IMI Cornelius, Inc. FCB Service Manual

Download

IMI CORNELIUS INC

www.cornelius.com

Installation/Service Manual FCB POST-MIX DISPENSER

W/HOT-GAS DEFROST AND V4 ELECTRONICS (DEFROST/ERROR INDICATOR LIGHTS)

IMPORTANT:

TO THE INSTALLER. It is the responsibility of

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

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

Part No. 560001279SER February 20, 2004 Revised: December 6, 2006 Revision: E

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

IMI CORNELIUS INC; 2004–2006©

PRINTED IN U.S.A

TABLE OF CONTENTS

SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RECOGNIZE SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNDERSTAND SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOLLOW SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CO2 (CARBON DIOXIDE) WARNING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIPPING, STORING, OR RELOCATING UNIT 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT DESCRIPTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 AND 3 H.P. TWO–FLAVOR OVERCOUNTER (OC2) UNITS 3. . . . . . . . . . . . . . .

TWO–FLAVOR FLOOR MODEL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOUR–FLAVOR FLOOR MODEL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFRIGERATION SYSTEMS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THEORY OF OPERATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEFROST SYSTEMS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL DEFROST SYSTEM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTOMATIC DEFROST SYSTEM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘SLEEP’’ (SLEEP TIME) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘WAKE UP’’ (WAKE UP TIME) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNPACKING AND INSPECTION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION OF LOOSE-SHIPPED PARTS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SELECTING LOCATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING UNIT 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING APPLICABLE CASTER KIT OR LEVELING LEGS 13. . . . . . . . . . . . . .

INSTALLING DRIP TRAY SUPPORTS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING DRIP TRAY DRAIN KIT 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLACING UNIT IN OPERATING LOCATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING PRIMARY CO2 REGULATOR ASSEMBLY ON CO2 CYLINDER

(SEE APPLICABLE FIGURE 4 OR 5) 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING SOFT DRINK TANKS CO2 LINES TO PRIMARY

CO2 REGULATOR ASSEMBLY (SEE APPLICABLE FIGURE 4 OR 5) 15. . . . .

PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT

DRINK TANKS (SEE APPLICABLE FIGURE 4 OR 5) 15. . . . . . . . . . . . . . . . . . .

CONNECTING CITY PLAIN WATER SOURCE LINE (S) TO UNIT 15. . . . . . . . . . .

CONNECTING CO2 SOURCE LINE TO UNIT

(SEE APPLICABLE FIGURE 4 OR 5) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING ELECTRICAL POWER SOURCE TO UNIT 16. . . . . . . . . . . . . . . . .

PREPARATION FOR OPERATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TWO–FLAVOR UNITS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOUR–FLAVOR UNITS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TURNING ON ELECTRICAL POWER TO UNIT 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

TURNING ON CO2 SUPPLY TO UNIT 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING CO2 REGULATORS (SEE APPLICABLE FIGURE 4 OR 5) 20. . . . . .

TURNING ON CITY PLAIN WATER SOURCE LINE TO UNIT 20. . . . . . . . . . . . . . . .

ACTIVATING SYRUP SOURCE SYSTEM 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING BRIX (WATER-TO-SYRUP “RATIO”) OF DISPENSED PRODUCT 21

FILLING FREEZE CYLINDERS WITH PRODUCT 22. . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING UNIT FOR SYRUP, CO2 AND PLAIN WATER LEAKS 22. . . . . . . . . . .

ADJUSTING “WATER-COOLED” UNIT REFRIGERATION SYSTEM

VARIABLE WATER REGULATOR 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS AND PROGRAMMING PROCEDURES 22. . . . . . . . . . . . . . . . . . . . . . .

SETTING CLOCK (TIME OF DAY) 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING DEFROST (AUTOMATIC) INTO UNIT ELECTRONICS 23. . . . .

PROGRAMMING “SLEEP” (SLEEP TIME) INTO UNIT ELECTRONICS 23. . . . . . .

PROGRAMMING “WAKE UP” (WAKE UP TIME) INTO

UNIT ELECTRONICS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING POINT OF SALE MESSAGE DISPLAY INTO UNIT

ELECTRONICS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING “VIS SET” (PRODUCT VISCOSITY) OF

DISPENSED PRODUCT 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“VIS READ” (ACTUAL VISCOSITY READOUT) OF

PRODUCT IN FREEZE CYLINDERS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND

COMMON OUTLET SENSORS TEMPERATURES 24. . . . . . . . . . . . . . . . . . . . .

“VOLTAGE” (DISPLAYED VOLTAGE READOUT) 24. . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING COMPONENTS “DIAGNOSE” (DIAGNOSTIC MODE)

INTO UNIT 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYING “TOTALS” (DISPLAYED CYCLES AND HOURS TOTALS)

ONTO MESSAGE DISPLAY 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS”

INTO UNIT ELECTRONICS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT

ELECTRONICS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“OPTIONS” (DIP SWITCHES 1 THROUGH 10) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING CALENDAR INTO UNIT ELECTRONICS 25. . . . . . . . . . . . . . . . . .

PROGRAMMING DST+1HR INTO UNIT ELECTRONICS 25. . . . . . . . . . . . . . . . . . .

PROGRAMMING DST–1HR INTO UNIT ELECTRONICS 25. . . . . . . . . . . . . . . . . . .

DISPLAYED ERROR CONDITIONS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE) 26. . . . . . . . . . . . . . . . .

PROGRAMMING/ADJUSTMENTS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATOR’S INSTRUCTIONS 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTAINING PRODUCT QUALITY

CORNELIUS FCB EQUIPMENT - OPERATOR INSTRUCTIONS 37. . . . . . . . . . . . .

1. DISPENSED PRODUCT THROUGHPUT 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. PROGRAMMED DEFROST SCHEDULING 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. VISCOSITY SETTING 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT ACCESS DOOR INDICATOR LIGHTS (SEE FIGURE 8) 38. . . . . . . . . . . . . . . .

TWO–FLAVOR UNITS 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOUR–FLAVOR UNITS 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL (KEYPAD) SECURITY 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL SWITCHES (SEE FIGURE 9) 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘SYRUP PRIME’’ SWITCHES 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘BLEND ON/OFF’’ SWITCHES 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘MOTOR’’ SWITCHES 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“ON’’ SWITCHES 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘OFF’’ SWITCHES 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘ERROR RESET’’ SWITCH 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL DISPLAY MESSAGES 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘FILL 1’’ AND ‘‘FILL 2’’ FAULT MESSAGES 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘ERROR 1’’ AND ‘‘ERROR 2’’ FAULT MESSAGES 41. . . . . . . . . . . . . . . . . . . . . . . . .

‘‘OFF 1’’ AND ‘‘OFF 2’’ FAULT MESSAGES 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘H2O OUT’’ FAULT MESSAGE 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘CO2 OUT’’ FAULT MESSAGE 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘SYRUP 1’’ OR ‘‘SYRUP 2’’ FAULT MESSAGES 41. . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘DEFROST 1’’ OR ‘‘DEFROST 2’’ DISPLAY MESSAGES 41. . . . . . . . . . . . . . . . . . .

‘‘POINT OF SALE’’ DISPLAY MESSAGES 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEFROST SYSTEMS 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL DEFROST SYSTEM 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTOMATIC DEFROST SYSTEM 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘SLEEP’’ (SLEEP TIME) 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘WAKE UP’’ (WAKE UP TIME) 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FACEPLATE RELIEF VALVES 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSING VALVES 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT CONDITIONS 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘OVERRUN’’, AS APPLIED TO FROZEN CARBONATED BEVERAGES 43. . . . . .

OPERATING CHARACTERISTICS 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT OPERATION 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING CO2 REGULATORS 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMARY CO2 REGULATOR 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY CO2 REGULATORS 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING BRIX (WATER-TO-SYRUP “RATIO”) OF DISPENSED PRODUCT 46. . .

REPLENISHING SYRUP SUPPLY 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP FLAVOR CHANGE 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING OF UNIT 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING SYRUP SYSTEMS 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CONDENSER COIL 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND MAINTENANCE 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING 47. . . . . . . . . . . . .

PERIODIC INSPECTION 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL OF PANELS 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIP TRAY 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BACK PANEL 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIDE PANELS 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOP PANEL 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOWER FRONT ACCESS PANEL 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSER COIL ACCESS PANEL 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPENING AND CLOSING FRONT ACCESS DOOR 48. . . . . . . . . . . . . . . . . . . . . . . . . . .

TWO–FLAVOR MODELS AND OVERCOUNTER (OC2) MODELS 48. . . . . . . . . . .

FOUR–FLAVOR FLOOR MODEL 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING PLAIN WATER PRESSURE REGULATOR

(SEE APPLICABLE FIGURE 4 OR 5) 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING CARBONATED WATER FLOW RATE

(SEE APPLICABLE FIGURE 4 OR 5 AND 16) 48. . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT CARBONATION ADJUSTMENT

(SEE APPLICABLE FIGURE 4 OR 5) 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICING DISPENSING VALVES CAGED O-RINGS AND

FREEZE CYLINDERS DRIVE SHAFT/ SEAL ASSEMBLIES 50. . . . . . . . . . . . . . . . .

SERVICING DISPENSING VALVES CAGED O-RINGS. (SEE FIGURE 10) 50. . . .

SERVICING FREEZE CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES. 52. . . . .

CLEANING CONDENSER COIL (SEE FIGURE 23) 55. . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT WITH AIR-COOLED REFRIGERATION SYSTEM 55. . . . . . . . . . . . . . . . . . . . .

UNIT WITH WATER-COOLED REFRIGERATION SYSTEM 55. . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING OF UNIT 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING SYRUP SYSTEMS 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YEARLY OR AFTER WATER SYSTEM DISRUPTION 58. . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICING CARBONATOR WATER PUMP WATER STRAINER SCREEN

(2 AND 3 H.P. OVERCOUNTER UNITS) 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING CARBONATOR WATER PUMP DOUBLE LIQUID

CHECK VALVE (SEE APPLICABLE FIGURE 4 OR 5 AND 14 OR 15) 59. . . . .

ADJUSTING CARBONATOR TANK LIQUID LEVEL 60. . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR (SEE FIGURE13) 61. . . .

REPLENISHING SYRUP SUPPLY 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP TANKS SYSTEM 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BAG–IN–BOX SYSTEM 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP FLAVOR CHANGE 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CO2 SYSTEM GAS CHECK VALVES

(SEE APPLICABLE FIGURE 4 OR 5 AND 18) 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX A 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE TORQUE AND STAKING 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTORMAN VALVE 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DELTA VALVE 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 1. TWO–FLAVOR FLOOR MODEL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 2. TWO–FLAVOR OVERCOUNTER (OC2) UNIT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 3. FOUR–FLAVOR FLOOR MODEL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 4. FLOW DIAGRAM. 3 H.P. DISPENSER (TWO–FLAVOR MODEL SHOWN) 9. . . .

FIGURE 5. FLOW DIAGRAM (2 AND 3 H.P. OVERCOUNTER OC2 DISPENSER) 10. . . . . . . .

FIGURE 6. CONTROL PANEL SWITCH/MESSAGE DISPLAY 27. . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 7. MASTER AND RELAY CIRCUIT BOARD 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 8. FRONT ACCESS DOOR INDICATOR LIGHTS 39. . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 9. CONTROL PANEL SWITCH IDENTIFICATION 39. . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 10. SELF-CLOSING DISPENSING VALVE 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 11. FREEZE CYLINDER CUTAWAY VIEW 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 12. BEATERS AND SCRAPER BLADES INSTALLATION 53. . . . . . . . . . . . . . . . . . . . . .

FIGURE 13. SERVICING BEATER MOTOR DRIVE SHAFT/SEAL ASSEMBLY 54. . . . . . . . . . .

FIGURE 14. DOUBLE LIQUID CHECK VALVE (3 H.P. FLOOR MODEL UNIT) 59. . . . . . . . . . .

FIGURE 15. DOUBLE LIQUID CHECK VALVE AND WATER STRAINER SCREEN

FIGURE 16. PARTS IDENTIFICATION 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 17. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT 64. . . . . . . .

FIGURE 18. CO2 GAS CHECK VALVE 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 19. WIRING DIAGRAM (3 H.P. FLOOR MODEL UNIT) 66. . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 20. WIRING DIAGRAM (2 AND 3 H.P. OVERCOUNTER OC2 UNITS) 67. . . . . . . . . .

FIGURE 21. WIRING DIAGRAM (TWO–FLAVOR UNITS) 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 22. WIRING DIAGRAM (FOUR–FLAVOR UNITS) 69. . . . . . . . . . . . . . . . . . . . . . . . . . . .

(OVERCOUNTER OC2 UNIT) 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 23. REFRIGERATION FLOW DIAGRAM (AIR-COOLED REFRIGERATION

SYSTEM) 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 24. REFRIGERATION FLOW DIAGRAM (WATER-COOLED REFRIGERATION

SYSTEM) 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY INFORMATION

Recognize Safety Information

This is the safety-alert symbol. When you see this symbol on our machine or in this manual, be alert to the potentially of personal injury.

Follow recommended precautions and safe operating practices.

Understand Signal Words

A signal word - DANGER, WARNING, OR CAUTION is used with the safety-alert symbol. DANGER identi- fies the most serious hazards.

DANGER

Safety signs with signal word DANGER or WARNING are typically near specific hazards.

General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

WARNING

CAUTION

Follow Safety Instructions

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Learn how to operate the machine and how to use the controls properly. Do not let anyone operate the machine without instructions. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair function and/or safety and affect the machine life.

CO2 (Carbon Dioxide) Warning

CO2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO2 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation.

Shipping, Storing, Or Relocating Unit

CAUTION: Before shipping, storing, or relocating the Unit, syrup systems must be sanitized and all sanitizing solution must be purged from the syrup systems. All water must also be purged from the plain and carbonated water systems. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the Unit to freeze resulting in damage to the internal components.

560001279SER 1

GENERAL INFORMATION

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

Warranty Registration Date

(to be filled out by customer)

Model Number:

Serial Number:

Install Date:

Local Authorized Service Center:

GENERAL DESCRIPTION

This section gives the description, theory of operation, and design data for the FCB Two and Four-Flavor Floor Model Post-Mix Dispenser and the FCB Two-Flavor Overcounter (OC2) Post-Mix Dispenser with Hot-Gas Defrost and V4+ Electronics (hereafter referred to as Units).

FIGURE 2. TWO–FLAVOR OVERCOUNTER (OC2) UNIT

FIGURE 1. TWO–FLAVOR FLOOR MODEL

FIGURE 3. FOUR–FLAVOR FLOOR MO

560001279SER

UNIT DESCRIPTION

2 AND 3 H.P. TWO–FLAVOR OVERCOUNTER (OC2) UNITS

The 2 and 3 H.P. Two–Flavor FCB Overcounter (OC2) Dispensers (see Figure 2 and Figure 5) consists basically of two freeze cylinders each containing an internal beater driven by an electric motor, one refrigeration system, one carbonator Tanks which feed both product blender tanks, a timer-controlled automatic hot-gas defrost system to defrost the freeze cylinders, and interconnecting tubing, components, and fittings necessary to regulate, transfer, and dispense product.

The Dispensers are equipped with V4 electronics and are also equipped with two indicator lights located on the front access door of the Unit. The purpose of the indicator lights is to inform the Operator if one or both of the freeze cylinders is in the defrost mode and also if an “OUT OF SYRUP”, “OUT OF WATER”, “OUT OF CO if an error condition exist.

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

TWO–FLAVOR FLOOR MODEL

”, or

The 3 H.P. Two–Flavor Floor Model FCB Dispenser (see Figure 1 and 4) consists basically of two freeze cylinders each containing an internal beater driven by an electric motor, one refrigeration system, two product blender tanks, two carbonator tanks which feed both product blender tanks, a timer-controlled automatic hot-gas defrost system to defrost the freeze cylinders, and interconnecting tubing, components, and fittings necessary to regulate, transfer, and dispense product.

The Unit is equipped with V4 electronics and is also equipped with two indicator lights located on the front access door of the Unit. The purpose of the indicator lights is to inform the Operator if one or both of the freeze cylinders is in the defrost mode and also if an “OUT OF SYRUP”, “OUT OF WATER”, “OUT OF CO2”, or if an error condition exist.

560001279SER 3

FOUR–FLAVOR FLOOR MODEL

The 2 H.P. Four–Flavor Floor Model FCB Dispenser (see Figure 3 and 4) consists basically of four freeze cylinders each containing an internal beater driven by an electric motor, two refrigeration systems, four product blender tanks, four carbonator tanks which feed the product blender tanks, a timer-controlled automatic hot-gas defrost system to defrost the freeze cylinders, and interconnecting tubing, components, and fittings necessary to regulate, transfer, and dispense product.

The Unit is equipped with V4 electronics and is also equipped with four indicator lights located on the front access door of the Unit. The purpose of the indicator lights is to inform the Operator if the freeze cylinders are in the defrost mode and also if an “OUT OF SYRUP”, “OUT OF WATER”, “OUT OF CO2”, or if an error condition exist.

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

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

560001279SER

Table 1. Design Data

Unit Part Numbers:

Two-Flavor 3 H.P. Floor Model (Air-Cooled), 230 VAC, 60 Hz 4166201000 Two-Flavor 3 H.P. Floor Model (Water-Cooled) 230 VAC, 60 Hz 4166221000 Two-Flavor 2 H.P. Overcounter (OC2) Air-Cooled 230 VAC, 60 Hz 4161361000 Two-Flavor 3 H.P. Overcounter (OC2) Air-Cooled (Top Condensing) 230

4161367000 VAC, 60 Hz Two-Flavor 3 H.P. Overcounter (OC2) Water-Cooled 230 VAC, 60 Hz 4161362000 Four-Flavor 2 H.P. Floor Model Air-Cooled 230 VAC, 60 Hz 4166001000

Overall Dimensions:

Two-Flavor Floor Model

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

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

32-1/2 inches

38 inches

Two-Flavor Overcounter (OC2) Model

Height

32 inches

Top Condenser Unit 44.5 inches

Width

19 inches Depth (W/O Drip Tray) Depth W/Drip Tray

31-1/8 inches

36 inches

Four-Flavor Floor Model

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

60-1/2 inches

32–1/2 inches

32-1/2 inches

38 inches

Shipping Weight: (approx)

Two-Flavor Floor Model 460 pounds Two-Flavor Overcounter (OC2) Model 420 pounds Four-Flavor Floor Model 837 pounds

Compressor Horsepower See Unit nameplate

Refrigeration System:

Refrigerant Type and Charge See Unit

Nameplate

Ambient Operating Temp. 40° F to 100° F

Electrical Requirements:

Operating Voltage See Unit Nameplate Current Draw See Unit Nameplate

560001279SER 5

Table 2. Accessories and Tools

ACCESSORIES

Installation kits 1155 Cup Holder 511005000 Cup Holder 511006000 CO2 Changeover Kit 511035000

GENERIC FLAVOR TABS

Cola 1085 Cherry 1086 Orange 1087 Lemon-Lime 1089 Strawberry 1090 Banana 1091

SERVICE TOOLS

3-gallon Sanitizing Tank 281884000 Socket Spanner, Shank Nut 620711709 Refractometer, 0-30 Scale 511004000 Wrench, Rear Seal Housing 2899 Tool, Drive/Coupler Adjustment Gauge 3810

REFRIGERATION SYSTEMS

NOTE: The FCB Dispenser (depending upon the model number) refrigeration system is either “air-cooled” or “water-cooled”.

“Air-Cooled”

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

“Water-Cooled”

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

560001279SER

THEORY OF OPERATION

(see applicable Figure 4 or 5)

A CO

cylinder or a bulk CO2 supply delivers carbon dioxide (CO2) gas to an adjustable primary CO2 regulator

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

regulator assembly in turn delivers CO2 gas to an

DEFROST SYSTEMS

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

MANUAL DEFROST SYSTEM

Two-Flavor FCB Dispenser.

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

Four-Flavor FCB Dispenser.

The Manual hot-gas defrost system may be activated at any time by pressing the “MANUAL DEFROST” switch on the control panel located behind the front access door on the Unit. The refrigeration compressor will operate for a short time, then both No. 1 and No.11 or No. 2 and No. 22 (depending upon which “MANUAL DEFROST” switch was pressed) freeze cylinder only will go into defrost and defrost for one minute. At the end of the manual defrost cycle, Unit will return to normal operation. Manual defrost may be cancelled at any time by pressing the “CANCEL DEFROST” switch.

560001279SER 7

AUTOMATIC DEFROST SYSTEM

NOTE: The following paragraph describes the Automatic Hot-Gas Defrost system operation for the Two-Flavor FCB Dispenser No. 1 and No. 2 freeze cylinders. This paragraph also describes the Automatic Hot-Gas Defrost system operation for the Four-Flavor FCB Dispenser No. 11 and No. 22 freeze cylinders, which is identical to the No. 1 and No. 2 freeze cylinders.

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

‘‘SLEEP’’ (SLEEP TIME)

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

‘‘WAKE UP’’ (WAKE UP TIME)

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

560001279SER

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

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

LINE LEGEND CO

PLAIN WATER CARB WATER SYRUP PRODUCT

CARBONATOR

TANK

PRODUCT BLENDER

TANK(2)

PRODUCT SHUTOFF

VALVE(2)

FREEZE

CYLINDER(2)

FREEZE CYLINDER

OVERFLOW TUBE

CARBONATED WATER

VOLUME SAMPLE VALVE

PRODUCT SAMPLE

VALVE(2)

CARBONATED WATER

SOLENOID VALVE(2)

CARBONATED WATER

FLOW REGULATOR(2)

SYRUP SOLENOID

VALVE(2)

PRIMARY CO

REGULATOR ASS’Y

SYRUP SOLD–OUT

FLOAT SWITCH(2)

**SYRUP SOLD–OUT

SWITCH

CYLINDER

CHECK

VALV E

SOFT DRINK

TANK(2)

CHECK

VALVE(3)

NOTE: THE 3 H.P. FOUR–FLAVOR MODEL IS BASICALLY TWO 3 H.P. TWO–FLAVOR MODELS JOINED TOGETHER.

SYRUP FLOW

REGULATOR(2)

LIQUID CHECK

VALVE(2)

CARBONATOR

WATER PUMP

SECONDARY CO2 REGULATORS

TO PRODUCT BLENDER

TANKS (60–PSI GAGE) (2)

SECONDARY CO2 REGULATOR

TO CARBONATOR TANK

(100–PSI GAGE)

DOUBLE

LIQUID

CHECK

VALV E

PRESSURE

SWITCH

*WATER PRESSURE

REGULATOR

WATER

PRESSURE

SWITCH

PLAIN WATER

SOURCE

FIGURE 4. FLOW DIAGRAM. 3 H.P. DISPENSER (TWO–FLAVOR MODEL SHOWN)

560001279SER 9

*WATER PRESSURE REGULATOR IS FACTORY ADJUSTED TO 45-PSI AND SHOULD NOT BE READJUSTED.

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

LINE LEGEND CO

PLAIN WATER CARB WATER SYRUP PRODUCT

CARBONATOR

PRODUCT BLENDER

TANK(2)

PRODUCT SHUTOFF

VALVE(2)

CYLINDER(2)

CARBONATED WATER

VOLUME SAMPLE VALVE

CARBONATED WATER

SOLENOID VALVE(2)

CARBONATED WATER FLOW REGULATOR(2)

SYRUP SOLENOID

VALVE(2)

PRIMARY CO

REGULATOR ASS’Y

SYRUP SOLD-OUT

FLOAT SWITCH(2)

**SYRUP SOLD-OUT

SWITCH

TANK

FREEZE

PRODUCT SAMPLE

VALVE(2)

SYRUP FLOW

REGULATOR(2)

FREEZE CYLINDER

OVERFLOW TUBE

LIQUID CHECK

VALVE(2)

*WATER PRESSURE

REGULATOR

PLAIN WATER

SOURCE

SHUTOFF

VALV E

CYLINDER

WATER

PRESSURE

SWITCH

CARBONATOR

WATER PUMP

PRESSURE

SWITCH

CHECK

VALVE(3)

CHECK

VALV E

SOFT DRINK

TANK(2)

DOUBLE

LIQUID

CHECK

VALV E

SECONDARY CO2 REGULATORS

TO PRODUCT BLENDER

TANKS (60–PSI GAGE) (2)

SECONDARY CO2 REGULATOR

TO CARBONATOR TANK

(100-PSI GAGE)

FIGURE 5. FLOW DIAGRAM (2 AND 3 H.P. OVERCOUNTER OC2 DISPENSER)

560001279SER

INSTALLATION

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

UNPACKING AND INSPECTION

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

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

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

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

Table 3. Loose-Shipped Parts

Qty.

Item

No. Part No. Name

Qty.

2–fl Floor

Model

Qty.

OC2 Model

(Air Cooled Top

Condensing)

Qty.

4–FL

Model

1 178025100 Tapered Gasket, White 5 4 4 7

2 325216000 Cleaning Brush 1 1 1 1

3 311304000 Tapered Gasket, Black 1 1 1 1

4 620708530

620708529

5 325282000 Thread Cutting Screw, Hx

6 620051268

620051269 620052090 620052091 620051266 620051297

7 620046231

620517149

8 326002000 Kit, Drip Tray Drain Hose 1 1 X 1

9 2899 Wrench, Rear Seal Housing 1 1 X 1

10 3810 Tool, Drive/Coupler

11 3184 Leveling Leg X 4 X X

Cup Rest, 2 FL Cup Rest, 4 FL

Hd.;No. 8 by 1/2-in. long

Drip Tray Support, LH Drip Tray Support, RH Drip Tray Support, LH Drip Tray Support, RH Drip Tray Support, LH Drip Tray Support, RH

Drip Tray, 2 FL Drip Tray, 4 FL

Adjustment Gauge

X 2 2 X

X X

1 X X

1 X

1 1 X 1

1 X X X X

1 X

X X

1 X X

1 X

X 1

X X X X 1 1

X 1

12 325018000 Caster Kit, 4-inch diameter

Casters

13 3247 Spacer, White X 2 X X

560001279SER 11

1 X X 1

Table 3. Loose-Shipped Parts (Cont’d)

Item

No. Part No. Name

Qty.

2–fl Floor

Model

Qty.

OC2 Model

Qty.

OC2 Model

(Air Cooled Top

Condensing)

Qty.

4–FL

Model

14 3221

560003645

15 3108 Thread Cutting Screw, Phil

16 319941000 Thread Rolling Screw, Hex

17 313802000 Snap Bushing, 875 Electric

18 560001561 Bolt, 3/8–16 X X 4 X

Front Access Panel Front Access Panel

Pan Hd; No. 10 by 32 by 1-in. long

Washer Hd; No. 8-32 by 3/8-in. Long

(used in the top panel if installing a Merchandiser)

X X

X 2 X X

4 2 X 4

1 1 X 1

X X

IDENTIFICATION OF LOOSE-SHIPPED PARTS

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

2. CLEANING BRUSH (item 2) is used to clean faceplate relief valves passages.

3. TAPERED GASKET, BLACK (item 3) is used to seal connection when connecting plain water source line to the Unit plain water inlet.

4. WRENCH, REAR SEAL HOUSING (item 9) used to remove the drive shaft/seal assembly from inside the freeze cylinder.

5. TOOL, DRIVE/COUPLER ADJUSTMENT GAUGE (item 10) is used for servicing the beater motor drive shaft/seal assembly (see Figure 13).

6. CASTER KIT (item 12) to be installed on the Floor Model Unit as instructed in Instructions provided in the Kit.

7. LEVELING LEGS (item 11) to be installed on the Overcounter (OC2) Unit base.

8. DRIP TRAY SUPPORTS (item 6) to be installed on front of the Unit and secured with applicable THREAD ROLLING SCREWS (item 16).

9. DRIP TRAY (item 7) to be installed on the drip tray supports, then CUP REST (item 4) is to be installed in the drip tray.

10. KIT, DRIP TRAY DRAIN HOSE (item 8) is to be installed on the Unit as instructed. Installation instructions are included in the Kit.

11. WRENCH REAR SEAL HOUSING (item 9) is used to remove the drive shaft/seal assembly from inside the freeze cylinder.

12. FRONT ACCESS PANEL (item 14) to be installed on the Overcounter (OC2) Unit and secured with THREAD CUTTING SCREWS (item 5), SPACERS, WHITE (item 13), and THREAD CUTTING SCREWS (item 15).

560001279SER

SELECTING LOCATION

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

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

Locate Unit so the following requirements are satisfied.

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

NOTE: “AIR-COOLED FCB DISPENSER

The “air-cooled” FCB Dispenser refrigeration system is equipped with a condenser coil that is cooled by condenser coil fan(s). Circulating air, required to cool the refrigeration system’s condenser coil, is drawn in through the grille on front and exhausted out through the sides and back of Unit. Restricting air circulation through the Unit will decrease its cooling efficiency.

2. A properly grounded 208–230 VAC, 60Hz single-phase electrical circuit with a 30 Amp minimum-rated disconnect switch (not provided) fused at 30 Amps (slow-blow) or circuit connected through an equivalent HACR circuit breaker must be available to the Unit (2 FL). 4 FL units require a 50 Amp minimum–rated disconnect switch (not provided) fused at 50 Amps (slow blow) or circuit connected through an equivalent HACR circuit breaker must be available to the Unit. ALL WIRING MUST CONFORM TO NATIONAL AND

LOCAL CODES. MAKE SURE UNIT IS PROPERLY GROUNDED.

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

3. When installing the Unit, do not allow obstruction to block grille on front which will block off air intake to inside of THE Unit. If installation dictates only one side or the back being unobstructed, allow 18-inches clearance between the Unit and the obstruction. If both sides or one side and the back are unobstructed, allow 12-inches clearance. If both sides and the back are unobstructed, allow 6-inches clearance. A minimum of 12-inches must be provided above the Unit for service and maintenance.

INSTALLING UNIT

INSTALLING APPLICABLE CASTER KIT OR LEVELING LEGS

Floor Model 3 H.P. Unit

Install CASTER KIT, 4-INCH (item 12) on four corners of the Unit base.

Overcounter (OC2) Model 2 and 3 H.P. Units

Very carefully, tilt Unit up and install four LEVELING LEGS (item 11) in four corners of the Unit base.

560001279SER 13

INSTALLING DRIP TRAY SUPPORTS

Overcounter (OC2) Model 2 and 3 H.P. Units

1. Install DRIP TRAY SUPPORT, LEFT and DRIP TRAY SUPPORT, RIGHT (item 6) on front of the Unit and secure with THREAD CUTTING SCREWS (item 5).

2. Place DRIP TRAY (item 7) on drip tray supports.

3. Place CUP REST (item 4) in drip tray.

Floor Model 3 H.P. Unit

1. Install DRIP TRAY SUPPORTS (item 6) on front of the Unit and secure with THREAD ROLLING SCREWS (item 16).

2. Place DRIP TRAY (item 7) on drip tray supports.

3. Place CUP REST (item 4) in drip tray

INSTALLING DRIP TRAY DRAIN KIT

1. Install DRIP TRAY DRAIN HOSE KIT (item 8) on Unit as instructed in Installation Instructions provided with the Kit.

NOTE: Drip tray drain hose may be routed to a waste container, but is not recommended due to sanitation and cleaning problems. Connection of drain hose to a permanent drain is most highly recommended.

2. Route drip tray drain hose to and connect to permanent drain.

3. Place CUP REST (item 4) in drip tray.

PLACING UNIT IN OPERATING LOCATION

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

2. Make sure the Unit is sitting in a level position by using a carpenters level and adjusting the adjustable casters (Floor Model Unit) or the adjustable leveling legs (Overcounter (OC2) Unit.

560001279SER

INSTALLING PRIMARY CO2 REGULATOR ASSEMBLY ON CO2 CYLINDER (see applicable Figure 4 or 5)

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

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

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

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

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

CONNECTING SOFT DRINK TANKS CO2 LINES TO PRIMARY CO2 REGULATOR ASSEMBLY (see applicable Figure 4 or 5)

1. Connect soft drink tanks CO2 lines to primary CO2 regulator manifold assembly as shown in applicable Figure 4 or 5.

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

TANKS AT THIS TIME.

PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT DRINK TANKS (see applicable Figure 4 or 5)

1. Route labeled Unit syrup inlet lines out through hole provided in the Unit base to the soft drink tanks location.

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

AT THIS TIME.

CONNECTING CITY PLAIN WATER SOURCE LINE (S) TO UNIT

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

560001279SER 15

Connecting City Plain Water Source Line to Unit Post-Mix System. (see applicable Figure 4 or 5)

NOTE: IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the city plain water source line (see applicable Figure 4 or 5) that provides plain water to the Dispenser post-mix system. A Cornelius Water Filter (P/N 313860000) and Quick Disconnect Set (P/N 313867000) are recommended.

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

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

NOTE: The carbonator plain water inlet adjustable water pressure regulator (see applicable Figure 4 or

5) is factory adjusted to 45-psi and should not be readjusted.

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

Connecting City Plain Water Source Line to Unit With Water-Cooled Refrigeration System. (See Figure 24)

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

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

2. Connect the refrigeration cooling coil plain water inlet line labeled “COOLING WATER IN” to the City plain water inlet line. Seal connection with TAPERED GASKET, BLACK (item 3).

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

CONNECTING CO

1. Connect and route a CO2 source line from the primary CO2 regulator up to the Unit.

2. Connect the CO2 source line to the Unit CO2 inlet line and seal connection with TAPERED GASKET, WHITE (item 1).

SOURCE LINE TO UNIT (see applicable Figure 4 or 5)

CONNECTING ELECTRICAL POWER SOURCE TO UNIT

IMPORTANT: The electrical power source voltage across L1 and L2 terminals on the contactor inside the lower electrical control box, with refrigeration compressor(s) operating, must be in the range of 208-230 VAC, 60Hz single-phase for proper operation. Use No. 10 AWG copper wire, or larger, depending upon line length, in suitable conduit or BX sheath. POWER CIRCUIT TO UNIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES.

560001279SER

Electrical Requirements

Refer to the nameplate to determine the power requirements before connecting electrical power to the unit. Voltage across contactor terminals L1 and L2, with the compressor running, must be within voltage limits described in Table .

Table 4

Unit Requirements

V–Series, 2 Flavor, Domestic 208–230V, 60Hz, 30 Amp V–Series, 2 Flavor, Export 218–242V, 50Hz, 30 Amp

(for AUS: 220–252V, 50Hz, 30 Amp)

V–Series, 4 Flavor 208–230V, 60Hz, 50 Amp

If the line voltage does not meet these requirements see the possible corrective actions in Table 5.

Table 5

Voltage Corrective Action

Below 180 VAC Do Not Connect Unit 180–190 VAC Boost voltage by +32 V 191–207 VAC Boost voltage by +16 V 208–230 VAC Use line voltage 231–246 VAC Reduce voltage by –16 V 247–262 VAC Reduce voltage by –32 V Above 262 VAC Do Not Connect Unit

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

Floor Model 3 H.P. Unit

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

terminals.

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

the Unit.

LOCAL CODES. MAKE SURE UNIT IS PROPERLY GROUNDED.

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

560001279SER 17

Overcounter (OC2) 2 and 3 H.P. Units.

1. Remove cover from electrical box located inside the Unit.

WARNING: This Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator. A ground lug is located inside the electrical box to connect the power circuit ground wire which will electrically ground the Unit.

LOCAL CODES. MAKE SURE UNIT IS PROPERLY GROUNDED.

3. Install cover on the electrical box.

560001279SER

PREPARATION FOR OPERATION

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

Four-flavor Unit- The No. 1 freeze cylinder is the left-hand cylinder facing the front of the Unit. The other three freeze cylinders, to the right of the No.1 freeze cylinder, are labeled 2, 11, and 22.

TWO–FLAVOR UNITS

NOTE: Two indicator lights are located on front of the Unit front access door (see Figure 8). The indicator light on the left side monitors conditions of the No. 1 system and the indicator light on the right side monitors conditions on the No. 2 system. A flashing red indicator light indicates a freeze cylinder is in the defrost mode. A flashing green indicator light indicates “OUT OF SYRUP”, “OUT OF WATER”, “OUT OF CO2”, or an “ERROR” condition has occured.

FOUR–FLAVOR UNITS

NOTE: Four indicator lights are located on front of the Unit front access door (see Figure 8). The indicator light on the left side monitors conditions of the No. 1 freeze cylinder and the indicator light on the right side monitors conditions on the No. 2 freeze cylinder. A flashing red indicator light indicates a freeze cylinder is in the defrost mode. A flashing green indicator light indicates “OUT OF SYRUP”, “OUT OF WATER”, “OUT OF CO2”, or an “ERROR” condition has occured. The other two indicator lights monitor conditions of the No. 11 and No. 22 freeze cylinders.

TURNING ON ELECTRICAL POWER TO UNIT

Turn on electrical power to the FCB Dispenser (Unit) at the disconnect switch or the HACR circuit breaker. Operational status of the Unit is now being displayed as fault messages on the control panel switch/ message display located behind the Unit front access door (see Figure 6).The following fault messages will be continuously displayed at 2-second intervals until all necessary operation requirements are satisfied.

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

Green flashing indicator lights on front of the Unit front access door will be flashing indicating an out of syrup, out of water, and an out of CO

condition exist.

TURNING ON CO2 SUPPLY TO UNIT

Unit Connected To a CO2 Cylinder.

Open the CO2 cylinder shutoff valve slightly to allow the lines to slowly fill with gas, then open the valve fully to back seat the valve. Back-seating the valve prevents leakage around the valve shaft. The “CO message on the Unit control panel message display should have gone out.

OUT” fault

Unit Connected To a Bulk CO2 Supply.

Open the bulk CO2 supply shutoff valve slightly to allow the lines to slowly fill with gas, then open the valve fully. The “CO

560001279SER 19

OUT” fault message on the Unit control panel message display should have gone out.

ADJUSTING CO2 REGULATORS (see applicable Figure 4 or 5)

Adjusting CO2 Source Primary CO2 Regulator.

Unit Connected to a Bag-In-Box Syrup Source System.

Adjust CO2 source (CO

cylinder or bulk CO

) primary CO

regulator to read not less then 80 psi.

Unit Connected to a Syrup Tanks Syrup Source System.

Adjust CO2 source (CO

cylinder or bulk CO

) primary CO

regulator to read 80 to 100 psi.

Adjusting Unit Secondary CO2 Regulators.

Product Blender Tanks Secondary CO

Regulators.

Check and if necessary, adjust the Unit product blender tanks secondary CO2 regulators with 60-psi gages at 25 to 30-psi for the best textured dispensed product.

IMPORTANT: The Carbonator(s) secondary CO

regulator(s) must be adjusted 25-psi higher or more

above the product blender tanks secondary CO2 regulators pressure settings. The carbonated water and syrup pressures must be able to overcome and vent the product blender tanks head pressures while the tanks are filling with carbonated water and syrup. The carbonator(s) tank(s) secondary CO

regulator(s) not adjusted high enough will cause decreased flow of carbonated water into the blender tanks which will increase BRIX of the dispensed product.

Carbonator(s) Secondary CO2 Regulator(s).

Adjust the carbonator(s) secondary CO2 regulator(s) with 100-psi gages to read 50 to 80-psi. Pull up on carbonator(s) tank(s) relief valves to purge air from tank(s).

TURNING ON CITY PLAIN WATER SOURCE LINE TO UNIT

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

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

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

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

560001279SER

ACTIVATING SYRUP SOURCE SYSTEM

IMPORTANT: The product shutoff valves, located in the product lines leading from the product blender tanks to the freeze cylinders (see applicable Figure 4 or 5), must be closed at this time. Closing the valves prevents product from filling the freeze cylinders while checking BRIX of the product in the product blender tanks.

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

2. Press “BLEND ON/OFF” control panel switches to display “BLNDOFF 1” and “BLNDOFF 2” on the message display.

3. Activate the syrup source system (syrup tanks or bag-in-box system) to begin providing syrup to the FCB Dispenser. CO2 source (CO2 cylinder or bulk CO2) primary CO2 regulator must be set at no less then

80-psi for the bag-in-box syrup pumps in a bag-in-box syrup system or 80 to 100-psi for the syrup tanks in a syrup tanks syrup system. The “OFF 1”, “OFF 2”, “SYRUP 1”, and the “SYRUP 2” fault messages will

continue to be displayed.

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

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

NOTE: The adjustable carbonated water flow regulators (see applicable Figure 4 or 5 and16) located in their respective systems, control carbonated water flow rate to the product blender tanks. The water flow regulators are factory adjusted at 1.3  0.05 oz/sec and should not normally require adjustment. If adjustment is necessary, refer to SERVICE AND MAINTENANCE section of this manual for adjustment procedure.

1. Press ‘‘SYRUP PRIME’’ switch to fill No. 1 syrup system sold-out float. ‘‘SYRUP 1’’ fault message will go out. The ‘‘OFF 1’’, ‘‘OFF 2’’, “BLNDOFF 1”, “BLNDOFF 2” and the “SYRUP 2” fault messages will continue to be displayed.

2. Press ‘‘BLEND ON/OFF’’ switch to fill No. 1 system product blender tank with product. ‘‘BLND 1’’ fault message will go out when ‘‘BLEND ON/OFF’’ switch is pressed. When product blender tank is full, press the ‘‘BLEND ON/OFF’’ switch again to prevent more product from entering the blender tank. ‘‘OFF 1’’, ‘‘OFF 2’’, and ‘‘SYRUP 2’’ fault messages will continue to be displayed.

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

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

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

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

5. Place container under No. 1 product sample valve. Open the valve to purge product out of the product blender tank, line, and valve, then close the valve.

6. Press ‘‘BLEND ON/OFF’’ switch to run new batch of product into the product blender tank. When the product blender tank is full, press the ‘‘BLEND ON/OFF’’ switch again to prevent more product from entering the tank. ‘‘OFF 1’’, ‘‘OFF 2’’, and ‘‘SYRUP 2’’ fault messages will continue to be displayed.

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

560001279SER 21

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

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

NOTE: Syrup systems should be sanitized at this time before putting Dispenser into operation. Refer to SERVICE AND MAINTENANCE section of this manual for sanitizing instructions.

FILLING FREEZE CYLINDERS WITH PRODUCT

1. Open product shutoff valves, located in product lines leading from product blender tanks to the freeze cylinders (see applicable Figure 4 or 5).

2. Press both “BLEND ON/OFF” switches to begin filling the freeze cylinders. Open the freeze cylinders faceplates relief valves to bleed air from the cylinders while filling them with product, then close the relief valves. Do not relieve pressure from the freeze cylinders too fast or product in the cylinders will foam

excessively causing a loss of product carbonation.

CHECKING UNIT FOR SYRUP, CO2 AND PLAIN WATER LEAKS

1. Inspect the entire Unit and the entire system for syrup, CO2 and plain water leaks and repair if evident.

2. Install the Unit lower access, sides, top, and back panels.

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

IMPORTANT NOTICE

Water-Cooled Refrigeration System Dispenser.

Water flow rate through the refrigeration cooling coil varies due to pressure change on the high side of the refrigeration compressor which influences opening and closing of the variable water regulator (see Figure 24). The variable water regulator must be adjusted to maintain 240-psi refrigeration high-side pressure.

Adjust the variable water regulator (see Figure 24) to maintain 240-psi refrigeration high-side pressure as instructed in the SERVICE AND MAINTENANCE section.

ADJUSTMENTS AND PROGRAMMING PROCEDURES

The following is a brief description of each item that may be programmed into the Dispenser electronics. After reviewing the brief descriptions, proceed to PROGRAMMING/ADJUSTMENTS and perform the Dispenser electronics programming procedures. After completing the Dispenser electronics programming procedures, proceed to and adjust the beaters motors currents into the Dispenser electronics as instructed in ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE).

560001279SER

SETTING CLOCK (TIME OF DAY)

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

The time of day (hour AM or PM and minutes) and the day of the week may be programmed into the Unit electronics to appear on the message “DISPLAY” when desired. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for programming instructions.

PROGRAMMING DEFROST (AUTOMATIC) INTO UNIT ELECTRONICS

The automatic defrost system may be programmed into the Unit electronics to occur up to nine different times during a day with a minimum of two hours between defrost time settings. If there is a daily defrost time defrost programmed into the Unit, the every day defrost are ignored. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for programming instructions.

PROGRAMMING “SLEEP” (SLEEP TIME) INTO UNIT ELECTRONICS

“SLEEP” (SLEEP TIME) may be programmed into the Unit electronics to occur any time of the day after the automatic defrost cycle has occurred. The Unit will shut down (go into sleep time) and will not wake up (return to normal operation) until programmed “WAKE UP” (WAKE UP TIME) has occurred. Refer to

PROGRAMMING /ADJUSTMENTS section of this manual for programming instructions.

PROGRAMMING “WAKE UP” (WAKE UP TIME) INTO UNIT ELECTRONICS

“WAKE UP” (WAKE UP TIME) may be programmed into the Unit electronics to occur any time of the day to wake the Unit up (return to normal operation) after “SLEEP TIME” has occurred. Refer to

PROGRAMMING/ADJUSTMENTS section of this manual for programming instructions.

PROGRAMMING POINT OF SALE MESSAGE DISPLAY INTO UNIT ELECTRONICS

NOTE: Point of sale display messages may be turned off by turning the No. 1 DIP SWITCH in the “OPTION” menu to the “OFF” position and No. 2 DIP SWITCH to “ON” position.

Three point of sale messages are available and the desired one may be programmed into the Unit electronics to appear on the message “DISPLAY”. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for programming instructions.

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

Adjusting the “VIS SET (PRODUCT VISCOSITY) determines what product consistency of the dispensed product will be present in each freeze cylinder. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for instructions to adjust product consistency of the dispensed product in each freeze cylinder .

560001279SER 23

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

“VIS READ” (ACTUAL VISCOSITY READOUT) may be displayed on the message “DISPLAY” to actually read the viscosity (product consistency) of product in the freeze cylinders while the Unit is in operation. Refer to PROGRAMING/ADJUSTMENTS section of this manual for instruction to display “VIS READ” (ACTUAL VISCOSITY READOUT) on the message display.

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES

The refrigeration coils inlet and common outlet temperature readings in Fahrenheit may be displayed on the message “DISPLAY”. Celsius readings instead of Fahrenheit readings may be displayed on the message “DISPLAY” by turning the No. 7 DIP SWITCH in the “OPTION” menu to “ON” position. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for instructions to display the refrigeration coils inlet and common outlet temperature readings on the message “DISPLAY”.

“VOLTAGE” (DISPLAYED VOLTAGE READOUT)

Displayed voltage readout may be displayed on the message “DISPLAY”. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for instructions to display “VOLTAGE” (DISPLAYED VOLTAGE READOUT) on the message “DISPLAY”.

PROGRAMMING COMPONENTS “DIAGNOSE” (DIAGNOSTIC MODE) INTO UNIT

“DIAGNOSE” (DIAGNOSTIC MODE) may be programmed into the Unit to check certain components for operation. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for instructions to program “DIAGNOSE” (DIAGNOSTIC MODE) into the Unit.

DISPLAYING “TOTALS” (DISPLAYED CYCLES AND HOURS TOTALS) ONTO MESSAGE DISPLAY

“TOTALS” (DISPLAYED CYCLES AND HOURS TOTALS) may be displayed on the message “DISPLAY”. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for instructions to display cycles and hours totals on the Unit message “DISPLAY”.

PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT ELECTRONICS

During new Unit installation or when replacing one of the beater motors, note the Manufacturer’s name (see Table 7) on the motor(s). The beater motor(s) Manufacturer’s name(s) must be programmed into the Unit electronics which will match the motor(s) to the Unit electronics. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for instructions to program the beater motor(s) into the Unit electronics.

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS

The Unit electronics must be programmed for the proper refrigeration pulse rate according to the type of refrigerant gas that has been installed in the refrigeration system. Note Unit name plate for the type of refrigerant gas that has been installed in the Unit. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for instructions to program the proper refrigerant type into the Unit electronics.

560001279SER

“OPTIONS” (DIP SWITCHES 1 THROUGH 10)

(see PROGRAMMING/ADJUSTMENTS section of this manual)

The “OPTIONS” (DIP SWITCHES 1 THROUGH 10) are used to:

1. Program one of three POINT OF SALE display messages to appear on the message display.

2. Program one of three POINT OF SALE display messages to appear on the message display.

3. Program in applicable pulse expansion valves or mechanical expansion valves the Unit is equipped with.

4. To adjust beater motor current (either side).

5. To enable or disable beater motors current from automatically self-calibrating at completion of each defrost cycle.

6. To enable or disable control panel security. When DIP switch is in “ON” position, the control panel switches

will disable (lock out) after 90-seconds. Pressing any switch on the control panel for 5-seconds will enable (activate) the control panel switches.

7. To choose Celsius or Fahrenheit temperature readings to be displayed on the message “DISPLAY”.

8. To enable daylight savings time to be programmed into the Unit.

9. Program in applicable hot-gas or electric defrost the Unit is equipped with.

10. DIP10 (DIP switch 10) is for service use only.

PROGRAMMING CALENDAR INTO UNIT ELECTRONICS

The month, day, and year may be programmed into the Unit electronics to appear on the message “DISPLAY”. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for instructions.

PROGRAMMING DST+1HR INTO UNIT ELECTRONICS

“DST+1HR” daylight (summer) savings time may if desired, be programmed into the Unit electronics. Refer to

PROGRAMMING/ADJUSTMENTS section of this manual for instructions.

PROGRAMMING DST–1HR INTO UNIT ELECTRONICS

“DST–1HR” standard (winter) time may if desired, be programmed into the Unit electronics. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for instructions.

560001279SER 25

DISPLAYED ERROR CONDITIONS

Displayed error conditions, associated errors, and items affected by the errors may be found in Table 6.

ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE)

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

1. Press and hold the “MENU/SELECT” (M/S) switch on the control panel (see Figure 6) until the word “CLOCK” appears on the message “DISPLAY”.

2. Use “CANCEL DEFROST” (FORWARD) switch to toggle to “OPTIONS” which will appear on the message ”DISPLAY”.

ITEMS AFFECTED BY ERROR

MESSAGE

DISPLAYED ERROR

MOTOR 1

ERROR

Low Current, < 109,

Sensed on Motor One

BEATER

MOTOR 1

OFF OFF

BEATER

MOTOR 2

REFRIG 1 REFRIG 2

MOTOR 2

ERROR

MOTOR 1

ERROR

MOTOR 2

ERROR

REFRIG

ERROR

SYRUP OUT

SIDE 1

SYRUP OUT

SIDE 2

CO2 OUT CO2 Out *** OFF *** OFF ***OFF ***OFF

H2O H2O Out *OFF *OFF

SENSOR 1

ERROR

SENSOR 2

ERROR

SENSOR 3

ERROR

**Maximum Run Time on Compressor OFF OFF OFF OFF

Low Current, < 109,

Sensed on Motor Two

High Current > 255,

Sensed on Motor One

High Current > 255,

Sensed on Motor Two

Syrup Out Side One OFF

Syrup Out Side Two OFF

Temp Sensor Inlet One OFF OFF

Temp Sensor Inlet Two OFF OFF

Temp Sensor Outlet OFF OFF

OFF OFF

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

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

*** Unit will complete a defrost cycle before beater motors will shut down.

TABLE 6. DISPLAYED ERROR CONDITIONS

560001279SER

3. Use “MENU/SELECT” (M/S) switch to toggle to “DIP4 OFF” (beater motor current readout switch) which will appear on the message “DISPLAY”.

4. Use “CANCEL DEFROST” (FORWARD) switch to change “DIP4 OFF” to “DIP4 ON” on which will appear on the message “DISPLAY” (“DIP4 ON” will be flashing on the display). Press “ERROR RESET”. Both freeze cylinders beater motors will start and operate and beaters motors current ratings will be displayed on the message “DISPLAY”.

NOTE: Motors must run at least 15 minutes before adjusting the current.

5. The “DISPLAY” should be adjusted to read A150 B150 ± 2 by adjusting the MOTOR CURRENT ADJUSTMENTS located on No. 1 and No. 2 relay circuit boards located inside the upper control box (see Figure 7 ). These figures will fluctuate with variations in line voltage and motor loads.

BLEND

Side 1

ON/OFF

MOTOR

SYRUP PRIME

OFF

ERROR

RESET

Display

Side 2

<(Backward)

Manual Defrost

(Forward)>

Cancel Defrost

Menu/Select

FIGURE 6. CONTROL PANEL SWITCH/MESSAGE DISPLAY

6. After completion of adjusting the beater motor current to A150 B150 ± 2, make sure the “DIP5” (motor current self-calibration switch) switch is in the “OFF” position. No. 5 switch in the “OFF” position allows the “MOTOR CURRENT SELF-CALIBRATION” electronics to automatically self calibrate the beater motors currents at completion of each defrost cycle.

CAUTION: IF the “DIP 4” (beater motor current readout switch) switch is placed in the ‘‘ON’’ position and the beater motor current readings were A155 B145 and the switch was then

placed back in the ‘‘OFF’’ position without readjusting to A150 B150 ± 2, the beater motor current has just been reset at A155 B145. Operating the FCB Dispenser at these current readings may have serious effects on its operation.

ANYTIME THE “DIP4” (BEATER MOTOR CURRENT READOUT SWITCH) SWITCH ON THE MESSAGE DISPLAY IS PLACED IN THE “ON” POSITION, THE BEATER MOTOR CURRENT READINGS MUST BE RE-ADJUSTED TO A150 B150± 2 AS INSTRUCTED, THEN THE SWITCH MUST BE PLACED BACK IN THE “OFF” POSITION.

560001279SER 27

MOTOR CURRENT ADJUSTMENT

DISPLAY CABLE

MASTER CIRCUIT

BOARD

TOUCH SWITCH

ASS’Y CABLE

DIAMOND SYMBOL

RELAY CIRCUIT

BOARD NO. 2

RELAY CIRCUIT

BOARD NO. 1

PIN CONNECTOR

SOCKET CONNECTOR

PIN CONNECTOR

PERSONALITY

MODULE

FIGURE 7. MASTER AND RELAY CIRCUIT BOARD

DISPLAYED MODEL HZ MOTOR DESCRIPTION

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

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

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

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

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

BODINE 60 Bodine 60 Special wide-range motor.

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

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

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

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

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

TABLE 7. MOTOR SELECT

560001279SER

PROGRAMMING/ADJUSTMENTS

QUICK REFERENCE

OPTIONS: (DIP SWITCHES 1 THROUGH 10)

GUIDE FCB V4 PROGRAMMING

BLEND

ON/OFF

Side 1

Side 2

SYRUP PRIME

MOTOR

CONTROL PANEL SWITCH IDENTIFICATION

ERROR

RESET

OFF

<(Backward)

Manual Defrost

Display

(Forward)>

Menu/Select

Cancel Defrost

DIP1

(POS MESSAGE)

DIP2

(POS MESSAGE)

DIP3

(EXPANSION VALVES)

DIP4 (BEATER MOTOR CURRENT CALIBRATION)

DIP5 (DISABLE AUTO CALIBRATION)

MENU SELECTIONS AND DESCRIPTIONS

Enter the Programming Mode, by pressing and holding the switch “Menu/Select” until “Clock” appears on “MESSAGE DISPLAY”.

To advance through the “MENU SELECTIONS” you must repeatedly press and release the “Forward” (Cancel Defrost) switch. The following is a list of menu selections and their brief descriptions.

MENU SELECTIONS

BRIEF DESCRIPTIONS

DIP6

(CONTROL PANEL SECURITY)

DIP7

(CELSIUS MODE)

DIP8

(DAYLIGHT

CLOCK (see NOTE 1)

DEFROST (AUTOMATIC)

SLEEP (SLEEP TIME)

WAKE UP (WAKE UP TIME)

VIS SET

VIS READ

SENSORS

VOLTAGE

DIAGNOSE

Checks Unit components for proper operation.

TOTALS MOTORS

REF TYPE

Programs beater motors into Unit electronics.

Programs refrigerant type into Unit electronics.

Time of day and the day of the week.

Time of day, defrost cycle is to occur.

Time of day, the Unit is to go to sleep.

Time of day, Unit is to wake up.

Adjust product viscosity setting.

Displays actual viscosity readout.

Displays sensors temperatures readout.

Displays voltage readout.

Displays cycles and hours totals.

SAVINGS TIME)

DIP9

(HOT-GAS DEFROST)

DIP10

CALENDAR

DST+1HR (see DIP8)

DST–1HR (see DIP8)

NOTE 1: The “CLOCK” (time of day) must be programmed into the Unit electronics before the Unit “DEFROST” (AUTOMATIC), SLEEP (SLEEP TIME), and “WAKE UP” (WAKE UP TIME) WILL FUNCTION.

NOTE 2: When DIP6 switch is in “ON” position, the control panel switches will disable (lock out) after 90-seconds. Pressing any switch on the control panel for 5-seconds will enable (activate) the control panel switches. When in programming menu, control panel security will not re-establish until after exiting programming menu. REVISED: 11/21/97

Used to program POINT OF SALE display messages into Unit electronics.

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

Used to adjust beater motor current (either side).

Switch in “ON” position prevents beater motors current from automatically self-calibrating at completion of each defrost cycle.

Switch in “ON” enables and switch in “OFF” disables control panel security. (see NOTE 2)

Switch “ON” for celsius or “OFF” for fahrenheit readings.

Switch No. 8 must be in “ON” position to enable daylight savings (summer) or standard (winter) time to be programmed into the Unit electronics.

Switch “ON” hot-gas defrost or “OFF” electric defrost.

Service use only.

Used to program month, day, and year into the Unit electronics.

Programming daylight savings time (summer) into Unit electronics.

Programming standard time (winter) into Unit electronics.

560001279SER 29

ÍÍÍ

M/S

ÍÍÍ

Operating mode

Press 5 seconds

CLOCK

M/S

CTU1015P

FORWARD>

CTU1015P

FORWARD>

M/S

CTU1015P

FORWARD>

M/S

CTU1015P

FORWARD>

M/S

<BACKWARD

FORWARD>

SELECT HOUR AM OR PM

SELECT MINUTES

SELECT DAY OF WEEK

LOCK SETTING

TO LOCK IN, ON THE HOUR MUST BE PRESSED THREE TIMES

M/S

One Defrost Per Setting

DEFROST

M/S

FORWARD>

M/S

1MO 315A

FORWARD>

1MO 315A

FORWARD>

1MO 415A

M/S

1MO 415A

FORWARD>

1MO 430A

M/S

1MO 430A

Operating mode

Defrost Same Time Every Day

M/S

SELECT DAY OF WEEK

LOCK

SELECT HOUR AM OR PM

SELECT MINUTES

LOCK

M/S

<BACKWARD

FORWARD>

NOTE: The “clock” (TIME OF DAY) must be prgrammed into the Unit before “DEFROST” (AUTOMATIC) “SLEEP” (SLEEP TIME) and “WAKE UP” (WAKE UP TIME) will fuction.

1 1015P

FORWARD>

USE SAME SEQUENCE AS ABOVE TO PROGRAM DEFROST 2 THRU 9

1 1015P

FORWARD>

M/S

SELECT HOUR AM PM

1 1015P

FORWARD>

M/S

1 1015P

Operating mode

SELECT MINUTES

M/S

2 715A

FORWARD>

USE THE SAME SEQUENCE AS ABOVE TO PROGRAM DEFROST 2 THRU 9

560001279SER

One Sleep Per Setting

ÍÍÍÍ

<BACKWARD

FORWARD>

SLEEP

M/S

FORWARD>

M/S

SMO

FORWARD>

SMO

FORWARD>

SMO 1200A

FORWARD>

Sleep Same Time Every Day

M/S

SELECT DAY OF WEEK

LOCK

SELECT HOUR AM OR PM

One Wake Up Per Setting

<BACKWARD

FORWARD>

WAKE UP

M/S

FORWARD>

M/S

SMO

FORWARD>

SMO

FORWARD>

SMO 1200A

FORWARD>

Wake Up Same Time Every Day

M/S

SELECT DAY OF WEEK

LOCK

SELECT HOUR AM OR PM

Operating mode

SMO 100A

M/S

SMO 100A

FORWARD>

SMO 115A

M/S

S 730A

FORWARD>

S 730A

FORWARD>

S 830A

M/S

S 830A

FORWARD>

S 845A

M/S

SELECT MINUTES

LOCK

SELECT HOUR AM OR PM

LOCK

SELECT MINUTES

Operating mode

SMO 100A

M/S

SMO 100A

FORWARD>

SMO 115A

M/S

S 730A

FORWARD>

S 730A

FORWARD>

S 830A

M/S

S 830A

FORWARD>

S 845A

M/S

SELECT MINUTES

LOCK

SELECT HOUR AM OR PM

LOCK

SELECT MINUTES

560001279SER 31

<BACKWARD

FORWARD>

LOCKS SETTING

Operating mode

VIS SET

M/S

FORWARD>

M/S

FORWARD>

M/S

Note: The direction of arrows (<< >>) on message display indicates which set of

numbers belongs to which freeze cylinder. A No. 4 setting indicates the thinnest product consistency, and a No. 12 setting indicates the thickest.

LEFT-SIDE VISCOSITY BLINKING

SELECT VISCOSITY NO.

RIGHT-SIDE VISCOSITY BLINKING

SELECT VISCOSITY NO.

<BACKWARD

FORWARD>

Operating mode

VOLTAGE

M/S

230

M/S

VOLTAGE READOUT

<BACKWARD

FORWARD>

Operating mode

<BACKWARD

FORWARD>

Operating mode

VIS READ

M/S

SENSORS

M/S

35 78 123

M/S

ACTUAL VISCOITY READĆ OUT OF PRODUCT IN EACH FREEZE CYLINDER

TEMPERATURE READOUT (3)

LOCK IN

LEFT READING

-REFREGERATION COILS INLET NO. 1

MIDDLE READING

-REFREGERATION COILS INLET NO. 2

RIGHT READING

-COMMON OUTLET

560001279SER

<BACKWARD

FORWARD>

DIAGNOSE

M/S

Operating mode

MOTOR 1

M/S

FORWARD>

MOTOR 2

M/S

FORWARD>

DEFROST 1

M/S

FORWARD>

DEFROST 2

M/S

FORWARD>

SYRUP 1

M/S

FORWARD>

SYRUP 2

M/S

FORWARD>

WATER 1

M/S

FORWARD>

WATER 2

M/S

FORWARD>

RF SOL 1

M/S

FORWARD>

RF SOL 2

M/S

FORWARD>

COMPRESS

M/S

FORWARD>

H2O PUMP

M/S

NO. 1 BEATER MOTOR WILL OPERATE WHILE SWITCH IS PUSHED

NO. 2 BEATER MOTOR WILL OPERATE WHILE SWITCH IS PUSHED

NO. 1 DEFROST SOLENOID WILL CLICK WHEN M/S SWITCH IS PUSHED

NO. 2 DEFROST SOLENOID WILL CLICK WHEN M/S SWITCH IS PUSHED

NO. 1 SYRUP SOLENOID WILL CLICK WHEN M/S SWITCH IS PUSHED

NO. 2 SYRUP SOLENOID WILL CLICK WHEN M/S SWITCH IS PUSHED

NO. 1 CARBONATED WATER SOLENOID WILL CLICK WHEN M/S SWITCH IS PUSHED

NO. 2 CARBONATED WATER SOLENOID WILL CLICK WHEN M/S SWITCH IS PUSHED

NO. 1 REFRIGERATION SOLENOID WILL CLICK WHEN M/S SWITCH IS PUSHED

NO. 2 REFRIGERATION SOLENOID WILL CLICK WHEN M/S SWITCH IS PUSHED

COMPRESSOR WILL OPERATE WHILE M/S SWITCH IS PUSHED

WATER PUMP RELAY ON MASTER CIRCUT BOARD WILL CLICK WHEN M/S SWITCH IS PUSHED

560001279SER 33

<BACKWARD

FORWARD>

PRESS AND HOLD M/S, FOR ALL

TOTALS

M/S

COMP HRS

M/S

FORWARD>

COMP CYC

M/S

FORWARD>

DFSTYC 1

M/S

FORWARD>

DFSTYC 2

M/S

FORWARD>

BLDRCYC 1

M/S

FORWARD>

BLDRCYC 2

M/S

FORWARD>

SOLDOUT 1

M/S

FORWARD>

SOLDOUT 2

M/S

FORWARD>

BMTRHRS 1

M/S

FORWARD>

BMTRHRS 2

M/S

FORWARD>

POW ON

M/S

FORWARD>

AUTO ON 1

M/S

COMPRESSOR RUN HOURS

COMPERSSOR CYCLES X 100

DEFROST SIDE 1 CYCLES

DEFROST SIDE 2 CYCLES

BLENDER SIDE 1 CYCLES X 100

BLENDER SIDE 2 CYCLES X 100

SOLDOUT SYRUP SIDE 1

SOLDOUT SYRUP SIDE 2

BEATER MOTOR 1 HOURS

BEATER MOTOR 2 HOURS

POWER ON HOURS

AUTO SIDE 1 HOURS

FORWARD>

AUTO ON 2

M/S

FORWARD>

ERR HRS 1

M/S

FORWARD>

ERR HRS 2

M/S

FORWARD>

SLEEP HRS

M/S

FORWARD>

SYR MIN 1

M/S

FORWARD>

SYR MIN 2

M/S

NOTE: DISPLAYING "SYR MIN 1" OR "SYR MIN 2" ON MESSAGE DISPLAY WILL INDICATE TIME IN MINUTES SYRUP ACTUALLY HAS BEEN DISPENSED. REFER TO TABLE AND FORMULA BELOW TO CALCULATE HOW MUCH SYRUP HAS BEEN DISPENSED.

AUTO SIDE 2 HOURS

ERROR SIDE 1 HOURS

ERROR SIDE 2 HOURS

SLEEP MODE HOURS

(SEE NOTE)

SYRUP MINUTES SIDE 1

(SEE NOTE)

SYRUP MINUTES SIDE 2

Operating mode

GALLONS= GALLON" OR LITER" X SYRUP MINUTES

Note: GALLON" or LITER" numbers are based upon 4.4 to 1 water to syrup "ratio".

Using the table below, choose the GALLON" or "LITER" number that corresponds to your BRIX setting. Multiply the GALLON" or LITER" number by the syrup minutes reading to obtain the amount (gallons) of syrup used.

BRIX "GALLON"

11.1 0.1358

11.5 0.1420

12.0 0.1481

12.5 0.1543

13.0 0.1605

13.5 0.1667

14.0 0.1728

14.5 0.1790

15.0 0.1852

15.5 0.1914

16.0 0.1975

"LITER"

.5140 .5375

.5606 .5840

.6074 .6310 .6540 .6775 .7010

.7244 .7475

560001279SER

<BACKWARD

ÍÍÍÍ

FORWARD>

Operating mode

<BACKWARD

FORWARD>

Operating mode

MOTORS

M/S

MOT_1MFG1

M/S

MOTOR NAME

FORWARD>

MOTOR NAME

FORWARD>

MOTOR NAME

M/S

MOT_MFG1

M/S

MOTOR NAME

FORWARD>

MOTOR NAME

FORWARD>

MOTOR NAME

M/S

REF TYPE

M/S

FORWARD>

R404 A 2 HP

M/S

REPRESENTS NO.1 FREEZE CYLINDER BEATER MOTOR.

NON-BLINKING MOTOR MANUFACTURERS NAME.

BLINKING MOTOR MANUFACTURERS NAME.

CHANGES TO ANOTHER MOTOR MANUFACTUREERS NAME AND WILL BE BLINKING. KEEP PRESSING AND RELEASEING "FORWARD" SWITCH UNTIL APPLICABLE MOTOR MANUFACTURERS NAME APPEARS. THIS INDICATES MOTOR MANUFACTURER'S NAME OF NO. 1 FREEZE CYLINDER (NEW UNIT OR REPLACEMENT MOTOR).

RETURN TO MOT_MFG1

NON-BLINKING MOTOR MANUFACTURERS NAME.

BLINKING MOTOR MANUFACTURERS NAME.

CHANGES TO ANOTHER MOTOR MANUFACTUREERS NAME FOR NO. 2 FREEZE CYLINDER (USE SAME PRECEDURE AS FOR NO.1).

MATCHES BEATER MOTOR TO UNIT ELECTRONICS

REFER TO SERIAL PLATE TO IDENTIFY TYPE OF REFRIGERANT INSTALLED. THE UNIT ELECTRONICS MUST BE PROGRAMMED FOR THE TYPE USED.

THE SUB MENU OF REFRIGERANT TYPES THAT MAY BE DISPLAYED ARE AS FOLLOWS:

1. R404 A 2HP

2. R404 A 3HP

3. R 502

4. R402 B50H

PRESS "FORWARD" AS MANY TIMES AS NECESSARY TO DISPLAY APPLICABLE REFRIGERANT TYPE.

PRESS "M/S" TO LOCK IN THE DISPLAY.

<BACKWARD

FORWARD>

Operating mode

OPTIONS

M/S

DIP 1 ON/OFF

M/S

DIP DIP

SWITCH SWITCH

NO.1 NO 2. *MESSAGE

OFF OFF See Note 1 OFF ON NOT USED-BLANK

ON OFF "HAVE A NICE DAY"

ON ON See Note 2

For special messages, contact your sales repesrntative.

DIP 2 ON/OFF

M/SM/S

DIP 3 ON/OFF

M/SM/S

DIP 4 ON/OFF

M/SM/S

DIP 5 ON/OFF

M/SM/S

DIP 6 ON/OFF

M/SM/S

DIP 7 ON/OFF

M/SM/S

DIP 8 ON/OFF

M/SM/S

DIP 9 ON/OFF

M/SM/S

DIP 10 ON/OFF

M/SM/S

(DIP SWITCHES 1 THRU 10)

LOCK IN

POS MESSAGE- IF DESIRED, PRESS "FORWARD" TO TURN DIP 1 TO "ON/OFF"

POS MESSAGE - SAME AS ABOVE

EXPANSION VALVES "ON" (MECHANICAL EXPANSION VALVES) "OFF" (PULSE EXPANSION VALVES)

MOTOR CALIBRATION

REFER TO MOTOR SELECT" TABLE IN MANUAL

DISABLE AUTO CALIBRATION

KEYPAD SECURITY - See Note Below "ON" (ENABLED) "OFF" (DISABLE)

CELSIUS MODE "ON" (CELSIUS ) "OFF" (DISABLE)

DAYLIGHT SAVINGS"ON" (ENABLED) "OFF" (DISABLE)

HOT GAS DEFROST "ON" (HOT GAS) "OFF" (ELECTRIC)

SERVICE USE ONLY

Note: When security is ON" the control panel switches will

lockĆout after 90 seconds. Pressing any switch for 5Ćseconds will activate the control panel switches. Security will reset after exiting programming.

Note 1: Message may either be ENJOY A FROZEN BEVERĆ AGE" or ICEE ITS THE COOLEST".

Note 2: Message may be either DISFRUTE UNA BEBIDA CONGELADA CARBONNATADA" or HAVE A BLAST"

560001279SER 35

<BACKWARD

FORWARD>

Operating mode

CALENDER

M/S

MO DAY YR

FORWARD>

M/S

MO DAY YR

FORWARD>

M/S

MO DAY YR

FORWARD>

M/S

LOCK IN

SELECT MONTH

SELECT DAY

SELECT YEAR

<BACKWARD

FORWARD>

LOCK IN

Operating mode

DST - HR

M/S

MO FRST/LST

M/S

MO FRST/LST

FORWARD>

M/S

MO FRST/LST

FORWARD>

M/S

PROGRAMMING STANDARD TIME (WINTER). DIP NO. 8 MUST BE ON"

NOT FLASHING

FLASHING MO (MONTH)

PUSH FORWARD TO SELECT MO (10)

FLASHING FIRST/LAST

PUSH FORWARD" TO SELECT "FIRST" 0R LAST"

<BACKWARD

FORWARD>

LOCK IN

Operating mode

DST + HR

M/S

MO FRST/LST

M/S

MO FRST/LST

FORWARD>

M/S

MO FRST/LST

FORWARD>

M/S

PROGRAMMING DAYLIGHT SAVINGS TIME (SUMMER). DIP NO. 8 MUST BE "ON"

NOT FLASHING

FLASHING MO (MONTH)

PUSH FORWARD TO SELECT MO (04)

FLASHING FRIST/LAST

PUSH "FORWARD" TO SELECT "FIRST" OR LAST"

560001279SER

OPERATOR’S INSTRUCTIONS

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

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

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.

supply,

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

V-Series Viscosity </= 8 Viscosity >8

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

Pinnacle Viscosity </= 4 Viscosity >4

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

48 oz 60 oz

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.

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.

560001279SER 37

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. 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.

3. 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”. With V-series there is a selectable Viscosity Setting range from 4–12, and with Pinnacle, the range is 1–9. 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 8-9 range for V-series and in the range of 4-5 for Pinnacle.

Diet FCB syrups freeze much more readily than sugar based syrups, so the Viscosity Setting should be selected at the minimum value available, 4 for V-series and 1 for Pinnacle equipment.

FRONT ACCESS DOOR INDICATOR LIGHTS (SEE FIGURE 8)

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

TWO–FLAVOR UNITS

560001279SER

FOUR–FLAVOR UNITS

, or an “ERROR” condition has occured. The other two

2”

indicator lights monitor conditions of the No. 11 and No. 22 freeze cylinders.

FIGURE 8. FRONT ACCESS DOOR INDICATOR LIGHTS

CONTROL PANEL (KEYPAD) SECURITY

The optional control panel (keypad) security (options DIP6 switch) may be programmed into the Unit to enable (activate) or disable (de-activate) the control panel security. When the control panel security is enabled, any control panel switch can be pushed and held for 5-seconds to override the control panel security. An audible beep will be heard when the switch is first pushed, then another beep will be heard when the security override has taken place and the switch may be released. Control panel security will be re-established 90-seconds after switch pushing activity has ceased. Control panel (keypad) security should be programmed into the Unit electronics by a qualified Service Person.

Note: When in programming menu, the control panel security will not re-establish until after exiting programming menu.

CONTROL PANEL SWITCHES (SEE FIGURE 9)

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

BLEND

ON/OFF

MOTOR

SYRUP PRIME

OFF

ERROR

RESET

Display

Side 1

Side 2

Manual Defrost

FIGURE 9. CONTROL PANEL SWITCH IDENTIFICATION

560001279SER 39

<(Backward)

(Forward)>

Cancel Defrost

Menu/Select

‘‘SYRUP PRIME’’ SWITCHES

The ‘‘SYRUP PRIME’’ switches, located on the control panel, are touch-type switches and require only pressing to activate. The ‘‘SYRUP PRIME’’ switches are used only when filling the syrup systems sold-out floats during syrup replenishing, syrup flavor changeover, or sanitizing the syrup systems.

‘‘BLEND ON/OFF’’ SWITCHES

The ‘‘BLEND ON/OFF” switches, located on the control panel, are touch-type switches and require only pressing to activate. These switches are used to fill the product blender tanks after the sold-out floats have been filled using the ‘‘SYRUP PRIME’’ switches. After the product blender tanks have been filled, the “BLEND ON/OFF” switches may be pressed again to prevent more product from entering the product blender tanks during BRIX test. The “ON” and “BLEND ON/OFF” switches must be pressed to operate the freeze cylinders beaters and refrigeration system during normal operation.

‘‘MOTOR’’ SWITCHES

The ‘‘MOTOR’’ switches, located on the control panel, are touch-type switches and require only pressing to activate. These switches are used to operate the freeze cylinders beaters with no refrigeration during sanitizing.

“ON’’ SWITCHES

The ‘‘ON’’ switches, located on the control panel, are touch-type switches and require only pressing to activate. These switches are used to operate the freeze cylinders beaters and refrigeration system after cylinders have been filled with product. The freeze cylinders beaters and refrigeration system may be stopped by pressing the ‘‘OFF’’ switches.

‘‘OFF’’ SWITCHES

The ‘‘OFF’’ switches, located on the control panel, are touch-type switches and require only pressing to activate. These switches are used to stop freeze cylinders beaters and refrigeration system.

‘‘ERROR RESET’’ SWITCH

‘‘ERROR RESET’’ switch, located on the control panel, is a touch-type switch and requires only pressing to activate. The ‘‘ERROR RESET’’ switch is used to restore normal operation after error within Unit (indicated by ‘‘ERROR 1’’ or ‘‘ERROR 2’’ on message display) has been corrected.

560001279SER

CONTROL PANEL DISPLAY MESSAGES

‘‘FILL 1’’ and ‘‘FILL 2’’ FAULT MESSAGES

‘‘FILL 1’’ and ‘‘FILL 2’’ fault messages will appear on the message display only after the “SYRUP PRIME” switches have been pressed and the syrup systems sold-out floats have been filled with product. ‘‘FILL 1’’ and ‘‘FILL 2’’ fault messages will continue to be displayed until the “BLEND ON/OFF” switches have been pressed to fill the product blender tanks with product.

‘‘ERROR 1’’ and ‘‘ERROR 2’’ FAULT MESSAGES

‘‘ERROR 1’’ and ‘‘ERROR 2’’ fault messages will appear on the message display only if an error within the Unit has developed interrupting normal operation. Error will have to be located and corrected, then press the ‘‘ERROR RESET’’ to restore the Unit to normal operation. ‘‘ERROR 1’’ or ‘‘ERROR 2’’ fault message will disappear from the display.

‘‘OFF 1’’ and ‘‘OFF 2’’ FAULT MESSAGES

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

‘‘H2O OUT’’ FAULT MESSAGE

The Unit plain water inlet system contains a water pressure switch. An “H2O OUT” fault message will appear on the message display if the plain water source to the unit has been disrupted or if a water pressure drop should occur. The Unit will continue to operate for 1-1/2 minutes after ‘‘H2O OUT’’ fault message has appeared. If the water pressure has not been restored or the water pressure improved after 1-1/2 minutes, the Unit operation will shut down. After plain water source has been restored or the water pressure has improved, the Unit will resume it’s normal operation and the ‘‘H2O OUT’’ fault message will disappear from the message display.

‘‘CO2 OUT’’ FAULT MESSAGE

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

‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ FAULT MESSAGES

‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages will appear on the message display if the syrup supply is not connected to the Unit syrup system or if the syrup supply is exhausted. The Unit syrup systems syrup float switches must be filled with syrup to extinguish the ‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages.

‘‘DEFROST 1’’ or ‘‘DEFROST 2’’ DISPLAY MESSAGES

‘‘DEFROST 1’’ or ‘‘DEFROST 2’’ display messages will appear on the message display if either freeze cylinder is in the defrost mode. ‘‘DEFROST 1’’ or ‘‘DEFROST 2’’ messages will remain on during the defrost cycle and will disappear when the cycle has ended.

‘‘POINT OF SALE’’ DISPLAY MESSAGES

Three ‘‘POINT OF SALE‘’ display messages are available to choose from and may be programmed into the Unit to appear on the message display. The “POINT OF SALE” display messages should be programmed into the Unit electronics by a qualified Service Person.

560001279SER 41

DEFROST SYSTEMS

NOTE: The automatic defrost, “SLEEP” (SLEEP TIME), and “WAKE UP” (WAKE UP TIME) should be programmed into the Unit electronics by a qualified Service Person.

MANUAL DEFROST SYSTEM

Two-Flavor FCB Dispenser.

Four-Flavor FCB Dispenser.

AUTOMATIC DEFROST SYSTEM

‘‘SLEEP’’ (SLEEP TIME)

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

‘‘WAKE UP’’ (WAKE UP TIME)

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

560001279SER

FACEPLATE RELIEF VALVES

The faceplate relief valves, located in each freeze cylinder faceplate (see Figure 11), are spring-loaded valves that protect the freeze cylinders from accidental over-pressure. The relief valve is also used to manually bleed CO2 gas from the freeze cylinder to atmosphere during filling with product and if gas pockets form in the cylinder during operation.

DISPENSING VALVES

Self-closing dispensing valves, located on the faceplates on front of the Unit (see Figure 10), are operated one at a time or simultaneously to deliver product to the customer.

DISPENSED PRODUCT CONDITIONS

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

Overrun Defined.

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

breakout and secondary by freezing.

Low Dispensing Volume Affects Overrun.

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

peakĆuse periods.

DRAWING 1

Carbonation Level in Liquid Product Affects Overrun.

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

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

DRAWING 2

DRAWING 3

Overrun is a Variable.

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

adjustment adjusts product texture from very wet to light.

560001279SER 43

Specific Product Ingredients Affect Overrun.

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

absorb carbonation and the way it will release carbonation.

BRIX Affects Overrun.

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

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

Freezing Affects Overrun.

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

560001279SER

OPERATING CHARACTERISTICS

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

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

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

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

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

UNIT OPERATION

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

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

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

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

4. Make sure both ‘‘BLEND ON/OFF’’ and both “ON” control switches are pressed for normal operation.

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

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

ADJUSTING CO2 REGULATORS

PRIMARY CO2 REGULATOR

The primary CO2 regulator controls CO2 pressure to the syrup tanks (syrup tanks syrup source system) or to the syrup pumps (bag-in-box syrup source system). If adjustment of this CO necessary, call a qualified Service Person to make the adjustment.

regulator should become

SECONDARY CO2 REGULATORS

The secondary CO2 regulators, located inside the Unit, control CO2 pressure to the Unit carbonator(s) and the product blender tanks. If adjustment of these CO Person to make the adjustments.

560001279SER 45

regulators should become necessary, call a qualified Service

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

BRIX is the Water-to-Syrup “Ratio” of the dispensed product and should be periodically checked and if necessary, be adjusted by a qualified Service Person.

REPLENISHING SYRUP SUPPLY

NOTE: Sugar-free diet syrup cannot be used with this Unit.

Although syrup replenishing can be done anytime, the syrup supply must be replenished when either the ‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages are displayed on the message display indicating either No. 1 or No. 2 syrup system syrup is depleted of syrup. Replenish syrup supply as instructed in SERVICE AND MAINTENANCE section of this manual.

SYRUP FLAVOR CHANGE

The Unit syrup system that the syrup flavor change will be made on must be sanitized before connecting new flavor syrup into the system. It may be necessary to readjust BRIX (Water-To-Syrup) “Ratio” of the dispensed product after making a syrup flavor change. Perform syrup flavor change as instructed in SERVICE AND MAINTENANCE section of this manual.

REPLENISHING CO2 SUPPLY

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

The Unit and it’s syrup supply source may be connected to either a bulk CO2 supply or to a CO2 cylinder. If your Unit is connected to a CO2 cylinder, refer to SERVICE AND MAINTENANCE section of this manual for instructions to replenish the CO2 supply.

CLEANING AND SANITIZING

DAILY CLEANING OF UNIT

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

SANITIZING SYRUP SYSTEMS

The Unit syrup systems should be sanitized every 120-days and before and after storage periods following parent company requirements and Sanitizer Manufacturer’s recommendations. Refer to SERVICE AND MAINTENANCE section of this manual for sanitizing instructions.

CLEANING CONDENSER COIL

Circulating air, required to to cool the refrigeration system condenser coil, is drawn in through the condenser coil and is exhausted out through louvers on sides and back of the Unit. MAKE SURE THE LOUVERS ARE NOT

OBSTRUCTED. RESTRICTING AIR CIRCULATION THROUGH THE UNIT WILL DECREASE IT’S COOLING EFFICIENCY. The condenser coil must be periodically cleaned by a qualified Service Person.

560001279SER

SERVICE AND MAINTENANCE

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

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

PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING

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

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

PERIODIC INSPECTION

1. If using a CO2 cylinder instead of a bulk CO2 supply, make sure the CO2 cylinder regulator assembly 1800-psi gage indicator is not in shaded (‘‘change CO2 cylinder’’) portion of the dial. If so, the CO2 cylinder is almost empty and must be replaced as instructed in this section of the manual.

2. Make sure syrup supply to the Unit is sufficient for proper operation.

3. Circulating air, required to cool the refrigeration system condenser coil, is drawn in through the condenser coil to inside of the Unit and is exhausted from inside the Unit out through louvers in the Unit panels. Make sure the louvers are not obstructed and refer to CLEANING CONDENSER COIL in this section for instructions to clean the condenser coil.

REMOVAL OF PANELS

DRIP TRAY

Lift drip tray up out of the drip tray supports.

BACK PANEL

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

SIDE PANELS

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

TOP PANEL

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

LOWER FRONT ACCESS PANEL

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

CONDENSER COIL ACCESS PANEL

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

560001279SER 47

OPENING AND CLOSING FRONT ACCESS DOOR

TWO–FLAVOR MODELS AND OVERCOUNTER (OC2) MODELS

1. Pull out on bottom right side of the front access door to disengage it’s latch, then open door to the left.

2. Close the front access door by carefully pushing the door shut until it’s latch engages.

FOUR–FLAVOR FLOOR MODEL

1. Pull out on bottom of the front access door to disengage it’s latch, then lift door up to open..

2. Close the front access door by carefully lowering the door the until it’s latch engages.

ADJUSTMENTS

ADJUSTING PLAIN WATER PRESSURE REGULATOR (see applicable Figure 4 or 5)

The carbonator(s) plain water inlet adjustable water pressure regulator is factory adjusted to 45-psi and should not be readjusted.

ADJUSTING CARBONATED WATER FLOW RATE (see applicable Figure 4 or 5 and 16)

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

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

2. Disconnect syrup source supply from applicable Unit syrup system.

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

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

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

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

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

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

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

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

11. Press applicable ‘‘BLEND ON/OFF’’ switch to activate the electrically operated carbonated water solenoid.

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

560001279SER

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

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

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

16. Turn the product blender tanks CO

regulator, with 60-psi gage, adjusting screw in (clockwise) until gage

registers pressure noted in step 7 preceding.

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

18. Restore syrup supply to the Unit syrup system.

19. Press the applicable ‘‘BLEND ON/OFF’’ switch to fill the product blender tank with product.

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

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

PRODUCT CARBONATION ADJUSTMENT (see applicable Figure 4 or 5)

Carbonation of dispensed product can also be varied to suit consumer preference by adjusting Unit carbonator(s) secondary CO2 regulator(s) as follows:

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

1. Remove Unit lower front access panel as instructed for access to the carbonator secondary CO2 regulator with 100-psi gage.

2. Observe pressure setting on the carbonator secondary CO2 regulator gage.

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

4. To raise CO2 pressure, turn regulator adjusting screw to the right (clockwise) until gage reads desired pressure. DO NOT SET PRESSURE HIGHER THAN 60 PSI. Make sure CO2 source primary CO

regulator is set at 80 to 100 psi. Tighten adjusting screw lock nut after each adjustment.

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

560001279SER 49

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

SERVICING DISPENSING VALVES CAGED O-RINGS. (see Figure 10)

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

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

NOTE: Item numbers in parentheses in this paragraph are in reference to Figure 11.

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

SPRING HOUSING

TORSION SPRING

SPRING FITTING

DISPENSING

VALVE BODY

CAGED O-RING

VALV E

LEVER

SLEEVE

SPRING

KNOB

RETAINING

SCREW(2)

HOLD-DOWN

PLATE(2)

FIGURE 10. SELF-CLOSING DISPENSING VALVE

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

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

5. Disassemble dispensing valve (see Figure 10) as follows:

A. Remove two screws and hold-down plates securing spring housing to dispensing valve body, then

remove housing.

B. Remove torsion spring from dispensing valve.

C. Remove knob, spring, sleeve, and lever from dispensing valve.

D. Remove spring fitting from dispensing valve.

E. Press valve, with caged O-ring, down and out of dispensing valve body.

F. Carefully remove caged O-ring from valve.

560001279SER

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

7. Submerge all parts in 4-percent solution of approved sanitizing agent for time recommended by the sanitizer manufacturer.

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

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

9. Assemble the dispensing valve as follows:

A. Lubricate caged O-ring. Carefully install caged O-ring on valve from straight end (opposite tapered

end). Lubricate grooves in which O-ring rides to fill in all void areas around O-ring.

B. Carefully install valve with caged O-ring in dispensing valve body.

15 16

1 Product Inlet Fitting 2 Scraper Blade (2) 3 Evaporator Coil

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

7 Hex Nut (4) 8 Faceplate 9 Relief Valve

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

18 Bearing Retainer 19 Beater Motor Drive Shaft

22 23

20 Beater Drive Motor

21 Drive Shaft Assembly

22 Viscosity Sensor

23 Spinner 24 Spring

25 Shaft Release

26 Bearing 27 Bearing Housing

121314

FIGURE 11. FREEZE CYLINDER CUTAWAY VIEW

560001279SER 51

C. Install spring fitting, knob and lever parts, torsion spring, and spring housing assembly by reversing

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

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

11. Proceed to SERVICING FREEZE CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES.

SERVICING FREEZE CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES.

(see Figure 13)

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

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

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

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

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

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

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

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

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

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

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

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

10. Re-assemble the drive shaft/seal assembly. Using TOOL, DRIVE/COUPLER ADJUSTMENT GAUGE (provided with the Unit), insert “DRIVE” end of adjustment gauge between drive-pin and housing (see Figure 13) to set the shaft end at 1.542-inches out of the plastic housing. Make sure Allen-Head set screw in each bearing is securely tightened and properly seated on the shaft flat surface.

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

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

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

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

560001279SER

BEATER

KEY ON END

OF POST

KEY ON END

OF POST

KEY SLOT

ON BLADE

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

FIGURE 12. BEATERS AND SCRAPER BLADES INSTALLATION

15. Position SCRAPER BLADES (item 2) on BEATER (item 13) as shown in Figure 12. Slide beater into freeze cylinder so slotted hooks engage DRIVE PIN (item 16) on DRIVE SHAFT (item 21) as shown in Figure 9. Turn beater to the right (clockwise) to lock in place.

16. Lubricate O-RING (item 5) with water to facilitate faceplate installation. Position O-RING (item 5) on FACEPLATE (item 8). Install faceplate on Unit so dispensing valve spout faces down. (MAKE SURE FEMALE END OF THE BEATER IS PLACED OVER THE FACEPLATE STAINLESS-STEEL STUD AND BUSHING BEFORE PUSHING THE FACEPLATE INTO POSITION ON ITS FOUR THREADED MOUNTING STUDS). Tighten hex nuts until faceplate touches freeze cylinder all around flange. CAUTION – DO NOT OVERTIGHTEN HEX NUTS.

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

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

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

20. Return Unit to operation.

560001279SER 53

BEATER

DRIVE MOTOR

DRIVE SHAFT/SEAL ASS’Y

BEATER DRIVE MOTOR SHAFT

COUPLING

ALLEN-HEAD

SET SCREW

PLASTIC

COUPLER

ALLEN-HEAD

SET SCREW

COUPLING

DRIVE SHAFT

COUPLER

DRIVE

BEATER

DRIVE

COUPLER

LOCK RING

BEARING

GAUGE, DRIVE/COUPLER

PLASTIC

HOUSING

O-RING

ALLEN-HEAD

SET SCREW (2)

DRIVE SHAFT/ SEAL ASSEMBLY

FIGURE 13. SERVICING BEATER MOTOR DRIVE SHAFT/SEAL ASSEMBLY

(ITEM 10)

SHAFT

560001279SER

CLEANING CONDENSER COIL (SEE FIGURE 23)

UNIT WITH AIR-COOLED REFRIGERATION SYSTEM

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

Periodically clean condenser coil as follows:

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

2. Remove condenser coil access panel and condenser coil air filter.

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

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

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

UNIT WITH WATER-COOLED REFRIGERATION SYSTEM

The high-pressure cutout switch, located inside the lower control box (see Figure 24), will shut the Unit refrigeration system down when overheated (high head pressure) caused by lack of cooling water. After problem has been corrected and the head pressure has decreased, the reset button on the high-pressure cutout switch must be pressed to restart the refrigeration system.

CLEANING AND SANITIZING

DAILY CLEANING OF UNIT

SANITIZING SYRUP SYSTEMS

NOTE: The Unit should be sanitized every 90-days by a qualified Service Person following the Sanitizer Manufacturer’s recommendation. Use Chlor-Tergent (Oakite Products, Inc.) or equivalent sanitizer.

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

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

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

3. Immediately press SIDE 2 ‘‘BLEND ON/OFF’’ switch to restart the beater in No. 2 freeze cylinder. Refrigeration in No. 2 cylinder will not be operating.

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

560001279SER 55

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

6. Press SIDE 1 “BLEND ON/OFF” switch to prevent more product from entering the product blender tank.

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

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

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

10. Syrup Tank Syrup System.

Disconnect syrup tank containing syrup from No. 1 syrup system.

Bag-in-Box Syrup System.

A. Disconnect No. 1 syrup pump syrup inlet line from bag-in-box containing syrup.

B. Cut connector from empty bag-in-box container, then connect connector to No. 1 syrup pump syrup

inlet line.

NOTE: Sanitizing solution is used in a more concentrated form because it will be diluted approximately four-to-one in the product blender tank. If a powder–type sanitizer is to be used, it must be thoroughly dissolved with water prior to adding to a sanitizing solution container.

11. Using a clean syrup tank (syrup tank system) or a clean 5-gallon pail (bag-in-box system), prepare a full tank or pail of sanitizing solution using Chlor-Tergent (Oakite Product, Inc.) or equivalent sanitizer. Mix sanitizing solution by using 70° F to 100° F (max) plain water and 2.65 oz./gallon sanitizer. This mixture will provide 800-ppm of chlorine. Sanitizing solution will be diluted to approximately 200-ppm inside the product blender tank after carbonated water has been mixed with the sanitizing solution.

12. Syrup Tank System.

Shake sanitizing solution tank thoroughly to mix the solution, then connect tank to the No. 1 syrup system.

Bag-in-Box Syrup System.

Mix pail of sanitizing solution thoroughly, then immerse end of No. 1 syrup pump syrup inlet line into pail of sanitizing solution.

13. Press SIDE 1 ‘‘SYRUP PRIME’’ switch to fill No. 1 syrup system syrup float switch with syrup.

14. Press SIDE 1 ‘‘BLEND ON/OFF’’ switch to fill No. 1 product blender tank with sanitizing solution. The carbonator water pump will start and begin pumping carbonated water into the product blender tank which will dilute sanitizing solution also entering the tank.

15. After carbonator water pump cycles off, completely fill No. 1 freeze cylinder with sanitizing solution by repeatedly pulling and releasing the relief valve knob on the freeze cylinder faceplate and until sanitizing solution comes out of the relief valve port. Open the dispensing valve until sanitizing solution flows from the valve, then close the valve. Open the product blender tank sample valve until sanitizing solution flows from the valve, then close the valve.

16. Press SIDE 1 ‘‘MOTOR’’ switch to start No. 1 freeze cylinder beater. Allow sanitizing solution to remain in the freeze cylinder for no less than 10 and no more than 15 minutes (max) contact time.

17. When sanitizing solution contact time has elapsed, press SIDE 1 ‘‘OFF’’ switch to stop the No. 1 freeze cylinder beater.

560001279SER

18. Press SIDE 1 “BLEND ON/OFF” switch to prevent more sanitizing solution from entering the product blender tank.

19. Place waste container under No. 1 dispensing valve nozzle. Open the dispensing valve and dispense all sanitizing solution from the freeze cylinder. As sanitizing solution level lowers in the freeze cylinder, partially close the valve to avoid spurting.

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

21. Syrup Tank System.

A. Disconnect sanitizing solution tank from No. 1 syrup system.

B. Connect syrup tank containing syrup into No. 1 syrup system.

Bag-in-Box Syrup System.

A. Remove end of No. 1 syrup pump syrup inlet line from pail of sanitizing solution.

B. Remove empty bag-in-box connector from No. 1 syrup pump syrup inlet line.

C. Connect No. 1 syrup pump syrup inlet line to bag-in-box containing syrup.

22. Press SIDE 1 “SYRUP PRIME” switch to fill No. 1 syrup system syrup float switch with syrup.

23. Press SIDE 1 ‘‘BLEND ON/OFF’’ switch to fill No. 1 product blender tank with product. Carbonator water pump will start and begin pumping carbonated water into the product blender tank along with syrup to make product.

WARNING: Flush residual sanitizing solution from the syrup system as instructed. Residual sanitizing solution left in the syrup system could create a health hazard.

24. After carbonator water pump cycles off, completely fill No.1 freeze cylinder with product by repeatedly pulling and releasing the faceplate relief valve and until product comes out of the relief valve port. Open the dispensing valve until product flows from the valve, then close the valve. Open No. 1 system product sample valve until product flows from the valve, then close the valve.

25. Press SIDE 1 “MOTOR” switch to start No. 1 freeze cylinder beater. Allow beater to operate for 5-minutes, then press SIDE 1 “OFF” switch to stop the beater.

26. Syrup Tank System.

A. Disconnect syrup tank containing syrup from No. 1 syrup system.

B. Connect empty syrup tank into No. 1 syrup system.

Bag-in-Box Syrup System.

A. Disconnect No.1 syrup pump syrup inlet line from bag-in-box containing syrup.

B. Install connector from empty bag-in-box on No. 1 syrup pump syrup inlet line.

27. Hold waste container under the dispensing valve and dispense until all product has been dispensed from the freeze cylinder. As product level lowers in the freeze cylinder, partially close the valve to avoid spurting.

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

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

560001279SER 57

29. Syrup Tank System.

A. Disconnect empty syrup tank from No. 1 syrup system.

B. Connect syrup tank containing syrup into No. 1 syrup system.

Bag-in-Box Syrup System.

A. Remove empty bag-in-box connector from No. 1 syrup pump syrup inlet line.

B. Connect No. 1 syrup pump syrup inlet line to bag-in-box containing syrup.

30. Press SIDE 1 “SYRUP PRIME” switch to fill No. 1 syrup system syrup float switch with syrup.

31. Press SIDE 1 ‘‘BLEND ON/OFF’’ switch to fill No. 1 product blender tank with product. Carbonator water pump will start and begin pumping carbonated water into the product blender tank along with syrup to make product.

32. After carbonator water pump cycles off, intermittently pull and release the No. 1 freeze cylinder faceplate relief valve. This bleeds CO2 from the freeze cylinder and allows product to enter and fill the cylinder.

33. Open No. 2 product blender tank product shutoff valve.

34. Press both ‘‘ON’’ switches to start both freeze cylinders beaters and refrigeration system. Product will be ready for dispensing in approximately 10 minutes.

35. Install right-hand side panel and lower front access panel by reversing removal procedure.

YEARLY OR AFTER WATER SYSTEM DISRUPTION

WARNING: The Unit plain water inlet line water strainer must be disassembled and it’s strainer screen must be inspected and cleaned and the water pump outlet double liquid

check valve (P/N 3253) must be replaced after any disruptions (plumbing work, earthquake, etc.) to the water supply system, and at least once a year under normal circumstances. A plain water inlet line water strainer with no strainer screen or a defective screen would allow foreign particles to foul the double liquid check valves. CO2 gas could then back flow into the water system and create a health hazard in the water system.

SERVICING CARBONATOR WATER PUMP WATER STRAINER SCREEN (2 AND 3 H.P. OVERCOUNTER UNITS)

(see Figure 5 and 15)

1. Press both ‘‘OFF’’ switches to stop freeze cylinders beaters and refrigeration systems.

2. Disconnect electrical power from Unit.

3. Shut off CO2 and water supplies to the Unit.

4. Remove lower front access panel and side panel as instructed for access to the Unit plain water inlet line water strainer.

5. Pull up on carbonator tank relief valve plastic cover to release CO2 pressure from the tank.

6. Loosen screen retainer in the water inlet water strainer, then remove screen retainer and strainer screen from the water strainer port.

7. Pull strainer screen from screen retainer. Clean any sediment from screen retainer and the water strainer port.

8. Inspect strainer screen for holes, restrictions, corrosion, and other damage. Discard strainer screen if damaged and replace with a new strainer screen (P/N 313253000).

9. Check O-ring on the screen retainer. Replace worn or damaged O-ring with new O-ring (P/N 310784000).

560001279SER

NOTE: A strainer screen should always be used otherwise particles could foul the double liquid check valve.

10. Install good or new strainer screen in the screen retainer, then screw the screen retainer into the water strainer port and tighten securely.

11. Proceed to SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE.

REPLACING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE (see applicable Figure 4 or 5 and 14 or 15)

1. Service water pump water strainer screen before replacing the water pump double liquid check valve.

2. Disconnect carbonator tank water line from the double liquid check valve assembly outlet.

3. Remove the double liquid check valve assembly from the water pump outlet connector.

DOUBLE LIQUID

CHECK VALVE ASS’Y

WATER PUMP

AND MOTOR

WATER PRESSURE

SWITCH

WATER PRESSURE

REGULATOR

FIGURE 14. DOUBLE LIQUID CHECK VALVE (3 H.P. FLOOR MODEL UNIT)

4. Install new double liquid check valve assembly (P/N 3253) in the water pump outlet fitting. Seal connection with teflon tape. DO NOT OVERTIGHTEN.

5. Connect carbonator tank water line to the double liquid check valve assembly outlet. DO NOT

OVERTIGHTEN.

6. Restore CO

and water supplies to the Unit. Check for water leaks and tighten any loose connections.

7. Install panels on the Unit by reversing removal procedures.

8. Connect electrical power to Unit.

9. Press both “ BLEND ON/OFF’’ switches.

560001279SER 59

O-RING (P/N 315349000)

SCREEN RETAINER

SCREEN (P/N 315348000)

WATER PUMP MOTOR

WATER PUMP

WATER PRESSURE SWITCH

DOUBLE LIQUID

CHECK VALVE ASS’Y

WHITE TAPERED

GASKET

WATER PRESSURE

REGULATOR

FIGURE 15. DOUBLE LIQUID CHECK VALVE AND WATER STRAINER SCREEN

(OVERCOUNTER OC2 UNIT)

ADJUSTING CARBONATOR TANK LIQUID LEVEL

The carbonator tank liquid level (pump cut-in and cutout) was adjusted at the factory and should require no further adjustment. However, if incorrect setting is suspected, check and make necessary adjustments as follows:

1. Remove Unit back and side panels as instructed for access to carbonator and carbonated water volume sample valve (see applicable Figure 4 or 5).

2. To check carbonator tank total fill; allow carbonator water pump motor to operate and fill tank with carbonated water. After pump cycles off, disconnect electrical power from Unit.

3. Using container graduated in ounces, open carbonator carbonated water sample valve and completely drain carbonator tank into container. Total carbonated water volume dispensed should be 40 to 58-ounces maximum.

4. If total carbonated water dispensed is below 40 ounces, loosen screw securing level control switches actuator bracket (see Figure 17) and move actuator bracket up slightly. If more than 58 ounces, maximum of carbonated water was dispensed, move actuator bracket down, then tighten screw. MAKE

ADJUSTMENTS IN SMALL INCREMENTS.

5. Connect electrical power to Unit and allow carbonator tank to fill with water until water pump cycles off.

6. Repeat steps 2 through 5 preceding as many times as necessary until correct carbonated water volume adjustment is achieved.

560001279SER

REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR (SEE FIGURE13)

IMPORTANT: Note in TABLE 7. MOTOR SELECT the number of freeze cylinders beater drive motors manufacturers that are listed. Your Unit was manufactured and equipped with freeze cylinders beater drive motors from one of these manufacturers. The replacement freeze cylinder beater drive motor is also manufactured by one of these manufacturers listed. WHEN REPLACING ONE OF THE BEATER MOTORS, NOTE THE MANUFACTURER’S NAME ON THE MOTOR. THE BEATER MOTOR MANUFACTURER’S NAME MUST BE PROGRAMMED INTO THE UNIT WHICH WILL MATCH THE MOTOR TO THE UNIT ELECTRONICS. Proceed as follows to replace the freeze cylinder beater drive motor.

1. Press “OFF 1” and “OFF 2” control switches to stop the refrigeration system and the beater drive motors.

2. Disconnect electrical power to the Unit.

3. Remove back and applicable side panels from the Unit.

4. Tag the beater drive motor electrical wiring for identification, then disconnect the wiring from the terminal block.

5. Remove bolts, hex nuts, and lockwashers securing the beater drive motor to the Unit frame.

6. Very carefully, remove the old beater drive motor from the Unit. BE CAREFUL NOT TO LOSE THE

LARGE PLASTIC DRIVE SHAFT COUPLER.

7. Remove the plastic coupler from the old beater drive motor shaft and install it on the new motor shaft.

MAKE SURE THE ALLEN-HEAD SET SCREWS ARE SECURELY TIGHTENED AND PROPERLY SEATED ON THE SHAFT FLAT SURFACE.

CAUTION: The new beater drive motor has a screw in the vent hole on top of the gear box that must be removed before the motor is put into operation.

8. Remove screw from the vent hole on top of the beater drive motor gear box. BE CAREFUL NOT TO LAY MOTOR ON IT’S SIDE–THIS WILL CAUSE OIL TO LEAK OUT OF THE GEAR BOX.

9. Very carefully, place the new beater drive motor into position in the Unit with the motor shaft engaged in the beater drive shaft large plastic coupler.

10. Secure beater drive motor to the Unit frame with bolts, hex nuts, and lock washers.

11. Connect the beater drive motor electrical wiring to the terminal block.

12. Install the sides and back panels by reversing the removal procedures.

13. Restore the Unit to operation.

14. Refer to “PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT

ELECTRONICS” in INSTALLATION section of this manual to program the new replacement beater

motor into the Unit to match the Unit electronics.

15. Remove the screw from the vent hole on top of the beater drive motor gear box. BE CAREFUL NOT TO LAY THE MOTOR ON IT’S SIDE – THIS WILL CAUSE OIL TO LEAK OUT OF THE GEAR BOX.

16. Very carefully, place the new beater drive motor into position in the Unit with the motor shaft engaged in the beater drive shaft large plastic coupler.

17. Secure beater drive motor to the Unit frame with bolt, hex nuts, and lockwashers.

560001279SER 61

REPLENISHING SYRUP SUPPLY

SYRUP TANKS SYSTEM

NOTE: Sugar-free diet syrup cannot be used with this Unit.

NOTE: The following instructions are applicable only when replenishing the syrup supply. Refer to SYRUP FLAVOR CHANGE when changing syrup flavors.

1. Press applicable ‘‘OFF’’ switch on the control panel to stop the applicable freeze cylinder beater and refrigeration system.

IMPORTANT: The following CO

and liquid disconnect and connecting procedure for the syrup tank

replacement or filling the syrup tank in place must be performed in the order as follows:

To disconnect syrup tank from the Unit syrup system.

First, disconnect liquid disconnect from the syrup tank. NOTE - Disconnecting the liquid quick disconnect from the syrup tank first prevents syrup from backflowing through the Unit syrup flow regulator which may alter the regulator adjustment.

Second, disconnect CO2 quick disconnect from the syrup tank.

SYRUP FLOW

REGULATOR (2)

CARBONATED WATER

SYRUP SOLENOID

VALVE (2)

FLOW REGULATOR (2)

SYRUP SOLD-OUT FLOAT SWITCH (2)

LIQUID CHECK

VALVE (4)

CARBONATED WATER

SOLENOID VALVE (2)

FIGURE 16. PARTS IDENTIFICATION

560001279SER

To connect syrup tank into the Unit syrup system.

First, connect CO2 quick disconnect to the syrup tank to pressurize the tank.

Second, connect liquid quick disconnect to the syrup tank.

2. Disconnect inlet (CO2) and outlet (syrup) lines from the empty syrup tank.

3. Check syrup tank quick disconnects for sticky or restricted operation. Rinse the disconnects in warm water.

4. First, pressurize the full syrup tank by connecting CO2 line to the tank, then connect the Unit syrup inlet line to the tank.

5. Press applicable ‘‘SYRUP PRIME’’ switch to fill applicable No. 1 or No. 2 syrup system syrup float switch with syrup.

6. Press applicable “BLEND ON/OFF’’ switch to fill applicable No. 1 or No. 2 system product blender tank with product.

7. Press applicable ‘‘ON’’ switch to start the refrigeration system and beater in applicable No. 1 or No. 2 freeze cylinder.

8. If freeze cylinder is not full of product, repeatedly pull and release the faceplate relief valve to slowly bleed CO2 from the freeze cylinder and allow product to fill the cylinder. Do not relieve freeze cylinder pressure too fast or the product will foam excessively in the cylinder and lose carbonation.

BAG–IN–BOX SYSTEM

1. Press applicable ‘‘OFF’’ switch on the control panel to stop the applicable freeze cylinder beater and refrigeration system.

2. Disconnect syrup outlet tube from empty bag-in-box container, then remove empty container.

3. Open flap on full bag-in-box container.

4. Pull bag-in-box container connector from the container, then remove dust cap from the connector.

5. Rinse syrup outlet tube in warm water.

6. Connect syrup outlet tube to full bag-in-box container. Make sure syrup outlet tube is securely connected to

the container.

7. Press applicable ‘‘SYRUP PRIME’’ switch to fill applicable No. 1 or No. 2 syrup system syrup float switch with syrup.

8. Press applicable “BLEND ON/OFF’’ switch to fill applicable No. 1 or No. 2 system product blender tank with product.

9. Press applicable ‘‘ON’’ switch to start the refrigeration system and beater in applicable No. 1 or No. 2 freeze cylinder.

10. If freeze cylinder is not full of product, repeatedly pull and release the faceplate relief valve to slowly bleed CO2 from the freeze cylinder and allow product to fill the cylinder. Do not relieve freeze cylinder pressure too fast or the product will foam excessively in the cylinder and lose carbonation.

560001279SER 63

REPLENISHING CO2 SUPPLY

The Unit may be connected to either a bulk CO2 supply or to a CO2 cylinder. If your Unit is connected to a CO cylinder, proceed as follows to replenish the CO2 supply.

RELIEF VALVE

CARBONATED

WATER TANK

SWITCHES

ACTUATOR BRACKET

LEVEL CONTROL

SWITCHES(2)

ACTUATOR BRACKET

ADJUSTMENT SCREW

FIGURE 17. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT

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

NOTE: When indicator on primary CO2 cylinder regulator assembly 1800-psi gage is in shaded (‘‘change CO2 cylinder’’) portion of the dial, CO2 cylinder is almost empty and should be changed.

560001279SER

1. Fully close (clockwise) CO2 cylinder valve.

2. Slowly loosen the primary CO

regulator assembly coupling nut allowing CO2 pressure to escape, then

remove regulator assembly from empty CO2 cylinder.

3. Unfasten safety chain and remove empty CO2 cylinder.

4. Position full CO2 cylinder and secure with safety chain.

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

5. Make sure gasket is in place inside the primary CO2 regulator coupling nut, then install regulator on CO cylinder.

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

7. Check CO2 connections for leaks. Tighten loose connections.

SYRUP FLAVOR CHANGE

The Unit syrup system that the syrup flavor change will be made on must be sanitized before connecting new flavor syrup to the system. It may be necessary to readjust BRIX (Water-To-Syrup) “Ratio” of the dispensed product after making a syrup flavor change.

CLEANING CO2 SYSTEM GAS CHECK VALVES (SEE APPLICABLE FIGURE 4 OR 5 AND 18)

The CO2 gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO2 system. ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS

CHECK VALVES ARE SERVICED.

QUAD RING

183294-000

BALL

183296-000

SPRING

183297-000

RETAINER

183298-000

BODY

183295-100

QUAD RING SEAL MUST BE REPLACED EACH TIME CHECK VALVE IS SERVICED.

FIGURE 18. CO2 GAS CHECK VALVE

560001279SER 65

FIGURE 19. WIRING DIAGRAM (3 H.P.

FLOOR MODEL UNIT)

3584 Rev: C

560001279SER

FOR MODELS:

416126-XXX1

496126-XXX1

FIGURE 20. WIRING DIAGRAM (2 AND 3 H.P.

OVERCOUNTER OC2 UNITS)

560001279SER 67

FOR MODELS:

416126-XXX1

496126-XXX1

FIGURE 21. WIRING DIAGRAM (TWO–FLAVOR UNITS)

560001279SER

FOR MODELS:

416126-XXX1

496126-XXX1

FIGURE 22. WIRING DIAGRAM (FOUR–FLAVOR UNITS)

560001279SER 69

HOT-GAS DEFROST

SOLENOID VALVE

ASS’Y (2)

ELECTRONIC

EXPANSION VALVE (2)

FREEZE CYLINDER (2)

EVAPORATOR

STRAINER/DRYER

ACCUMULATOR

COMPRESSOR

RECEIVER TANK

NOTE: One refrigeration system is shown in this illustration. A two-flavor Unit has one refrigeration system. A four–flavor Unit has two refrigeration systems.

FIGURE 23. REFRIGERATION FLOW DIAGRAM (AIR-COOLED REFRIGERATION SYSTEM)

CONDENSER COIL

FAN ASS’Y

560001279SER

HOT GAS DEFROST

SOLENOID VALVE

ASS’Y (2)

*WATER FLOW RATE THROUGH COIL VARIES DUE TO PRESSURE CHANGE ON HIGH SIDE OF COMPRESSOR WHICH INFLUENCES OPENING AND CLOSING OF VARIABLE WATER REGULATOR. ADJUST VARIABLE WATER REGULATOR TO MAINTAIN 240-PSI REFRIGERATION HIGH-SIDE PRESSURE.

EVAPORATOR

COOLING WATER OUT

(TO DRAIN)

ELECTRONIC

EXPANSION VALVE (2)

FREEZE CYLINDER (2)

COOLING WATER IN

(CITY PLAIN WATER)

*VARIABLE WATER

REGULATOR

ACCUMULATOR COMPRESSOR

NOTE: One refrigeration system is shown in this illustration. A twoflavor Unit has one refrigeration system.

RECEIVER TANK

HIGH-PRESSURE CUTOUT SWITCH

ADJUSTMENT

SCREW

CAPILLARY

TUBE

REFRIGERATION

COOLING COIL ASS’Y

LOWER ELECTRICAL

CONTROL BOX

FIGURE 24. REFRIGERATION FLOW DIAGRAM (WATER-COOLED REFRIGERATION SYSTEM)

560001279SER 71

TROUBLESHOOTING

IMPORTANT: Only qualified personnel should service internal components or electrical wiring.

WARNING: If repairs are to be made to a product system, remove quick disconnects from the applicable product tank, then relieve the system pressure before proceeding. If repairs

are to be made to the CO system pressure before proceeding. If repairs are to be made to the refrigeration system, make sure electrical power is disconnected from the unit.

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

1. To disconnect soft drink tank from Unit syrup system.

A. Disconnect liquid disconnect from soft drink tank. NOTE - Disconnecting liquid quick

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

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

2. To connect soft drink tank into Unit syrup system.

system, stop dispensing, shut off the CO

supply, then relieve the

A. First, connect CO2 quick disconnect to soft drink tank to pressurize tank.

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

TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES

Trouble Probable Cause Remedy

ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING.

A. Flat cable not properly

connected to control switch module or master circuit

A. Properly connect flat cable to

control switch module or master circuit board.

board.

B. Flat cable connected between

control switch module and master circuit board pinched

B. Check cable for pinched or

broken wire condition and repair

or replace as necessary. and shorted out or broken wire in cable.

C. Inoperable switch(s) on control

panel switch module.

D. Master circuit board not

C. Replace control panel switch

module.

D. Replace master circuit board.

operating properly.

560001279SER

Trouble RemedyProbable Cause

ALL CONTROL PANEL SWITCHES NOT OPERATING.

A. Electric power disconnected

A. Restore electric power to Unit.

from Unit.

B. Control panel security enabled. B. Press and hold any one of the

control panel switches for 5-seconds to override the control panel security. Control panel security will return 90-seconds after switches have not been pressed.

C. Flat cable not properly

connected to control switch module or master circuit

C. Properly connect flat cable to

control switch module or master circuit board.

board.

D. Flat cable connected between

control switch module and master circuit board pinched

D. Check cable for pinched or

broken wire condition and repair

or replace as necessary. and shorted out or broken wire in cable.

E. Master circuit board not

E. Replace master circuit board.

operating properly.

F. ‘‘SECURITY SWITCH’’

inoperable.

F. Replace control panel switch

module.

PARTIAL MESSAGE OR DULL (POORLY ILLUMINATED) DISPLAY.

ONE OR MORE FAULT MESSAGES NOT OPERATING.

A. Extremely low power source

voltage.

A. Flat cable not properly

connected to fault message module or master circuit board.

B. Flat cable connected between

fault message module and master circuit board pinched and shorted out or broken wire in cable.

C. External sensing device failing

to signal master circuit board, which in turn signals fault message display.

D. External sensing devices cable

connectors not securely connected to master circuit board connectors.

E. Disconnected or broken wire

between master circuit board connector and external sensing device.

A. Upgrade power source voltage.

A. Properly connect flat cable to fault

message module or master circuit

board.

B. Check cable for pinched or

broken wire condition and repair

or replace as necessary.

C. Replace or repair external sensing

device.

D. Make sure external sensing

devices cable connectors are

securely connected to master

circuit board connectors.

E. Connect or repair wire between

master circuit board connector

and external sensing device.

F. Master circuit board not

operating properly.

G. Fault message display

module not operating properly.

560001279SER 73

F. Replace master circuit board.

G. Replace fault message display

module.

Trouble RemedyProbable Cause

ALL FAULT MESSAGES NOT OPERATING.

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

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

A. No electrical power to Unit. A. Connect electrical power to Unit.

B. Flat cable not properly

connected to fault message module or master circuit

B. Properly connect flat cable to fault

message module or master circuit board.

board.

C. Flat cable connected between

fault message module and master circuit board pinched

C. Check cable for pinched or

broken wire condition and repair

or replace as necessary. and shorted out or broken wire in cable.

D. Master circuit board not

D. Replace master circuit board.

operating.

E. Fault message display module

not operating properly.

A. CO2 supply turned off or

E. Replace fault message display

module.

A. Restore CO

supply to the Unit.

exhausted.

B. Primary CO2 regulator set too

low.

C. Inoperable CO2 pressure

B. Adjust primary CO2 regulator as

instructed.

C. Replace CO2 pressure switch.

switch.

A. Water supply to the Unit

turned off or water pressure inadequate.

A. Turn on water supply to the Unit

or check water supply line

pressure.

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

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

FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT OPERATE.

B. Plugged water filter or water

inlet line strainer screen.

B. Change water filter or clean water

inlet line strainer screen as

instructed.

C. Inoperative water pressure

C. Replace water pressure switch.

switch.

A. Syrup supply exhausted. A. Replenish syrup supply.

A. Error within Unit has

developed interrupting normal operation.

A. Loose or broken electrical

A. Locate and correct error, then

press ‘‘ERROR RESET’’ switch to

restore normal operation.

A. Repair electrical wires.

wires.

B. Inoperable automatic defrost

B. Replace master circuit board.

timer.

560001279SER

Trouble RemedyProbable Cause

UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE.

MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN ‘‘MANUAL DEFROST’’ SWITCH IS PRESSED.

DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING ‘‘CANCEL DEFROST ’’ SWITCH.

A. Automatic defrost timer stuck

A. Replace master circuit board.

in automatic defrost cycle.

A. Flat cable not properly

connected to control switch module or master circuit

A. Properly connect flat cable to

control switch module or master circuit board.

board.

B. Flat cable connected between

control switch module and master circuit board pinched

B. Check cable for pinched or

broken wire condition and repair

or replace as necessary. and shorted out or broken wire in cable.

C. Inoperable ‘‘MANUAL

DEFROST’’ switch on control

C. Replace control panel switch

module. panel switch module.

D. Loose or broken wire. D. Repair wire.

E. Master circuit board not

E. Replace master circuit board.

operating properly.

A. Flat cable not properly

connected to control switch module or master circuit

A. Properly connect flat cable to

control switch module or master

circuit board. board.

B. Flat cable connected between

control switch module and master circuit board pinched and shorted out or broken wire in cable.

C. Inoperable ‘‘CANCEL

DEFROST’’ switch on control panel switch module.

D. Master circuit board not

operating properly.

B. Check cable for pinched or

broken wire condition and repair

or replace as necessary.

C. Replace control panel switch

module.

D. Replace master circuit board.

560001279SER 75

Trouble RemedyProbable Cause

TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATORS

CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE.

CARBONATOR WATER PUMP WILL NOT SHUT OFF.

A. No electrical power to Unit. A. Connect electrical power to Unit.

Check power source.

B. ‘‘BLEND ON/OFF’’ switches

have not been pressed.

C. ‘‘H

O OUT’’ fault message is

B. Press ‘‘BLEND ON/OFF’’

switches.

C. Restore water supply to Unit.

on.

D. ‘‘CO

OUT’’ fault message is

D. Restore CO2 supply to the Unit.

on.

E. Loose or broken electrical

wires.

F. Overheated water pump motor

cut off by overload protector.

G. Inoperative water pump/motor

assembly.

H. Inoperative carbonated water

E. Tighten connections or replace

wires.

F. Check for proper line voltage.

Check for restricted pump.

G. Replace water pump/motor

assembly.

H. Replace level control switches.

tank level control switches.

I. Binding, damaged, or dirty

carbonated water tank balance

I. Clean, repair, or replace balance

mechanism.

A. Binding, damaged, or dirty

carbonated water tank balance

A. Clean, repair, or replace balance

mechanism.

ERRATIC CARBONATOR WATER PUMP CYCLING.

A. Insufficient water supply

pressure. ‘‘H2O OUT’’ fault message goes on and off intermittently and water pump cycles on and off during carbonator tank fill cycle.

B. Water filter restricted. B. Replace water filter.

TROUBLESHOOTING DISPENSED PRODUCT

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

A. Quick disconnect not secure

on soft drink tank.

B. Syrup flow regulator set too

low.

C. Water flow regulator set too

high.

D. Syrup flow regulators stuck. D. Clean syrup flow regulators.

E. Restriction in syrup line. E. Sanitize Unit as instructed.

F. Syrup Baume not in proper

range.

A. Increase water inlet supply line

pressure. Water inlet supply line must have large enough I.D.

A. Secure tank quick disconnect.

B. Adjust BRIX of dispensed product

as instructed.

C. Water flow regulator must be set

at 1.3 ± 0.05 oz/sec.

F. Change syrup supply as

instructed.

560001279SER

Trouble RemedyProbable Cause

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

IMPROPER PRODUCT DISPENSED.

PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE, IN ONLY SMALL AMOUNTS, OR ONLY LIQUID.

A. Syrup flow regulators set too

high.

B. Water flow regulator set too

low.

A. Adjust BRIX of dispensed product

as instructed.

B. Water flow regulator must be set

for 1.3 ± 0.05 oz/sec.

C. Water flow regulator stuck. C. Clean regulator.

D. Syrup Baume not in proper

range.

D. Change syrup supply as

instructed.

E. Restricted water filter. E. Replace water filter.

A. Secondary CO2 regulators not

properly adjusted.

B. Dirty CO2 supply. CO2 must

be clean and free of water, oil,

A. Adjust secondary CO2 regulators

as instructed.

B. Replace CO2 supply as

instructed. and dirt. Water will not absorb dirty CO2 gas in same way as clean gas. This can also cause off-taste problems.

A. Dispensing valve has ice

particles in it.

A. Open and close dispensing valve

repeatedly. Defrost freeze cylinder

as instructed. If necessary, check

and adjust BRIX as instructed.

Adjust viscosity of dispensed

product as instructed.

FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING.

FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY.

CYLINDER FREEZE-UP.

B. Cylinder freeze-up. B. Refer to CYLINDER FREEZE-UP. A. ‘‘BLEND ON/OFF’’ switch not

A. Press ‘‘BLEND ON/OFF’’ switch.

pressed.

B. Carbonator water pump not

operating.

B. Check carbonator and restore to

operation.

C. Lines restricted. C. Sanitize Unit as instructed.

A. Dispensed product BRIX

A. See Below

varying because:

Restricted syrup and/or water

a. Clean regulator(s).

flow regulator.

Primary CO2 regulator pressure

insufficient.

B. Cylinder freeze-up causing ice

b. Primary CO2 regulator must be

adjusted from 80 to 100-psi.

B. Refer to CYLINDER FREEZE-UP. formation in center of cylinder and liquid product channels around ice formation.

NOTE: Defrost affected freeze cylinder as instructed.

A. Dispensed product BRIX too

low.

B. Viscosity of dispensed product

not properly adjusted.

A. Refer to BRIX (Water-to-Syrup)

‘‘Ratio’’ too low.

B. Adjust dispensed product

viscosity as instructed.

560001279SER 77

Trouble RemedyProbable Cause

TROUBLESHOOTING REFRIGERATION SYSTEM

UNIT EQUIPPED WITH AIR-COOLED REFRIGERATION SYSTEM

UNIT EQUIPPED WITH WATER-COOLED REFRIGERATION SYSTEM

A. Dispenser refrigeration system

overheating.

A. Clean Unit condenser coil as

instructed (see NOTE below)

NOTE: The Dispenser condenser coil must be periodically cleaned to maintain proper cooling of the refrigeration system.

A. Water supply to refrigeration

cooling coil assembly disruppted.

B. Insufficient water supply to

refrigeration cooling coil assembly disruppted.

C. Variable water regulator on the

refrigeration cooling coil

A. Restore water supply to

refrigeration cooling coil assembly.

B. Increase water supply to

refrigeration cooling coil assembly.

C. Properly adjust variable water

regulator as instructed in manual. assembly not properly adjusted.

560001279SER

WARRANTY

IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire product, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number, serial number and the date of purchase.

IMI Cornelius Offices

Locate your local office on www.cornelius.com under the contact menu.

560001279SER 79

APPENDIX A

VALVE TORQUE AND STAKING

IMI 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 763–488–3000.

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.

The following procedure details the proper method to apply torque to the shank nut on V–Series 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 Servicing Dispensing Valves Page 50 for instructions to drain barrels).

1. Loosen splash panel, as shown.

560001279SER

2. Remove splash panel.

3. Remove nut and plastic pieces from rear of faceplate to obtain unobstructed access to shank nut. Do this for BOTH Motorman and Delta type valves (Delta not shown).

560001279SER 81

Motorman Valve

1. Attach one nut finger tight to bottom, right of Barrel #1. Attach Faceplate to bottom, left of Barrel #2, as shown, with top edge of faceplate resting on first nut. Attach second nut finger tight to faceplate to hold it in place.

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 socket. Torque wrench setting is 10 lb–ft (or 120 lb–in).

NOTE: Do not use any other tool or method to tighten the shank nut.

560001279SER

3. After applying torque, inspect the threads and shank nut to ensure proper thread engagement.

Motorman Shank Nut

This is what the Motorman shank nut clearance should look like.

S Shank nut surface 0.1965 below valve shank surface.

Shank Nut Surface

Valve Shank Surface

560001279SER 83

Delta Valve

1. Rotate faceplate, as shown, with valve facing barrel. Attach faceplate to two studs with 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.

560001279SER

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.

4. Place point of punch in slot on shank nut right against valve threads.

5. Strike end of punch with hammer.

560001279SER 85

6. After applying torque and performing staking (stainless steel valve threads only) inspect the threads and shank nut to ensure proper thread engagement.

Delta Shank Nut

This is what the Delta shank nut clearance should look like.

S Shank nut surface 0.1025 below valve shank surface.

Shank Nut Surface

Valve Shank Surface

Staking mark on threads inside notch in shank nut.

560001279SER

IMI Cornelius, Inc. FCB Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual