high-side pressure.

Adjust the variable water regulator (see Figure 16) to maintain 240-psi refrigeration high-side pressure as instructed in the SERVICE AND MAINTENANCE section.

ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE)

1. Remove four screws securing the upper control box cover, then remove cover for access to the master circuit board inside the control box.

2. Adjust beaters motors currents as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING MAIN MENU SELECTIONS ONTO the MESSAGE DISPLAY

The MAIN MENU SELECTIONS (see Table 3) may be brought up on message display as instructed in SERVICE AND MAINTENANCE section.

Program ‘‘CLOCK’’ (TIME OF DAY) into Unit as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO the UNIT

The automatic defrost system may be programmed into the Unit to occur up to nine different times during a day with a minimum of two hours between defrost time settings. Program automatic defrost time settings into the Unit as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO the UNIT

‘‘SLEEP’’ (SLEEP TIME) may be programmed into the Unit to occur any time of the day after the Unit automatic defrost cycle has occurred. The Unit will shut down (go into sleep time) and will not wake up (return to normal operation) until programmed ‘‘WAKE UP’’ (WAKE UP TIME) has occurred. Program ‘‘SLEEP’’ (SLEEP TIME) into the Unit as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING ‘‘WAKE UP’’ (WAKE UP) TIME INTO the UNIT

‘‘WAKE UP’’ (WAKE UP TIME) May be programmed into the Unit to occur any time of the day to wake the Unit up (return to normal operation) after ‘‘sleep time’’ has occurred. Program ‘‘WAKE UP’’ into the Unit as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING POINT OF SALE MESSAGE DISPLAY

Three point of sale display messages are available to choose from and may be programmed into the Unit by placing No. 1 and No. 2 switches on the DIP SWITCH assembly on the master circuit board in appropriate positions. Program point of sale display messages into the Unit as instructed in SERVICE AND MAINTENANCE section.

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ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED PRODUCT

Adjust ‘‘VIS SET’’ (PRODUCT VISCOSITY) determines what product consistency of the dispensed product will be present in each freeze cylinder. Adjust ‘‘VIS SET’’ (PRODUCT VISCOSITY) of the dispensed product as instructed in SERVICE AND MAINTENANCE section.

“VIS READ” (ACTUAL VISCOSITY READOUT) OF PRODUCT IN FREEZE CYLINDERS

“VIS READ” (actual viscosity readout) may be brought up on the message display to actually read the viscosity (product consistency) of product in the freeze cylinders while the Unit is in operation as instructed in SERVICE AND MAINTENANCE section.

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES

Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be displayed on the message display as instructed in SERVICE AND MAINTENANCE section.

‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT)

Displayed voltage readout may be displayed on the message display as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) INTO the UNIT

‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) may be programmed into the Unit to check certain components for operation. Program ‘‘DIAGNOSE’’ into Unit the and check components for proper operation as instructed in SERVICE AND MAINTENANCE section.

DISPLAYING ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS) ONTO the MESSAGE DISPLAY

‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS) may be displayed on the message display as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT ELECTRONICS

IMPORTANT: Note in TABLE 5 MOTOR SELECT the number of freeze cylinders beater drive motors Manufacturer’s that are listed. Your Unit was manufactured and equipped with freeze cylinders beater drive motors from one of these Manufacturer’s. The beater motors were programmed at the factory to match the Unit electronics. THE BEATER MOTORS PROGRAMMING MUST BE RE-CHECKED AT THE TIME OF UNIT INSTALLATION as instructed in “PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS” in SERVICE AND MAINTENANCE section.

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS

The Dispenser electronics must be programmed for the proper refrigeration pulse rate according to the type of refrigerant gas that has been installed in the refrigeration system. Note Dispenser serial plate for the type of refrigerant gas that has been installed, then proceed to SERVICE AND MAINTENANCE section for programming instructions.

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DISPLAYED ERROR CONDITIONS

Displayed error conditions, associated errors, and items affected by the errors are found in Table 8 DISPLAYED ERROR CONDITIONS.

INSTALLING CONTROL BOX COVER AND BACK, SIDES LOWER ACCESS, AND TOP PANELS ON UNIT

1. Install upper electrical control box cover and secure with four screws.

2. Install back, sides, lower access, and top panels on Unit by reversing removal procedures.

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THIS PAGE LEFT BLANK INTENTIONALLY

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OPERATORS INSTRUCTIONS

This section describes operating controls and indicators, dispensed product conditions, operating characteristics, Unit operation, replenishing syrup supply, product flavor change, checking CO supply, operators daily cleaning of Unit, and sanitizing requirements.

WARNING: Disconnect electrical power to the Unit to prevent personnel injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring.

NOTE: The No. 1 freeze cylinder (see Figure 4) is the left-hand cylinder facing the front of the Unit. No. 2 freeze cylinder is to the right of No. 1 freeze cylinder.

CONTROL PANEL SWITCHES AND DISPLAYED MESSAGES

CONTROL PANEL SWITCHES

The Unit is equipped with one control panel which is equipped with a message display (See Figure 4). The control panel controls operation of the No. 1 and the No. 2 freeze cylinders.

‘‘FILL 1’’ and ‘‘FILL 2’’ Control Switches.

‘‘FILL 1’’ and ‘‘FILL 2’’ control switches, located on control panel (see Figure 4), are touch-type switches and

require only pressing to activate. ‘‘FILL 1’’ and ‘‘FILL 2’’ control switches are used when filling syrup systems sold-out floats during syrup replenishing, syrup flavor changeover, or sanitizing syrup systems. After syrup systems sold-out floats have been filled, ‘‘FILL 1’’ and ‘‘FILL 2’’ switches may be used to prevent more product entering product blender tanks during BRIX test.

‘‘AUTO BLEND 1’’ and ‘‘AUTO BLEND 2’’ Control Switches.

‘‘AUTO BLEND 1’’ and ‘‘AUTO BLEND 2’’ control switches, located on control panel (see Figure 4), are

touch-type switches and require only pressing to activate. These switches are used to fill product blender tanks after sold-out floats have been filled using ‘‘FILL 1’’ and ‘‘FILL 2’’ switches. ‘‘AUTO BLEND 1’’ and ‘‘AUTO BLEND 2’’ and ‘‘AUTO 1’’ and ‘‘AUTO 2’’ switches must be pressed to operate freeze cylinders beaters and refrigeration system during normal operation.

‘‘WASH 1’’ and ‘‘WASH 2’’ Control Switches.

‘‘WASH 1’’ and ‘‘WASH 2’’ control switches, located on control panel (see Figure 4), are touch-type switches and

require only pressing to activate. These switches are used to operate freeze cylinders beaters with no refrigeration during sanitizing.

’’AUTO 1’’ and ‘‘AUTO 2’’ Control Switches.

‘‘AUTO 1’’ and ‘‘AUTO 2’’ control switches, located on control panel (see Figure 4), are touch-type switches and

require only pressing to activate. These switches are used to operate freeze cylinders beaters and refrigeration system after cylinders have been filled with product. Freeze cylinders beaters and refrigeration system may be stopped by pressing ‘‘OFF 1’’ or ‘‘OFF 2’’ switches.

‘‘OFF 1’’ and ‘‘OFF 2’’ Control Switches.

‘‘OFF 1’’ and ‘‘OFF 2’’ control switches, located on control panel (see Figure 4), are touch-type switches and

require only pressing to activate. These switches are used to stop freeze cylinders beaters and refrigeration system.

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‘‘ERROR RESET’’ Control Switch.

‘‘ERROR RESET’’ control switch, located on control panel (see Figure 4), is a touch-type switch and requires

only pressing to activate. ‘‘ERROR RESET’’ switch is used to restore normal operation after error within Unit (indicated by ‘‘ERROR 1’’ or ‘‘ERROR 2’’ on message display) has been corrected.

‘‘SECURITY SWITCH.’’

The Unit is equipped with a hidden ‘‘SECURITY SWITCH’’ located between ‘‘FILL 1’’ switch and ‘‘ERROR RESET’’ switch on control panel (see Figure 4). Pressing in and holding ‘‘SECURITY SWITCH’’ for 3-seconds deactivates control switches preventing tampering with Unit normal operation. To reactivate control switches, press in and hold ‘‘SECURITY SWITCH’’ for 3-seconds.

CONTROL PANEL DISPLAY MESSAGES

(see Figure 4)

‘‘FILL 1’’ and ‘‘FILL 2’’ Fault Messages.

‘‘FILL 1’’ and ‘‘FILL 2’’ fault messages will appear on message display only when ‘‘FILL 1’’ and ‘‘FILL 2’’ control

switches have been pressed and syrup systems sold-out floats have been filled with product. ‘‘FILL 1’’ and ‘‘FILL 2’’ fault messages will continue to be displayed until ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ control switches have been pressed to fill product blender tanks with product.

‘‘ERROR 1’’ and ‘‘ERROR 2’’ Fault Messages.

‘‘ERROR 1’’ and ‘‘ERROR 2’’ fault messages will appear on message display only if error within Unit has

developed interrupting normal operation. Error will have to be located and corrected, then press ‘‘ERROR RESET’’ to restore normal operation. ‘‘ERROR 1’’ or ‘‘ERROR 2’’ fault message will disappear from display.

‘‘OFF 1’’ and ‘‘OFF 2’’ Fault Messages.

‘‘OFF 1’’ and ‘‘OFF 2’’ fault messages will appear on message display when either freeze cylinder beater is not

operating.

‘‘H2O OUT’’ Fault Message.

The Unit plain water inlet system contains a water pressure switch. Should the plain water source to the Unit be disrupted or a water pressure drop occur, will cause ‘‘H2O OUT’’ fault message to appear on message display. Unit will continue to operate for 1–1/2 minutes after ‘‘H2O OUT’’ fault message has appeared and if water pressure has not been restored or water pressure improved after 1–1/2 minutes, Unit operation will shut down. After plain water source has been restored or water pressure has improved, Unit will resume operation and

‘‘H2O OUT’’ fault message will disappear from message display.

‘‘CO2 OUT’’ Fault Message.

‘‘CO2 OUT’’ fault message will appear on message display when CO2 supply to Unit has been turned off or if CO2 pressure drops below 50–psi. A minimum CO2 pressure of 75-psi must be available to Unit to extinguish ‘‘CO2 OUT’’ fault message.

‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ Fault Messages.

‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages will appear on message display if product tanks are not connected to

Unit or product tanks are empty. Syrup systems syrup float switches must be filled with syrup to extinguish ‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages.

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‘‘DEFROST 1’’ or ‘‘DEFROST 2’’ Display Messages.

‘‘DEFROST 1’’ or ‘‘DEFROST 2’’ display messages will appear on message display if either freeze cylinder is in

defrost mode. ‘‘DEFROST 1’’ or ‘‘DEFROST 2’’ messages will remain on during defrost cycle and will disappear when cycle has ended.

‘‘POINT OF SALE’’ Display Message.

Three ‘‘POINT OF SALE‘’ display messages are available to choose from and may be programmed into Unit as instructed to appear on message display.

Common Outlet Temperatures.

Evaporator refrigeration coils inlet 1 and inlet 2 and common outlet temperatures may be displayed on control panel message display as instructed.

FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS

MANUAL DEFROST SYSTEM

The Manual hot-gas defrost system may be activated at any time by pressing ‘‘DEFROST’’ switch on front of the Unit. Refrigeration compressor will operate for a short time, then both freeze cylinders will go into defrost and defrost for approximately 60-seconds. At end of manual defrost cycle, Unit will return to normal operation. Manual defrost may be cancelled at any time by pressing ‘‘CANCEL DEFROST’’ switch.

AUTOMATIC DEFROST SYSTEM

The automatic hot–gas defrost system may be programmed into the Unit of occur up to nine different times a day with a minimum of two hours between defrost settings. At start of each automatic defrost cycle, refrigeration compressor will operate for 30-seconds to pump freon out of freeze cylinders evaporator coils. After freon has been pumped out of freeze cylinders evaporator coils, No. 1 freeze cylinder only will go into defrost and defrost for approximately 7-minutes then will return to normal operation. This ends automatic defrost cycle of No. 1 freeze cylinder. No. 2 freeze cylinder will defrost 30-minutes after the start of No. 1 freeze cylinder. The next automatic defrost cycle will occur according to time programmed into the Unit.

‘‘SLEEP’’ (SLEEP TIME)

‘‘SLEEP’’ (SLEEP TIME( may be programmed into Unit to allow Unit to go into sleep time (Unit shut down, freeze cylinders beaters and refrigeration systems not operating). At start of sleep time refrigeration compressor will operate for 30-seconds to pump freon out of freeze cylinders evaporator coils. Then No. 1 freeze cylinder will go into defrost for and defrost 60-seconds. After No. 1 freeze cylinder has defrosted, No. 2 freeze cylinder will go into defrost and defrost for 60-seconds. At end of No. 2 freeze cylinder defrost, Unit will shut down and go into sleep time.

‘‘WAKE UP’’ (WAKE UP TIME)

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NOTE: Automatic defrost, sleep time, and wake up time may be used in any combination together or separately.

FACEPLATE RELIEF VALVES

The faceplate relief valves (see Figure 4), located in each freeze cylinder faceplate, are spring-loaded valves that protect freeze cylinders from accidental over-pressure. The relief valve is also used to manually bleed CO gas from freeze cylinder to atmosphere during filling with product and if gas pockets form in cylinder during operation.

PRODUCT SAMPLE VALVES

The two product sample valves, are located behind the lower front access panel (see Figure 2) and are manually operated lever-type ball valves used to check product BRIX. Turn valve lever to line up with attached line to open valve and at a 90° angle with line to close the valve.

PRODUCT SHUTOFF VALVES

The two product shutoff valves, located in lines leading from the product blender tanks to the freeze cylinders (see Figure 2), are manually operated lever-type ball valves and are used to prevent product from entering and filling freeze cylinders while adjusting BRIX of dispensed product. Shutoff valves may also be used to shut off product to individual freeze cylinder for service and maintenance without disrupting operation of other freeze cylinder.

PRIMARY CO2 REGULATOR

The primary CO2 regulator (see Figure 2) controls CO2 pressure to the soft drink tanks and the Unit secondary CO2 regulators located behind the lower front access panel. If necessary to adjust the primary CO2 regulator, adjust as instructed in SERVICE AND MAINTENANCE section.

SECONDARY CO2 REGULATORS

The secondary CO2 regulators, located behind the lower front access panel (see Figure 5), control CO pressure to the two carbonated water tanks and the two product blender tanks. If necessary to adjust the secondary CO2 regulators, adjust as instructed in SERVICE AND MAINTENANCE section

CARBONATED WATER FLOW REGULATORS

The adjustable carbonated water flow regulators (see Figure 2 and Figure 5), located in their respective systems, control carbonated water flow rate to the product blender tanks. The water flow regulators are factory adjusted at 1.3 ± 0.05 oz/sec and should not normally require adjustment. If adjustment is necessary, adjust as instructed in SERVICE AND MAINTENANCE section.

SYRUP FLOW REGULATORS

The syrup flow regulators (see Figure 2 and 5) , located in their respective systems, are adjustable regulators that control syrup flow rate to the product blender tanks for desired BRIX of dispensed product. Adjust syrup flow regulators for desired BRIX as instructed in SERVICE AND MAINTENANCE section.

DISPENSING VALVES

Self-closing dispensing valves (see Figure 3 and 4), located on faceplates on front of Unit, are operated one at a time or simultaneously to deliver product to the customer.

DISPENSED PRODUCT CONDITIONS

‘‘OVERRUN’’, AS APPLIED TO FROZEN CARBONATED BEVERAGES

Overrun Defined.

Overrun is product expansion that takes place in the frozen carbonated drink. It is caused primarily by CO2 gas

breakout and secondary by freezing.

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Overrun is a Variable.

The percentage or degree of overrun depends on a number of factors. The specific syrup, BRIX, low dispensing volume, carbonation level in liquid product, and freezing, all affect overrun. After these factors have been considered, desired viscosity (product consistency) adjustment may be made on the Unit. The viscosity

adjustment adjusts product texture from very wet to light.

Specific Product Ingredients Affect Overrun.

Each syrup has its own specific formulation of makeup. Baume, an important ingredient factor, may fall within an extremely wide range. Fruit flavors contain citric acids that colas do not. Colas also differ in ingredients from one brand to another. Each product formulation has its own peculiarities regarding the way the product will

absorb carbonation and the way it will release carbonation.

BRIX Affects Overrun.

Sugar in carbonated drinks is like anti–freeze in water. The higher the BRIX in a product, the greater resistance the product has to freezing. Conversely, in products with lower BRIX, freezing takes place at higher temperatures than for high–BRIX products. Thus, BRIX affects overrun because the amount of sugar in a drink

has a direct bearing on the product’s freezing characteristics.

DRAWING 1

Low Dispensing Volume Affects Overrun.

When Unit sits idle for a period of time and no drinks are dispensed, CO2 gas in the system takes a ‘‘set’’. When first few drinks are drawn off after an idle period, CO2 gas has less tendency to break out as drink is dispensed.

The result is these casual drinks have less overrun than drinks dispensed during peak-use periods.

Carbonation Level in Liquid Product Affects Overrun.

The higher the specific carbonation level in a given product, the greater the potential for carbonation breakout in frozen carbonated form of that drink. For example, drinks with 3.0 volume of carbonation will have more gas

breakout in frozen carbonated form, and more overrun, than will drinks that contain 2.0 volumes of CO2 gas.

Freezing Affects Overrun.

Freezing causes approximately a 10 percent expansion in dispensed frozen carbonated drink. The degree of freezing is limited because finished drink is intended to be sipped through a straw. This is not possible if product is too ‘‘solid’’.

DRAWING 2

DRAWING 3

OPERATING CHARACTERISTICS

The product viscosity (product consistency) can be varied by adjustment and secondary CO2 regulator setting from a high overrun light drink to a wet heavy drink. The length of freezing cycle and amount of CO2 present in product combine to create drink dispensed. The dispensed product will have a normal variance due to the following conditions:

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1. If some time has elapsed since the last drink was drawn from a particular freeze cylinder and the compressor has not cycled on, the drink dispensed will have a tendency to be wetter, have slightly less overrun than normal for the setting, and will not mound up as high. See Drawing 1.

NOTE: A cylinder freeze–up may be expected under casual draw conditions if an attempt is made to eliminate drink described above by adjusting viscosity.

2. If product is drawn from freeze cylinder quite regularly, its viscosity (product consistency) will be maintained at whatever viscosity adjustment was made within the normal variance of the compressor off and on cycle. See Drawing 2.

3. If product is drawn continuously from freeze cylinder and rate is approaching capacity of the dispensing unit, overrun of drink will increase just prior to point capacity is exceeded, and drink dispensed will turn slightly wetter (see Drawing 3).

OPERATING UNIT

NOTE: The No. 1 freeze cylinder (see Figure 4) is the left–hand cylinder facing the front of the Unit. No. 2 freeze cylinder is to the right of No. 1 freeze cylinder.

1. Make sure ‘‘H2O OUT’’ fault message is not displayed on message display. This indicates no water supply to Unit.

2. Make sure ‘‘CO2 OUT’’ fault message is not displayed on message display. This indicates no CO2 gas supply to Unit.

3. Make sure ‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages are not displayed on message display. This indicates no syrup supply to Unit.

4. Make sure ‘‘AUTO BLEND 1’’, ‘‘AUTO BLEND 2’’, ‘‘AUTO 1’’, and ‘‘AUTO 2’’ control switches are pressed for normal operation.

5. Place cup under dispensing valve, then dispense until cup is full of product.

6. Make sure viscosity (product consistency) is as desired. If not, adjust as instructed.

REPLENISHING SYRUP SUPPLY

IMPORTANT: The following CO2 and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows:

1. To disconnect soft drink tank from Unit syrup system. A. Disconnect liquid disconnect from soft drink tank. NOTE – Disconnecting liquid quick

disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment.

B. Second, disconnect CO2 quick disconnect from soft drink tank.

2. To connect soft drink tank into Unit syrup system. A. First, connect CO2 quick disconnect to soft drink tank to pressurize tank.

B. Second, connect liquid quick disconnect to soft drink tank.

Syrup supply should be checked daily and if necessary, replenished as instructed.

PRODUCT FLAVOR CHANGE

Perform syrup flavor change as instructed.

CHECKING CO2 SUPPLY

WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is

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Make sure CO2 cylinder shutoff valve is fully opened and regulator assembly 1800-psi gage indicator is not in shaded (‘‘change CO instructed.

cylinder’’) portion of dial. If so, CO2 cylinder is almost empty and must be replaced as

CLEANING AND SANITIZING

DAILY CLEANING

Daily; or more often if necessary, wash all external surfaces of Unit, rinse with clean water, then wipe dry with clean soft cloth. DO NOT USE ABRASIVE CLEANERS. Remove and wash drip tray and cup rest with warm water and mild detergent, rinse with clean water, then install them on Unit.

SANITIZING

The Unit should be sanitized as instructed every 120-days and before and after storage periods following parent company requirements and sanitizer manufacturers recommendations.

CLEANING CONDENSER COIL

Circulating air, required to cool the refrigeration system condenser coil (see Figure 15), is drawn in through louvers on front and exhausted out through louvers on sides and back of Unit. Restricting air circulation through the Unit will decrease its cooling efficiency. The condenser coil air filter and the condenser coil must be cleaned periodically as instructed in SERVICE AND MAINTENANCE section.

LUBRICATION

The carbonator pump motor must be lubricated as instructed.

ADJUSTMENTS

CARBONATED WATER FLOW RATE

The black carbonated water flow regulators (see applicable Figure 2 and 5), which control carbonated water flow rate into product blender tanks, are factory adjusted and normally do not require further adjustment. If adjustment should become necessary, adjust as instructed in SERVICE AND MAINTENANCE section.

CO2 REGULATORS

Primary CO2 Regulator.

The primary CO2 regulator (see Figure 2) regulates CO2 pressure to the soft drink tanks (also to the bag-in-box syrup system if used) and also to the secondary CO2 regulators located inside the Unit. If necessary to adjust the primary CO2 regulator, adjust as instructed in SERVICE AND MAINTENANCE section.

Secondary CO2 Regulators.

The secondary CO2 regulators (see applicable Figure 2 and 5) regulate CO2 pressure to the carbonated water tanks and the product blender tanks. If necessary to adjust secondary CO2 regulators, adjust as instructed in SERVICE AND MAINTENANCE section.

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ADJUSTING BEATERS MOTORS CURRENTS

Beaters motors currents must be adjusted as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY

The MAIN MENU SELECTIONS (see Table 3) may be brought up on message display as instructed in SERVICE AND MAINTENANCE section.

SETTING ‘‘CLOCK’’ (TIME OF DAY)

NOTE: ‘‘CLOCK’’ (TIME OF DAY) must be programmed into Unit before ‘‘DEFROST’’ (AUTOMATIC), ‘‘SLEEP’’ (SLEEP TIME), and ‘‘WAKE UP’’ (WAKE UP TIME) can be programmed into the Unit.

Program ‘‘CLOCK’’ (TIME OF DAY) into Unit as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT

PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT

‘‘SLEEP’’ (SLEEP TIME) may be programmed into Unit to occur any time of the day after the Unit automatic defrost cycle has occurred. Unit will shut down (go into sleep time) and will not wake up (return to normal operation) until programmed ‘‘WAKE UP’’ (WAKE UP TIME) has occurred. Program ‘‘SLEEP’’ (SLEEP TIME) into Unit as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING ‘‘WAKE UP’’ (WAKE UP) TIME INTO UNIT

‘‘WAKE UP’’ (WAKE UP TIME) May be programmed into Unit to occur any time of the day to wake Unit up (return to normal operation) after‘‘sleep time’’ has occurred. Program ‘‘WAKE UP’’ into Unit as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING POINT OF SALE MESSAGE DISPLAY

Three point of sale display messages are available to choose from and may be programmed into Unit by placing No.1 and No. 2, switches on DIP SWITCH assembly on master circuit board in appropriate positions. Program point of sale display messages into Unit as instructed in SERVICE AND MAINTENANCE section.

ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED PRODUCT

Adjusting ‘‘VIS SET’’ (PRODUCT VISCOSITY) determines what product consistency of the dispensed product will be present in each freeze cylinder. Adjust ‘‘VIS SET’’ (PRODUCT VISCOSITY) of the dispensed product as instructed in SERVICE AND MAINTENANCE section.

“VIS READ” (ACTUAL VISCOSITY READOUT) OF PRODUCT IN FREEZE CYLINDERS

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DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES

Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be displayed on message display as instructed in SERVICE AND MAINTENANCE section.

‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT)

Displayed voltage readout may be displayed on message display as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) INTO UNIT

‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) may be programmed into the Unit to check certain components for operation. Program ‘‘DIAGNOSE’’ into Unit and check components for proper operation as instructed in SERVICE AND MAINTENANCE section.

DISPLAYING ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS) ONTO MESSAGE DISPLAY

‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS) may be displayed on the message display as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT ELECTRONICS

Note in TABLE 5 “MOTOR SELECT” the number of freeze cylinders beater motors Manufacturer ’s that are listed. Your Unit was manufactured and equipped with motors from one of these Manufacturer’s. A replacement freeze cylinder beater motor is also manufactured by one of these Manufacturer’s listed. NOTE THE MANUFACTURER’S NAME ON THE MOTOR(S). THE BEATER MOTOR(S) MANUFACTURER’S NAME(S) MUST BE PROGRAMMED INTO THE UNIT WHICH WILL MATCH THE MOTOR(S) TO THE UNIT ELECTRONICS as instructed in SERVICE AND MAINTENANCE section.

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS

DISPLAYED ERROR CONDITIONS

Displayed error conditions, associated errors, and items affected by the errors are found in TABLE 8 DISPLAYED ERROR CONDITIONS.

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W ATER PUMP DOUBLE LIQUID CHECK VALVE MAINTENANCE

(see Figures 2 and 13)

WARNING: The carbonator water pump double liquid check valve must be inspected and

serviced after any disruptions (plumbing work, earthquake, etc.) to the water supply

system, and at least once a year under normal circumstances. Foreign particles lodged in the double liquid check valve could cause CO health hazard in the system.

Service water water pump double liquid check valve as instructed in SERVICE AND MAINTENANCE section.

CLEANING CO2 GAS CHECK VALVES

(see applicable Figure 2 and 12) The CO2 gas check valves must be inspected and serviced at least once a year under normal conditions, and

after any servicing or disruption of the CO2 system as instructed in SERVICE AND MAINTENANCE section.

gas to back flow into the water system and create a

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SERVICE AND MAINTENANCE

This section describes service and maintenance to be performed on the Unit.

WARNING: Disconnect electrical power to Unit to prevent personnel injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring.

PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING

CAUTION: Before shipping, storing, or relocating Unit, syrup systems must be sanitized and all sanitizing solution must be purged from syrup systems. All water must also be

PERIODIC INSPECTION

1. Make sure CO2 cylinder valve is fully opened and primary CO2 cylinder regulator assembly 1800-psi gage indicator is not in shaded (‘‘change CO2 cylinder’’) portion of dial. If so, CO2 cylinder is almost empty and must be replaced.

2. Make sure soft drink tanks contain sufficient amount of syrup for Unit operation.

3. Circulating air, required to cool the refrigeration systems condenser coil (see Figure 15), is drawn in through louvers on front and exhausted out through louvers on sides and back of Unit. Make sure louvers are not obstructed and refer to CLEANING CONDENSER COILS in this section.

REMOVAL OF DRIP TRAY, AND BACK, SIDES, TOP, LOWER FRONT ACCESS, AND CONDENSER COIL ACCESS PANELS

(see Figure 4)

DRIP TRAY

Pull drip tray forward to disengage from drip tray supports.

BACK PANEL

Remove two screws securing bottom of back panel, then lift panel straight up to remove.

SIDE PANELS

Remove screw securing bottom of side panel, then lift panel straight up to remove.

TOP PANEL

Remove two screws securing top panel, then lift panel up off Unit.

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LOWER FRONT ACCESS PANEL

Remove two screws securing lower front panel, then pull panel down to remove from Unit.

CONDENSER COIL ACCESS PANEL

Pull out on top of condenser coil access panel, then lift panel up and out to remove.

LUBRICATION

CARBONATOR WATER PUMP MOTOR

(see Figure 13) The carbonator water pump motor bearings must be lubricated periodically. Refer to oiling instructions on motor.

DO NOT OVER OIL.

SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES

Servicing Dispensing Valves Caged O-Rings.

(see Figure 3)

NOTE: Dispensing valves caged O-Rings should be serviced (lubricated) every six months and O-Rings should be replaced once a year.

SPRING HOUSING

TORSION SPRING

SPRING FITTING

DISPENSING

VALVE BODY

CAGED O-RING

VALVE

LEVER

SLEEVE

SPRING

RETAINING

SCREW(2)

HOLD-DOWN

PLATE(2)

KNOB

FIGURE 3. SELF-CLOSING DISPENSING VALVE

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TOP PANEL RETAINING

MASTER CIRCUIT BOARD

CONTROL PANEL

FACEPLATE RELIEF

VALVE (2)

CONTROL P ANEL HIDDEN “SECURITY SWITCH”

TOP PANEL

UPPER CONTROL BOX

SCREW (2)

FAULT MESSAGE DISPLAY

RELAY CIRCUIT BOARD NO. 1

RELAY CIRCUIT BOARD NO. 2

LOWER FRONT ACCESS PANEL

CUP REST

DRIP TRAY

SOUND BAFFLE

NOTE: The No. 1 freeze cylinder is the left–hand cylinder facing the front of the Unit. No. 2 freeze cylinder is to the right of No. 1 freeze cylinder.

BACK PANEL

FACEPLATE (2)

DISPENSING VALVE (2)

SIDE PANEL (2)

VENTILATION LOUVERS

SIDE PANEL

RETAINING SCREW

FIGURE 4. OPERATING CONTROLS

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RELIEF VALVE (2)

PRODUCT BLENDER T ANK (2)

UPPER CONTROL BOX COVER RETAINING SCREW (2)

UPPER CONTROL BOX COVER

FAULT MESSAGE DISPLAY

CARBONATED WATER FLOW REGULATOR (2)

SYRUP FLOW REGULATOR (2)

FREEZE CYLINDER (2)

SECONDARY CO REGULATOR (4)

RECEIVER TANK

BEATER DRIVE MOTOR (2)

CARBONATED WATER TANK (2)

REFRIGERATION COMPRESSOR

LOWER CONTROL BOX

CONDENSER COIL

FIGURE 5. UNIT INTERNAL COMPONENTS

ACCUMULATOR

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1. Defrost freeze cylinders, shut Unit down, disconnect electrical power from Unit, close product shutoff valves in lines leading from the product blender tanks to the freeze cylinders, then drain product from the freeze cylinders.

Note: Item numbers in parentheses in this paragraph are in reference to Figure 6 .

2. Remove HEX NUTS (item 7) and FLATWASHERS (item 6) securing FACEPLATE (item 8) to freeze cylinder, then remove faceplate from cylinder.

3. Carefully remove large O-RING (item 5) from FACEPLATE (item 8).

4. Unscrew RELIEF VALVE (item 9) from FACEPLATE (item 8).

5. Disassemble dispensing valve (see Figure 3) as follows: A. Remove two screws and hold-down plates securing spring housing to dispensing valve body, then

remove housing. B. Remove torsion spring from dispensing valve. C. Remove knob, spring, sleeve, and lever from dispensing valve. D. Remove spring fitting from dispensing valve. E. Press valve, with caged O-ring, down and out of dispensing valve body. F. Carefully remove caged O-ring from valve.

6. Wash all parts in warm water. Remove all traces of syrup and lubricant, especially from faceplate, O-rings, and dispensing valve. If parts are excessively coated, wipe clean with paper towel to remove syrup and lubricant, especially from caged O-ring and dispensing valve. Use BRUSH (item 3, Table 2) to clean faceplates relief valve passages.

7. Submerge all parts in four percent solution of approved sanitizing agent for time recommended by sanitizer manufacturer.

8. Remove parts from sanitizing solution and place on clean paper towels.

NOTE: Use Dow-Corning DC-111 (P/N 321471000) light grade silicone lubricant.

9. Assemble dispensing valve as follows: A. Lubricate caged O-ring. Carefully install caged O-ring on valve from straight end (opposite tapered

end). Lubricate grooves in which O-ring rides to fill in all void areas around O-ring. B. Carefully install valve with caged O-ring in dispensing valve body. C. Install spring fitting, knob and lever parts, torsion spring, and spring housing assembly by reversing

removal procedure. Do not tighten down hold-down plates securing spring housing at this time.

10. Thoroughly clean RELIEF VALVE (item 9), then screw relief valve into FACEPLATE (item 8).

11. Proceed to Servicing Beater Motor Drive Shaft/Seal Assemblies

Servicing Freeze Cylinders Drive Shaft/Seal Assemblies.

(see Figure 7)

IMPORTANT: The freeze cylinders drive shaft/seal assemblies must be removed and inspected every four months. Their shafts and bearings must be inspected and replaced if necessary. All O-Ring seals must be replaced at this time.

NOTE: Use Dow-Corning DC-111 (P/N 321471000) light grade silicone lubricant.

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1 Product Inlet Fitting 2 Scraper Blade (2) 3 Evaporator Coi.l

4 Relief Valve Port 5 O-Ring 6 Flatwasher (4)

7 Hex Nut (4) 8 Faceplate 9 Relief Valve

10 Valve Lever 11 Knob 12 Dispensing Valve 13 Beater 14 Allen Head Setscrew 15 Beater Shaft Coupling 16 Drive Pin 17 Bearing Housing Locking T ab (4)

18 Bearing Retainer

19 Beater Motor Drive Shaft

20 Beater Drive Motor 21 Drive Shaft Assembly

22 Viscosity Sensor 23 Spinner

24 spring 25 Shaft Release 26 Bearing

27 Bearing Housing

10 11

121314

15 16

21 22 23

FIGURE 6. FREEZE CYLINDER CUTAWAY VIEW

Page 40

BEATER

DRIVE MOT OR

DRIVE SHAFT/SEAL ASS’Y

BEATER DRIVE MOTOR SHAFT

COUPLING

ALLEN-HEAD

SET SCREW

PLASTIC

COUPLER

ALLEN-HEAD

SET SCREW

COUPLING

DRIVE SHAFT

COUPLER

DRIVE

BEATER

DRIVE

COUPLER

LOCK RING

BEARING

ALLEN-HEAD

SET SCREW (2)

GAUGE, DRIVE/COUPLER

(ITEM 6)

PLASTIC

HOUSING

O-RING

SHAFT

DRIVE SHAFT/ SEAL ASSEMBL Y

FIGURE 7. SERVICING BEATER MOTOR DRIVE SHAFT/SEAL ASSEMBLY

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BEATER

KEY ON END OF POST

KEY SLOT ON BLADE

SCRAPER BLADES MUST BE MOUNTED TO THE BEATER BODY AS SHOWN USING THE PERFORATED EDGE AS THE LEADING EDGE. LINE UP KEY ON END OF POSTS WITH KEY SLOT IN SCRAPER BLADES.

FIGURE 8. BEATERS AND SCRAPER BLADES INSTALLATION

1. Pull BEATER (item 13) and SCRAPER BLADES (item 2) from freeze cylinder.

2. Using WRENCH (item 5) reach into the freeze cylinder and turn the drive shaft/seal assembly to the right (clockwise) to unlock its four locking tabs from the notches in the freeze cylinder retainer. Pull the assembly out of the freeze cylinder retainer using the beater as a puller..

3. Remove the coupling end fitting from the shaft by loosening the set screw in the coupling, then slide coupling off the shaft.

4. Remove the lock-ring bearing retainer from the end of the plastic housing.

5. Using a block of wood, tap the drive shaft and both bearings out of the plastic housing.

6. Loosen bearings and remove shaft. Remove two old inner drive shaft O-Rings seals and two outer O-Rings seals from the plastic housing. Discard the old O-Ring seals.

NOTE: If old lubricant cannot be removed from the plastic housing by washing, use a nylon ‘‘pot and pan’’ scrubber (3M Company ‘‘Scotchbrite’’, or equivalent) to remove the residue. Do not scrape plastic housing. Replace any housing that has rough edges in O-Ring sealing areas.

7. Remove old lubricant from the plastic housing with paper towel. DO NOT SCRAPE THE PLASTIC HOUSING. Wash the housing and the back of the freeze cylinder with warm water.

8. Lubricate two new drive shaft O-Ring seals with a generous amount of special light-grade silicone grease, then install O-Rings inside the plastic housing.

9. Inspect the drive shaft and both bearings. Replace the drive shaft if worn and bearing(s) if found to be rough.

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10. Reassemble the drive shaft/seal assembly. Using TOOL, DRIVE/COUPLER ADJUSTMENT GAUGE (item

6), insert “DRIVE” end of adjustment gauge between drive-pin and housing (see Figure 7) to set the shaft end at 1.542-inches out of the plastic housing. Make sure Allen-Head set screw in each bearing is securely tightened and properly seated on the shaft flat surface.

11. Install coupling end fitting on end of the drive shaft. Insert “COUPLER” end of the adjustment gauge between coupling end fitting and the plastic housing. The adjustment gauge in place places the coupling end fitting 0.750-inch away from the plastic housing. Make sure Allen-Head set screw in the coupling end fitting is securely tightened and properly seated on the shaft flat surface.

12. Lubricate the two outer O-Ring seals on the outside of the plastic housing with a generous amount of special light-grade silicone grease.

13. Reinstall the drive shaft/seal assembly in the freeze cylinder.

14. Push in and turn the drive shaft/seal assembly to the left (counterclockwise) to lock its four locking tabs into four notches in the freeze cylinder retainer.

15. Position SCRAPER BLADES (item 2) on BEATER (item 13) as shown in Figure 8. Slide beater into freeze cylinder so slotted hooks engage DRIVE PIN (item 17) on DRIVE SHAFT (item 19) as shown in Figure 6. Turn beater to the right (clockwise) to lock in place.

16. Lubricate O-RING (item 5) with water to facilitate faceplate installation. Position O-RING (item 5) on FACEPLATE (item 8). Install faceplate on Unit so dispensing valve spout faces down. (MAKE SURE FEMALE END OF THE BEATER IS PLACED OVER THE FACEPLATE STAINLESS-STEEL STUD AND BUSHING BEFORE PUSHING THE FACEPLATE INTO POSITION ON ITS FOUR THREADED MOUNTING STUDS). Tighten hex nuts until faceplate touches freeze cylinder all around flange. CAUTION

- DO NOT OVERTIGHTEN HEX NUTS.

17. Turn dispensing valve spring housing to the left (counterclockwise) to put tension on torsion spring, then tighten hold-down plates to secure spring housing.

18. Test dispensing valve to make sure it closes by itself when lever is released. If not, readjust torsion spring tension.

19. Sanitize syrup system as instructed in CLEANING AND SANITIZING.

20. Return Unit to operation.

CLEANING CONDENSER COIL

UNIT WITH AIR-COOLED REFRIGERATION SYSTEM

(see Figure 5)

NOTE: Circulating air, required to cool the refrigeration system condenser coil, is drawn in through louvers on front and exhausted out through louvers on sides and back of Unit. Restricting air circulation through Unit will decrease its cooling efficiency.

Periodically clean condenser coil as follows:

1. Press ‘‘OFF 1’’ and ‘‘OFF 2’’ switches on Unit control panel to stop refrigeration system and beaters motors.

2. Remove condenser coil access panel and condenser coil air filter(s).

3. Clean condenser coil and condenser coil air filter(s) with vacuum cleaner, low pressure compressed air, or a soft brush.

4. Install condenser coil air filter(s) and condenser coil access panel by reversing removal procedure.

5. Press ‘‘AUTO 1’’ and ‘‘AUTO 2’’ switches on Unit control panel to start refrigeration system and beaters motors.

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UNIT WITH WATER-COOLED REFRIGERATION SYSTEM

The high-pressure cutout switch, located inside the lower control box (see Figure 16), will shut the Unit refrigeration system down when overheated (high head pressure) caused by lack of cooling water. After problem has been corrected and the head pressure has decreased, the reset button on the high-pressure cutout switch must be pressed to restart the refrigeration system.

ADJUSTMENTS

ADJUSTING PLAIN WATER PRESSURE REGULATOR

(see Figure 2 and 13) The carbonator water pump plain water inlet adjustable water pressure regulator is factory adjusted to 45-psi

and should not be readjusted.

ADJUSTING CARBONATED WATER FLOW RATE

The carbonated water flow regulators (see Figure 2 and 5), which control carbonated water flow rate into the product blender tanks, are factory adjusted for a flow rate of 1.3 ± 0.05 ounces per second and normally do not require adjustment. However, if adjustment is necessary, proceed as follows:

1. Press applicable ‘‘OFF 1’’ or ‘‘OFF 2’’ switch to prevent more product from entering the applicable product blender tank.

2. Disconnect Unit syrup inlet line from the applicable soft drink tank.

3. Remove applicable side panel from the Unit as instructed for access to the applicable carbonated water flow regulator, product shutoff valve, and product sample valve.

4. Close applicable product shutoff valve to prevent more product from entering the freeze cylinder.

5. Place container under applicable product sample valve. Open the valve and allow all product to be purged from the product blender tank, then close the valve.

6. Remove the lower front access panel as instructed for access to the secondary CO2 regulators.

7. Note pressure setting on the applicable secondary CO2 regulator with 60-psi gage for the applicable product blender tank. Turn regulator adjusting screw out (counterclockwise) until gage reads 0-psi. Pull up on the applicable product blender tank relief valve to release CO2 pressure from the tank.

8. Disconnect carbonated water line from the outlet side of the applicable carbonated water flow regulator.

9. Connect line, long enough to reach to the outside of the Unit, to the water flow regulator outlet, then route the line to the outside of the Unit.

10. Place end of the carbonated water line, routed to the outside of the Unit, in the container.

11. Press applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch to activate the electrically operated carbonated water solenoid.

12. When steady stream of water is flowing from the added length of line, catch carbonated water in a container graduated in ounces for exactly 10-seconds. Press applicable ‘‘FILL 1’’ or ‘‘FILL 2’’ switch to deactivate the carbonated water solenoid. In 10-seconds, 12 to 14-ounces of water should have been dispensed.

13. If adjustment is necessary, turn the carbonated water flow regulator adjusting screw to the left (counterclockwise) to reduce carbonated water flow rate or turn the screw to the right (clockwise) to increase the flow rate.

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14. Repeat steps 11 through 13 until the desired carbonated water flow rate is achieved.

15. Remove added length of line from the outlet side of the carbonated water flow regulator. Connect the carbonated water line, disconnected from the carbonated water flow regulator in step 8 preceding, to the regulator outlet.

16. Turn the product blender tanks CO2 regulator, with 60-psi gage, adjusting screw in (clockwise) until gage registers pressure noted in step 7 preceding.

17. Pull relief valve on the applicable product blender tank to purge air from the tank, then close the valve.

18. Connect Unit syrup inlet line to the soft drink tank.

19. Press the applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch to fill the product blender tank with product.

20. Open the product shutoff valve that was closed in step 4 preceding.

21. Install the side panel and the lower front access panel by reversing removal procedure.

ADJUSTING CO2 REGULATORS

NOTE: To readjust CO2 regulator to a lower setting, loosen the adjusting screw lock nut, then turn the screw to the left (counterclockwise) until the pressure gage reads 5-psi lower than the new setting will be. Turn the adjusting screw to the right (clockwise) until the gage registers new setting, then tighten the lock nut.

Primary CO2 Regulator. (see Figure 2)

Adjust the primary CO2 regulator by turning the regulator adjusting screw to the right (clockwise) until the regulator pressure reads 80 to 100-psig.

Product Blender Tanks Secondary CO2 Regulators. (see Figure 2)

1. Remove the Unit lower front stainless steel access panel as instructed for access to the product blender tanks secondary CO2 regulators.

2. Adjust the product blender tanks secondary CO2 regulators, with 60-psi gages, by turning their regulator adjusting screws to the right (clockwise) until their gages read 25 to 30-psig.

3. Install the lower front stainless steel access panel by reversing the removal procedure.

Carbonated Water Tank Secondary CO2 Regulators. (see Figure 2)

1. Remove the Unit lower front access panel as instructed for access to the carbonated water tanks secondary CO2 regulators.

IMPORTANT: The carbonated water tanks secondary CO2 regulators must be adjusted 25-psi higher or more above the product blender tanks secondary CO2 regulators pressure settings. The Carbonated water and syrup pressures must be able to overcome and vent the product blender tanks head pressures while the tanks are filling with carbonated water and syrup. Carbonated water tanks secondary CO2 regulators not adjusted high enough will cause a decreased flow of carbonated water into the blender tanks which will increase the brix of the dispensed product.

2. Adjust carbonated water tanks secondary CO2 regulators, with 100-psi gages, by turning regulators adjusting screws to the right (clockwise) until gages reads 50 to 60-psig.

3. Install the lower front access panel by reversing the removal procedure.

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ADJUSTING BRIX (WATER-TO-SYRUP) “RATIO” OF DISPENSED PRODUCT

(see Figures 2 and 5)

1. Remove Unit front lower stainless steel access panel as instructed for access to product blender tanks secondary CO2 regulators and product sample valves.

2. Check product blender tanks secondary CO2 regulators, with 60-psi gages, for proper pressure settings which is set at 25 to 30-psi for best textured dispensed product. If adjustment is necessary, adjust as instructed.

3. Remove both Unit side panels as instructed for access to product shutoff valves located close to product blender tanks.

4. Close product shutoff valve in line between applicable product blender tank and associated freeze cylinder BRIX adjustment will be performed on.

5. Press applicable ‘‘FILL 1’’ or ‘‘FILL 2’’ switch to prevent more product from filling product blender tank.

6. Open applicable product blender tank product sample valve and take sample (approximately 6-ounces) of product in cup.

NOTE: Temperature compensated hand-type refractometers (P/N 511004000) are available from the Cornelius Company.

7. Check product BRIX with a temperature compensated hand-type refractometer. BRIX should read 13 ± 1. If BRIX is not within tolerance, adjust applicable white syrup flow regulator as follows:

Turn syrup flow regulator adjusting screw to the left (counterclockwise) no more than 1/8-turn at a time to reduce syrup flow rate or turn screw to the right (clockwise) no more than 1/8-turn to increase flow rate.

8. Place container under applicable product sample valve. Open valve to purge product out of product blender tank, line, and valve, then close valve.

9. Press applicable ‘‘AUTO BLEND 1‘’ or ‘‘AUTO BLEND 2’’ switch to fill product blender tank 1/4-full of new batch of product. When product blender tank is 1/4-full of product, press applicable ‘‘FILL 1’’ or ‘‘FILL 2’’ switch to prevent more product from entering product blender tank.

10. Repeat steps 6 and 7 preceding to check product sample for BRIX.

11. Repeat steps 7 through 10 preceding until proper BRIX adjustment is achieved.

12. Open product shutoff valve in line between product blender tank and freeze cylinder.

13. Press applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch.

14. Install Unit side panels and front lower access panel by reversing removal procedures.

PRODUCT CARBONATION ADJUSTMENT

(see Figures 2 and 5) Carbonation of dispensed product can also be varied to suit consumer preference by adjusting Unit carbonated

water tanks secondary CO2 regulators as follows:

1. Remove Unit front lower stainless steel access panel as instructed for access to the carbonated water tanks secondary CO2 regulators with 100-psi gages.

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HIDDEN SECURITY

SWITCH

MESSAGE DISPLAY

FIGURE 9. CONTROL PANEL

2. Observe pressure settings on the carbonated water tanks secondary CO2 regulators gages.

3. To lower CO2 pressure, loosen regulator adjusting screw lock nut. Turn adjusting screw to the left (counterclockwise) until pressure gage reads 15-psi below desired reading, then turn screw to the right (clockwise) until gage reads desired pressure. DO NOT SET CO2 REGULATOR PRESSURE BELOW 25-PSI HIGHER THAN PRODUCT BLENDER TANKS CO2 REGULATORS ARE ADJUSTED TO (SEE PRECEDING IMPORTANT NOTE). Tighten adjusting screw lock nut after each adjustment.

4. To raise CO2 pressure, turn regulator adjusting screw to the right (clockwise) until gage reads desired pressure. DO NOT SET PRESSURE HIGHER THAN 60-PSI. Make sure primary CO2 regulator on CO cylinder is set at 80 to 100-psi. Tighten adjusting screw lock nut after each adjustment.

5. Install Unit front lower access panel by reversing removal procedure.

ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE)

Adjusting beater motor current (either side) procedure is very important and must be performed as instructed. Be sure you fully understand the instructions before performing the current adjustments or doing any preventative maintenance current readings check.

Any current adjustments or preventative maintenance current readings check on the beater motor current (either side) must be performed with both freeze cylinders fully defrosted. A partially defrosted freeze cylinder will cause false current readings to be displayed on the message display. Adjust beater motor current (either side) as follows:

1. Place No. 4 ‘‘BEATER MOTOR CURRENT READOUT’’ switch on DIP SWITCH assembly on master circuit board (see Figure 10) in ‘‘ON’’ position. Both freeze cylinders beater motors will start and operate and beaters motors current ratings will be displayed on message display.

2. Display should be adjusted to read A150 B150 ± 2 by adjusting MOTOR CURRENT ADJUSTMENTS located on No. 1 and No. 2 relay circuit boards (see Figure 10). These figures will fluctuate slightly with variations in line voltage and motor loads.

3. After completion of adjusting beater motor current to A150 B150 ± 2, make sure No. 5 ‘‘MOTOR CURRENT SELF-CALIBRATION’’ switch on DIP SWITCH assembly on master circuit board (see Figure

10) is in ‘‘OFF’’ position. No. 5 switch in ‘‘OFF’’ position allows the ‘‘MOTOR CURRENT’’ SELFCALIBRATION’’ electronics to automatically self calibrate the beaters motors currents at completion of each defrost cycle.

CAUTION: IF NO. 4 ‘‘BEATER MOTOR CURRENT READOUT’’ SWITCH ON DIP SWITCH assembly is placed in ‘‘ON’’ position and beater motor current readings were A155 B145 and switch was then placed back in ‘‘OFF’’ position without readjusting to A150 B150 ± 2,

beater motor current has just been reset at A155 B145. Operating the FCB Dispenser at these current readings may have serious effects on its operation.

ANY TIME THE NO. 4 ‘‘BEATER MOTOR CURRENT READOUT’’ SWITCH ON DIP SWITCH ASSEMBLY IS PLACED IN ‘‘ON’’ POSITION, THE BEATER MOTOR CURRENT READINGS MUST BE READJUSTED TO A150B150 ± 2 AS INSTRUCTED, THEN SWITCH MUST BE PLACE BACK IN THE ‘‘OFF’’ POSITION.

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MENU SELECTIONS

“CLOCK” (TIME OF DAY) see note below C _ 1 2 - 0 0 A “DEFROST” (AUTOMATIC) 3 D 1 0 - 0 0 A “SLEEP” (SLEEP TIME) S 1 2 - 3 0 A _ “WAKE UP” (WAKE UP TIME) W _ 0 7 - 1 5 A “VIS SET” (PRODUCT VISCOSITY SETTING) 1 2 _ _ _ _ 1 0 “VIS READ” (ACTUAL VISCOSITY READOUT) 1 6 _ _ _ _ 1 1 “SENSORS (TEMPERATURES READOUT) 7 5 * 7 5 * 7 5 “VOLTAGE” (DISPLAYED VOLTAGE READOUT) V R M S * 2 3 0

“DIAGNOSE” (DIAGNOSTIC MODE)

“TOTALS”

“MOTORS” (BEATER MOTOR MANUFACTURER) See Table 5

“REF TYPE” (REFRIGERANT TYPE)

NOTE: the “CLOCK” (TIME OF DAY) must be programmed into the Unit before “DEFROST” (AUTOMATIC) “SLEEP” (SLEEP TIME), and “WAKE UP” (WAKE UP TIME) will function.

See Programming Components Diagnose into Unit.

See Table 7 and programming “TOTALS” (DISPLAYED CYCLES AND HOURS TOTALS) into unit.

See PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS

MESSAGE DISPLAY

(EXAMPLE READOUTS)

TABLE 3. MAIN MENU SELECTIONS

ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS INTO UNIT

Note: The Unit control panel switches are as shown in Figure 9.

The following instructions outline adjustments and programming main menu selections, components ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE), and ‘‘TOTALS’ (DISPLAYED CYCLES AND HOURS TOTALS) into the Unit.

NOTE: Plain water, CO2 and syrup supplies to Unit must be satisfied to turn off ‘‘H2O OUT’’, ‘‘CO OUT’’, ‘‘SYRUP 1’’, and ‘‘SYRUP 2’’ fault messages on message display before adjustments and programming procedures can be performed on the Unit.

PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY

The MAIN MENU SELECTIONS (see TABLE 3) may be brought up on the message display as follows:

1. Press ‘‘AUTO 1’’, ‘‘WASH 1’’, and ‘‘BLEND 1’’ control switches (see Figure 9) at the same time and hold them pressed for a minimum of 1/2 second to bring up MAIN MENU SELECTIONS on message display. The word ‘‘CLOCK’’ will appear on display. You are now in the MAIN MENU SELECTIONS as shown in 3 To advance through the MENU SELECTIONS, repeatedly press the ‘‘CANCEL DEFROST’’ (ADVANCE) switch. Once you reach the desired selection, press the ‘‘DEFROST’’ (SELECT) switch to lock in on the selection.

NOTE: To exit MENU SELECTION and go back to MAIN MENU SELECTIONS, press ‘‘ERROR RESET’’ (RESET) switch. Press ‘‘ERROR RESET (RESET) switch again to exit from MAIN MENU SELECTIONS.

SETTING CLOCK (TIME OF DAY)

NOTE: The CLOCK (TIME OF DAY) must be programmed into Unit before ‘‘DEFROST’’ (AUTOMATIC), ‘‘SLEEP’’ (SLEEP TIME), and ‘‘WAKE UP’’ (WAKE UP TIME) can be programmed into the Unit.

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Program ‘‘CLOCK’’ (TIME OF DAY) into Unit as follows:

1. Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up ‘‘CLOCK’’ on display. Press ‘‘DEFROST’’ (SELECT) switch to lock in on selection.

2. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to bring up flashing hour number on display.

3. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance hours on display to desired hour. Press ‘‘DEFROST’’ (SELECT) switch to lock in hour on display.

4. After hour (time of day) has been locked in on message display, minute numbers will be flashing on display. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance minute numbers to desired minutes (time of day). Press ‘‘DEFROST’’ (SELECT) switch to lock in minute (time of day) on display.

5. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTION.

PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT

1. Refer to PROGRAMMING MAIN MENU SELECTIONS ON TO MESSAGE DISPLAY and bring up ‘‘DEFROST’’ on message display. Press ‘‘DEFROST’’ (SELECT) switch to lock in on selection.

2. Press ‘‘CANCEL DEFROST’’(ADVANCE) switch to bring up flashing hour number on display.

3. Press ‘‘CANCEL DEFROST’’(ADVANCE) switch to advance hours on display to desired hour. Press ‘‘DEFROST’’(SELECT) switch to lock in hour on display.

5. Press ‘‘DEFROST’’ (SELECT) switch, then repeat steps 2, 3, and 4 to program in next defrost time setting. MAKE SURE A MINIMUM OF TWO HOURS IS MAINTAINED BETWEEN DEFROST TIME SETTINGS. IF A TIME SETTING OF LESS THAN TWO HOURS IS PROGRAMMED INTO THE UNIT, A MOMENTARY ‘‘ERROR’’ MESSAGE WILL APPEAR ON THE MESSAGE DISPLAY WHEN OPERATOR TRIES TO EXIT ‘‘DEFROST’’. THE PROGRAM WILL NOT ALLOW THE OPERATOR TO EXIT THE DEFROST SETTING UNTIL THE LESS THEN TWO HOUR DEFROST TIME IS CORRECTED. THE OPERATOR MUST PRESS ‘‘CANCEL DEFROST’’ (ADVANCE) SWITCH, THEN REPEAT STEPS 2, 3, and 4 ) TO PROGRAM CORRECTED DEFROST TIME INTO UNIT.

6. Repeat step 5 as many times as necessary to program desired number of defrost time settings into the Unit.

7. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.

PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT

‘‘SLEEP’’ (SLEEP TIME) may be programmed into Unit to occur any time of the day after Unit automatic defrost cycle has occurred. Unit will shut down (go into sleep time) and will not wake up (return to normal operation) until programmed ‘‘WAKE UP’’ (WAKE UP TIME) has occurred. Program ‘‘SLEEP’’ (SLEEP TIME) into Unit as follows:

1. Refer to PROGRAMMING MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up ‘‘SLEEP’’ on message display. Press ‘‘DEFROST’’ (SELECT) switch to lock in on selection.

2. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to bring up flashing hour number on display.

3. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance hours on display to desired hour. Press ‘‘DEFROST’’ (SELECT) switch to lock in hour on display.

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SWITCH

NO. FUNCTION

1 POINT OF SALE MESSAGE SELECT See Table 6 2 POINT OF SALE MESSAGE SELECT See Table 6 3 See Note 4 BEATER MOTOR CURRENT READOUT ON- Display current readout.

OFF- No displayed current readout.

5 MOTOR CURRENT SELF CALIBRATION ON- Disabled.

OFF- Operating. 6 NOT USED 7 NOT USED 8 NOT USED 9 DEFROST ON- Hot gas.

OFF- Electric.

10 SERVICE USE

Note: Switch No. 3 must be in “OFF” position for standard Units with pulse expansion valves. Switch No. 3 must be in “ON” position for older Units with mechanical expansion valves.

TABLE 4. DIP SWITCH SETTINGS

DISPLAYED MODEL HZ MOTOR DESCRIPTION

KLBER–60 Klauber 60 Over/under gear box with a GE wide range voltage motor. FASV3+60 Fasco/VW 60 Over/under gear box with a Fasco wide range-voltage motor.

FASCWR 60 Fasco/VW 60 Standard gear box using a Fasco wide-range voltage motor.

VW/GE 60 Fasco/VW 60 Standard gear box with a GE 219/242 volt motor.

BODINE 60 Bodine 60 Special wide-range motor.

EMRSN 60 Emerson 60 Over/under gear box with an Emerson wide-range motor.

KLBER–50 Klauber 50 Over/under gear box with a GE wide-range voltage motor. FASV3+50 Fasco/VW 50 Over/under gear box with a Fasco wide-range voltage motor.

FASCWR 50 Fasco/VW 50 Standard gear box using a Fasco wide-range voltage motor.

VW/GE 50 Fasco/VW 50 Standard gear box with a GE 219/242 volt motor.

EMRSN 50 Emerson 50 Over/under gear box with an Emerson wide-range motor.

TABLE 5. MOTOR SELECT

DIP SWITCH

NO. 1

DIP SWITCH

NO. 2 *MESSAGE

OFF OFF “ENJOY A FROZEN BEVERAGE” OFF ON NOT USED - BLANK

ON OFF “HAVE A NICE DAY” ON ON “DISFRUTE UNA BEBIDA CONGELADA CARBONATADA”

*For special messages, contact you local sales representative

TABLE 6. POINT OF SALE DISPLAY MESSAGES

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5. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.

PROGRAMMING ‘‘WAKE UP’’ (WAKE UP TIME) INTO UNIT

‘‘WAKE UP’’ (WAKE UP TIME) may be programmed into Unit to occur any time of the day to wake Unit up (return to normal operation) after ‘‘sleep time’’ has occurred. Program ‘‘WAKE UP’’ into Unit as follows:

1. Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up ‘‘WAKE UP’’ on message display. Press ‘‘DEFROST’’ (SELECT) switch to lock in on selection.

2. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance hours on display to desired hour. Press ‘‘DEFROST’’ (SELECT) switch to lock in hour on display.

3. After hour (time of day) has been locked in on message display, minute numbers will be flashing on display. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance minute numbers to desired minutes (time of day). Press ‘‘DEFROST’’ (SELECT) switch to lock in minutes (time of day) on display.

4. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to bring up flashing hour number on display.

5. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.

PROGRAMMING POINT OF SALE MESSAGE DISPLAY

(see Figure 10 and TABLE 6)

Note: Point of sale display messages may be turned off by placing No. 1 DIP SWITCH on master circuit board in “OFF” position and No. 2 DIP SWITCH in “ON” position (see Figure 10 and 4 and 6) assembly in appropriate positions.

Three point of sales display messages are available and the desired one may be programmed in to appear on the message display by placing No. 1 and No. 2 switches (see Figure 10 and TABLE 4 and TABLE 6) on the DIP SWITCH ASSEMBLY in the appropriate positions.

ADJUSTING “VIS SET” (PRODUCT VISCOSITY) OF DISPENSED PRODUCT

Adjusting “VIS SET” (PRODUCT VISCOSITY) determines what product consistency of the dispensed product will be present in each freeze cylinder. Adjust “VIS SET” (PRODUCT VISCOSITY) of the dispensed product as follows.

1. Refer to PROGRAMMING MAIN MENU SELECTIONS INTO MESSAGE DISPLAY and bring up “VIS SET” on message display.

2. Press “DEFROST” (SELECT) switch to bring up numbers on message display.

Note: The direction of arrows (% &) on message display indicates which set of numbers belongs to which freeze cylinder. A No. 4 setting indicates the thinnest product consistency of dispensed product and a No. 12 setting indicates the thickest consistency of product dispensed.

3. Press “CANCEL DEFROST” (ADVANCE) switch. The left-side freeze cylinder viscosity number will be flashing on message display.

4. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance viscosity number to desired setting. Press ‘‘DEFROST’’ (SELECT) switch to lock in viscosity setting. The right-side freeze cylinder viscosity number will now be flashing.

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5. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance viscosity number to desired setting. Press ‘‘DEFROST’’ (SELECT) switch to lock in viscosity setting.

6. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.

‘‘VIS READ’’ (ACTUAL VISCOSITY READOUT) OF PRODUCT IN FREEZE CYLINDERS

‘‘VIS READ’’ (ACTUAL VISCOSITY READOUT) may be brought up on message display to actually read the viscosity (product consistency) of the product in the freeze cylinders while the Unit is in operation. Bring ‘‘VIS READ’’ up on message display as follows:

1. Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up ‘‘VIS READ’’ of product in freeze cylinders.

2. Press ‘‘DEFROST’’ (SELECT) switch to bring up actual viscosity readout of product in each freeze cylinder.

3. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES.

Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be displayed on message displays as follows:

1. Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up ‘‘SENSORS’’ (TEMPERATURES READOUT) on message display.

2. Press ‘‘DEFROST’’ (SELECT) switch to bring up evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit.

Left Reading–Refrigeration Coils Inlet No. 1 Middle Reading–Refrigeration Coils Inlet No. 2 Right Reading–Common Outlet

3. Press ‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.

‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT)

Displayed voltage readout may be displayed on message display as follows:

1. Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up ‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) on message display.

2. Press ‘‘DEFROST’’ (SELECT) switch to bring up voltage readout on message display.

3. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.

PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) INTO UNIT

1. Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up the word ‘‘CLOCK’’ on display.

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REFRIGERATION COMMON OUTLET TEMPERATURES

NO. 1 AND NO. 2 EVAPORATOR COILS

NO. 2 EVAPORATOR REFRIGERATION

COIL INLET TEMPERATURE

NO. 1 EVAPORATOR REFRIGERATION

COIL INLET TEMPERATURE

RELAY CIRCUIT

BOARD NO. 1

MASTER CIRCUIT

BOARD

RELAY CIRCUIT

BOARD NO. 2

MOTOR CURRENT

ADJUSTMENT

DIP SWITCH

ASS’Y

1 2

3 4 5 6 7

8 9

POINT OF SALE MESSAGE DISPLA Y SELECT

}

SEE NOTE

BEATER MOT ORS CURRENT READOUT (SEE TABLE 4)

MOTOR CURRENT SELF CALIBRATION (SEE TABLE 4)

NOT USED

}

APPLICABLE ELECTRIC OR GAS DEFROST (SEE TABLE 4)

SERVICE USE ONLY

(SEE TABLE 6)

Note: Switch No. 3 must be in “OFF” position for standard Units with pulse expansion valves. Switch No. 3 must be in “ON” position for Units with mechanical expansion valves.

FIGURE 10. MASTER AND RELAY CIRCUIT BOARD

2. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to bring up ‘‘DIAGNOSE’’ menu on message display. Press ‘‘DEFROST’’ (SELECT) switch to lock in place. The word ‘‘MOTOR 1’’ will appear on message display.

3. Press ‘‘DEFROST’’ (SELECT) switch. No. 1 beater motor will start and operate while switch is pressed.

4. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up the word ‘‘MOTOR 2’’ on message display.

5. Press ‘‘DEFROST’’ (SELECT) switch. No. 2 beater motor will start and operate while switch is pressed.

6. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘DEFROST 1’’ on message display.

7. Press ‘‘DEFROST’’ (SELECT) switch. No. 1 defrost relay will click when switch is pressed.

8. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘DEFROST 2’’ on message display.

9. Press ‘‘DEFROST’’ (SELECT) switch. No. 2 defrost relay will click when switch is pressed.

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10. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘SYRUP 1’’ on message display.

11. Press ‘‘DEFROST’’ (SELECT) switch. No. 1 syrup solenoid relay will click when switch is pressed.

12. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘SYRUP 2’’ on message display.

13. Press ‘‘DEFROST’’ (SELECT) switch. No.2 syrup solenoid relay will click when switch is pressed.

14. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘WATER 1’’ message display.

15. Press ‘‘DEFROST’’ (SELECT) switch. No. 1 carbonated water solenoid relay will click when switch is pressed.

16. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘WATER 2’’ on message display.

17. Press ‘’DEFROST’’ (SELECT) switch. No. 2 carbonated water solenoid relay will click when switch is pressed.

18. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘RF SOL 1’’ on message display.

19. Press ‘‘DEFROST’’ (SELECT) switch. Refrigeration relay clicks when switch is pressed.

20. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘RF SOL 2’’ on message display.

21. Press ‘‘DEFROST’’ (SELECT) switch. No. 2 refrigeration solenoid clicks when switch is pressed.

22. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘COMPRESS’’ on Message display.

23. Press ‘‘DEFROST’’ (SELECT) switch. Compressor and condenser fan motor will start and operate while switch is pressed.

24. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘HO PUMP’’ on message display.

25. Press ‘‘DEFROST’’ (SELECT) switch. Carbonator water pump relay on master circuit board clicks when switch is pressed.

26. ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.

DISPLAYING ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS) ONTO MESSAGE DISPLAY

(see TABLE 3 and TABLE 7).

1. ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS) may be displayed on message display as follows:

2. Refer to PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY and bring up the word ‘‘CLOCK’’ on message display.

3. Repeatedly press and release ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance through main menu until ‘‘TOTALS’’ menu appears on message display. Press ‘‘DEFROST’’ (SELECT) switch to lock ‘‘TOTALS’’ menu in place. The word ‘‘COMP HRS’’ will appear on message display.

4. Press and hold ‘‘DEFROST’’ (SELECT) switch. Compressor run hours will appear on message display.

5. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘COMP CYC’’ on message display.

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TOTALS MENU COMMANDS DESCRIPTION

COMP HRS COMPRESSOR RUN HOURS COMP CYC COMPRESSOR CYCLES X100 DFSTYC1 DEFROST SIDE 1 CYCLES DFSTYC2 DEFROST SIDE 2 CYCLES BLDRCYC1 BLENDER SIDE 1 CYCLES X100 BLDRCYC2 BLENDER SIDE 2 CYCLES X100 SOLDOUT 1 SOLDOUT SYRUP SIDE 1 SOLDOUT 2 SOLDOUT SYRUP SIDE 2 BMTRHRS1 BEATER MOTOR 1 HOURS BMTRHRS2 BEATER MOTOR 2 HOURS PWR ON POWER ON HOURS AUTO ON 1 AUTO SIDE 1 HOURS AUTO ON 2 AUTO SIDE 2 HOURS ERR HRS 1 ERROR SIDE 1 HOURS ERR HRS 2 ERROR SIDE 2 HOURS SLEEP HRS SLEEP MODE HOURS SYR MIN 1 (see NOTE) SYRUP MINUTES (SIDE 1) SYR MIN 2 (see NOTE) SYRUP MINUTES (SIDE 2)

NOTE: displaying “SYR MIN 1” or “SYR MIN 2” on message display will indicate time in minutes syrup actually has been dispensed. Refer to table and formula below to calculate how much syrup has been dispensed.

BRIX “A”

11.0 0.1358

11.5 0.1420

12.0 0.1481

12.5 0.1543

13.0 0.1605

13.5 0.1667

14.0 0.1728

14.5 0.1790

15.0 0.1852

15.5 0.1914

16.0 0.1975

GALLONS = “A” x SYRUP MINUTES

Using the table to the left, choose the “A” num-

Note: “A” numbers are based upon a

4.4 to 1 water to syrup “ratio”.

ber that corresponds to your BRIX setting. Multiply the “A” number by the syrup minutes reading to obtain the amount (gallons) of syrup used.

TABLE 7. “TOTALS” (DISPLAYED CYCLES AND HOURS TOTALS) MENU

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MESSAGE

DISPLAYED ERROR

Motor 1 Low Current, < 109,

Sensed on motor one

ITEMS AFFECTED BY ERROR

BEATER

MOTOR 1

OFF OFF

BEATER

MOTOR 2

REFRIG 1 REFRIG 2

Motor 2 Low Current, < 109,

Sensed on motor two

Motor 1 High current > 255,

Sensed on motor one

Motor 2 High current > 255,

Sensed on motor two

REFRIG ** Maximum Run Time on compressor OFF OFF OFF OFF SYRUP 1 Syrup Out Side One OFF SYRUP 2 Syrup Out Side Two OFF CO2 OUT CO2 Out OFF OFF

H2O H2O Out *OFF *OFF SENSOR 1 Temp Sensor Inlet One OFF OFF OFF OFF SENSOR 2 Temp Sensor Inlet Two OFF OFF OFF OFF SENSOR 3 Temp Sensor Outlet OFF OFF OFF OFF

* The refrigeration system and carbonator shall continue to operate for 1.5 minutes after a water pressure loss has been detected. If water pressure loss continues beyond 1.5 minutes, the refrigeration system and carbonator will stop.

OFF OFF

** 25–minutes on Standard System, 30–minutes on Remote System.

TABLE 8 DISPLAYED ERROR CONDITIONS

6. Press and hold ‘‘DEFROST’’ (SELECT) switch. Compressor cycles x 100 will appear on message display.

7. Use CANCEL DEFROST (ADVANCE) switch to advance through remaining ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTAL MENU) see TABLE 7. Press ‘‘DEFROST’’ (SELECT) switch to obtain message display readings of the individual menu selections.

8. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.

PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT ELECTRONICS

IMPORTANT: Note in “5 MOTOR SELECT” the number of freeze cylinders beater motors Manufacturer’s that are listed. Your Unit was manufactured and equipped with motors from one of these Manufacturer’s. A replacement freeze cylinder beater motor is also manufactured by one of these Manufacturer’s listed. DURING NEW UNIT INSTALLATION, OR WHEN REPLACING ONE OF THE BEATER MOTORS, NOTE THE MANUFACTURER’S NAME ON THE MOTOR(S). THE BEATER MOTOR(S) MANUFACTURER’S NAME(S) MUST BE PROGRAMMED INTO THE UNIT WHICH WILL MATCH THE MOTOR(S) TO THE UNIT ELECTRONICS. Proceed as follows to program the beater motors into the Unit electronics.

1. Refer to “PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY” and bring up “MOTORS” on the message display. Press “DEFROST” (SELECT) switch to lock in on the selection. “MOT_1 MFG 1” (represents No. 1 freeze cylinder beater motor) will appear on the message display.

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2. Press “DEFROST” (SELECT) switch again. A motor Manufacturer ’s name (see TABLE 5) will appear on the message display and will be non-blinking.

3. Press “CANCEL DEFROST” (ADVANCE) switch. The motor Manufacturer’s name will start blinking.

4. Press the “CANCEL DEFROST” (ADVANCE) switch again which will change to another blinking Manufacturer’s name.

5. Keep pressing and releasing the “CANCEL DEFROST’ (ADVANCE) switch until the applicable blinking Manufacturer’s name appears on the message display. This indicates Manufacturer’s name of the No. 1 freeze cylinder beater motor (new Unit installation) or the new installed replacement motor.

6. After applicable beater motor Manufacturer’s name has been selected, press “DEFROST” (SELECT) switch which will match the beater motor to the Unit electronics. The motor Manufacturer’s name will no longer be blinking.

7. Press “DEFROST” (SELECT) switch to return to “MOT_MFG1”.

8. Press “CANCEL DEFROST” (ADVANCE) switch to go from “MOT_MFG1” to “MOT_MFG2” (represents No. 2 freeze cylinder beater motor) which will appear on the message display.

9. Repeat steps 2 through 6 to program in the correct beater motor Manufacturer’s name for No. 2 freeze cylinder.

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS

The Dispenser electronics must be programmed for the proper refrigeration pulse rate according to the type of refrigerant gas that has been istalled in the refrigeration system. Note Dispenser serial plate for the type of refrigerant gas that has been installed, then proceed as follows to program the Dispenser.

1. Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up “REF TYPE” (REFRIGERANT TYPE) on the message display. Press “DEFROST (SELECT) switch to lock in on the selection. The sub menu of refrigerant types that may be brought up on the MESSAGE DISPLAY from “REF TYPE” (REFRIGERANT TYPE) are as follows:

A. “R404A2HP”

(V3+ Dispenser with 2 H.P. Copeland Compressor and R-404A Refrigerant).

B. “R404A3HP”

(V3+ Dispenser with 3 H.P. Copeland Compressor and R-404A refrigerant).

C. “R502”

(V3 and V3+ Dispensers using Bristol or Tecumseh Compressor and R502 refrigerant).

D. “R402B5OH

V3 and V3+ Dispensers using a Bristol Compressor and R-402B refrigerant).

2. Refer to Dispenser serial plate to identify the type of refrigerant gas installed in the refrigeration system.

3. Press “CANCEL DEFROST” (ADVANCE) switch as many times as necessary to bring up applicable refrigerant type from sub menu of “REF TYPE” (REFRIGERANT TYPE) on MESSAGE DISPLAY.

4. Press “DEFROST” (SELECT) switch to lock in on the selection. This programs the proper refrigeration pulse rate into the Dispenser electronics.

5. Press “ERROR RESET” switch two times to exit from “MAIN MENU SELECTIONS”.

DISPLAYED ERROR CONDITIONS

Displayed error conditions, associated errors, and items affected by the errors are found in TABLE 8 DISPLAYED ERROR CONDITIONS.

49 312026000

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CLEANING AND SANITIZING

DAILY CLEANING OF UNIT

Daily, or more often if necessary, wash all external surfaces of Unit with a mild soap solution. Rinse with clean water, then wipe dry with a clean soft cloth. DO NOT USE ABRASIVE-TYPE CLEANERS. Remove and wash drip tray in mild soap solution, rinse with clean water, then install drip tray on Unit.

SANITIZING SYRUP SYSTEMS

NOTE: The Unit should be sanitized every 120-days following Sanitizer Manufacturer ’s recommendation. Use Chlor-Tergent (Oakite Products, Inc.) or equivalent sanitizer.

The Unit should be sanitized every 120-days and before and after storage periods following parent company requirements and sanitizer manufacturer’s recommendations. One or both syrup systems may be sanitized at one time for routine 120-days sanitizing requirements. The following sanitizing instructions use No. 1 syrup system as an example. No. 2 syrup systems sanitizing instructions are identical to No. 1 syrup system with exception of using applicable system switches. Proceed as follows:

1. Press ‘‘OFF 2’’ switch to stop beater motor and refrigeration in No. 2 freeze cylinder which is not to be defrosted. ‘‘OFF 2’’ fault message will appear on message display.

2. Press ‘‘DEFROST’’ switch to start defrost cycle on No. 1 freeze cylinder. ‘‘DEFROST 1’’ message will appear on message display as long as defrost cycle is in progress.

3. Immediately press ‘‘AUTO 2’’ control switch to restart beater in No. 2 freeze cylinder. Refrigeration in No. 2 cylinder will not be operating.

4. Remove right-hand side panel as instructed for access to No. 2 product blender tank product shutoff valve.

5. Close No. 2 product blender tank product shutoff valve to prevent product bleeding back into No. 1 product blender tank during sanitizing procedure.

IMPORTANT: The following CO2 and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows:

6. To disconnect soft drink tank from Unit syrup system. A. Disconnect liquid disconnect soft drink tank. NOTE - Disconnecting liquid quick disconnect

from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustments.

B. Second, disconnect CO2 quick disconnect from soft drink tank.

7. To connect soft drink tank into Unit syrup system. A. First, connect CO2 quick disconnect to soft drink tank to pressurize tank.

B. Second, connect liquid quick disconnect to soft drink tank.

8. Disconnect soft drink tank containing syrup from No. 1 syrup system.

9. Connect clean empty soft drink tank into No. 1 syrup system.

10. Place waste container under No. 1 cylinder dispensing valve nozzle. Open dispensing valve and dispense all product from cylinder. As product level lowers in cylinder, partially close valve to avoid spurting.

11. Remove Unit front lower access panel as instructed for access to No. 1 product blender tank product sample valve.

12. Place waste container under No. 1 product blender tank product sample valve. Slowly open valve and purge remaining product out of tank, then close valve.

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13. Disconnect empty soft drink tank from No. 1 syrup system.

14. Refer to SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES under LUBRICATION and perform procedure to lubricate dispensing valve caged O-ring and drive shaft seal assembly.

WARNING: To avoid possible injury or property damage, do not attempt to remove soft drink tank cover until CO2 pressure has been released from tank.

15. Pull up on empty soft drink tank cover relief valve to release CO2 pressure from tank.

WARNING: If powder type sanitizer is used, it must be thoroughly dissolved with water prior to adding to soft drink tank.

NOTE: Sanitizing solution is used in a more concentrated form because it will be diluted approximately four-to-one in product blender tank.

16. Using clean empty soft drink tank, prepare full tank of sanitizing solution using Chlor-Tergent (Oakite Product, Inc.) or equivalent sanitizer. Mix sanitizing solution by using 70° F to 100° F (max) plain water and

2.65 oz./gallon sanitizer. This mixture will provide 800-ppm of chlorine. Sanitizing solution will be diluted to approximately 200-ppm inside product blender tank after carbonated water has been mixed with sanitizing solution.

17. Shake sanitizing solution tank to thoroughly mix solution, then connect tank into No. 1 syrup system.

18. Press ‘‘FILL 1’’ switch to fill No. 1 syrup system syrup float switch with sanitizing solution ‘‘SYRUP 1’’ fault message on message display will go out indicating syrup float switch has been filled with sanitizing solution.

19. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 product blender tank with sanitizing solution. Carbonator water pump will start and begin pumping carbonated water into product blender tank which will dilute sanitizing solution also entering tank.

20. After carbonator water pump cycles off, completely fill No. 1 freeze cylinder with sanitizing solution by repeatedly pulling and releasing relief valve knob on freeze cylinder faceplate and until sanitizing solution comes out of relief valve port. Open dispensing valve until sanitizing solution flows from valve, then close valve. Open product blender tank sample valve until sanitizing solution flows from valve, then close valve.

21. Press ‘‘WASH 1’’ switch to start No. 1 freeze cylinder beater. Allow sanitizing solution to remain in freeze cylinder for no less than 10 and no more than 15-minutes (max) contact time.

22. When sanitizing solution contact time has elapsed, press ‘‘OFF 1’’ switch to stop No. 1 freeze cylinder beater.

23. Hold appropriate container under dispensing valve and dispense until soft drink tank containing sanitizing solution is empty and all sanitizing solution has been dispensed from freeze cylinder. As sanitizing solution level lowers in freeze cylinder, partially close valve to avoid spurting. Dispose of sanitizing solution in a safe way.

24. Place waste container under No. 1 system product sample valve. Slowly open valve and purge remaining sanitizing solution out of product blender tank, then close valve.

25. Disconnect empty sanitizing solution tank from No. 1 syrup system.

26. Connect soft drink tank containing syrup into No. 1 syrup system.

WARNING: Flush residual sanitizing solution from syrup system as instructed. Residual solution left in system could create a heath hazard.

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27. Press ‘‘FILL 1’’ switch to fill No. 1 syrup system syrup float switch with syrup. ‘‘SYRUP 1’’ fault message on message display will go out indicating syrup float switch has been filled with syrup.

28. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 Product blender tank with product. Carbonator water pump will start and begin pumping carbonated water into product blender tank along with syrup to make product.

29. After carbonator water pump cycles off, completely fill No. 1 freeze cylinder with product by repeatedly pulling and releasing faceplate relief valve and until product comes out of relief valve port. Open dispensing valve until product flows from valve, then close valve. Open No. 1 system product sample valve until product flows from valve, then close valve.

30. Press ‘‘WASH 1’’ switch to start No. 1 freeze cylinder beater. Allow beater to operate for five minutes, then press ‘‘OFF 1’’ switch to stop beater.

31. Disconnect soft drink tank containing syrup from No. 1 syrup system.

32. Connect clean empty soft drink tank into No. 1 syrup system.

33. Hold appropriate container under dispensing valve and dispense until all Product has been dispensed from freeze cylinder. As product level lowers in freeze cylinder, partially close valve to avoid spurting.

34. Place waste container under No. 1 system product sample valve. Slowly open valve and purge remaining product out of product blender tank.

35. Disconnect empty soft drink tank from No. 1 syrup system and install tank containing syrup.

36. Press ‘‘FILL 1’’ switch to fill No. 1 syrup system syrup float switch with syrup. ‘‘SYRUP 1’’ fault message on message display will go out indicating syrup float switch has been filled with syrup.

37. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 product blender tank with product. Carbonator water pump will start and begin pumping carbonated water into product blender tank along with syrup to make product.

CAUTION: Do not relieve freeze cylinder pressure too fast or product will foam excessively in cylinder and lose carbonation.

38. After carbonator water pump cycles off, intermittently pull and release No. 1 freeze cylinder faceplate relief valve. This bleeds CO2 from freeze cylinder and allows product to enter and fill cylinder.

39. Open No. 2 product blender tank product shutoff valve.

40. Press both ‘‘AUTO 1’’ and ‘‘AUTO 2‘’ switches to start both freeze cylinders beaters and refrigeration system. Product will be ready for dispensing in approximately 10-minutes.

41. Install right-hand side panel and front lower access panel by reversing removal procedure.

YEARLY OR AFTER WATER SYSTEM DISRUPTION)

WARNING: The carbonator water pump double liquid check valve must be Inspected and serviced after any disruptions (plumbing work, earthquake, etc.) to the water supply

system, and at least once a year under normal circumstances. Foreign particles lodged in the double liquid check valve could cause CO2 gas to back flow into the water system and create a health hazard in the system.

SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE

(see Figure 2 and 13)

1. Press ‘‘OFF 1’’ and ‘‘OFF 2’’ switches to stop freeze cylinders beaters and refrigeration systems.

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2. Disconnect electrical power from Unit.

3. Close CO2 cylinder and water inlet supply line shutoff valve.

4. Remove lower front access panel and left-side panel as instructed for access to the water pump double liquid check valve assembly.

5. Pull up on carbonator tank relief valve plastic cover to release CO2 pressure from tank.

6. Disconnect carbonator tank water line from double liquid check valve assembly outlet.

7. Remove double liquid check valve assembly from elbow in water pump outlet port. Retain white tapered gasket inside inlet (female) end of double liquid check valve.

8. Disassemble each check valve as shown in Figure 11.

9. Wipe each part with clean lint-free cloth. Inspect each part, especially ball for burrs, nicks, corrosion, deterioration, and other damage. Discard ball seat and any damaged or suspicious parts and replace with new parts during reassemble.

10. Reassemble liquid check valves as shown in Figure 11. ALWAYS INSTALL NEW BALL SEAT (QUAD RING) P/N 312418000.

NOTE: Make sure when assembling check valves together, check valve female end with white tapered gasket inside is on inlet side of double liquid check valve assembly.

11. Assemble check valves together. DO NO OVERTIGHTEN.

12. Make sure white tapered gasket is in place inside female end of double liquid check valve assembly, then install check valve assembly on elbow in water pump outlet port.

13. Connect carbonator tank water line to double liquid check valve assembly outlet. DO NOT OVERTIGHTEN.

14. Open CO2 cylinder and water inlet supply lines shutoff valves. Check for water leaks and tighten any loose connections.

15. Install Unit back panel by reversing removal procedure.

16. Connect electrical power to Unit.

17. Press both ‘‘AUTO BLEND 1’’ and ‘‘AUTO BLEND 2’’ switches.

18. Press both ‘‘AUTO 1’’ and ‘‘AUTO 2’’ switches to start freeze cylinders beaters and refrigeration system.

REPLENISHING SYRUP SUPPLY

NOTE: Sugar free diet syrup cannot be used with this Unit.

Although syrup replenishing can be done anytime, syrup supply must be replenished when either ‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages are displayed on message display indicating either No. 1 or No. 2 syrup system soft

drink tank is empty.

NOTE: The following instructions are applicable only when replenishing syrup supply. Refer to SYRUP FLAVOR CHANGE when changing syrup flavors.

1. Press applicable ‘‘OFF 1’’ or ‘‘OFF 2’’ switch to stop applicable freeze cylinder beater and refrigeration system.

IMPORTANT: The following CO2 and liquid disconnect and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows:

2. To disconnect soft drink tank from Unit syrup system. A. Disconnect liquid disconnect from soft drink tank. NOTE - Disconnecting liquid quick

disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment.

B. Second, disconnect CO2 quick disconnect from soft drink tank.

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index no part

1 317965000 Retainer 2 312196000 Spring 3 312419000 Ball 4 312415000 Washer, .300 I.D. 5 312418000 Quad Ring 6 317963000 Body

no name

*Install new ball seat each servicing.

FIGURE 11. LIQUID CHECK VALVE ASSEMBLY

3. To connect soft drink tank into Unit syrup system. A. First, connect CO2 quick disconnect to soft drink tank to pressurize tank.

B. Second, connect liquid quick disconnect to soft drink tank.

4. Disconnect inlet (CO2) and outlet (syrup) lines from empty soft drink tank.

5. Check soft drink tank quick disconnects for sticky or restricted operation. Rinse disconnects in warm water.

6. First, pressurize full soft drink tank by connecting CO2 line to tank, then connect Unit syrup inlet line to tank.

7. Press applicable ‘‘FILL 1’’ or ‘‘FILL 2’’ switch to fill applicable No. 1 or No. 2 syrup system syrup float switch with syrup.

8. Press applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch to fill applicable No. 1 or No. 2 system product blender tank with product.

9. Press applicable ‘‘AUTO 1’’ or ‘‘AUTO 2’’ switch to start refrigeration system and beater in applicable No. 1 or No. 2 freeze cylinder.

10. If freeze cylinder is not full of product, repeatedly pull and release faceplate relief valve to slowly bleed CO from freeze cylinder and allow product to fill cylinder. Do not relieve freeze cylinder pressure too fast or product will foam excessively in cylinder and lose carbonation.

REPLENISHING CO2 SUPPLY

WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is

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NOTE: When indicator on primary CO2 cylinder regulator assembly 1800-psi gage is in shaded (‘‘change CO2 cylinder’’) portion of the dial, CO2 cylinder is almost empty and should be changed.

1. Fully close (clockwise) CO2 cylinder valve.

2. Slowly loosen CO2 regulator assembly coupling nut allowing CO2 pressure to escape, then remove regulator assembly from empty CO2 cylinder.

3. Unfasten safety chain and remove empty CO2 cylinder.

4. Position full CO2 cylinder and secure with safety chain.

WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder in upright position with safety chain to prevent it from falling over. Should valve become accidentally damaged or broken off, CO2 cylinder can cause serious personal injury.

5. Make sure gasket is in place inside CO2 regulator coupling nut, then install regulator on CO2 cylinder.

6. Open (counterclockwise) CO2 cylinder valve slightly to allow lines to slowly fill with gas, then open valve fully to back-seat valve. (Back-seating valve prevents leakage around valve shaft).

7. Check CO2 connections for leaks. Tighten loose connections.

SYRUP FLAVOR CHANGE

One or both syrup flavors can be changed at the same time. Perform flavor change on one system as follows:

1. Perform sanitizing procedure on syrup system syrup flavor change will be made on as instructed in SERVICE AND MAINTENANCE SECTION.

IMPORTANT: The following CO2 and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows:

2. To disconnect soft drink tank from Unit syrup system. A. Disconnect liquid disconnect from soft drink tank. NOTE - Disconnecting liquid disconnect

from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment.

B. Second, disconnect CO2 quick disconnect from soft drink tank.

3. To connect soft drink tank into Unit syrup system. A. First, connect CO2 quick disconnect to soft drink tank to pressurize tank.

B. Second, connect liquid quick disconnect to soft drink tank.

4. First, pressurize soft drink tank containing new flavor syrup by connecting CO2 line to tank, then connect Unit syrup inlet line to tank.

5. Press applicable ‘‘FILL 1’’ or ‘‘FILL 2’’ switch to fill applicable No. 1 or No. 2 syrup system syrup float switch with syrup.

6. Press applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch to fill applicable No. 1 or No. 2 system product blender tank with product.

7. Press applicable ‘‘AUTO 1’’ or ‘‘AUTO 2’’ switch to start refrigeration system and beater in applicable No. 1 or No. 2 freeze cylinder.

CAUTION: Do not relieve freeze cylinder pressure too fast or product will foam excessively in freeze cylinder and lose carbonation.

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8. After carbonator water pump cycles off, intermittently pull and release applicable No. 1 or No. 2 freeze cylinder faceplate relief valve. This bleeds CO2 from freeze cylinder and allows product to enter and fill cylinder.

9. If necessary, adjust BRIX, product viscosity (product consistency), and product carbonation of dispensed product as instructed.

QUAD RING

183294000

BALL

183290000

SPRING

183297000

RETAINER 183298000

BODY

183295100

QUAD RING SEAL MUST BE REPLACED EACH TIME CHECK VALVE IS SERVICED.

FIGURE 12. CO2 GAS CHECK VALVE

CLEANING CO2 GAS CHECK VALVES

(see Figure 2 and 12) The CO2 gas check valves must be inspected and serviced at least once a year under normal conditions and

after any servicing or disruption of the CO2 system. ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED.

REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR

(see Figures 5 and 7)

IMPORTANT: Note in “5 MOTOR SELECT” the number of freeze cylinders beater drive motors Manufacturer’s that are listed. Your Unit was manufactured and equipped with freeze cylinders beater drive motors from one of these Manufacturer’s. The replacement freeze cylinder beater drive motor is also manufactured by one of these Manufacturer’s listed. WHEN REPLACING ONE OF THE BEATER MOTORS, NOTE THE MANUFACTURER’S NAME ON THE MOTOR. THE BEATER MOTOR MANUFACTURER’S NAME MUST BE PROGRAMMED INTO THE UNIT WHICH WILL MATCH THE MOTOR TO THE UNIT ELECTRONICS. Proceed as follows to replace the freeze cylinder beater drive motor.

1. Press “OFF 1” and “OFF 2” control switches to stop the refrigeration system and the beater drive motors.

2. Disconnect electrical power to the Unit.

3. Remove back and applicable side panels from the Unit.

4. Tag the beater drive motor electrical wiring for identification, then disconnect the wiring from the terminal block.

5. Remove the bolt, hex nuts,and lockwashers securing the beater drive motor to the Unit frame.

6. Very carefully, remove the old beater drive motor from the Unit. BE CAREFUL NOT TO LOSE THE LARGE RUBBER DRIVE SHAFT COUPLER.

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WATER PRESSURE

REGULATOR

DOUBLE LIQUID

CHECK VALVE ASS’Y (2)

WHITE TAPERED

GASKET (2)

WATER PUMP AND

WATER PUMP MOTOR (2)

SYRUP SOLD-OUT FLOAT S W I T C H ( 2 )

LIQUID CHECK

VALVE (4)

CARBONATED WATER

SOLENOID VALVE (2)

CARBONATED WATER FLOW REGULATOR (2)

SYRUP FLOW

REGULATOR (2)

SYRUP SOLENOID

VALVE (2)

FIGURE 13. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE

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7. Remove platic coupler from the old beater drive motor shaft and install on the new motor shaft. MAKE SURE THE ALLEN-HEAD SET SCREWS ARE SECURELY TIGHTENED AND PROPERLY SEATED ON THE SHAFT FLAT SURFACE.

CAUTION: The new beater drive motor has a screw in the vent hole on top of the gear box that must be removed before the motor is put into operation.

8. Remove the screw from the vent hole on top of the beater drive motor gear box. BE CAREFUL NOT TO LAY THE MOTOR ON IT’S SIDE WHICH WILL CAUSE OIL TO LEAK OUT OF THE GEAR BOX.

9. Very carefully, place the new beater drive motor into position in the Unit with the motor shaft engaged in the beater drive shaft large plastic coupler.

10. Secure beater drive motor to the Unit frame with bolt, hex nuts, and lockwashers.

11. Connect the beater drive motor electrical wiring to the terminal block.

12. Install the sides and back panels by reversing the removal procedures.

13. Restore the Unit to operation.

14. Refer to “PROGRAMMING FREEZE CYLINDER BEATER MOTORS INTO UNIT ELECTRONICS” in the SERVICE AND MAINTENANCE section to program the new replacement beater motor into the Unit to match the Unit electronics.

ADJUSTING CARBONATED WATER TANKS LIQUID LEVEL

The carbonated water tank liquid level (pump cut-in and cutout) was adjusted at the factory and should require no further adjustment. However, if incorrect setting is suspected, check and make necessary adjustments as follows:

1. Remove Unit back and side panels as instructed for access to the carbonated water tanks and the carbonated water volume sample valves (see Figure 2 and 5).

2. To check carbonator tank total fill; allow carbonator water pump motor to operate and fill tank with carbonated water. After pump cycles off, disconnect electrical power from Unit.

3. Using container graduated in ounces, open applicable carbonated water tank carbonated water sample valve and completely drain carbonated water tank into the container. Total carbonated water volume dispensed should be 40 to 58-ounces maximum.

4. If total carbonated water dispensed is below 40-ounces, loosen screw securing level control switches actuator bracket (see Figure 14) and move actuator bracket up slightly. If more than 58-ounces, maximum of carbonated water was dispensed, move actuator bracket down, then tighten screw. MAKE ADJUSTMENTS IN SMALL INCREMENTS.

5. Connect electrical power to Unit and allow carbonated water tank to fill with water and until water pump cycles off.

6. Repeat steps 2 through 5 preceding as many times as necessary until correct carbonated water volume adjustment is achieved.

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LEVEL CONTROL

SWITCHES(2)

RELIEF VAL VE

CARBONATED

WATER TANK

SWITCHES

ACTUATOR BRACKET

ACTUATOR BRACKET ADJUSTMENT SCREW

FIGURE 14. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT

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HOT-GAS D E F R O S T

SOLENOID VALVE

ASS’Y (2)

ELECTRONIC

EXPANSION VALVE (2)

FREEZE CYLINDER (2)

EVAPORATOR

STRAINER/DRYER

ACCUMULATOR

COMPRESSOR

FIGURE 15. REFRIGERATION FLOW DIAGRAM (AIR-COOLED REFRIGERATION SYSTEM)

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CONDENSER COIL

FAN ASS’Y

Page 68

HOT GAS DEFROST

SOLENOID VALVE

ASS’Y (2)

*WATER FLOW RATE THROUGH COIL VARIES DUE TO PRESSURE CHANGE ON HIGH SIDE OF COMPRESSOR WHICH INFLUENCES OPENING AND CLOSING OF VARIABLE WATER REGULATOR. ADJUST VARIABLE WATER REGULATOR TO MAINTAIN 240-PSI REFRIGERATION HIGH-SIDE PRESSURE.

EVAPORATOR

COOLING WATER OUT

(TO DRAIN)

ELECTRONIC

EXPANSION VALVE (2)

FREEZE CYLINDER (2)

COOLING WATER IN

(CITY PLAIN WATER)

*VARIABLE WATER

REGULATOR

ACCUMULATOR COMPRESSOR

NOTE: One refrigeration system is shown in this illustration. A twoflavor Unit has one refrigeration system.

RECEIVER TANK

HIGH-PRESSURE CUTOUT SWITCH

ADJUSTMENT

SCREW

CAPILLARY

TUBE

REFRIGERATION

COOLING COIL ASS’Y

LOWER ELECTRICAL

CONTROL BOX

FIGURE 16. REFRIGERATION FLOW DIAGRAM (WATER-COOLED REFRIGERATION SYSTEM)

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FIGURE 17. WIRING DIAGRAM

3584 Rev: C

Page 71

TROUBLESHOOTING

IMPORTANT: Only qualified personnel should service internal components or electrical wiring.

WARNING: If repairs are to be made to a product system, remove quick disconnects from the applicable product tank, then relieve the system pressure before proceeding. If repairs are to be made to the CO

system, stop dispensing, shut off the CO

system pressure before proceeding. If repairs are to be made to the refrigeration system, make sure electrical power is disconnected from the unit.

IMPORTANT: The following CO2 and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows:

1. To disconnect soft drink tank from Unit syrup system. A. Disconnect liquid disconnect from soft drink tank. NOTE – Disconnecting liquid quick

disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment.

B. Second, disconnect CO2 quick disconnect from soft drink tank.

2. To connect soft drink tank into Unit syrup system. A. First, connect CO2 quick disconnect to soft drink tank to pressurize tank.

supply, then relieve the

B. Second, connect liquid quick disconnect to soft drink tank.

TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES

Trouble Probable Cause Remedy

ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING.

A. Flat cable not properly

connected to control switch module or master circuit

A. Properly connect flat cable to

control switch module or master circuit board.

board.

B. Flat cable connected between

control switch module and master circuit board pinched

B. Check cable for pinched or

broken wire condition and repair

or replace as necessary. and shorted out or broken wire in cable.

C. Inoperable switch(s) on control

panel switch module.

D. Master circuit board not

C. Replace control panel switch

module.

D. Replace master circuit board.

operating properly.

ALL CONTROL PANEL SWITCHES NOT OPERATING.

A. Electric power disconnected

from Unit.

B. ‘‘SECURITY SWITCH’’ has

not been pressed to activate control panel switches.

A. Restore electric power to Unit.

B. Press and hold ‘‘SECURITY

SWITCH’’ for 3–seconds to

restore control panel switches to

operation.

C. ‘‘SECURITY SWITCH’’

inoperable (control switches deactivated).

D. Flat cable not properly

connected to control switch module or master circuit board.

C. Replace control panel switch

module.

D. Properly connect flat cable to

control switch module or master

circuit board.

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Trouble RemedyProbable Cause

ALL CONTROL PANEL SWITCHES NOT OPERATING. (cond’t)

CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED.

PARTIAL MESSAGE OR DULL (POORLY ILLUMINATED) DISPLAY.

ONE OR MORE FAULT MESSAGES NOT OPERATING.

E. Flat cable connected between

control switch module and master circuit board pinched

E. Check cable for pinched or

broken wire condition and repair

or replace as necessary. and shorted out or broken wire in cable.

F. Master circuit board not

F. Replace master circuit board.

operating properly.

A. Not pressing and holding

‘‘SECURITY SWITCH’’ for 3–seconds to deactivate

A. Press and hold ‘‘SECURITY

SWITCH’’ for 3–seconds to

deactivate control switches. control switches.

B. ‘‘SECURITY SWITCH’’

inoperable.

B. Replace control panel switch

module.

A. Extremely low voltage. A. Upgrade voltage.

A. Flat cable not properly

connected to fault message module or master circuit

A. Properly connect flat cable to fault

message module or master circuit

board. board.

B. Flat cable connected between

fault message module and master circuit board pinched

B. Check cable for pinched or

broken wire condition and repair

or replace as necessary. and shorted out or broken wire in cable.

ALL FAULT MESSAGES NOT OPERATING.

C. External sensing device failing

to signal master circuit board

C. Replace or repair external sensing

device. which in turn signals fault message display.

D. External sensing devices cable

connectors not securely connected to master circuit board connectors.

E. Disconnected or broken wire

between master circuit board connector and external

D. Make sure external sensing

devices cable connectors are

securely connected to master

circuit board connectors.

E. Connect or repair wire between

master circuit board connector

and external sensing device. sensing device.

F. Master circuit board not

F. Replace master circuit board.

operating properly.

G. Fault message display

module not operating properly.

G. Replace fault message display

module.

A. No electrical power to Unit. A. Connect electrical power to Unit.

B. Flat cable not properly

connected to fault message module or master circuit

B. Properly connect flat cable to fault

message module or master circuit

board. board.

C. Flat cable connected between

fault message module and master circuit board pinched and shorted out or broken wire in cable.

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C. Check cable for pinched or

broken wire condition and repair

or replace as necessary.

Page 73

Trouble RemedyProbable Cause

ALL FAULT MESSAGES NOT OPERATING. (cond’t)

‘‘CO2 OUT’’ FAULT MESSAGE GOES ON DURING OPERATION.

‘‘H2O OUT’’ FAULT MESSAGE GOES ON DURING OPERATION.

‘‘SYRUP 1’’ OR ‘‘SYRUP 2’’ FAULT MESSAGE GOES ON DURING OPERATION.

D. Master circuit board not

D. Replace master circuit board.

operating.

E. Fault message display module

not operating properly.

A. CO2 supply turned off or

exhausted.

E. Replace fault message display

module.

A. Open CO2 cylinder shutoff valve

or replenish CO2 supply as instructed.

B. Primary CO2 regulator set too

low.

C. Inoperable CO2 pressure

B. Adjust primary CO2 regulator as

instructed.

C. Replace CO2 pressure switch.

switch.

A. Water supply turned off or

water pressure inadequate.

B. Plugged water filter or water

pump strainer screen.

A. Turn on water supply or check

water supply line pressure.

B. Change water filter or clean water

pump strainer screen as instructed.

C. Inoperative water pressure

C. Replace water pressure switch.

switch.

A. Soft drink tank empty. A. Replenish syrup supply as

instructed.

‘‘ERROR 1’’ OR ‘‘ERROR 2’’ FAULT MESSAGE GOES ON DURING OPERATION.

FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT OPERATE.

UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE.

MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN ‘‘DEFROST’’ SWITCH IS PRESSED.

A. Error within Unit has

developed interrupting normal operation.

A. Loose or broken electrical

wires.

B. Inoperable automatic defrost

timer.

A. Automatic defrost timer stuck

in automatic defrost cycle.

A. Flat cable not properly

connected to control switch module or master circuit board.

B. Flat cable connected between

control switch module and master circuit board pinched and shorted out or broken wire in cable.

C. Inoperable ‘‘DEFROST’’ switch

on control panel switch module.

A. Locate and correct error, then

press ‘‘ERROR RESET’’ switch to restore normal operation.

A. Repair electrical wires.

B. Replace master circuit board.

A. Replace master circuit board.

A. Properly connect flat cable to

control switch module or master circuit board.

B. Check cable for pinched or

broken wire condition and repair or replace as necessary.

C. Replace control panel switch

module.

D. Loose or broken wire. D. Repair wire. E. Master circuit board not

E. Replace master circuit board.

operating properly.

312026000

Page 74

Trouble RemedyProbable Cause

DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING ‘‘CANCEL DEFROST ’’ SWITCH.

A. Flat cable not properly

connected to control switch module or master circuit board.

B. Flat cable connected between

A. Properly connect flat cable to

B. Check cable for pinched or control switch module and master circuit board pinched and shorted out or broken wire in cable.

C. Inoperable ‘‘CANCEL

C. Replace control panel switch DEFROST’’ switch on control panel switch module.

D. Master circuit board not

D. Replace master circuit board. operating properly.

TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATORS

CARBONATOR WATER PUMP

A. No electrical power to Unit. A. Connect electrical power to Unit.

MOTOR WILL NOT OPERATE.

B. ‘‘AUTO BLEND 1’’ or ‘‘AUTO

B. Press ‘‘AUTO BLEND 1’’ or BLEND 2’’ switches have not been pressed.

C. ‘‘H2O OUT’’ fault message is

C. Restore water supply to Unit. on.

controls switch module or master circuit board.

broken wire condition and repair or replace as necessary.

module.

Check power source.

‘‘AUTO BLEND 2’’ switch.

CARBONATOR WATER PUMP WILL NOT SHUT OFF.

ERRATIC CARBONATOR WATER PUMP CYCLING.

D. ‘‘CO2 OUT’’ fault message is

on.

E. Loose or broken electrical

wires.

F. Overheated water pump motor

cut off by overload protector.

G. Inoperative water pump and/or

motor.

H. Inoperative carbonated water

tank level control switches.

I. Binding, damaged, or dirty

carbonated water tank balance mechanism.

J. Inoperative water pump and/or

motor.

A. Binding, damaged, or dirty

carbonated water tank balance mechanism.

A. Insufficient water supply

pressure. ‘‘H2O OUT’’ fault message goes on and off intermittently and water pump cycles on and off during carbonator tank fill cycle.

D. Replenish CO2 supply as

instructed.

E. Tighten connections or replace

wires.

F. Check for proper line voltage.

Check for restricted pump discharge.

G. Replace pump and/or motor.

H. Replace level control switches.

I. Clean, repair, or replace balance

mechanism.

J. Replace water pump and/or

motor.

A. Clean, repair, or replace balance

mechanism.

A. Increase water inlet supply line

pressure. Water inlet supply line must have large enough I.D.

B. Water filter restricted. B. Replace water filter.

66312026000

Page 75

Trouble RemedyProbable Cause

TROUBLESHOOTING DISPENSED PRODUCT

BRIX (WATER–TO–SYRUP) ‘‘RATIO’’ TOO LOW.

BRIX (WATER–TO–SYRUP) ‘‘RATIO’’ TOO HIGH.

IMPROPER PRODUCT DISPENSED.

A. Quick disconnect not secure

A. Secure tank quick disconnect.

on soft drink tank.

B. Syrup flow regulator set too

low.

C. Water flow regulator set too

high.

B. Adjust BRIX of dispensed product

as instructed.

C. Water flow regulator must be set

at 1.3 ± 0.05 oz/sec. D. Syrup flow regulators stuck. D. Clean syrup flow regulators. E. Restriction in syrup line. E. Sanitize Unit as instructed. F. Syrup Baume not in proper

range.

A. Syrup flow regulators set too

high.

B. Water flow regulator set too

low.

F. Change syrup supply as

instructed.

A. Adjust BRIX of dispensed product

as instructed.

B. Water flow regulator must be set

for 1.3 ± 0.05 oz/sec. C. Water flow regulator stuck. C. Clean regulator. D. Syrup Baume not in proper

range.

D. Change syrup supply as

instructed. E. Restricted water filter. E. Replace water filter. A. Secondary CO2 regulators not

properly adjusted.

A. Adjust secondary CO2 regulators

as instructed.

PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE, IN ONLY SMALL AMOUNTS, OR ONLY LIQUID.

FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING.

FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY.

B. Dirty CO2 supply. CO2 must

be clean and free of water, oil,

B. Replace CO2 supply as

instructed.

and dirt. Water will not absorb dirty CO2 gas in same way as clean gas. This can also cause off–taste problems.

A. Dispensing valve has ice

particles in it.

A. Open and close dispensing valve

repeatedly. Defrost freeze cylinder

as instructed. If necessary, check

and adjust BRIX as instructed.

Adjust viscosity of dispensed

product as instructed. B. Cylinder freeze–up. B. Refer to CYLINDER

FREEZE–UP. A. ‘‘AUTO BLEND 1’’ or ‘‘AUTO

BLEND 2’’ switch not pressed.

B. Carbonator water pump not

operating.

A. Press ‘‘AUTO BLEND 1’’ or

‘‘AUTO BLEND 2’’ switch.

B. Check carbonator and restore to

operation. C. Lines restricted. C. Sanitize Unit as instructed.

A. Dispensed product BRIX

varying because:

Syrup and/or water flow

regulator sticking.

Primary CO2 regulator pressure

insufficient.

a.Clean regulator(s).

b.Primary CO2 regulator must be

adjusted from 80 to 100–psi.

312026000

Page 76

Trouble RemedyProbable Cause

FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY. (cont’d)

B. Cylinder freeze-up causing ice

formation in center of cylinder and liquid product channels around ice formation.

NOTE: DEFROST AFFECTED FREEZE CYLINDER AS INSTRUCTED.

CYLINDER FREEZE–UP. A. Dispensed product BRIX too

low.

B. Viscosity of dispensed product

not properly adjusted.

TROUBLESHOOTING REFRIGERATION SYSTEM

UNIT EQUIPPED WITH AIR-COOLED

A. Dispenser refrigeration system

overheating.

REFRIGERATION SYSTEM

NOTE: The Dispenser condenser coil must be periodically cleaned to maintain proper cooling of the refrigeration system.

UNIT EQUIPPED WITH WATER-COOLED REFRIGERATION SYSTEM

A. Water supply to refrigeration

cooling coil assembly disruppted.

B. Insufficient water supply to

refrigeration cooling coil assembly disruppted.

B. Refer to CYLINDER

FREEZE–UP.

A. Refer to BRIX (Water–to–Syrup)

‘‘Ratio’’ too low.

B. Adjust dispensed product

viscosity as instructed

A. Clean Unit condenser coil as

instructed (see NOTE below)

A. Restore water supply to

refrigeration cooling coil assembly.

B. Increase water supply to

refrigeration cooling coil assembly.

C. Variable water regulator on the

refrigeration cooling coil

C. Properly adjust variable water

regulator as instructed in manual. assembly not properly adjusted.

ACCESSORIES AND TOOLS

ACCESSORIES

1155 Installation Kit 511005000 Cup Holder 511006000 Cup Holder 511035000 CO2 Changeover Kit 1040 Seal Kit, Rear O–Ring Housing and O-Rings

GENERIC FLAVOR TABS

1085 Cola 1086 Cherry 1087 Orange 1088 Grape 1089 Lemon–Lime 1090 Strawberry 1091 Banana

SERVICE TOOLS

281884000 3–gallon Sanitizing Tank 322859000 Spanner Wrench, Dispensing Valve 511004000 Refractometer, 0–30 Scale 2899 Wrench, rear Seal Housing 3810 Gauge, Shaft/Housing Adjustment

68312026000

Page 77

WARRANTY

IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire product, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number, serial number and the date of purchase.

IMI Cornelius Offices

AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166

D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930

AUSTRIA

D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307

BELGIUM

D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829

BRAZIL ENGLAND

D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644

D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201

FRANCE GERMANY GREECE HONG ITALY NEW SINGAPORE SPAIN USA

D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438

D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491

KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222

D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814

ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361

D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604

D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379

D ONE CORNELIUS PLACE D ANOKA, MI NNESOTA D (612) 421-6120 D FAX (612) 422-3255

LD004

4/21/98

Page 78

IMI CORNELIUS INC.

CORPORATE HEADQUARTERS:

One Cornelius Place Anoka, Minnesota 55303-6234 (612) 421-6120 (800) 238-3600