Cornelius Viper 2 Service Manual

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Page 1

FCB PINNACLE

2 and 4 Flavor

Service Manual

FCB - 2 Flavor FCB - 4 Flavor

Release Date: October 30, 2003

Publication Number: 560007298SER

Revision Date: May 07, 2014

Revision: J

Page 2

CONTACT INFORMATION

The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical equipment. Appropriate safety precautions should be followed and all local safety and construction requirements should be met.

To inquire about current revisions of this and other documentation, or for assistance with any Cornelius product contact:

www.cornelius.com

800-238-3600

This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius.

Page 3

TABLE OF CONTENTS

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Read and Follow all Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Recognize Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Qualified Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Magnet Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Accessories — Included . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Accessories — Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Operation and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Maintaining Product Quality

Cornelius FCB Equipment - Operator Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1. Dispensed Product Throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2. Programmed Defrost Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3. Sleep Mode Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4. Viscosity Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Preventive Maintenance Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Cleaning Air Filter (Integral Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Stainless Steel Double Check Valve Inspection & Cleaning . . . . . . . . . . . . . . . .11

Check BRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Water, Syrup, & CO2 Regulator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Pinnacle Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Control System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Control Panel Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Control Panel Error Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Component Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Magnet Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

DC Control Drive Motor Board Replacement - Emerson . . . . . . . . . . . . . . . . . . . . . 40

Main and Product Delivery Board Replacement - Emerson . . . . . . . . . . . . . . . . . . 40

Chip Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

DC Inverter Board Replacement - Baldor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Main and Product Delivery Board Replacement - Baldor . . . . . . . . . . . . . . . . . . . . 42

Display Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Merchandiser Light Ballast Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Page 4

Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Contactor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Start Components Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Pump Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Agitator Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Syrup/Water Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

CO2 Regulator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Blendonator Float Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Blendonator Tank Replacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Hy-Pot Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Hall Effect Sensor Diagnosis & Replacement - Baldor . . . . . . . . . . . . . . . . . . . . . . 48

Hall Board Diagnostic Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

DC Stator Test - Emerson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

DC Stator Test - Baldor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

DC Stator Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

DC Stator Assembly Replacement - Baldor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Condenser Fan Motor Replacement (Integral Only) . . . . . . . . . . . . . . . . . . . . . . . . 53

Condenser Filter Replacement (Integral Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Foam Pack Replacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Compressor Replacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Hot Gas Valve Rebuilding:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Pulse Valve Replacement:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Water Pressure Regulator / Switch Replacement:. . . . . . . . . . . . . . . . . . . . . . . . . . 56

Water Strainer Cleaning: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Merchandiser Lamp Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Troubleshooting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Troubleshooting Product Not Cold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Appendix A - Historic Brix Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Section 1: 3-Way Valve Brixing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Section 2: Shut-Off Valve and Blendonator Outlet Brix Sample Tube Procedure . . 66

Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Valve Torque and Staking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Delta Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Motorman Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

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SAFETY

SAFETY INSTRUCTIONS

Read and Follow all Safety Instructions

Read and follow all safety instructions in this manual and on the machine (decals, labels, and laminated

cards).

Read and understand all applicable OSHA (Occupation Safety and Health Administration) safety regula-

tions before operating the machine.

Recognize Safety Alerts

This is the safety alert symbol. When you see it in this manual or on the machine be alert to the potential of personal injury or damage to the machine.

Different Types of Alerts

There are 3 types of safety alerts:

DANGER — Indicates an immediate hazardous situation which if not avoided WILL result in seri-

ous injury, death, or equipment damage.

Pinnacle 2 and 4 Flavor Service Manual

WARNING — Indicates a potentially hazardous situation which, if not avoided, COULD result in

serious injury, death, or equipment damage.

CAUTION — Indicates a potentially hazardous situation which, if not avoided, MAY result in

minor or moderate injury or equipment damage.

SAFETY TIPS

• Carefully read all safety messages in this manual and safety signs on the machine.

• Keep safety signs in good condition and 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 proper training. This appliance is not intended for use

by very young children or infirm persons without supervision. Young children should be supervised to

ensure that they do not play with the appliance.

• Keep your machine in proper working condition and do not allow unauthorized modifications to the

machine.

QUALIFIED SERVICE PERSONNEL

CAUTION — Only trained and certified electrical, plumbing and refrigeration technicians should

service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES.

CO2 (CARBON DIOXIDE) WARNING

WARNING

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 CO

rapidly by loss of consciousness.

— CO2 Displaces Oxygen. Strict Attention must be observed in the prevention of

gas will experience tremors which are followed

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SHIPPING AND STORAGE

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 liquids, after sanitizing, must be purged from the unit. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the Unit to freeze resulting in damage to the internal components.

MAGNET WARNING

CAUTION — After removing the very strong magnet from the freeze cylinder, be careful to avoid

crushing fingers between the magnet and any ferrous metal. Keep the magnet free from metallic debris and wipe clean prior to reinstallation.

WARNING — Strong Magnetic Field.

Person wearing pacemaker, implanted cardioverter defibrillator, or other implanted medical device may be affected by the magnetic field and must keep the magnet at 6 or more inches from the device. The magnetic field can affect operation of these devices which may cause bodily injury or death.

If disruption of device occurs or operation is adversely effected, immediately move the victim far away from magnet and seek medical assistance.

Pinnacle 2 and 4 Flavor Service Manual

Page 7

PRODUCT OVERVIEW

The 2 and 4 Flavor Pinnacle (see pictures below) consists of the following:

• 2 or 4 freeze cylinders each containing an internal beater bar driven by DC electric motors, utilizing

external stator coils and internal rotor magnets. These motors contain no seals there by eliminating leak-

age and minimizing preventive maintenance.

• A DC motor using magnetics to drive the beater bars in each cylinder.

• 1 refrigeration systems per 2 barrels, 1 blendonator assembly per barrel, a programmable defrost sys-

tem to defrost the freeze cylinders, and interconnecting tubing, components and fittings necessary to reg-

ulate, transfer, and dispense a quality frozen carbonated product.

• The components are enclosed in a steel frame. The frame is then covered with panels.

• The panels enclosing the components and frame are easily removable to facilitate installation, service,

and maintenance.

• Each barrel has a transparent faceplate, with an integral relief valve and a removable self-closing dis-

pensing valve mounted on the front of each faceplate.

• A removable drip tray, with cup rest is located directly below the dispensing valves.

Pinnacle 2 and 4 Flavor Service Manual

SYSTEM OVERVIEW

• Lighted merchandising compliments each unit.

• 2 or 4 blendonators using a refrigerated ice coil and water bath to cool the product before carbonating.

• 1 self contained refrigeration system for the 2 flavor and 2 for the 4 flavor.

• A programmable system to defrost the freeze cylinders, and components that dispense the product.

• Control Panel with 5 buttons that control operational and diagnostic functions and settings.

Lighted Display Panel

Double Refrigeration System

Steel Frame

Dispensing Valves & Face Plates Control Panel

FIGURE 1 FIGURE 2

Foam Pack& Motor

Page 8

SPECIFICATIONS

Dimensions

Pinnacle 2 and 4 Flavor Service Manual

Height

Width

Depth

Shipping

weight

Line Voltage

The recommended line voltages for the Pinnacle unit are as follows:

The unit has a low voltage cut out at 180 VAC and a high voltage cut out at 260 VAC.

Overcounter

Integral/Remote 2

Flavor

43.75 in. 43.75 in. 74.75 in. 74.75 in.

14.5 in. 28 in. 14.5 in. 28 in.

31 in. 36 in. (with drip tray)

429 lbs. (approx.) 732 lbs. (approx.) 525 lbs. (approx.) 858 lbs. (approx.)

Voltage Corrective Action

Below 180 V Do not connect unit.

180 to 190 VAC Boost voltage by +32 V.

Overcounter

Integral/Remote 4

Flavor

31 in. 36 in. (with drip tray)

Overcounter

Integral/Remote 2

Flavor w/ Cornelius

Cart

32 in. 37 in. (with drip tray)

Overcounter

Integral/Remote 4

Flavor w/ Cornelius

Cart

32 in. 37 in. (with drip tray)

191 to 207 VAC Boost voltage by +16 V.

208 to 240 VAC Use line voltage.

241 to 253 VAC Reduce voltage by -16 V.

254 to 272 VAC Reduce voltage by -32 V.

Above 272 VAC Do not connect unit.

Accessories — Included

Magnet puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560003662

John Guest fitting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560003481

Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325216000

Page 9

Accessories — Optional

Installation kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1155

Cup holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511006000

Cornelius refractometer, 0-30 scale . . . . . . . . . . . . . . . . . . . . . . . 511004000

Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325674000

Remote Condensing Unit (one required for each two barrels) . . . 631700512

Refrigeration line sets (one required for each two barrels) . . . . . 561441250

Refrigeration line sets with flexible end and 90 degree fittings

(one required for each two barrels). . . . . . . . . . . . . . . . . . . . . . . . 561441253

Cornelius cart, stainless steel, 2 Flavor . . . . . . . . . . . . . . . . . . . . 620201705

Cornelius cart, stainless steel, 4 Flavor . . . . . . . . . . . . . . . . . . . . 620201701

Leg 4” Height (4 required per unit) . . . . . . . . . . . . . . . . . . . . . . . . 3184

2 FL Generic main graphic and flavor card set . . . . . . . . . . . . . . . 560007299

4 FL Generic main graphic and flavor card set . . . . . . . . . . . . . . . 560007300

Pinnacle 2 and 4 Flavor Service Manual

Page 10

Pinnacle 2 and 4 Flavor Service Manual

OPERATION AND SERVICE

MAINTAINING PRODUCT QUALITY CORNELIUS FCB EQUIPMENT - OPERATOR INSTRUCTIONS

It has been determined that the following factors can affect the rate at which product quality diminishes

(as indicated by a change in product appearance).

1. Dispensed Product Throughput

2. Programmed Defrost Scheduling

3. Viscosity Setting

Cornelius recommends the following instructions be read and followed relative to operating and

establishing settings with the FCB equipment. Cornelius equipment service manuals contain instructions

on how to program settings within the control system. Operators who have not been trained on servicing

Cornelius FCB equipment should not attempt to modify equipment settings but should contact an

accredited service provider.

Cornelius makes the following recommendations to help assure maximum product quality:

1. Dispensed Product Throughput

FCB equipment is designed to provide a high throughput of frozen carbonated dispensed product to meet

peak draw demands. Where low product throughput is experienced, there is the potential for product

quality to diminish. The matrix below outlines the minimum throughput per barrel that must be dispensed

on a 24 hour basis.

Dispensed product throughput matrix

Pinnacle Viscosity </= 4 Viscosity >4

Volume of dispensed product per barrel per 24 hours required to maintain product quality.

Cornelius recommends that, in conditions where the FCB machine is operational and the

minimum throughput (set forth in the matrix above) is not met on a per barrel basis, product

should be dispensed and discarded to increase throughput and help assure that product quality

is maintained.

2. Programmed Defrost Scheduling

The control system in Cornelius FCB equipment includes a function to automatically defrost product in

the barrel at programmed times. Programmed defrosts must be scheduled frequently to ensure that

product quality within the barrel is maintained. Failure to defrost regularly during periods of low

throughput will allow increased ice crystal growth, with a possible decrease in product quality and will

cause drive errors. Regular throughput of dispensed product will replenish the barrel frequently with liquid

and reduce the requirements of programmed defrosts.

Cornelius recommends that programmed defrosts be scheduled to occur during any 3 hour

window during which time dispensed product throughput is low. Low throughput is defined as

less than 8 x 16oz drinks per barrel during any 3-hour window.

48 oz 60 oz

1. Data in matrix assumes equipment has been correctly installed, commissioned and calibrated as per

directions contained in all technical literature published by Cornelius and the recommendations contained in this document have been followed.

Page 11

3. Sleep Mode Recommendations

Cornelius recommends programming a sleep for any period of time, over 3 hours, in which the unit will

not have any usage. If the programmed sleep is longer than 6 hours, Cornelius also recommends turning

the ice bank off in the options menu. This will increase the life of the machine and reduce the energy con-

sumption.

A wake time must be programmed to return the unit to normal operation. Cornelius recommends pro-

gramming the wake 30 minutes before the unit is needed if the ice bank option is set to ON and 60 min-

utes before the unit is needed if the ice bank option is set to OFF. These are the time recommended if the

ambient temperature is at 75

ambient temperature require more time for the ice bank to build).

F. The times will vary depending on the ambient temperature (a higher

4. Viscosity Setting

The control system in Cornelius FCB equipment includes a function to select the desired product

viscosity. This function is referred to as “Viscosity Setting”. There is a selectable Viscosity range of 1–9

for the Pinnacle. The higher the number selected the more viscous the frozen product in the barrel will

become. This increased viscosity is achieved by freezing the product in the barrel to a lower temperature

thereby increasing ice crystal size/growth. As the ice crystal size increases, however, there is potential for

product quality to diminish.

Cornelius recommends that the viscosity settings be set at the lowest possible setting to achieve

the desired drink quality. In most typical installations using a sugar-based syrup, acceptable

drink quality can be achieved by programmed Viscosity Settings in the range of 3-5 for Pinnacle.

Pinnacle 2 and 4 Flavor Service Manual

Diet FCB syrups freeze much more readily than sugar based syrups, so the Viscosity Setting

should be selected at the minimum value available (which is 1 for the Pinnacle).

Page 12

Pinnacle 2 and 4 Flavor Service Manual

SERVICE

CAUTION — Only trained and certified electrical, plumbing and refrigeration technicians should

service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES.

PREVENTIVE MAINTENANCE

Preventive Maintenance Summary

Procedure Frequency

Clean air filter (on air cooled units) Monthly or as necessary

Clean condenser every 6 months

Sanitize unit every 6 months

Change or rotate scraper blades every 6 months

Inspect Double Liquid Check Valve every 6 months

Check for leaks every 6 months

Check BRIX every 6 months

Clean BIB connectors every 6 months

Check clock setting every 6 months

Cleaning Air Filter (Integral Only)

1. The air filter should be cleaned every month. Remove the filter by sliding it straight back. Wash with

mild soap solution, rinse with clean water, and shake out excess water (or blow with low pressure com-

pressed air if available).

2. Vacuum the condenser coil or blow it out with low pressure compressed air before reinstalling the air

filter.

3. Reinstall the air filter.

Sanitizing

The syrup systems should be sanitized every 6 months per the following procedure using a non-scented

liquid household bleach containing a 5.25% sodium hypochlorite concentration.

1. Press <OFF> from the BARREL STATUS menu on the Control Panels to stop beater and refrigeration

on all cylinders.

2. Take the following actions from the Control Panel:

• From the BARREL STATUS menu, press <MENU>.

• From the CHOOSE MODE menu, select <MANUAL DEFROST> and press <GO>.

• Select barrel and press <DFRST>.

Page 13

Pinnacle 2 and 4 Flavor Service Manual

3. Close barrel # 1 freeze cylinder shutoff valve (see below).

Freeze

Cylinder

Shutoff Valve

FIGURE 3

4. Turn blendonator #1 OFF (from the BLENDONATOR menu) to prevent more product from entering the

blendonator.

5. Place container under barrel # 1 dispensing valve. Open the valve and dispense all product from the

freeze cylinder and the blendonator. As product level lowers in the freeze cylinder partially close the valve

to avoid spurting.

6. Disconnect bag-in-box from barrel # 1.

7. Wash the system by completing the following steps:

• Use a clean 5-gallon pail (bag-in-box system) filled with a solution of household liquid detergent and warm water. Mix approximately 1 ounce of household liquid detergent per gallon of warm water.

• Connect the sanitizing fitting (p/n cc 28688) to the bag-in-box connector. Put the connector in the bucket of wash water.

• Turn barrel # 1 blendonator ON (from BLENDONATOR menu) to fill blendonator.

• Fill barrel # 1 with washing solution by repeatedly pulling and releasing the faceplate relief valve until solution comes out.

• Open the dispensing valve until solution flows from the valve, then close the valve.

• Open blendonator sample valve (see FIGURE 4) until solution flows from the valve, then close the valve.

BRIX Sample

Valves

FIGURE 4

• Place barrel # 1 in MOTOR mode (from ON/OFF/MOTOR menu) to start barrel # 1 beater. Allow beater to operate for 5–minutes, then place barrel # 1 in OFF mode (from ON/OFF/MOTOR menu) to stop the beater.

Page 14

Pinnacle 2 and 4 Flavor Service Manual

8. Flush the wash water from the system by completing the following steps:

• Turn barrel # 1 blendonator OFF (from BLENDONATOR menu) to prevent more wash water from entering the blendonator.

• Place container under barrel # 1 dispensing valve. Open the dispense valve and dispense all wash water from the freeze cylinder and the blendonator. As the wash water level lowers in the freeze cylinder partially close the valve to avoid spurting.

• Use a clean syrup tank (syrup tank system) or a clean 5-gallon pail (bag-in-box system) filled with plain water.

• Connect the sanitizing fitting to the bag-in-box connector. Put the connector in the bucket of plain water.

• Turn barrel # 1 blendonator ON (from BLENDONATOR menu) to fill blendonator.

• Fill barrel # 1 with plain water by repeatedly pulling and releasing the faceplate relief valve until solution comes out.

• Open the dispensing valve until water flows from the valve, then close the valve.

• Open blendonator sample valve (see FIGURE 4) until water flows from the valve, then close the valve.

• Place barrel # 1 in MOTOR mode (from ON/OFF/MOTOR menu) to start barrel # 1 beater. Allow beater to operate for 2–minutes, then place barrel # 1 in OFF mode (from ON/OFF/MOTOR menu) to stop the beater.

9. Sanitize the system by completing the following steps:

• Turn barrel # 1 blendonator OFF (from BLENDONATOR menu) to prevent more plain water from entering the blendonator.

• Place container under barrel # 1 dispensing valve. Open the dispense valve and dispense all plain water from the freeze cylinder and the blendonator. As the plain water level lowers in the freeze cylinder partially close the valve to avoid spurting.

• Use a clean 5-gallon pail (bag-in-box system) to prepare sanitizing solution. Mix approximately 1 ounce of household bleach per gallon of warm water. When the blendonator runs it mixes with potable water to give proper mixture.

• Put the sanitizing connector in the bucket of sanitizing solution.

NOTE: This mixture will provide 800-ppm of chlorine. Sanitizing solution will be diluted to approx-

imately 200-ppm inside the blendonator tank after carbonated water has been mixed with the san-

itizing solution.

NOTE: If powder sanitizer is used be sure it is thoroughly dissolved and mixed with the correct

amount of water.

• Turn barrel # 1 blendonator ON (from BLENDONATOR menu) to fill blendonator.

• Fill barrel # 1 with sanitizing solution by repeatedly pulling and releasing the faceplate relief valve until solution comes out.

• Open the dispensing valve until solution flows from the valve, then close the valve.

• Open blendonator sample valve (see FIGURE 4) until solution flows from the valve, then close the valve.

• Place barrel # 1 in MOTOR mode (from ON/OFF/MOTOR menu) to start barrel # 1 beater. Allow beater to operate for at least 10 minutes but not more than 15 minutes. Then place barrel # 1 in OFF mode (from ON/OFF/MOTOR menu) to stop the beater.

• Turn barrel # 1 blendonator OFF (from BLENDONATOR menu) to prevent more sanitizing solution from entering the blender tank.

Page 15

Pinnacle 2 and 4 Flavor Service Manual

• Place container under barrel # 1 dispensing valve. Open the valve and dispense all sanitizing solution from the cylinder. As sanitizing solution level lowers in the cylinder, partially close the valve to avoid spurting.

• Disconnect sanitizing solution syrup inlet line from pail of sanitizing solution.

10. Flush the system by completing the following steps:

CAUTION — Flush the system thoroughly, residual sanitizing solution left in the system could create a health hazard.

• Use a clean 5-gallon pail (bag-in-box system) filled with plain water.

• Turn barrel # 1 blendonator ON (from BLENDONATOR menu) to fill blendonator.

• Fill barrel # 1 with plain water by repeatedly pulling and releasing the faceplate relief valve until solution comes out.

• Open the dispensing valve until water flows from the valve, then close the valve.

• Open blendonator tank sample valve (see FIGURE 4) until water flows from the valve, then close the valve.

11. Repeat procedure for side 2, 3, and 4.

Stainless Steel Double Check Valve Inspection & Cleaning

CAUTION — The product pump, double-liquid check valve must be inspected after any disrup-

tions to the water supply system (plumbing work, earth quakes, etc.) It should also be inspected at least once a year under normal conditions. If particles lodge in the check valve CO

flow into the water system and create a health hazard.

1. Press both <OFF> switches to stop cylinders beaters and refrigeration system.

2. Disconnect electrical power to the unit.

3. Shut OFF CO

4. Disassemble valve.

5. Check seat and O-rings. Replace if necessary.

6. Reassemble valve.

7. Check for leaks.

, syrup, and water supplies to the unit.

Check BRIX

Should be done whenever flavors are changed or any service is preformed.

gas could back

Page 16

ADJUSTMENTS

Water, Syrup, & CO2 Regulator Settings

Regulator Settings

source (at unit) 60 psi

Blendonator 22 - 28 psi

Water source (at unit) (minimum) 25 psi flowing

Syrup source (at unit) 60 psi

PINNACLE CONTROL SYSTEM

Control System Overview

The Pinnacle uses a control system that monitors the major systems and components of the machine.

Temperatures and pressures are monitored, and pumps, valves and the refrigeration system are man-

aged by the control system to provide a consistently high quality product with optimal efficiency.

The control system is pre-programmed at the factory to perform the tasks necessary to keep the Pinnacle

operating correctly. In addition to controlling the Pinnacle, the control system keeps track of the diagnos-

tic information used when adjusting and/or repairing the machine.

The control system needs to be accessed in the following situations:

• Installing the Pinnacle,

Pinnacle 2 and 4 Flavor Service Manual

• Checking performance,

• Servicing/repairing the machine,

• Checking for error messages.

The control system is accessed with the control panel located behind the lighted merchandiser. There

are 2 levels of access to the control panel: 1 used by the operator for normal operations and 1 used by

qualified service technicians for installation and service functions. The service functions can be secured

(locked out) so that the operator will not have access to them. See the Security Lockout Function section

under menu 15 for more information.

Control Panel

Display

FIGURE 5

Page 17

Pinnacle 2 and 4 Flavor Service Manual

The control panel has a variety of displays called menus. The first menu (menu #1) that is displayed is the

BARREL STATUS menu. From each menu there is a button to return to the previous menu and another

button to advance to the next menu. The menus currently programmed into the computer are the follow-

ing:

BARREL STATUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 1

CHOOSE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 2

CHANGE BARREL STATUS (ON/OFF motor) . . . . . . . . . . . . . . . menu 3

SET CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 4

SET WAKE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 5

SET SLEEP TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 6

SET DEFROST (select time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 7

SET DEFROST (set time). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 7A

VISC SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 8

VISC DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 9

EVAPORATOR TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . menu 10

TOTALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 11

DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 12

BARREL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 13

BLENDONATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 14

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 15

BRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 16

MANUAL DEFROST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 17

VOLT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 18

ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . menu 19

The Control Panel display has 2 main areas. The first area presents information about the status and set-

tings of the machine. It also displays menus of actions that are taken to change the functioning of the

machine.

Control Panel Display

Control Panel

Display Area

Control Panel Action Buttons

FIGURE 6

Page 18

Pinnacle 2 and 4 Flavor Service Manual

Control Panel Buttons

The second display area is the button area. There are 5 buttons that are pressed to activate various func-

tions of the control system. Each button has a label directly above it that describes what happens if that

button is pressed.

Title

System

Time

Button #1

Button #2 Button #3 Button #4 Button #5

Message Display Area

Button Labels

FIGURE 7

Pressing a button performs the action labeled just above the button. For example, from the BARREL

STATUS menu, pressing button 1 (labeled MENU) displays a menu with more options — pressing button

5 (labeled ERR) displays error messages from the control system.

Page 19

Control Panel Menu Descriptions

The following section describes the information displayed on each Control Panel menu and the actions

that are taken from each menu.

Menu 1 - BARREL STATUS

Button Labels

The BARREL STATUS menu is the main menu of the Control Panel. This menu displays the system clock

and to the right of the words BARREL STATUS the present status of each cylinder. Listed below are the

status messages that may be displayed for each cylinder.

BARREL STATUS Menu Button Descriptions:

#1 - MENU . . . . . . . bring up the CHOOSE MODE menu (menu 2)

Pinnacle 2 and 4 Flavor Service Manual

Cylinder Status

FIGURE 8

#2 - ON. . . . . . . . . . turn all freeze cylinders ON (beater bar TURNING and refrigeration ACTIVE)

#3 - OFF. . . . . . . . . turn all freeze cylinders OFF (beater bar OFF and refrigeration INACTIVE)

#5 - ERR . . . . . . . . Pressing ERR displays the ERROR menu which lists all system errors.

NOTE: If there are no errors, the ERR message is not displayed for button #5.

BARREL STATUS Menu Non-Error Messages:

ON . . . . . . . . . . . . . beater bar is TURNING and refrigeration to this freeze cylinder is ACTIVE

OFF . . . . . . . . . . . . beater bar is NOT TURNING and refrigeration to this freeze cylinder is

INACTIVE

MOTOR . . . . . . . . . beater bar is TURNING and refrigeration to this freeze cylinder is INACTIVE

DFRST . . . . . . . . . . freeze cylinder is presently in DEFROST mode

From the BARREL STATUS menu pressing <MENU> displays the CHOOSE MODE menu (menu 2).

NOTE: See the Control Panel Error Descriptions for a description of the system errors.

Page 20

Menu 2 - CHOOSE MODE

Pinnacle 2 and 4 Flavor Service Manual

Item

Pointer

Button Labels

FIGURE 9

Menu Scroll List (not all items on the list are displayed at once)

Use UP and DOWN buttons to scroll the list up and down

System menus are chosen from the CHOOSE MODE menu. The VOLT menu is accessed from this

menu. The menu list is scrolled up and down pressing <UP> and <DOWN> buttons. The menu item that

has the pointer in front of it is activated when <GO> is pressed.

CHOOSE MODE Menu Button Descriptions:

#1 - BACK . . . . . . . . . . . . . . . . .go back to the BARREL STATUS menu (menu 1)

#2 - GO . . . . . . . . . . . . . . . . . . .go to the menu that is selected by the pointer

#3 - VOLT . . . . . . . . . . . . . . . . . .go to the VOLT menu (menu 19)

#4 - UP . . . . . . . . . . . . . . . . . . . .scroll up the menu list

#5 - DOWN. . . . . . . . . . . . . . . . .scroll down the menu list

CHOOSE MODE Menu Scroll List Item:

ON/OFF/MOTOR . . . . . . . . . . . .go to change BARREL STATUS menu

SET CLOCK. . . . . . . . . . . . . . . .go to SET CLOCK menu

SET WAKE UP. . . . . . . . . . . . . .go to SET WAKE UP menu

SET SLEEP . . . . . . . . . . . . . . . .go to SET SLEEP TIME menu

SET DEFROSTS . . . . . . . . . . . .go to SET DEFROST menu

VISCOSITY SET . . . . . . . . . . . .go to VISC SET Menu menu

VISC DISPLAY. . . . . . . . . . . . . .go to VISC DISPLAY menu

EVAPORATOR TEMPS . . . . . . .go to EVAPORATOR TEMPERATURE menu

TOTALS . . . . . . . . . . . . . . . . . . .go to TOTALS menu

DIAGNOSTICS . . . . . . . . . . . . .go to DIAGNOSTICS menu

BARREL DATA . . . . . . . . . . . . . .go to BARREL DATA menu

BLENDONATOR . . . . . . . . . . . .go to BLENDONATOR menu

OPTIONS . . . . . . . . . . . . . . . . . .go to OPTIONS menu

BRIX. . . . . . . . . . . . . . . . . . . . . .go to BRIX menu

MANUAL DEFROST . . . . . . . . .go to MANUAL DEFROST menu

From the CHOOSE MODE menu pressing <BACK> will display the BARREL STATUS menu and press-

ing <GO> will display the scroll list item with the pointer in front of it.

Page 21

Menu 3 - CHANGE BARREL STATUS (ON/OFF/MOTOR)

Pinnacle 2 and 4 Flavor Service Manual

Item

Pointer

FIGURE 10

Cylinder Status Messages

The CHANGE BARREL STATUS menu allows the operator to select the operational mode for each of the

cylinders on a cylinder by cylinder basis. The present status of each cylinder is also displayed (see menu

1 for a list of messages).

CHOOSE MODE Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - ON. . . . . . . . . . turn the selected cylinder “ON” (beater bar TURNING and refrigeration ACTIVE)

#3 - OFF. . . . . . . . . turn the selected cylinder “OFF” (beater bar OFF and refrigeration INACTIVE)

#4 - MOTOR. . . . . . turn the selected cylinder “MOTOR” (beater bar TURNING and refrigeration

INACTIVE)

#5 - DOWN. . . . . . . scroll down the menu list

Page 22

Menu 4 - SET CLOCK

Pinnacle 2 and 4 Flavor Service Manual

System

Time

FIGURE 11

System Date

From the SET CLOCK menu the system (computer) time and date are entered or changed. The time is

displayed in 12 or 24 hour format. The time display format is selected in the OPTIONS menu (menu 15).

The date is displayed in either a US format (mm/dd/yy) or a European format (dd/mm/yy). The date dis-

play format is selected in the OPTIONS menu (menu 15).

To set the time and/or date press <NEXT> to select 1 of 6 fields (HOURS, MINUTES, AM/PM if used,

DAY, MONTH, YEAR). Press <UP> and <DOWN> to change the field. Then press <BACK> to save the

changes.

The clock can be set to automatically adjust for Daylight Savings time using the OPTIONS menu (menu

15).

SET CLOCK Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#3 - NEXT . . . . . . . select the next field

#4 - UP . . . . . . . . . . increase the selected field by 1 (hour, day, etc.)

#5 - DOWN. . . . . . . decrease the selected field by 1

Page 23

Pinnacle 2 and 4 Flavor Service Manual

Menu 5 - SET WAKE UP

Wake Up

Time

FIGURE 12

Day

From the SET WAKE UP menu the system wake up times are set. These are the times when the system

will resume normal operation (freeze cylinder refrigeration and beater motor operation) after an inactive

period (sleep). Each day of the week can have a separate wake up time, or “ALL DAYS” of the week can

be programmed to wake up at the same time.

Each cylinder will wake up in the mode that it was in when it went to sleep. For instance, if cylinder #1

was ON, and cylinder #2 was in MOTOR before going to sleep, the cylinders will wake up in those modes.

Wake up times can be set in 15 minute increments. When NONE appears, it means that no wake up time

has been set for that day. The preset time format used by the system will be used by the SET WAKE UP

menu.

A WAKE UP must be set for every SLEEP.

The wake up program will run a 2 minute defrost, whether it follows a sleep or not, on each barrel before

returning the unit to normal operation.

SET WAKE UP Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - DAY . . . . . . . . . cycle through the list of days

#3 - NEXT . . . . . . . cycle through the time fields

#4 - UP . . . . . . . . . . increase the selected field by 1 hour or 15 minute increment

#5 - DOWN. . . . . . . decrease the selected field by 1 hour or 15 minute increment

To set wake up times:

1. Press <DAY> to select 1 of 8 options (SUNDAY, MONDAY, TUESDAY, WEDNESDAY, THURSDAY,

FRIDAY, SATURDAY, ALL DAYS)

2. Press <NEXT> to change the field from HOURS to MINUTES

3. Press <UP> and <DOWN> to change the setting in the field

4. Press <BACK> to save the changes.

Page 24

Pinnacle 2 and 4 Flavor Service Manual

Menu 6 - SET SLEEP TIME

Sleep

Time

FIGURE 13

Day

From the SET SLEEP TIME menu the system sleep times are set. These are the times when the system

will discontinue normal operation (cylinder refrigeration and beater motor operation). Each day of the

week can have a separate sleep time, or all days of the week can be programmed to sleep at the same

time.

An item on the OPTIONS menu (menu 15) will allow the Ice Bank to be maintained during sleep, or allow

the Ice Bank to discontinue normal operation.

Sleep times can be set in 15 minute increments. When NONE appears, it means that no sleep time has

been set for that day. The preset time format used by the system will be used by the SET SLEEP TIME

menu.

A WAKE UP must be set for every SLEEP.

See “3. Sleep Mode Recommendations” on page 7.

The merchandiser will stay ON during the SLEEP and the Motors and Barrel Refrigeration will be OFF.

The function of the ice bank during the SLEEP will depend on the setting in OPTIONS.

The unit can be manually activated by pressing ON from the main menu.

SET SLEEP TIME Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - DAY . . . . . . . . . cycle through the list of days

#3 - NEXT . . . . . . . cycle through the time fields

#4 - UP . . . . . . . . . . increase the selected field by 1 hour or 15 minute increment

#5 - DOWN. . . . . . . decrease the selected field by 1 hour or 15 minute increment

To set sleep times:

1. Press <DAY> to select 1 of 8 options (SUNDAY, MONDAY, TUESDAY, WEDNESDAY, THURSDAY,

FRIDAY, SATURDAY, ALL DAYS)

2. Press <NEXT> to change the field from HOURS to MINUTES

3. Press <UP> and <DOWN> to change the setting in the field

4. Press <BACK> to save the changes.

Page 25

Menu 7 - SELECT DEFROST TIME & SET DEFROST TIME

Select

defrost

cycle

FIGURE 14

Pinnacle 2 and 4 Flavor Service Manual

Defrost Time Number

Defrost Time

Defrost Day

Defrost Time Number

Defrost Time

Defrost Day

FIGURE 15

From the SELECT DEFROST TIME menu the system automatic defrost cycles are set. These menus

program the automatic hot-gas defrost cycle for each freeze cylinder. The first menu sets the defrost

day(s) and the second menu sets the defrost time(s).

When ALL DAYS is selected, the defrost time entered into a specific defrost number will be scheduled for

every day of the week. When NONE appears, it means 1 of the following:

• no defrost time has been set for that defrost number;

• all of the times for that defrost number are not the same.

NOTE: All days can NOT be used to verify defrost times, only to set them.

SELECT DEFROST TIME Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - DAY . . . . . . . . . cycle through the list of days

#3 - GO . . . . . . . . . go to the second defrost menu (SET DEFROST TIME)

#4 - UP . . . . . . . . . . increase the defrost number for this day (#1-9)

#5 - DOWN. . . . . . . decrease the defrost number for this day (#1-9)

SET DEFROST TIME Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - DEF#. . . . . . . . cycle through the list of 9 defrost times per day

#3 - NEXT . . . . . . . cycle through time fields

#4 - UP . . . . . . . . . . increase item by 1 unit (hour or 15 minute segment)

#5 - DOWN. . . . . . . decrease item by 1 unit (hour or 15 minute segment)

Defrost times can be set in 30 minute increments. When NONE appears, it means that no sleep time has

been set for that day. The preset time format used by the system will be used by the SET DEFROST

TIME menu. See “3. Sleep Mode Recommendations” on page 7.

Page 26

Pinnacle 2 and 4 Flavor Service Manual

Each freeze cylinder defrost cycle will terminate either when the suction temperature reaches 50°F or it

will time out after 8 minutes. There may be 9 defrost times scheduled for each of the 7 days of the week.

Cylinder 1 will begin defrosting at the set defrost time. Cylinder 2 will begin defrosting 30 minutes after

cylinder 1 began defrosting. There are no defrosts programmed from the factory.

To set defrost times:

1. Press <DAY> to select 1 of 8 options (SUNDAY, MONDAY, TUESDAY, WEDNESDAY, THURSDAY,

FRIDAY, SATURDAY, ALL DAYS).

2. Press <GO> to advance to the SET DEFROST TIME menu.

3. Press <NEXT> to change the field from HOURS to MINUTES.

4. Press <UP> and <DOWN> to change the setting in the fields.

5. Press <BACK> to save the changes.

6. If desired, repeat steps 2–5 to set more defrost times for the selected day.

7. If desired, repeat steps 1–6 to select different days and times.

Page 27

Pinnacle 2 and 4 Flavor Service Manual

Menu 8 - VISC SET (Set Cylinder Viscosity)

Selection

Pointer

Cylinder

Numbers

FIGURE 16

Viscosity Settings

The desired viscosity (thickness) of the product in each cylinder is set from this menu. The viscosity set

point can be set between 1 and 9. A viscosity setting of 1 produces a very thin watery product and a set-

ting of 9 produces a very thick icy product. The factory default is 4.

VISC SET TIME Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - ALL . . . . . . . . . sets the viscosity of all cylinders to the setting of the currently selected cylinder

#3 - GO . . . . . . . . . toggle between “cylinder selection” and “viscosity setting”

#4 - UP . . . . . . . . . . increase the selected field by 1 hour or 15 minute increment

#5 - DOWN. . . . . . . decrease the selected field by 1 hour or 15 minute increment

To change the viscosity setting for a cylinder:

1. Press <UP> or <DOWN> to select the cylinder to be adjusted. The pointer will be in front of the cur-

rently selected cylinder.

2. Press <GO> to move the selection pointer to the viscosity setting for that cylinder.

3. Press <UP> or <DOWN> to increase or decrease the viscosity setting.

4. Press <GO> to move selection pointer back to the cylinder selection.

5. Repeat steps 1 - 4 for remaining cylinders.

Page 28

Pinnacle 2 and 4 Flavor Service Manual

Menu 9 - VISC DISPLAY (Actual Cylinder Viscosity)

Actual Viscosity

Cylinder

Numbers

FIGURE 17

Reading

This menu displays the actual viscosity value for each cylinder. The smaller the number the lower the vis-

cosity (thinner product).

VISC DISPLAY Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

The table below identifies the maximum and minimum viscosity values for specific viscosity settings. For

example, with a viscosity setting of 2, the system calls for refrigeration when the viscosity drops below 43.

Refrigeration continues until the viscosity reaches 60 when leveling begins.

NOTE: There is a 2 minute timer to prevent the compressor from short cycling. This timer is can-

celed out by a Blendonator actuation.

Viscosity Setting

Maximum Viscosity

Val ue

Minimum Viscosity

Val ue

15036

26043

37058

48068

59078

610086

711096

8120106

9130116

Page 29

Menu 10 - EVAPORATOR TEMPERATURES

Pinnacle 2 and 4 Flavor Service Manual

Cylinders

Fahrenheit

or Celsius

Ice Bank

FIGURE 18

Input & Output Temperatures

The input and output temperatures of each system evaporator (both product freeze cylinders and ice

bank) are displayed. In the display the IN represents the inlet temperature and the OUT represents the

outlet temperature. The temperature scale used (°F or °C) is based on your input in the OPTIONS menu

(menu 15). The maximum temperatures are 97°F for the barrels (BRL #1 or #2) and 48°F for the ice bank

(IB #1). The minimum temperatures for both the barrel and ice bank is -30°F.

EVAPORATOR TEMPERATURES Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

Page 30

Menu 11 - TOTALS

Pinnacle 2 and 4 Flavor Service Manual

Selection

Pointer

Item or

Subsystem

FIGURE 19

Totals (see chart below)

The TOTALS menu displays operational totals for the system. The totals tracked by the computer are

listed below. Those totals marked with an * can be reset to zero. The RESET button will only appear

when the reset option is enabled.

The reset option is enabled/disabled from the OPTIONS menu (menu 15).

TOTALS Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#4 - UP . . . . . . . . . . scroll totals list up

#5 - DOWN. . . . . . . scroll totals list down

TOTALS Menu Messages:

POWER ON . . . . . . xxxxx HRnumber of hours the system has been powered ON

SLEEP . . . . . . . . . . xxxxx HRnumber of hours system has been in SLEEP mode

COMP #n . . . . . . . . xxxxx HR*number of hours compressor “n” has run

COMP #n . . . . . . . . xxxxx CYC*number of run cycles compressor “n” has performed

AGITAT #n . . . . . . . xxxxx HR*number of hours agitator motor “n” has run

BRL ON #n. . . . . . . xxxxx HRnumber of hours cylinder “n” has been in ON mode

MOTOR #n . . . . . . . xxxxx HR*number of hours cylinder motor “n” has run

SYRUP #n . . . . . . . xxxxx MIN*number of minutes syrup flow “n” has been called for

ERROR #n . . . . . . . xxxxx HR*number of hours cylinder “n” has had any errors

SYR SO #n. . . . . . . xxxxx HRnumber of hours cylinder “n” is out of syrup

DEFRST #n . . . . . . xxxxx HRnumber of hours cylinder “n” has been in auto defrost

BLENDR #n . . . . . . xxxxx HRnumber of blender cycles on cylinder “n”

* = resetting these totals to zero is allowed

Page 31

Pinnacle 2 and 4 Flavor Service Manual

Menu 12 - DIAGNOSTICS

Selection

Pointer

Item or

Subsystem

FIGURE 20

The DIAGNOSTICS menu allows the selection of manual or automatic display of system information. The

manual mode allows the operator to select which output is activated. The automatic mode cycles through

all of the outputs 1 after the other.

The automatic mode begins at the selection pointer and stops at the end of the list or when the AUTO is

pressed again. The automatic mode cycles through each output for 2 seconds ON and 3 seconds OFF.

The output list scrolls down as the automatic mode progresses.

All system functions and controls are disabled/terminated during the diagnostic mode.

The diagnostic display order is organized on a cylinder-by-cylinder basis. All outputs associated with a

specific cylinder displayed as a group. When that cylinder is done the next cylinder group will begin. After

the cylinders the ice banks information is displayed on an ice bank by ice bank basis.

DIAGNOSTICS Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - AUTO . . . . . . . toggle begin/end of automatic mode

#3 - EXEC . . . . . . . activate the output at the selection pointer

#4 - UP . . . . . . . . . . scroll list up

#5 - DOWN. . . . . . . scroll list down

DIAGNOSTICS Menu Messages:

AUDIBLE ALARM. . activate audible alarm on display board

Cylinder Group #X:

BRL PULSE VLV #Xactivate cylinder pulse valve

H20 SOLENOID #X activate water solenoid

DEFROST VLV #X activate cylinder defrost valve

DISP VALVE LO #X activate dispense valve lockout

CARB MTR PUMP #Xactivate carbonator pump motor

SYR SOLENOID #Xactivate syrup solenoid

BEATER MOTOR #Xmake beater motor turn

BRL STAT LITE #X activate cylinder status light (red & green)

AUDIBLE ALARM . activate audible alarm on main logic board

Page 32

Pinnacle 2 and 4 Flavor Service Manual

Menu 13 - BARREL DATA

Information

Items

FIGURE 21

The BARREL DATA menu displays information about major system components for each cylinder.

BARAL DATA Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#4 - UP . . . . . . . . . . scroll list up

#5 - DOWN. . . . . . . scroll list down

BARREL DATA menu information:

BARREL # . . . . . . . status of cylinder #n (ON, OFF, MOTOR, DEFROST, ERROR)

EVAPS IN . . . . . . . evaporator temperature IN

EVAPS OUT . . . . . evaporator temperature OUT

VISC SET. . . . . . . . viscosity set value

ACT . . . . . . . . . . . . actual viscosity value

BLENDONATOR . . blendonator mode (ON, OFF)

Page 33

Menu 14 - BLENDONATOR (Blendonator Status)

Pinnacle 2 and 4 Flavor Service Manual

Cylinder

Number

Selection

Pointer

FIGURE 22

Fill Mode Status

The BLENDONATOR menu allows the selection of automatic blendonator tank filling. With automatic

mode ON the blendonator tank will fill when the float drops.

Scroll the selection pointer to the desired cylinder number and press <ON> or <OFF> to turn the auto-

matic filling ON or OFF.

BLENDONATOR Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - ON. . . . . . . . . . turns blendonator automatic fill mode ON

#3 - OFF. . . . . . . . . turns blendonator automatic fill mode OFF

#4 - UP . . . . . . . . . . move selection pointer up

#5 - DOWN. . . . . . . move selection pointer down

Page 34

Pinnacle 2 and 4 Flavor Service Manual

Menu 15 - OPTION SELECT STATUS

Option Name

Option Status

FIGURE 23

The OPTION SELECT STATUS menu allows system options to be selected and customized. These

options will be displayed on the OPTIONS menu.

OPTION SELECT STATUS Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - OPTION #1 . . . select this option (the button label changes depending on the option being displayed)

#3 - OPTION #2 . . . select this option (the button label changes depending on the option being displayed)

#4 - UP . . . . . . . . . . scrolls list up

#5 - DOWN. . . . . . . scrolls list down

To display, select, and change system options:

1. Press <UP> or <DOWN> to select the desired option

2. Press the <OPTION #1> button to change that option

3. Press the <OPTION #2> button to change that option

4. Press <UP> or <DOWN> to display the next option.

The options that can be displayed and changed are described below.

Option Name Button #1 Button #2 Description

DAYLT SAVINGS NO YES disable/enable Daylight Savings Time

CELCIUS/FAHREN FAHR CELS select temperature for display

DATE FORMAT USA EURO selects date format (U.S. mm/dd/yy or European dd/

mm/yy)

TIME FORMAT 12HR 24HR selects 12 hour (AM/PM) or 24 hour time format

SECURITY OFF ON disable/enable security lockout of system parameters

LANGUAGE ENGL OTHER select language (as available)

VALVE LOCK OUT DISAB ENAB Not Used

RESET TOTALS DISAB ENAB disable/enable resetting of totals in the TOTALS menu

ICE BANK/SLEEP OFF ON Ice Bank and Ice Bank Agitator remains OFF/ON while

system is sleeping

KEY BEEP OFF ON turns beeping of key inputs OFF/ON

SYRUP SOURCE BOX TANKS What is source of syrup. TANKS will enable “Syrup

Prime” on syrup sold out.

Security Lockout Function:

The security function is enabled in the OPTION SELECT STATUS menu. When the security lockout is

enabled, lockout will engage 15 minutes after last button press. Once lockout is engaged the display goes

to BARREL STATUS menu, and the MENU button (#1) is disabled. Security is disengaged by pressing

button #1 (far left) and #5 (far right) at the same time.

Page 35

Menu 16 - BRIX

Pinnacle 2 and 4 Flavor Service Manual

Cylinder

Number

Selection

Pointer

BRIX Status

FIGURE 24

The BRIX menu allows the activation of syrup and water solenoids, and blendonator pump motor for a

selected cylinder.

PRESSURE SWITCH AND

WATER

FLOW REGULATOR AND SOLENOID VALVE

SYRUP

SOLD-OUT SWITCH

WATER REGULATOR

SINGLE CHECK VALV E

PRODUCT PUMP

(SYRUP AND WATER

ARE MIXED)

PRODUCT SAMPLE VALVE

COOLING COIL

DOUBLE CHECK VALV E

WATER ICE BATH

FREEZE CYLINDER

PRODUCT SHUTOFF VALV E

BLENDONATOR

FIGURE 25

1. Make sure the status of all cylinders is OFF on the display.

2. Turn product supply valve to the 90 degree (OFF) position for the barrel you are using. It is recommended to close both valves to be sure the correct valve is chosen.

3. Press MENU. Then press UP repeatedly until BRIX is displayed. Press GO and select cylinder you wish to Brix. NOTE: Pressing CANCEL will stop the process.

4. Locate the appropriate (correct barrel) sample tube and hold a cup under it.

NOTE: If Product Sample Valve is located in a different position then FIGURE 25 see the schematics in Appendix A for the two alternate constructions (section 1 and 2) and their respective Brixing instructions.

5. Open the valve at the end of the sample tube. Press GO and wait 3-5 seconds. The product pump will pump product for approximately 3 seconds. After sample is dispensed Press Go twice more to dispense product two more times. Discard these first three samples.

Page 36

Pinnacle 2 and 4 Flavor Service Manual

6. Press GO again. Collect sample from cup and close valve at end of sample tube. Place adequate amount on refractometer and read Brix. A target Brix reading of 13.0 (+/- 1.0) is normally desired for sugar-based syrups. Lower values for some diet syrups can be specified. Check with the syrup manufacturer if you are not sure.

7. If reading is out of specification the syrup level needs to be adjusted. NEVER change the WATER FLOW CONTROL setting to adjust Brix (FIGURE 26).

Syrup Flow Control

Water Flow Control

FIGURE 26

8. To increase Brix reading, turn syrup regulator clockwise. Turn counter-clockwise to decrease Brix. Adjust flow control in no more than ½-turn increments. Repeat steps 4 through 6 for each adjustment until desired Brix setting is achieved.

9. After finishing step 8 for first barrel, repeat steps 1 through 8 for next barrel.

NOTE: If Brix percent cannot be set in step 8, check the water flow rate. To do this verify flow in cup is at least 6.3 to 6.9 oz. (186 to 204 ml) in 3 seconds.

NOTE: If water flow is low, boost incoming water pressure.

BRIX Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - GO . . . . . . . . . turn ON syrup and water solenoids, and blendonator pump for selected cylinder

for 3 seconds

#3 - CANCL . . . . . . turn OFF syrup and water solenoids, and blendonator pump for selected cylinder

#4 - UP . . . . . . . . . . move selection pointer up

#5 - DOWN. . . . . . . move selection pointer down

Page 37

Pinnacle 2 and 4 Flavor Service Manual

Menu 17 - MANUAL DEFRST

Cylinder

Number

Selection

Pointer

FIGURE 27

Defrost Status

The MANUAL DEFRST menu allows the activation of 2 minute manual defrost mode for a selected cylinder. This defrost cycle can begin with the cylinder in any mode (ON, OFF, Motor) and will return the cylinder to that same mode. Manual defrost can be activated on only 1 cylinder associated with a compressor at a time.

The description of the button 2 will change based on the status of the selected cylinder. When not in defrost, button 2 will read DFRST. When in defrost, button 2 will read CANCL.

Pressing DFRST will begin a manual defrost on the selected cylinder, and pressing CANCL will end the manual defrost on the selected cylinder.

MANUAL DEFRST Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

#2 - DRFST . . . . . . begin manual defrost on selected cylinder (defrost will last approx 2 minutes)

#4 - UP . . . . . . . . . . move selection pointer up

#5 - DOWN. . . . . . . move selection pointer down

Page 38

Pinnacle 2 and 4 Flavor Service Manual

Menu 18 - VOLT

Voltage

FIGURE 28

The VOLT menu displays line voltage at the contactor. The voltage will be displayed in Volts RMS.

VOLT Menu Button Descriptions:

#1 - BACK . . . . . . . go back to the previous menu

Page 39

Pinnacle 2 and 4 Flavor Service Manual

Menu 19 - ERROR

FIGURE 29

The ERROR menu displays a list of errors that are presently on the system. All system errors will be displayed on this list in the priority order. The error list will scroll if necessary. The display of the error list will be updated every 3 seconds.

The RESET function will silence the beeper (if sounding), and reset the errors that are capable of MANUAL ERROR RESET. As “automatically” correctable errors are satisfied, the error list will reflect this when updated.

NOTE: The Syrup Sold Out condition is not effected by the RESET button.

ERROR Menu Button Descriptions:

#1 - MENU . . . . . . go back to the previous menu

#2 - ON. . . . . . . . . . go to SYRUP SOLD OUT menu

#3 - OFF. . . . . . . . . begin MANUAL ERROR RESET

#4 - UP . . . . . . . . . . scrolls list up

#5 - DOWN. . . . . . . scrolls list down

Error History Log Information

FIGURE 30

The error history log records errors to diagnose potential issues. The error log will retain information on the 50 most recent sets of events. All errors dated will have occurred during testing and set up. This is a default that is used before the time clock is programmed.

The error log history is only accessible from the BARREL STATUS menu. To enter the error history you must press the 2 far right buttons on the display panel. This will bring up the error history log menu and the most recent event will be displayed. PREV moves you backwards in the list of events and NEXT moves you forwards in the list of events.

The error history can be accessed while the security lock out is activated. To return to the main menu press BACK.

#1 - BACK . . . . . . . go back to the BARREL STATUS menu

#4 - NEXT . . . . . . . display the next (later) error log entry

#5 - PREV . . . . . . . display previous (earlier) error log entry.

Page 40

Control Panel Error Descriptions

The following section describes the error messages displayed on the Control Panel, the error priority, and the appropriate actions to be taken. Errors are displayed on the following menus:

• Main menu (BARREL STATUS) - menu 1

• ON/OFF/MOTOR menu (CHANGE BARREL STATUS) - menu 3

• BARREL DATA menu - menu 13

• SET DEFROST menu - menu 17

• ERROR menu - menu 20

Errors are displayed in the above menus differently. The response to error conditions are listed below.

COMO Error: There is no communication between the J1 connector on the display board and the J17 connector on the main board.

ELECTRONICS Error: Means 1 of 2 things:

• Communication has been not established or broken between the main board and 1 or more of the product delivery boards for ten consecutive communication cycles.

• Failure of the real time clock chip. The new controls will display a “CLOCK ERROR” message.

HOT GAS Error X: Indicates that the barrel outlet sensor for barrel X exceeded 120°F for 2 minutes. Do not restart unit. Immediately call Service at (800) 238-3600.

HIGH VOLTAGE GENERATED Errors: It is possible to generate Electronic or Como errors by routing phone lines or low voltage communication lines in the vicinity of high voltage components on the Inverter Board.

LOW VOLTAGE GENERATED Errors: It is also possible to generate these errors if low voltage communication wires or phone cables are in the vicinity of the Inductor on the Main Board. That would be the black capacitors on the Invertor Board and the wire wrapped coil on the Main Board.

LOW or HIGH VOLTAGE Error: This message means that the incoming voltage is out of specification (180V to 260V) for the unit.

Pinnacle 2 and 4 Flavor Service Manual

LOW VOLTAG E E r ro r : If the voltage at the junction box is good, high voltage may not be getting up to the main board. Check this voltage at J10 on the main board. If the voltage is good at the board and the low voltage error remains, main board is bad. Display voltage to be

±5 VAC from measured J10 Voltage.

DRIVE Error: The motor has been commanded to rotate but will not rotate.

OVER TORQUE Error: This error occurs when the motor load is greatly increased and causes the barrel

viscosity to be more than 250 and the motor is still turning. It can also occur when the inverter board has a problem. If the viscosity is less than 25 with the motor running, the high viscosity reading could have been because of a mechanical load.

REFRIG Error: Means that a specific evaporator has NOT been satisfied within a set time limit. The entire refrigeration system will be disabled. The REFRIG error time limits are:

• Freeze Barrel: 46 minutes; Ice Bath: 120 minutes for 60Hz or 240 minutes for 50Hz.

SYRUP Error: Syrup supply empty.

CO2 Error: Carbon dioxide supply empty.

H2O Error: Water supply empty.

SENSOR Error: Means that a thermal sensor (thermistor) is not functioning properly.

During a refrigeration cycle, if a barrel sensor’s reading is at 97

F or at -30oF for more than 600 seconds,

the control system will display a SENSOR ERROR for that evaporator. During a refrigeration cycle, if a ice bank sensor’s reading is at 49

F or at -30o F for more than 2400 seconds, the control system will dis-

play a SENSOR ERROR for the Ice Bank.

NOTE: The 5600075xx Series controls will have an upper limit of 150°F for barrel sensors.

Page 41

3 - The “Cylinder Status Light” of the affected cylinder will flash green at a 1 Hz rate (50% DC) on all errors.

4 - The Blender will NOT respond to float activations wen “OFF”, and will respond when “ON” only is previously enabled.

1 - The “motor condition means the motor will continue operating if it was in operation prior to the error. If the motor was OFF it will remain OFF.

2 - The “Beeper” will give a 5 beep sequence for each new error that occurs after a beeping sequence is completed.

Pinnacle 2 and 4 Flavor Service Manual

** - The compressor associated with this freeze cylinder/ice bank will stop providing cooling to this specific evaporator.

Footnotes:

* - The compressor associated with this refrigeration system where the error occurs will be commanded OFF (not “no longer needed).

Ice Bank Sensor 10 Manual IB OFF** OFF OFF “Last Known

Cylinder Sensor 10 Manual Cylinder

H2O Sold Out 9 Auto OFF* Motor OFF “Last Known

CO2 Sold Out 8 Auto OFF* Motor OFF “Last Known

Syrup Sold Out 7 Auto Cylinder

Ice Bank Refg 6 Manual OFF* OFF ON “Last Known

Cylinder Refg 5 Manual OFF* OFF ON “Last Known

Over Torque 4 Manual Cylinder

Cylinder Drive 3 Manual Cylinder

Low Voltage 2b Auto OFF* OFF OFF “Last Known

Real Time Clock 1c Cycle

Hot Gas Valve 1d Cycle

High Voltage 2a Auto OFF* OFF OFF “Last Known

Electronics 1b Cycle

Communication 1a Cycle

Error

Priority

Response

Power

OFF**

OFF* OFF OFF

OFF* OFF OFF OFF CLOCK

OFF* OFF OFF OFF COMMO COMMUNICATION

OFF* OFF OFF OFF ERROR ELECTRONICS

Display

Error Reset

Comp

OFF OFF “Last Known

Motor OFF “Last Known

OFF ON “Last Known

OFF

Motor

Blend

System Response Display Output

State” of System

SENSOR IB SENSOR #Y

SENSOR BRL SENSOR #X

State” of System

H2O H2O OUT

State” of System

CO2 CO2 OUT

SYRUP SYRUP #X

State” of System

OFF HOT GAS #X HOT GAS #X

Condition After

Error Reset

REFRIG IB REFRIG #Y

REFRIG BRL REFRIG #X

TORQUE TORQUE #X

DRIVE DRIVE #X

VOLT LOW VOLTAGE

VOLT HIGH VOLTAGE

ERROR

Menu 1,3,13,17 Menu 20

CLOCK ERROR

Page 42

COMPONENT SERVICE

NOTE: IF the LED on display panel is ON please see Tech Tip TT-04-13, on www.cornelius.com, for information on the Production Safety System Response.

The following are procedures for servicing the major components of the Pinnacle.

MAGNET ASSEMBLY REPLACEMENT

1. Defrost the cylinder.

2. Turn the blendonator OFF.

3. Drain the cylinder by opening the dispensing valve. When only CO

valve off. Relieve CO pressure relief valve.

4. Remove the cylinder face plate (4 nuts and washers).

comes out, turn the cylinder product supply

pressure by opening the faceplate

Pinnacle 2 and 4 Flavor Service Manual

Relieve CO2 pressure

5. Remove beater bar and scraper blades.

6. Use the magnet puller tool (p/n 560003662) that comes with the unit to remove the magnet.

NOTE: Sufficient force must be used to break the magnet lose from the end of the cylinder.

CAUTION — The magnet is very strong,

heavy, and fragile. Be careful not to pinch hands and fingers between the magnet and a steel object. Make sure no foreign objects are attached

to the magnet.

WARNING — Strong Magnetic Field.

Person wearing pacemaker, implanted cardioverter defibrillator, or other implanted medical

device may be affected by the magnetic field and must keep the magnet at 6 or more inches from the device. The magnetic field can affect operation of these devices which may cause bodily injury or death.

If disruption of device occurs or operation is adversely effected, immediately move the victim far away from magnet and seek medical assistance.

Remove nuts (x4)

FIGURE 30

Tool hooks

into magnet

FIGURE 31

Page 43

7. Install the magnet in the reverse order to removing it. Use the magnet puller tool to install the magnet being careful to insert the magnet slowly and not let it slam into the end of the cylinder.

Pinnacle 2 and 4 Flavor Service Manual

Magnet removal tool

DO NOT let magnet slam into end of cylinder

FIGURE 32

8. Inspect parts to see if they should be replaced, including the beater bars, face plate, O-ring, and beater bar bushing.

NOTE: Install faceplate by pressing until it contacts the front of the cylinder. Reinstall 4 washers and nuts finger tight. Then approximately 1/4 turn with a wrench.

9. When all the hardware is securely in place turn the blendonator ON, then turn the product cylinder supply valve ON, bleed the cylinder, and use the control panel to turn the cylinder ON. There is a short delay before the beater bar starts rotating.

Align

notched

hole in

beater bar

with

notched

rod on

shaft

FIGURE 33

Make sure

bushing on face

plate/beater bar

shaft is in good

condition

FIGURE 34

Page 44

Pinnacle 2 and 4 Flavor Service Manual

DC CONTROL DRIVE MOTOR BOARD REPLACEMENT - EMERSON

CAUTION - Use a grounding strap.

1. Disconnect the power to the unit.

DC Control Drive Motor Board

FIGURE 35

2. Open the merchandiser door, then remove the top front panel and front hinged panel.

DANGER — HIGH VOLTAGE, after disconnecting power wait for approximately 5 minutes to

work on the unit. Working on the unit before the 5 minutes have passed could result in electrical shock or death!

3. Unscrew the 3 mounting screws on the Control Drive Motor board mounting bracket and slide the bracket up while tilting it out. Do NOT detach the wires from the board yet.

4. Secure the new board in place. One at time remove the wires from the old board and connect them to the new board. Make sure that the thermistor harness is not removed with the old board.

5. Connect the power.

6. Re-attach the panels.

MAIN AND PRODUCT DELIVERY BOARD REPLACEMENT - EMERSON

1. Disconnect the power to the unit.

2. Open the merchandiser door then remove top front panel and front hinged panel.

DANGER — HIGH VOLTAGE, after discon-

necting power wait approximately 5 minuets to work on the unit. Working on the unit before the 5 minutes have passed could result in electrical

shock or death!

3. Remove all wires from board being replaced.

4. Disconnect the 4 mounting standoffs and remove the board.

5. Secure the new board in place and reconnect the wiring.

6. If the Main Board was replaced, program the previous setting for time, defrost, sleep, walk-up, and viscosity.

7. Re-attach the panels.

Product Delivery

Boards

DC Control Drive

Motor Boards

Main Boards

FIGURE 36

Product Delivery

Boards

Page 45

CHIP CHANGE PROCEDURE

The purpose of this notice is to describe the proper method for changing a chip on the master board of a Cornelius machine should it become necessary.

NOTE: Static electricity can destroy sensitive electronic circuits. Always wear static straps or keep yourself grounded to the machine while working in the electronic boards.

Tools needed:

• 32 pin dip extractor (chip puller) 790327

Wrist ground strap 790326

1. Unplug machine.

2. Remove top panel on floor models. Open door to access the control box on the OC2 machine.

3. Remove lid to control box on.

4. Place the chip puller and new chip on the machine (chip still in the container).

5. Attach ground strap to the bare metal control box.

6. Carefully remove the new chip from shipping container. Save shipping container to pack old chip in.

7. Place chip puller on chip and gently squeeze until tool grips the chip.

8. Pull the chip puller straight up with a gentle end–to–end rocking motion to remove the chip. Place old chip in the original container.

9. Pull the chip puller straight up with a gentle end–to–end rocking motion to remove the chip. Place old chip in the original container.

Pinnacle 2 and 4 Flavor Service Manual

10. Carefully place new chip in the socket and make sure all pins are started in their holes. Press firmly straight down on the chip until it is fully engaged in the socket. Note: Proper placement of the chip can be confirmed by aligning the small indent on one end of the chip with the indent on the outline that is drawn on the board.

11. Remove ground strap.

12. Replace control box lid.

13. Replace top machine panel or close access door.

14. Plug in machine.

15. Defrost both barrels.

16. Check Viscosity read. If both sides read 0 go to 17.

17. If either side reads other than 0, beater motor currents needs to be reset.

18. Turn machine on auto and check for normal operation.

19. Secure machine.

Page 46

Pinnacle 2 and 4 Flavor Service Manual

DC INVERTER BOARD REPLACEMENT - BALDOR

CAUTION - Use a grounding strap.

1. Disconnect the power to the unit.

DC Inverter board (Baldor)

D33 light (Baldor)

FIGURE 37

2. Open the merchandiser door, then remove the top front panel and front hinged panel.

DANGER — HIGH VOLTAGE, after disconnecting power wait for the D33 red light to go out indi-

cating that it is safe to work on the unit. Working on the unit when the red D33 light is lit could result in electrical shock or death!

3. Unscrew the 4 mounting screws on the DC inverter board mounting bracket and slide the bracket up while tilting it out. Do NOT detach the wires from the board yet.

4. Secure the new board in place. One at time remove the wires from the old board and connect them to the new board.

5. Connect the power and check that the D33 light comes on.

6. Re-attach the panels.

MAIN AND PRODUCT DELIVERY BOARD REPLACEMENT - BALDOR

1. Disconnect the power to the unit.

2. Open the merchandiser door then remove top front panel and front hinged panel.

DANGER — HIGH VOLTAGE, after discon-

necting power wait for the D33 red light to go out indicating that it is safe to work on the unit. Work-

result in electrical shock or death!

3. Remove all wires from board being replaced.

ing on the unit when the red D33 light is lit could

Product Delivery

Boards

Inverter Boards

(Emerson

roduct Delivery

Boards

4. Disconnect the 4 mounting standoffs and remove the board.

5. Secure the new board in place and reconnect the wiring.

Main Boards

FIGURE 38

6. If the Main Board was replaced, program the previous setting for time, defrost, sleep, walk-up, and viscosity.

7. Re-attach the panels.

Page 47

Pinnacle 2 and 4 Flavor Service Manual

DISPLAY BOARD REPLACEMENT

1. Disconnect the power to the unit.

2. Open the merchandiser door then remove top front panel and hinged panel.

DANGER — HIGH VOLTAGE, after disconnecting power wait for the D33 red light to go out indi-

cating that it is safe to work on the unit. Working on the unit when the red D33 light is lit could result in electrical shock or death!

3. Unscrew the 4 screws holding the board cover. Carefully reach behind the cover and disconnect the wires (ribbon cable, phone cable, power cable).

Mounting

standoff (4)

Display

Board

4. Remove the board from the 4 standoffs.

Cover

FIGURE 39

5. Install the new board with the ribbon cable protruding through the top.

Ribbon cable

FIGURE 40

6. Reconnect the wires while installing the cover.

7. Connect the power and check to see that the control panel works properly. Secure the circuit board door and follow a normal startup procedure.

8. Re-attach the panels.

NOTE: The error log is stored on the display board.

MERCHANDISER LIGHT BALLAST REPLACEMENT

1. Disconnect the power to the unit.

2. Lift the merchandiser and slide it left or right to lock it in place.

3. Remove the ballast cover (2 screws).

4. Remove the ballast (2 screws).

5. One ballast at a time, remove the wires from the old one then insert the wires to the same connector on the new ballast.

6. Install the new ballast and ballast cover (2 screws each). Flip the merchandiser back down and go through a normal start-up procedure.

FIGURE 41

Page 48

TRANSFORMER REPLACEMENT

Pinnacle 2 and 4 Flavor Service Manual

1. Disconnect the power to the unit.

2. Remove right side panel (3 screws).

3. Remove all 4 wires from the transformer, note the connection locations.

4. Remove the 2 nuts from the screws and remove the transformer.

5. Attach the new transformer with the 2 nuts.

NOTE: The Coil on the Pinnacle Contactor has 24 VAC.

6. Re-attach the wires to the tabs on the transformer.

NOTE: Make sure the wires are replaced in the same location noted in step 3.

Transformer (2)

Contactor (2)

FIGURE 42

CONTACTOR REPLACEMENT

1. Disconnect the power to the unit.

2. Remove side panel.

3. Remove contactor/starter cover (1 screw). Disconnect contactor (2 nuts). Do NOT detach the wires from the contactor yet.

4. One at a time, remove the wires from the old contactor and connect them to the new contactor.

5. Secure the new contactor in place, install the cover, and re-attach the side panel.

START COMPONENTS REPLACEMENT

1. Disconnect the power to the unit.

2. Remove side panel.

3. Unfasten the strap (1 screw).

4. Replace all start and run components, note connection locations. Reassemble, re-connect power, and go through a normal startup procedure.

Start relay

Run capacitor

Start capacitor

FIGURE 43

Page 49

Pinnacle 2 and 4 Flavor Service Manual

PUMP MOTOR REPLACEMENT

1. Disconnect the power to the unit. Remove splash panel (2 screws), drip tray, and drip tray panel (2 screws).

2. Turn off CO

3. Loosen 2 bolts holding Tray from sliding out during ship (1 in each corner). Slide tray out.

4. Disconnect Guest fitting from pump. Disconnect electrical leads.

5. Remove 2 screws holding motor on angled brackets.

6. Replace the bad pump in the reverse order of steps 3 through 6.

7. Re-connect the CO

8. Re-connect the power and go through the normal start-up procedure.

, water, and syrup sources. Bleed pressure from the feed lines at the rear disconnects.

CO2 Regulators (x4)

FIGURE 44

, water, and syrup. Turn the bottom blendonator/brix valve to blendonator position.

AGITATOR MOTOR REPLACEMENT

1. Disconnect the power to the unit. Remove the side panel (3 screws).

2. Unplug motor. Remove 4 screws. Remove ground wire (green/ yellow wire) from motor. Lift motor.

3. Reverse the procedure to install new motor.

2 screws on each side Ground screw

FIGURE 45

SYRUP/WATER VALVE REPLACEMENT

1. Follow the instruction (629088599INS) included with the replacement kit, also located on www.cornelius.com.

Page 50

Pinnacle 2 and 4 Flavor Service Manual

CO2 REGULATOR REPLACEMENT

1. Disconnect the power to the unit. If applicable remove the drip tray, drip tray mounting panel (2 screws), and splash panel (2 screws). Remove the side panel (3 screw) by the faulty regulator.

2. Turn off CO

source then turn off the cylinder product supply valve. Relieve pressure from blendonator by

opening the face plate relief valve.

3. Disconnect 3 quick disconnect fittings to CO

regulator using a spanner tool. Remove 2 nuts from mounting

bracket. Disconnect pressure switch wires.

4. Remove regulator assembly and replace regulator.

5. Reverse the procedure to install regulator assembly. Be sure to check for leaks after pressurizing the system.

6. Reset regulator pressure to desired setting.

BLENDONATOR FLOAT SWITCH REPLACEMENT

1. Use the control panel to turn the blendonator OFF. Remove the drip tray, drip tray mounting panel (2 screws), and splash panel (2 screws).

2. Turn off the cylinder product supply valve. Slide the product tray out by removing the 2 screws on the top and front side.

3. Turn CO blendonator by opening face plate relief valve.

off at the source. Relieve pressure from

4. Disconnect quick disconnect from float assembly. Unplug wires. Unscrew float assembly. Remove pins from wire

Wire

connector

connector.

5. Unscrew float from assembly.

6. Reverse the procedure to install new float switch. Be sure

Connector

pin removal

and check for leaks after pressurizing the system.

7. Bleed air from blendonator using pressure relief valve.

8. Go through the normal start-up procedure.

Quick disconnect

FIGURE 46

Float assembly

BLENDONATOR TANK REPLACEMENT:

1. Use the control panel to turn the blendonator OFF.

2. Remove the drip tray, drip tray mounting panel (2 screws), splash panel (2 screws), and side panel closest to the faulty blendonator tank (3 screws).

3. Turn off the cylinder product supply valve.

4. Slide out the product tray by removing the 2 screws on the front, top side.

5. Turn CO blendonator by opening faceplate pressure relief valve.

off at the source. Relieve pressure from

6. Disconnect all quick disconnects. Lift blendonator up, note the location of the blendonator tank inputs.

Blendonator

tank

NOTE: The waterbath cover and agitator motor bracket may need to be removed to get the blendanator tank out.

FIGURE 47

7. Reverse the procedure to install new blendonator. Be sure and check for leaks after pressurizing the system.

8. Bleed air from blendonator using pressure relief valve.

9. Run through the normal start-up procedure.

Page 51

HY-POT TEST PROCEDURE

The purpose of this test is to check earth leakage (insulation integrity) by applying 1450 VDC for 60 seconds across line and ground. In order to pass this test the current should be less than 4 mA.

1. Remove ground lead from terminal marked P2 on both Emerson Inverter Boards prior to Hy-Pot test (as indicated in FIGURE 48).

Pinnacle 2 and 4 Flavor Service Manual

2. Set Hy-Pot tester to the following parameters (see FIGURE 49):

Test Voltage ............................... 1.45 kVDC.

Time........................................... 60 seconds.

Hi-Limit ...................................... 4.00 mA.

Low-Limit ................................... 0.00 mA.

Ramp ......................................... 6.0 seconds.

Continuity................................... ON

3. Connect UK power cord plug to UK receptacle on the Hy-Pot tester (as indicated in FIGURE 49).

4. Push compressor contactor in with as electrically insulated bar (as shown in FIGURE 50).

FIGURE 48. Emerson Inverter Board with disconnected Ground Lead

FIGURE 49. Hy-Pot Tester with UK plug/receptacle FIGURE 50. Compressor contactor pushed in during test.

5. Press “Test” button on the Hy-Pot tester.

6. Record result (Pass or Fail) as indicated by the display on the Hy-Pot tester.

Page 52

Pinnacle 2 and 4 Flavor Service Manual

HALL EFFECT SENSOR DIAGNOSIS & REPLACEMENT - BALDOR

Hall Board Diagnostic Procedure:

DANGER — HIGH VOLTAGE, this testing is done with the Pinnacle power ON. Care must be

taken to avoid high voltage areas of the inverter board.

This procedure will test the Hall Board on Barrel #1.

1. Locate Connector 'J2' on the Inverter Board

• Pin 1 - Red - +5 volts

• Pin 2 - White - Hall #1

• Pin 3 - Brown - Hall #2

• Pin 4 - Green - Hall #3

• Pin 5 - Black - Ground

Using a voltmeter in the 'DC' mode, measure 5 volts between Pin 1 and Pin 5 (Red and Black). If 5 volts is present, continue. If not, remove the connector from “J2”, and measure the same pins on the Inverter board. If 5 volts is present, the cabling to the Hall board, or the Hall board itself, is bad. Replace it. If the 5 volts is not present, the Inverter board is bad. Replace it.

Connect black

lead from the meter to the black wire connection at

connector.

Rotate slowly and

watch for the hall

board to switch.

Move the red lead

and repeat test.

FIGURE 51

2. Place Barrel #1 in the OFF mode. Remove the product and face plate from barrel #1. Keep the beater bar engaged with the drive magnet in the back of the freeze cylinder. You will be slowly turning the beater bar by hand.

Rotate slowly.

FIGURE 52

Page 53

Pinnacle 2 and 4 Flavor Service Manual

3. Using a voltmeter in the 'DC' mode, place the black probe on pin 5 (Black), and the red probe on pin 2 (White). Slowly turn (5 to 10 degrees per second) the beater bar in either direction. Watch the voltmeter. If the Hall sensor is operating properly, the voltage will be changing between 0 volts and 5 volts. If you are turning at a uniform speed, the voltage on the voltmeter should toggle back and forth uniformly. If the voltage is NOT changing, replace the Hall Board. If the voltage is changing very erratically, replace the Hall Board.

Voltage should switch from 5 V.D.C. to .025 (approx.).

FIGURE 53 FIGURE 54

4. Repeat step 4 above between Pins 3 & 5, as well as Pins 4 & 5. If any of these three combinations show erratic voltage changing, replace the Hall board.

5. To test the Hall Board on Barrel #2, do steps 1 through 5 on connector J3 of the inverter board.

DC STATOR TEST - EMERSON

1. Remove the stator connection from the inverter board. Test stator and connecting wiring at the inverter board.

2. Check the resistance of all 3 (yellow, red, and blue) of the terminals.

FIGURE 55

The correct

reading should be

approximately 37

ohms.

FIGURE 56 FIGURE 57

Page 54

DC STATOR TEST - BALDOR

1. Remove the stator connection from the inverter board. Test stator and connecting wiring at the inverter board.

2. Check the resistance of all three of the terminals.

Pinnacle 2 and 4 Flavor Service Manual

FIGURE 58

FIGURE 59

The correct

reading should be

approximately

80ohms.

FIGURE 60 FIGURE 61

Page 55

Pinnacle 2 and 4 Flavor Service Manual

DC STATOR ASSEMBLY REPLACEMENT

1. Disconnect the power to the unit. Remove back panel (4 screws) and side panels (3 screws each).

2. Turn off the blendonator valve.

3. Drain the cylinder of the faulty motor by opening the dispensing valve. When only CO cylinder product supply valve off. Relieve CO

pressure by opening the faceplate pressure relief valve.

4. Remove the cylinder face plate (4 nuts).

5. Remove beater bar and scraper blades.

6. Use the magnet puller tool (p/n 560003662) that comes with the unit to remove the magnet.

NOTE: Sufficient force must be used to break the magnet lose from the end of the cylinder.

CAUTION — The magnet is very strong and heavy. Be careful not to pinch hands and fingers

between the magnet and a steel object.

comes out, turn the

WARNING — Strong Magnetic Field.

Stator Assembly

Person wearing pacemaker, implanted cardioverter defibrillator, or other implanted medical

device may be effected by the magnetic field and must keep the magnet at 6 or more inches from the device. The magnetic field can affect operation of these devices which may cause bodily injury or death.

Nuts (4)

Product

supply line

If disruption of device occurs or operation is adversely effected, immediately move the victim far away from magnet and seek medical assistance.

Wire

harnesses

7. Disconnect product supply line. Disconnect wire harness. Remove foam insulation. Remove thermostat in center of stator assembly. Unbend the index tabs and remove end cap.

Stator

mounting

tabs

FIGURE 62

8. Remove stator assembly from cylinder (4 nuts).

9. Apply silicon grease (Dow Corning NC111) around the inside of the new stator and on the outside of the cylinder. Be sure to put a new gasket in the cylinder inlet tube.

Silicon grease

inside of

stator

Silicon grease

outside of

cylinder

10. Slide new stator on end of cylinder. Torque nuts to 15-18 foot pounds. Replace end cap and bend index tabs

FIGURE 63 FIGURE 64

down. Replace thermostat, be careful not to overtighten the brass insert, the threads may snap off inside the steel boss. Replace foam insulation. Reconnect wire harness. Reconnect product supply line.

11. Replace magnet into opening of cylinder. Use magnet removal tool to slowly and carefully push magnet to back of cylinder.

NOTE: As magnet approaches end of cylinder the magnet force increases and care must be taken to not let the magnet slam into the end of the cylinder.

12. Reinstall the beater bar and scrapper blades. Be sure the bushing is on the front of the beater bar shaft. Make sure that the beater bar is engaged with the magnet.

13. Reinstall the faceplate by pressing until it contacts the front of the cylinder and then install the washers and nuts (finger tight only).

14. Re-connect the power and go through the normal start-up procedure.

Page 56

Pinnacle 2 and 4 Flavor Service Manual

DC STATOR ASSEMBLY REPLACEMENT - BALDOR

1. Disconnect the power to the unit. Remove back panel (4 screws) and side panels (3 screws each).

2. Turn off the blendonator valve.

3. Drain the cylinder of the faulty motor by opening the dispensing valve. When only CO cylinder product supply valve off. Relieve CO

pressure by opening the faceplate pressure relief valve.

4. Remove the cylinder face plate (4 nuts).

5. Remove beater bar and scraper blades.

6. Use the magnet puller tool (p/n 560003662) that comes with the unit to remove the magnet.

NOTE: Sufficient force must be used to break the magnet lose from the end of the cylinder.

CAUTION — The magnet is very strong and heavy. Be careful not to pinch hands and fingers

between the magnet and a steel object.

WARNING — Strong Magnetic Field.

Person wearing pacemaker, implanted cardioverter defibrillator, or other implanted medical device may be effected by the magnetic field and must keep the magnet at 6 or more inches from the

death.

If disruption of device occurs or operation is adversely effected, immediately move the victim far away from magnet and seek medical assistance.

device. The magnetic field can affect operation of these devices which may cause bodily injury or

comes out, turn the

7. Disconnect product supply line. Disconnect wire harness. Remove foam insulation. Remove thermostat in center of stator assembly. Unbend the index tabs and remove end cap.

Stator Assembly

Index tabs

Product supply line

FIGURE 65

Nuts (4)

Wire harnesses connector

Safety thermostat

8. Remove stator assembly from cylinder (4 nuts).

9. Apply silicon grease around the inside of the new stator and on the outside of the cylinder. Be sure to put a new gasket in the cylinder inlet tube.

Silicon

Silicon grease

inside of

stator

grease

outside of

cylinder

10. Slide new stator on end of cylinder. Torque nuts to 15-18 foot pounds. Replace end cap and bend index

FIGURE 66 FIGURE 67

tabs down. Replace thermostat, be careful not to over tighten the brass insert, the threads may snap off inside the steel boss. Replace foam insulation. Reconnect wire harness. Reconnect product supply line.

Page 57

Pinnacle 2 and 4 Flavor Service Manual

11. Replace magnet into opening of cylinder. Use magnet removal tool to slowly and carefully push magnet to back of cylinder.

NOTE: As magnet approaches end of cylinder the magnet force increases and care must be taken to not let the magnet slam into the end of the cylinder.

12. Reinstall the beater bar and scrapper blades. Be sure the bushing is on the front of the beater bar shaft. Make sure that the beater bar is engaged with the magnet.

13. Reinstall the faceplate by pressing until it contacts the front of the cylinder and then install the washers and nuts (finger tight only).

14. Re-connect the power and go through the normal start-up procedure.

CONDENSER FAN MOTOR REPLACEMENT (INTEGRAL ONLY)

1. Disconnect the power to the unit. Remove top cover (1 screw).

2. Unplug motor wiring harness and remove air filter.

3. Remove 4 screws securing fan shroud to frame.

4. Lift fan motor and shroud out.

5. Remove 4 screws securing fan motor to shroud.

6. Remove 2 fan covers and place them on the new fan.

7. Reverse the procedure to install new motor.

ONDENSER FILTER REPLACEMENT (INTEGRAL ONLY)

1. Slide filters out of tracks right and left side.

2. Clean or replace.

3. Re-install.

Screws

FIGURE 68

FIGURE 69

Page 58

Pinnacle 2 and 4 Flavor Service Manual

FOAM PACK REPLACEMENT:

1. Disconnect the power to the unit. Remove back middle panel (4 screws) and side panels (3 screw each).

2. Turn OFF the blendonator valve.

3. Drain the cylinder of the faulty foam pack by opening the dispensing valve. When only CO the cylinder product supply valve off. Relieve CO

pressure by opening the faceplate pressure relief valve.

4. Remove the cylinder face plate (4 nuts).

5. Remove beater bar and scrapper blades.

6. Use the magnet puller tool (p/n 560003662) that comes with the unit to remove the magnet.

NOTE: Sufficient force must be used to break the magnet lose from the end of the cylinder.

CAUTION — The magnet is very strong and heavy. Be careful not to pinch hands and fingers

between the magnet and a steel object.

WARNING — Strong Magnetic Field.

Person wearing pacemaker, implanted cardioverter defibrillator, or other implanted medical device may be effected by the magnetic field and must keep the magnet at 6 or more inches from the

death.

If disruption of device occurs or operation is adversely effected, immediately move the victim far away from magnet and seek medical assistance.

device. The magnetic field can affect operation of these devices which may cause bodily injury or

comes out, turn

7. Disconnect product supply line. Disconnect wire harness. Remove foam insulation. Remove screw in center of stator assembly. Unbend the index tabs and remove end cap.

8. Remove the stator assembly from the cylinder (4 nuts).

9. Reclaim refrigerant.

10. Remove 4 bolts and pry off stator plate.

11. Remove front splash panel and drip tray mounting panel.

12. Remove 2 nuts on bottom of foam pack front and rear

Underside of

Foam pack

mounting bars.

Slot in Frame

Back of Unit

FIGURE 70

Face plate screws (2)

FIGURE 71

13. Remove refrigeration line insulation from back of foam pack and remove thermistors (sensors) from refrigeration lines. Unsweat fittings from the back of the foam pack. Lift the foam pack out the front of the unit.

14. Reverse the procedure to install new foam pack. Replace the dryer. Evacuate and recharge the system.

Page 59

Pinnacle 2 and 4 Flavor Service Manual

COMPRESSOR REPLACEMENT:

1. Disconnect the power to the unit. Remove bottom rear cover (4 screws) and side panels (3 screws each).

2. Disconnect all wires to compressor. Remove 4 mounting nuts.

Nuts (4)

Compressor

FIGURE 72

3. Reclaim refrigerant. Remove insulation from around fittings. Unsweat suction line first. Cut the discharge line on top of the compressor (be careful so the line can be spliced back together).

4. Remove the compressor and unsweat the discharge line. Reverse the procedure to install new compressor. Replace the dryer. Evacuate and recharge the system.

OT GAS VALVE REBUILDING:

1. Disconnect the power to the unit. Remove side panels (3 screws each).

2. Reclaim refrigerant.

3. Rebuild the hot gas valve per the manufacturer’s instructions.

4. Replace the dryer. Evacuate and recharge the system.

Hot gas

valve body

(inside)

FIGURE 73

Coil screw

Page 60

Pinnacle 2 and 4 Flavor Service Manual

PULSE VALVE REPLACEMENT:

1. Disconnect the power to the unit. Remove side panels (3 screws each) and rear panels if necessary.

CAUTION — There are 6 pulse valves on a 4

Flavor unit, one for each cylinder and one for each water bath. The pulse valve for the water bath and the pulse valves for the cylinders are

NOT the same. DO NOT interchange these valves.

2. Reclaim refrigerant. Disconnect pulse valve wires. Remove coil (1 screw).

3. Unsweat and remove valve.

4. Install new valve by reversing the procedure. Be sure to place a heat sink on the valve body when sweating the new valve to avoid damage to the valve components.

5. Replace the dryer. Evacuate and recharge the system.

ATER PRESSURE REGULATOR / SWITCH REPLACEMENT:

1. Disconnect the power to the unit. Remove back lower and middle panel (4 screws each).

2. Turn off water at source. Bleed pressure from water feed line at the rear disconnect.

3. Disconnect wires on pressure switch. Disconnect 2 quick disconnect fittings using a spanner tool.

Water

pressure

regulator

Coil

Pulse

Val ve

body

FIGURE 74

Water

filter cap

Water switch

FIGURE 75

4. Remove and replace the regulator and/or switch.

5. Reassemble in the reverse order. Be sure and check for leaks after pressurizing the system.

6. Check regulator pressure setting.

ATER STRAINER CLEANING:

1. Disconnect the power to the unit. Remove rear middle panel (4 screws)

2. Turn off water source then bleed pressure from water feed line at the rear disconnect.

3. Unscrew cap and remove Strainer.

4. Clean Strainer and reassemble in the reverse order. Be sure and check for leaks after pressurizing the system.

Page 61

Pinnacle 2 and 4 Flavor Service Manual

MERCHANDISER LAMP REMOVAL AND INSTALLATION

Removal

1. SHUT OFF POWER TO UNIT. Remove lens and lens support.

FIGURE 76

2. Press lamp locks to unlock lamp pins.

3. Disengage lamp pins by pulling lamp in a direction forward away from reflector surface and remove lamp.

NOTE: Pulling down on lamp to disengage pins may result in damage to lampholders and spring clips.

FIGURE 77

Reflector Surface

Lampholder

FIGURE 78

Page 62

FIGURE 79 demonstrates lampholder with lock completely disengaged (lamp omitted for clarity).

NOTE: Locks must be completely disengaged before removing lamp or damage to the lamp or the lock may result.

Installation

1. Slide lamp into spring clips at bottom of reflector.

Pinnacle 2 and 4 Flavor Service Manual

FIGURE 79

2. Engage lamp pins by pushing lamp in a direction toward the reflector surface, making certain pins are fully engaged in lampholder (see FIGURE

81).

NOTE: Pushing up on lamp to engage pins may result in damage to lampholders.

FIGURE 80

Pins MUST be

Fully Engaged!!

FIGURE 81

Page 63

3. Press the lamp into the lampholder firmly to engage locks. Reinstall lens and lens support. Restore power to unit.

FIGURE 83 demonstrates lampholder with lock properly engaged (lamp omitted for clarity).

WARNING: For proper and effective lamp function, locks must be completely engaged.

Pinnacle 2 and 4 Flavor Service Manual

Locks

FIGURE 82

FIGURE 83

Page 64

TROUBLESHOOTING

• If foul smell or bad taste, check water filter.

• If water out message, check water filter.

TROUBLESHOOTING THE SYSTEM

Problem Probable Cause Remedy

Pinnacle 2 and 4 Flavor Service Manual

Unit will not run. A. Unit not plugged in.

B. Circuit breaker. C. No power at L1 or L2 on contac-

tor. D. Low voltage at T1 or T2. E. Solid Red LED above display.

“Sleep” display on cylinder status menu.

Barrel status OFF #1 and #2.

Low/High voltage ERROR.

Como ERROR. A. Display board is not communicat-

A. Sleep time set. B. Clock incorrectly set. C. No wake time set.

A. Not activated. B. Error has shut off motors.

C. Unit in Diagnostics.

D. Defective touch switch.

A. Line Voltage out of SPEC (spec is

198-253 VAC for 60 Hz and 196-

265 VAC for 50 Hz). B. Error range 180/260.

ing with the main board.

A. Plug in unit. B. Reset/replace circuit breaker C. Check voltage at outlet.

Check wiring to contactor. D. Replace the contactor. E. If LED is lighted, do not restart

dispenser. Immediately call

Service at (800) 238-3600.

A. Check programming. B. Check programming. C. Check programming.

A. Turn to ON or MOTOR. B. Correct error & turn to ON or

MOTOR mode. C. Exit diagnostics & turn to ON or

MOTOR mode. D. Replace.

A. 1 - Check line voltage.

2 - Check T1/T2 with Compressor

running. B. Correct line voltage.

A. Check connections at J6 and J17.

See display board test in the Ser-

vice manual.

Torque ERROR. A. Freeze up.

B. Magnet and stator not aligned.

C. Magnet binding.

Electronic ERROR. A. Clock chip or bad line frequency.

B. Faulty communication.

Drive ERROR. A. Motor not turning when it is com-

manded to. Freeze up.

B. Bad inverter board (Emerson).

A. Defective pulse valve. B. Stator or magnet not installed cor-

rectly. C. Inspect and correct problem.

A. Replace the clock chip. B. Check phone connections.

A. 1 - Check Brix.

2 - Check sold out.

3 - Check for leaking pulse valve.

4 - Defective binding magnet

5 - Broken beater bar. B. Test and replace as necessary.

Page 65

Pinnacle 2 and 4 Flavor Service Manual

Frozen Cylinder A. Low Brix

B. Pulse valve leaking C. Broken beater bar D. Broken drive coupler. E. No defrost. F. Are defrosts programmed all

days?

Detective Stator A. Open or shorted. A. See stator test.

Defective Hall Board (Baldor)

Stator or Misalignment A. Loose mounting nuts.

No Power to Stator A. Blown inverter fuse.

A. Open or shorted. A. See Hall board test.

B. Missing or extra gasket. C. Debris causing interference. D. Hall board not mounted correctly.

B. Blown thermistor (Emerson). C. One side of inverter is defective.

D. Incorrect wiring.

E. Poor connections.

A. Correct cause and reset Brix. B. Replace pulse valve. C. Replace beater bar. D. Replace the drive coupler. E. Program defrosts in unit. F. Reprogram to all days.

A. Tighten nuts. B. Add or remove gasket. C. Remove debris and tighten. D. Assemble correctly.

A. Emerson - replace board.

Baldor - replace fuse. B. Replace thermistor harness. C. Swap side 1 & 2 controls, see if

motor will run. D. Check wiring with Pinnacle sche-

matic. E. Check all connections.

Bad Magnet A. Defective beater bar coupler.

B. Worn magnet bushing. C. Cracked/damaged magnet hous-

ing.

D. Cylinder shaft not aligned.

TROUBLESHOOTING PRODUCT NOT COLD

Problem Probable Cause Remedy

Compressor not Running

A. Cylinder not in ON mode. B. No voltage to compressor.

C. Bad start components. D. Compressor’s thermal overload

protector “open”.

E. Open or shorted compressor

windings.

F. Bad control board.

A. Replace the defective part. B. Replace bushing assembly/check

cylinder shaft. C. Replace magnet. D. Replace foam pack.

A. Turn cylinder to ON. B. Check power at contactor L1, L2 -

T1, T2. C. Check components and wiring. D. Check resistance of compressor

windings and check incoming line

voltage. E. Check resistance of compressor

windings. F. Troubleshoot, replace if neces-

sary.

Page 66

Pinnacle 2 and 4 Flavor Service Manual

Compressor Running

A. Low refrigerant.

but not Cooling

B. Restricted condenser/filter. C. Condenser fan motor/blade

defective.

D. Any pulse valve stuck open or

closed. E. Hot gas valve leaking or open. F. Defective compressor.

Restricted Air Flow A. Dirty filter.

B. Dirty condenser. C. Damaged fins. D. Not enough “clearance” around

unit.

Fan Motor A. Bad connection

B. Bad motor C. Cracked or bent fan blade

Pulse Valve A. Miswired.

B. Defective coil. C. Defective valve. D. Defective product delivery board.

Hot Gas Valve A. Miswired.

B. Defective coil. C. Defective product delivery board.

A. Repair leak and weigh in new

charge. B. Clean or repair. C. Repair or replace.

D. Replace.

E. Repair or replace. F. Repair or replace.

A. Clean filter. B. Clean condenser. C. Repair/replace if necessary. D. Ensure proper spacing around

unit.

A. Check/connect B. Replace motor C. Replace fan blade

A. Correct wiring. B. Replace coil. C. Replace valve. D. Replace board.

A. Correct wiring. B. Replace coil. C. Replace.

No/Low Refrigerant A. Leak. A. Repair and weigh in new charge.

Sensors A. Bad connection.

B. Bad sensor. C. Sensor out of position. D. Defective product delivery board.

A. Correct wiring. B. Replace sensor. C. Reposition sensor and clip. D. Replace.

Page 67

APPENDIX A - HISTORIC BRIX PROCEDURES

NOTE: See page 28, step 4 to determine if Section 1 or 2 applies to the unit.

SECTION 1: 3-WAY VALVE BRIXING PROCEDURE

PRESSURE SWITCH AND WATER REGULATOR

COOLING COIL

Pinnacle 2 and 4 Flavor Service Manual

WATER

FLOW REGULATOR AND SOLENOID VALVE

SYRUP

Number 1 cylinder

SINGLE CHECK VALV E

PRODUCT PUMP

(SYRUP AND WATER

ARE MIXED)

3-WAY PRODUCT

BRIX VALVE

DOUBLE CHECK VALV E

WATER ICE BATH

PRODUCT SAMPLE TUBE

FIGURE 5

FREEZE CYLINDER

PRODUCT SHUTOFF VALV E

BLENDONATOR

Product Shut Off Valve

FIGURE 6

Syrup Valves

3-Way Product Brix Valve

Product Sample Tubes

FIGURE 7

1. Make sure the status of all cylinders is OFF.

2. Press MENU, press UP until BRIX is selected, press GO, select cylinder to be BRIXed.

NOTE: Pressing CANCLE will stop the process.

Page 68

Pinnacle 2 and 4 Flavor Service Manual

1. Turn three-way product valve to BRIX position. Hold a 12 ounce cup under the appropriate sample tube.

Sample

tube

FIGURE 2

3. Press GO and wait 3-5 seconds. The unit will dispense product for 3 seconds. Discard this first sample.

4. Hold cup under the tube again and press GO.

5. Put sample on refractometer and read BRIX.

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

6. Adjust syrup regulator to get a BRIX reading of 13 ± 1. To increase reading, turn syrup regulator clockwise.

Syrup

regulator

valve

FIGURE 7

8. After BRIX is adjusted, turn 3-way product valve to blendonator position.

9. Repeat procedure for additional freeze cylinders.

10. Turn the freeze cylinder shutoff valves to the ON position. Press MENU, press UP until blendonator is selected, press GO, select the desired cylinder, press ON.

Page 69

Pinnacle 2 and 4 Flavor Service Manual

11. When the cylinders have stopped filling pull the faceplate relief valves until product comes out. Do not bleed air too fast or product will foam in the freeze cylinders.

Relief

valve

FIGURE 12

13. Repeat steps 10 and 11 for the other freeze cylinders.

14. Press BACK twice to go to the Main menu.

15. Press ON, after 5 seconds the compressor will start and the beater bars will rotate counterclockwise. Wait 10 – 15 minutes and test the product.

NOTE: Make sure the controller is programmed before pressing ON.

16. Install the second side panel, splash panel, drip tray, and top cover.

Page 70

Pinnacle 2 and 4 Flavor Service Manual

WATER

PRESSURE SWITCH AND WATER REGULATOR

FLOW REGULATOR AND SOLENOID VALVE

SINGLE CHECK VALV E

PRODUCT PUMP

(SYRUP AND WATER

ARE MIXED)

CHECK VALVE

COOLING COIL

FREEZE CYLINDER

BLENDONATOR

SYRUP

PRODUCT SHUTOFF VALV E

WATER ICE BATH

PRODUCT SAMPLE VALVE

SECTION 2: SHUT-OFF VALVE AND BLENDONATOR OUTLET BRIX SAMPLE T

UBE PROCEDURE

FIGURE 17

The BRIX menu allows the activation of syrup and water solenoids, and blendonator pump motor for a selected cylinder.

1. Press MENU.

2. Scroll up to BLENDONATOR.

3. Turn Blendonators 1 and 2 OFF.

4. Drain each Blendonator through the BRIX Sample Valve.

5. Press BACK.

6. Scroll down to BRIX.

7. Press GO.

8. Once the BRIX SELECT menu is selected press GO to partially fill Blendonator #1 with a BRIX sample.

9. After the sample is complete (Blendonator pump has stopped turning), remove the sample from the Blendonator (through the BRIX Sample Valve) for refractometer testing.

10. If the BRIX reading is within specification, the BRIX adjustment for this barrel is complete.

11. If the BRIX reading is NOT within specification, adjust the syrup Flow Control to bring the product within specification (clockwise to increase BRIX, counter-clockwise to decrease BRIX). Adjust Flow Control in no more than 1/2 turn increments.

12. Repeat step 8 above 3 times, drain the Blendonator, and dispose of this product.

13. Repeat steps 8 and 9 above and measure the sample with the refractometer.

14. Repeat steps 11-13 until the product BRIX is within specification.

15. Repeat steps 8-14 until Blendonator #2 product BRIX is within specification.

16. Scroll to the BLENDONATOR menu and turn both Blendonators ON.

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VALVE TORQUE AND STAKING

Cornelius provided Service Bulletin number TSB-06-3 concerning the proper torquing and staking of FCB equipment using the Delta stainless steel dispensing valve. The procedures in the Service Bulletin ensured that the shank nut used to retain the Delta dispensing valve to the faceplate was tightened to the correct torque and then staked so that the shank nut could not be dislodged. All newly manufactured equipment utilizing the Delta dispense valve, beginning with serial numbers 62B0620FC001, has been staked in the factory. Consequently, all Delta valves should now be torqued and staked. A procedure for properly attaching and torquing a Motorman Valve is also included.

This dispensing valve shank nut torque procedure must be followed (a) if a Delta valve has not previously been torqued and staked, (b) if the shank nut on a Delta stainless steel valve that has been staked is later removed and then reinstalled, or (c) the FCB equipment has a Motorman valve. The processes for checking the torque of the shank nut for both the Delta and Motorman valve configurations and for staking the shank nut (Delta valve configuration ONLY) are detailed in this Procedure. The Cornelius tool (part number 620711709) to be used to torque the shank nut can be purchased by contacting BEVCORe at 763488-3000.

NOTE: When reinstalling a shank nut that has been removed from a staked Delta valve, the shank nut must be FLUSH with the faceplate before applying the torque setting. If the thread or shank nut have been damaged during removal and/or the shank nut cannot be installed flush with the faceplate, the valve should be replaced.

Pinnacle 2 and 4 Flavor Service Manual

APPENDIX B

WARNING: Failure to torque the shank nut to 10 lb-ft (120 lb-in) may result in loosening of shank nut which eventually may become detached from valve. Valve will then be forced from face plate and contents of dispenser will spill out. Follow torquing and staking procedures carefully using tools designated to retain shank nut on valve.

The following procedure details the proper method to apply torque to the shank nut on Pinnacle dispensing valves, both Delta and Motorman configurations. This procedure begins with the faceplate assembly removed from the barrel and the inside surface of faceplate wiped dry, especially around shank nut. (See section “COMPONENT SERVICE” steps 1-4 on Page 38 for instructions to drain barrels).

Page 72

Delta Valve

1. Remove and rotate faceplate, as shown, with valve facing Barrel. Attach faceplate to two studs with cap nuts finger tight. This holds assembly in place for applying torque to shank nut.

2. Place special spanner socket in two slots on shank nut, making sure slots are fully engaged. Tighten shank nut, as shown, with torque wrench and spanner socket. Torque wrench setting is 10 lb-ft (or 120 lb-in). Socket part number is

620711709.

NOTE: Do not use any other tool or method to tighten the shank nut.

Pinnacle 2 and 4 Flavor Service Manual

3. After torquing shank nut locate hammer and punch. The faceplate must be removed from the unit and secured to sustain impact from staking.

NOTE: This procedure is used for the stainless steel Delta valve only. DO NOT use on plastic Motorman Valve threads.

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4. Place point of punch in slot on shank nut right against valve threads.

5. Strike end of punch with hammer.

Pinnacle 2 and 4 Flavor Service Manual

6. After applying torque and performing staking (stainless steel valve

Valve Shank Surface

threads only) inspect the threads and shank nut to ensure proper thread engagement.

This is what the Delta shank nut clearance should look like.

• Shank nut surface flush-to-0.023”

above Valve surface.

Staking mark on threads inside notch in Shank Nut.

Shank Nut Surface

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Motorman Valve

1. Remove and rotate faceplate, as shown, with valve facing Barrel. Attach faceplate to two studs with cap nuts finger tight.

2. Place the special spanner socket in two slots on shank nut, making sure slots are fully engaged. Tighten shank nut, as shown, with torque wrench and socket. Torque wrench setting is 10 lb-ft (or 120 lbin). Socket part number is

620711709.

NOTE: Do not use any other tool or method to tighten the shank nut.

Pinnacle 2 and 4 Flavor Service Manual

3. After applying torque, inspect the threads and shank nut to ensure

Valve Surface

proper thread engagement.

This is what the Motorman shank nut clearance should look like.

• Shank nut surface 0.083” below

valve surface.

Shank Nut Surface

Page 75

Page 76

Cornelius Inc.

www.cornelius.com

Cornelius Viper 2 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual