Cornelius R-404A User Manual
Operator’s Manual
FCB POST-MIX DISPENSER
WITH V4 FEATURES
(R-404A REFRIGERANT)
Part No 312030002
May 8, 1996
Control Code A
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 1996
PRINTED IN U.S.A
TABLE OF CONTENTS
SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOGNIZE SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDERSTAND SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOLLOW SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO2 (CARBON DIOXIDE) WARNING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIPPING, STORING, OR RELOCATING UNIT 1. . . . . . . . . . . . . . . . . . . . . . .
OPERATOR’S INSTRUCTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL (KEYPAD) SECURITY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL SWITCHES 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘SYRUP PRIME’’ SWITCHES. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘BLEND ON/OFF’’ SWITCHES. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘MOTOR’’ SWITCHES. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
’’ON’’ SWITCHES. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘OFF’’ SWITCHES. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘ERROR RESET’’ SWITCH. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL DISPLAY MESSAGES 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘FILL 1’’ AND ‘‘FILL 2’’ FAULT MESSAGES. 6. . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘ERROR 1’’ AND ‘‘ERROR 2’’ FAULT MESSAGES. 6. . . . . . . . . . . . . . . . . . . .
‘‘OFF 1’’ AND ‘‘OFF 2’’ FAULT MESSAGES. 6. . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘H2O OUT’’ FAULT MESSAGE. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘CO2 OUT’’ FAULT MESSAGE. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘SYRUP 1’’ OR ‘‘SYRUP 2’’ FAULT MESSAGES. 6. . . . . . . . . . . . . . . . . . . . . .
‘‘DEFROST 1’’ OR ‘‘DEFROST 2’’ DISPLAY MESSAGES. 6. . . . . . . . . . . . . .
‘‘POINT OF SALE’’ DISPLAY MESSAGES. 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
DEFROST SYSTEMS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNITS EQUIPPED WITH HOT-GAS DEFROST SYSTEMS 7. . . . . . . . . . . . .
UNITS EQUIPPED WITH ELECTRIC DEFROST SYSTEMS 7. . . . . . . . . . . .
‘‘SLEEP’’ (SLEEP TIME) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNITS EQUIPPED WITH HOT-GAS DEFROST SYSTEMS 8. . . . . . . . . . . . .
UNITS EQUIPPED WITH ELECTRIC DEFROST SYSTEMS 8. . . . . . . . . . . .
‘‘WAKE UP’’ (WAKE UP TIME) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FACEPLATE RELIEF VALVES 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSING VALVES 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSED PRODUCT CONDITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
‘‘OVERRUN’’, AS APPLIED TO FROZEN CARBONATED BEVERAGES 9. . . . . .
OPERATING CHARACTERISTICS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING UNIT 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING CO2 REGULATORS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIMARY CO2 REGULATOR 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECONDARY CO2 REGULATORS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING BRIX (WATER-TO-SYRUP “RATIO”) OF DISPENSED PRODUCT 11
REPLENISHING SYRUP SUPPLY 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYRUP TANKS SYSTEM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (cont’d)
BAG–IN–BOX SYSTEM 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYRUP FLAVOR CHANGE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLENISHING CO2 SUPPLY 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING AND SANITIZING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY CLEANING OF UNIT 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZING SYRUP SYSTEMS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING CONDENSER COIL 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT WITH AIR-COOLED REFRIGERATION SYSTEM 16. . . . . . . . . . . . . . . .
UNIT WITH REMOTE CONDENSING REFRIGERATION 16. . . . . . . . . . . . . . .
TROUBLESHOOTING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT
MESSAGES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING. 17. . . . .
ALL CONTROL PANEL SWITCHES NOT OPERATING. 17. . . . . . . . . . . . . . . .
PARTIAL MESSAGE OR DULL (POORLY ILLUMINATED) DISPLAY. 17. . . . .
ONE OR MORE FAULT MESSAGES NOT OPERATING. 17. . . . . . . . . . . . . . .
ALL FAULT MESSAGES NOT OPERATING. 17. . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘CO2 OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. 18. . . . . .
‘‘H2O OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. 18. . . . . .
‘‘SYRUP 1’’ OR ‘‘SYRUP 2’’ FAULT MESSAGE GOES ON DURING
OPERATION. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
‘‘ERROR 1’’ OR ‘‘ERROR 2’’ FAULT MESSAGE GOES ON DURING
OPERATION. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT
OPERATE. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE. 18. . . . . . . . . . .
MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN ‘‘DEFROST’’
SWITCH IS PRESSED. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING ‘‘CANCEL
DEFROST ’’ SWITCH. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATORS 18.
CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE. 18. . . . . . . . .
CARBONATOR WATER PUMP WILL NOT SHUT OFF. 19. . . . . . . . . . . . . . . .
ERRATIC CARBONATOR WATER PUMP CYCLING. 19. . . . . . . . . . . . . . . . . .
TROUBLESHOOTING DISPENSED PRODUCT 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ OF DISPENSED PRODUCT TOO
LOW. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ OF DISPENSED PRODUCT TOO
HIGH. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPROPER PRODUCT DISPENSED. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE, IN ONLY
SMALL AMOUNTS, OR ONLY LIQUID. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN
DISPENSING. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY. 19. . . . . . . . .
Page
ii312030002
TABLE OF CONTENTS (cont’d)
CYLINDER FREEZE-UP. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES
FIGURE 1. FCB POST-MIX DISPENSERS WITH V4 FEATURES 3. . . . . . . . . . . .
FIGURE 2. CONTROL PANEL SWITCH IDENTIFICATION 4. . . . . . . . . . . . . . . . . .
FIGURE 3. OPERATING CONTROLS (FOUR-FLAVOR UNIT SHOWN) 5. . . . . .
Page
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iv312030002
SAFETY INFORMATION
Recognize Safety Information
This is the safety-alert symbol. When you see this
symbol on our machine or in this manual, be alert to
the potentially of personal injury.
Follow recommended precautions and safe operating
practices.
Understand Signal Words
A signal word - DANGER, WARNING, OR CAUTION
is used with the safety-alert symbol. DANGER identi-
fies the most serious hazards.
DANGER
Safety signs with signal word DANGER or WARNING
are typically near specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety messages in this manual.
WARNING
CAUTION
Follow Safety Instructions
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in
good condition. Replace missing or damaged safety signs. Learn how to operate the machine and how to
use the controls properly. Do not let anyone operate the machine without instructions. Keep your machine in
proper working condition. Unauthorized modifications to the machine may impair function and/or safety and
affect the machine life.
CO2 (Carbon Dioxide) 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.
Shipping, Storing, Or Relocating Unit
CAUTION: Before shipping, storing, or relocating the Unit, syrup systems must be sanitized and all
sanitizing solution must be purged from the syrup systems. All water must also be purged from the
plain and carbonated water systems. A freezing ambient environment will cause residual sanitizing
solution or water remaining inside the Unit to freeze resulting in damage to the internal components.
1
312030002
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312030002 2
OPERATOR’S INSTRUCTIONS
This section describes operating controls and indicators, dispensed product conditions, operating characteristics, Unit operation, replenishing syrup supply, product flavor change, checking CO
cleaning of Unit, and sanitizing requirements.
SOUND BAFFLE/DRIP
TRAY ASS’Y PROVIDED
ONLY WITH 3 H.P. UNIT.
supply, operators daily
2
TWO-FLAVOR DISPENSER
FIGURE 1. FCB POST-MIX DISPENSERS WITH V4 FEATURES
WARNING: Disconnect electrical power to the Unit to prevent personal injury before
attempting any internal maintenance. Only qualified personnel should service internal
components or electrical wiring.
OVERCOUNTER DISPENSER
FOUR-FLAVOR DISPENSER
CONTROL PANEL (KEYPAD) SECURITY
The optional control panel (keypad) security (options DIP6 switch) may be programmed into the Unit to enable
(activate) or disable (de-activate) the control panel security. When the control panel security is enabled, any
control panel switch can be pushed and held for 5-seconds to override the control panel security. An audible
beep will be heard when the switch is first pushed, then another beep will be heard when the security override
has taken place and the switch may be released. Control panel security will be re-established 90-seconds after
switch pushing activity has ceased. Control panel (keypad) security should be programmed into the Unit electronics by a qualified Service Person.
Note: When in programming menu, the control panel security will not re-establish until after exiting
programming menu.
CONTROL PANEL SWITCHES
(see Figure 2)
NOTE: Two-flavor Unit- 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 the No. 1 freeze cylinder.
Four-flavor Unit- The No. 1 freeze cylinder is the left-hand cylinder facing the front of the Unit. The other three freeze cylinders, to the right of the No.1 freeze cylinder, are labeled 2, 11, and 22.
3120300023
Side 1
BLEND
ON/OFF
ON
MOTOR
SYRUP PRIME
OFF
ERROR
RESET
ER
Display
Side 2
<(Backward)
Manual Defrost
(Forward)>
Cancel Defrost
Menu/Select
MS
FIGURE 2. CONTROL PANEL SWITCH IDENTIFICATION
‘‘SYRUP PRIME’’ Switches.
The ‘‘SYRUP PRIME’’ switches, located on the control panel, are touch-type switches and require only pressing
to activate. The ‘‘SYRUP PRIME’’ switches are used only when filling the syrup systems sold-out floats during
syrup replenishing, syrup flavor changeover, or sanitizing the syrup systems.
‘‘BLEND ON/OFF’’ Switches.
The ‘‘BLEND ON/OFF” switches, located on the control panel, are touch-type switches and require only pressing to activate. These switches are used to fill the product blender tanks after the sold-out floats have been filled
using the ‘‘SYRUP PRIME’’ switches. After the product blender tanks have been filled, the “BLEND ON/OFF”
switches may be pressed again to prevent more product from entering the product blender tanks during BRIX
test. The “ON” and “BLEND ON/OFF” switches must be pressed to operate the freeze cylinders beaters and
refrigeration system during normal operation.
‘‘MOTOR’’ Switches.
The ‘‘MOTOR’’ switches, located on the control panel, are touch-type switches and require only pressing to activate. These switches are used to operate the freeze cylinders beaters with no refrigeration during sanitizing.
’’ON’’ Switches.
The ‘‘ON’’ switches, located on the control panel, are touch-type switches and require only pressing to activate.
These switches are used to operate the freeze cylinders beaters and refrigeration system after cylinders have
been filled with product. The freeze cylinders beaters and refrigeration system may be stopped by pressing the
‘‘OFF’’ switches.
‘‘OFF’’ Switches.
The ‘‘OFF’’ switches, located on the control panel, are touch-type switches and require only pressing to activate.
These switches are used to stop freeze cylinders beaters and refrigeration system.
‘‘ERROR RESET’’ Switch.
‘‘ERROR RESET’’ switch, located on the control panel, is a touch-type switch and requires only pressing to activate. The ‘‘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.
312030002 4
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