Multiplex MA-8-2AF Service Manual

Blend-in-Cup® (BIC)

Manual Fill Beverage System

Service Manual

This manual is updated as new information and models are released. Visit our website for the latest manual. www.manitowocfsg.com

Part Number 9294938 07/29/2016

Safety Notices

As you work on Manitowoc equipment, be sure to pay close attention to the safety notices in this manual. Disregarding the notices may lead to serious injury and/or damage to the equipment.

Throughout this manual, you will see the following types of safety notices:

Warning

Text in a Warning box alerts you to a potential personal injury situation. Be sure to read the Warning statement before proceeding, and work carefully.

Caution

Text in a Caution box alerts you to a situation in which you could damage the equipment. Be sure to read the Caution statement before proceeding, and work carefully.

Procedural Notices

As you work on Manitowoc equipment, be sure to read the procedural notices in this manual. These notices supply helpful information which may assist you as you work.

Throughout this manual, you will see the following types of procedural notices:

Important

Text in an Important box provides you with information that may help you perform a procedure more efficiently. Disregarding this information will not cause damage or injury, but it may slow you down as you work.

NOTE: Text set off as a Note provides you with simple, but useful, extra information about the procedure you are performing.

Read These Before Proceeding

Caution

Proper installation, care and maintenance are essential for maximum performance and trouble-free operation of your equipment. Visit our website www. manitowocfsg.com for manual updates, translations, or contact information for service agents in your area.

Important

Routine adjustments and maintenance procedures outlined in this manual are not covered by the warranty.

Warning

Read this manual thoroughly before operating, installing or performing maintenance on the equipment. Failure to follow instructions in this manual can cause property damage, injury or death.

Warning

Do not use electrical appliances or accessories other than those supplied by Manitowoc for your ice machine model.

Warning

Two or more people or a lifting device are required to lift this appliance.

Warning

This equipment contains high voltage electricity and refrigerant charge. Installation and repairs are to be performed by properly trained technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure. The technician must also be certified in proper refrigerant handling and servicing procedures. All lockout and tag out procedures must be followed when working on this equipment.

Warning

Do not damage the refrigeration circuit when installing, maintaining or servicing the unit.

Warning

Do not store explosive substances in refrigerator.

Warning

Do not operate equipment that has been misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision concerning use of the appliance by a person responsible for their safety. Do not allow children to play with this appliance.

Warning

All covers and access panels must be in place and properly secured, before operating this equipment.

Warning

Do not obstruct machine vents or openings.

Warning

Do not store gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

Warning

Do not clean with water jet.

Warning

It is the responsibility of the equipment owner to perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures.

Warning

When using electric appliances, basic precautions must always be followed, including the following:

a. Read all the instructions before using the

appliance.

b. To reduce the risk of injury, close supervision

is necessary when an appliance is used near

children. c. Do not contact moving parts. d. Only use attachments recommended or sold by

the manufacturer. e. Do not use outdoors. f. For a cord-connected appliance, the following

must be included:

• Do not unplug by pulling on cord. To unplug, grasp the plug, not the cord.

• Unplug from outlet when not in use and before servicing or cleaning.

• Do not operate any appliance with a damaged cord or plug, or after the appliance malfunctions or is dropped or damaged in any manner. Contact the nearest authorized service facility for examination, repair, or electrical or mechanical adjustment.

g. Follow applicable lock out tag out procedures

before working on equipment.

h. Connect to a properly grounded outlet only.

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Section 1 General Information

Section 2 Installation

Table of Contents

Model Numbers .................................................................................................................. 9

Model Nomenclature: ..........................................................................................................................9

About Blend-In-Cup ...........................................................................................................9

Serial Number Location ..................................................................................................... 9

Specifications ...................................................................................................................10

Dimensions ............................................................................................................................................ 10

Capacity & Weight ............................................................................................................................... 10

Product Delivery Location ................................................................................................................ 11

Refrigerant Charge .............................................................................................................................. 11

Electrical............................................................................................................................12

Air / CO2, Plain & Chilled Water ...................................................................................................... 13

System Pressures ................................................................................................................................. 13

Regulator Settings & Location ........................................................................................................ 14

Drain Connections .............................................................................................................................. 14

Section 3 Operation

Step-by-Step Installation .................................................................................................15

Pre-installation Checklist .................................................................................................................. 15

Connections .......................................................................................................................................... 16

Start-up & Cleaning ............................................................................................................................ 17

Serial Number ....................................................................................................................................... 17

Post Installation Checklist ................................................................................................................ 19

Sequence of Operation ....................................................................................................21

Product Dispense Operation ........................................................................................... 21

Operation ............................................................................................................................................... 21

Refrigerated Cabinet Operation .....................................................................................22

Normal Operations ............................................................................................................................. 22

Evaporator & Condenser Fan Motor Operation ........................................................................ 22

Operation in the Clean/Sanitize Cycle ......................................................................................... 22

Adaptive Defrost ..................................................................................................................................22

High Temp Alarm .................................................................................................................................22

Thermistor Failure ...............................................................................................................................22

Other Operations .............................................................................................................23

Recommended Cups ..........................................................................................................................23

Changing the Cup Dispenser Size ................................................................................................. 23

Manual Fill Ice ....................................................................................................................................... 23

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Section 4 Maintenance

Section 5 Controls

Table of Contents (continued)

General Maintenance .......................................................................................................25

Daily, Weekly, Monthly ...................................................................................................................... 25

Quarterly & Biannual .......................................................................................................................... 25

Annual, Shutdown & Start-up ......................................................................................................... 25

Door Gasket Maintenance ............................................................................................................... 25

Drain Maintenance - Inside Lower Cabinet ................................................................................25

Refrigerator ............................................................................................................................................ 26

Stainless Steel Care & Cleaning ...................................................................................................... 26

Doors/Hinges ........................................................................................................................................ 26

Preventing Corrosion ......................................................................................................................... 26

Cleaning Kits ......................................................................................................................................... 26

Other Monthly Tasks ........................................................................................................................... 27

Daily Cleaning - Zone 1 ....................................................................................................28

Weekly Cleaning - Zone 2 ................................................................................................28

Product Line Flush ............................................................................................................29

Annual Planned Maintenance .........................................................................................29

Section 6 Troubleshooting

Touch Screens ................................................................................................................... 31

Drink Selection Screen ...................................................................................................................... 31

Flavor Selection Screen ..................................................................................................................... 32

Size Screen ............................................................................................................................................. 32

Main Menu Screen .............................................................................................................................. 34

Manager’s Menu Screen....................................................................................................................35

Updates ................................................................................................................................................... 43

Product Inventory Screen .................................................................................................................50

Cleaning Screen ................................................................................................................................... 52

Store Manager Level ........................................................................................................53

Before Calling For Service Checklist ............................................................................................. 53

Technician Level ...............................................................................................................55

This troubleshooting is to be used only by qualified service technicians. .................55

Display Errors ...................................................................................................................55

Control System ..................................................................................................................................... 57

Beverage System ................................................................................................................................. 58

Water System Checklist ..................................................................................................................... 59

Blender Controls Flowchart ............................................................................................................. 60

Blender Controls Flowchart (Continued) .................................................................................... 61

Refrigerated Cabinet ........................................................................................................62

Refrigerated Cabinet Flowchart ..................................................................................................... 62

How to Check Air/CO2 Pressure .......................................................................................64

How to Adjust Air/CO2 Pressure ..................................................................................................... 65

How to Check Plain Water Pressure ................................................................................66

6 Part Number 9294938 07/29/2016

Section 7 Component Check Procedures

Component Identification ...............................................................................................67

External ................................................................................................................................................... 67

Internal .................................................................................................................................................... 68

Control System .................................................................................................................70

ON/OFF Rocker Switch ...................................................................................................................... 70

Power Relay ........................................................................................................................................... 70

UI (User Interface - Touchscreen) ................................................................................................... 71

Control Boards ..................................................................................................................................... 73

Blender Control Board ....................................................................................................................... 76

Syrup Solenoid Valve.......................................................................................................................... 77

Non Drip Valve ...................................................................................................................................... 78

Product Pump .......................................................................................................................................78

Step Motor ............................................................................................................................................. 79

Blender Motor ....................................................................................................................................... 79

Shaver Motor.........................................................................................................................................80

Home Position Switch ........................................................................................................................81

Door Switches ....................................................................................................................................... 81

Ice Bin Lid Microswitch ...................................................................................................................... 82

Water Rinse Solenoid Valve..............................................................................................................83

Refrigerated Cabinet ........................................................................................................84

Temperature Thermistor - Nozzle, Cabinet or Defrost ........................................................... 84

Evaporator Fan Motor ........................................................................................................................ 85

Duct Fan Motor .................................................................................................................................... 85

Condenser Fan Motor ........................................................................................................................ 85

Reach-in Temperature Out of Range ............................................................................................ 86

High Product Temperature ..............................................................................................................87

Refrigeration System Diagnostics ..................................................................................88

Analyzing Discharge Pressure or Temperature ......................................................................... 88

Analyzing Suction Pressure or Temperature .............................................................................88

Compressor Drawing Locked Rotor .............................................................................................. 89

Diagnosing Capacitors ...................................................................................................................... 89

Filter-Driers .......................................................................................................................89

Section 8 Charts

Table of Contents (continued)

Total System Refrigerant Charge ....................................................................................91

Nominal Operating Voltage ............................................................................................92

Nominal Operating Voltage for Loaded Electrical Components ........................................ 92

Nominal Operating Voltage for Sensors ..................................................................................... 92

Section 9 Diagrams

Wiring & Plumbing Diagrams ..........................................................................................93

Control Boards Wiring Diagram ..................................................................................................... 94

Lower Refrigeration Cabinet Wiring Diagram ........................................................................... 95

Shaver Motor & Harness Wiring .....................................................................................................95

Lower Refrigeration Cabinet Plumbing Diagram ....................................................................96

Product Plumbing & LMS Valve Layout ....................................................................................... 97

Dispense System Diagram ............................................................................................................... 98

Part Number 9294938 07/29/2016 7

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Section 1

General Information

Model Numbers

This manual covers the following models:

MA-8-2, MA-8-2BF, MA-8-2AF

MODEL NOMENCLATURE:

MA - 8 - 1 6 - xxxx

I II III IV V

Brand Name

(Manual Fill)

Number of

Flavors

Blenders

1 = One

Blenders

2 = Two Blender

Ice

Capacity

(Not used on

Manual Fill)

Optional

Customer

Specific

Characters

About Blend-In-Cup

The Blend-In-Cup beverage system is a self-contained dispensing unit that allows the operator to make flavor combinations of blended and non-blended drinks. It holds product flavoring in a refrigerated reach-in base enclosure, has a refrigerated ice making machine and includes one or two mixing modules.

The operator controls and accesses the unit using a lighted touch screen. Icons on the drink selection screens represent the primary flavor combinations for the drinks. There are multiple drink size options. Menu changes and additions are uploaded using a USB mass storage device and the Menu Connect Software platform.

On-screen instructions also include operator procedures for cleaning/sanitizing, checking inventory, replacing product bags, selecting drink sizes and manually preparing drinks. Managers and technicians have access to menu/software updates, diagnostics and other service screens.

NOTE: These units are intended for indoor use.

Serial Number Location

The Blend-In-Cup beverage system serial number is listed on the serial number decal affixed to the middle of the lower back panel. Another serial number decal is located on the right side of the machine.

Sample Serial Tag

Part Number 9294938 07/29/2016 9

General Information Section 1

* H

Specifications

DIMENSIONS

Elevation View Side View

Plan View

NOTE: This illustration covers all models, grayed out areas are options that may be on the unit. Dimension C is the same on all models.

* Low profile casters reduce height by 1.5” (4 cm)

A 71.25" (181 cm) C 26.00" (66 cm) E 60.25" (153 cm) G 33.74" (86 cm) I 36.15" (92 cm) B 32.82" (83 cm) D 40.10" (102 cm) F 26.00" (66 cm) *H 63.48" (161 cm) J 39.09" (99 cm)

Warning

To avoid instability the installation area must be capable of supporting the weight of the equipment and a full bin of ice. Additionally the equipment must be level side to side and front to back.

CAPACITY & WEIGHT

Ice Capacity HP Max Product

Lower Cabinet – 1/5 19.8 lbs

Ice Bin 23 lbs (10 kg) – –

BinLoad

(9 kg)

Shipping

Weight

461 lbs

(209 kg)

Crated

Empty Weight Full Weight

347 lbs

(157 kg)

Unpacked No

Ice/Product

500 lbs

(227 kg)

With Ice/

Product

10 Part Number 9294938 07/29/2016

Section 1 General Information

PRODUCT DELIVERY LOCATION

The location selected for the Blend-In-Cup Beverage System must meet the following criteria.

• The air temperature must be at least 40°F (4°C), but must not exceed 90°F (32°C), climate class 4.

• The location must not be near heat-generating equipment or in direct sunlight and must be protected from weather.

• Plain or Chilled Inlet Water Temperature: min/max = 40°F / 90°F (4°C / 32°C).

• Always use the water supply line supplied when installing this appliance. Never reuse an old supply line.

• Verify floor of install location is level front to back, side to side.

• Keep equipment area clear of combustible material.

Warning

Carbon Dioxide (CO2) displaces oxygen. Exposure to a high concentration of CO2 gas causes tremors, which are followed rapidly by loss of consciousness and suffocation. If a CO2 gas leak is suspected, particularly in a small area, immediately ventilate the area before repairing the leak. CO2 lines and pumps must not be installed in an enclosed space. An enclosed space can be a cooler or small room or closet. This may include convenience stores with glass door self serve coolers. If you suspect CO2 may build up in an area, venting of the B-I-B pumps and / or CO2 monitors must be utilized.

REFRIGERANT CHARGE

Important

Due to continuous improvements, this information is for reference only. Please refer to the serial number tag to verify electrical data. Serial tag information overrides information listed on this page.

R-404a

Lower Cabinet

(Cabinet 1)

12 oz.

(339 g)

Clearances

Top 18" (46 cm)

Sides 0" (0 cm)

Back 6” (15 cm)

Front 30" (76 cm)

Warning

Do not obstruct machine vents or openings.

Heat of Rejection

Models Heat of Rejection

BTU/h

R404a Base Cabinet (Cabinet 1) 2100

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General Information Section 1

Electrical

Warning

All wiring must conform to local, state and national codes.

Minimum Circuit Ampacity

The minimum circuit ampacity is used to help select the wire size of the electrical supply. (Minimum circuit ampacity is not the Blend-In-Cup Beverage System’s running amp load.) The wire size (or gauge) is also dependent upon location, materials used, length of run, etc., it must be determined by a qualified electrician.

Electrical Requirements

Refer to Blend-In-Cup Beverage System Model/Serial Plate for voltage/amperage specifications.

Caution

Operate equipment only on the type of electricity indicated on the specification plate.

Voltage

The standard voltage is 230 VAC-50 Hz. A dedicated electrical circuit is required, a power cord is provided with all units.

Some models are available in different voltages and may be equipped with a different plug, for details on each model always refer to the serial number tag to verify electrical data.

Minimum Circuit Amperage Chart

Important

Model Voltage/Cycle/

Phase

MA-8-2 120/60/1 8.6

MA-8-2AF 230-240/50/1

Grounding Instructions

The machine must be grounded in accordance with national and local electrical codes.

This appliance must be grounded. In the event of malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the

Total Amps Breaker Size

5.0

Warning

(Max)

20AMA-8-2BF 220/60/1

risk of electric shock. This appliance is equipped with a cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Bonding Instructions (230-240V 50 Hz Models Only)

This appliance must be connected to the potential equalization system in accordance with EN60335-1 and EN60335-2-75. A bonding lug is provided on the lower right front corner of the appliance.

Warning

This machine must be connected to the potential equalization system.

Warning

When using electric appliances, basic precautions must always be followed, including the following:

a. Read all the instructions before using the

appliance.

b. To reduce the risk of injury, close supervision

is necessary when an appliance is used near

children. c. Do not contact moving parts. d. Only use attachments recommended or sold by

the manufacturer. e. Do not use outdoors. f. For a cord-connected appliance, the following

must be included:

• Do not unplug by pulling on cord. To unplug, grasp the plug, not the cord.

• Unplug from outlet when not in use and before servicing or cleaning.

g. Follow applicable lock out tag out procedures

before working on equipment.

h. Always unplug before replacing the lamp.

Replace the bulb with the same type.

i. Connect to a properly grounded outlet only. See

Grounding Instructions.

12 Part Number 9294938 07/29/2016

Section 1 General Information

AIR / CO2, PLAIN & CHILLED WATER

Warning

Connect to a potable water supply only.

• Use supplied 3/8” (.95 cm) panel-mounted hose barb and 6’ (1.8 m) of beverage tubing to connect labeled coupling body fitting(s) on back of unit for each supply connection.

• Do not connect either water connection to a hot water supply. Be sure all hot water restrictors installed for other equipment are working. (Check valves on sink faucets, dishwashers, etc.)

• Install a water shut-off valve in the water line at the rear of the machine.

• Insulate water inlet lines to prevent condensation.

Drain

OUT

Plain

Water

Air/CO2 IN

Hard Water

In areas where the water is highly concentrated with minerals the water should be tested by a water treatment specialist, and the recommendations of the specialist regarding filtration and/or treatment should be followed.

SYSTEM PRESSURES

Supply to the Unit

Warning

Do not supply more than 80 psi (0.551 MPa , 551 kPa,

5.51 bar) Air/CO2 to the unit, excessive pressure to product pumps may cause failure.

This table shows the Minimum / Maximum supply of Water and Air/CO2 required at the rear of the machine at no flow conditions.

MINIMUM MAXIMUM

Air / CO

Supply

Plain Water

Supply

(..345 MPa , 345 kPa, 3.45 bar)

(0.448 MPa , 448 kPa, 4.48 bar)

50 psi

65 psi

80 psi

(0.551 MPa , 551 kPa, 5.51 bar)

90 psi

(0.620 MPa, 620 kPa, 6.20 bar)

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General Information Section 1

REGULATOR SETTINGS & LOCATION

Regulator Settings

Important

Air/CO2 Requires the pressure measurement to be taken

ON/OFF

Switch

Air/CO2 (Pumps)

Regulator

35 psi (0.24 MPa,

241 kPa, 2.41 bar)

USB Port

Plain Water Regulator

35 psi (0.24 MPa, 241 kPa, 2.41 bar)

only when a product pump is being activated (product pump during flow conditions).

Important

Water requires the pressure measurement to be taken only when rinse water is spraying (flowing conditions) in a blender chamber.

Important

Water pressure affects the blender area cleaning, a water booster may be required if pressure is too low.

REGULATOR SETTINGS (During Flowing Conditions)

Pumps

Air / CO

Plain Water

(0.24 MPa, 241 kPa, 2.41 bar)

35 psi

DRAIN CONNECTIONS

• Connect supplied 1” ID hose to hose-barb connection on machine.

• Drain lines must have a 1.5 inch drop per 5 feet of run (2.5 cm per meter), and must not create traps.

• The floor drain must be large enough to accommodate drainage from all drains.

• An air gap is included in the design of the machine for back flow prevention. Plumb to local code.

14 Part Number 9294938 07/29/2016

Installation

Step-by-Step Installation

These instructions are provided to assist the qualified installer. Contact your Manitowoc Foodservice Service Agent or call Manitowoc Foodservice for information regarding start-up services.

Important

Failure to follow these installation guidelines may affect warranty coverage.

Section 2

PREINSTALLATION CHECKLIST

Keep product bags in a cooler at least 24 hours prior to installation.

Any damage should be noted and reported to the delivering carrier immediately.

Check the lower portion of the unit to be sure casters are not bent.

Visually inspect the refrigeration package, compressor compartment housing. Be sure lines are secure and base is still intact.

Inspect installation location behind the BIC for electrical outlet location, CO2, water hose fittings, and shutoff.

Check voltage at outlet dedicated for BIC.

Verify floor of install location is level front to back, side to side and all casters are touching the floor.

Warning

The mass of this appliance will allow it to move uncontrolled on an inclined surface. Adequate means must be provided to prevent uncontrolled movement at all times.

Remove the side panels from the unit to make the board connections, Air/CO2 and Water Regulator gauges accessible.

Check that board connections are secure and did not vibrate loose during shipment.

Check that both micro switches are in line with the motor above the blenders.

Part Number 9294938 07/29/2016 15

Installation Section 2

CONNECTIONS

See “System Pressures” on page 13 and “Regulator Settings & Location” on page 14

1. Confirm correct orientation of Water and Air/CO2 fittings.

2. The line set included with the unit should be equipped with male quick connect fitting(s) for the water supply line(s) and female quick connect fitting(s) for the Air/

Electrical

See “Electrical” on page 12

5. If all electrical and grounding requirements have been followed proceed to insert electrical plug from BIC into wall receptacle.

6. Turn power switch on the left hand side of the unit to the ON position.

CO2 supply line

Important

Leave enough slack in the water/CO2/drain lines to allow access to the rear of the machine without disconnecting the lines.

REGULATOR SETTINGS (During Flowing Conditions)

Pumps

Air / CO

Plain Water

(0.24 MPa, , 241 kPa, 2.41 bar)

(0.24 MPa, 241 kPa, 2.41 bar)

35 psi

ON/OFF

Switch

Air/CO2 (Pumps)

Regulator

35 psi (0.24 MPa,

241 kPa, 2.41 bar)

USB Port

Plain Water Regulator

35 psi (0.24 MPa, 241 kPa, 2.41 bar)

Important

Regulators are factory set but will need to be checked and possibly adjusted under flowing conditions once the unit is operational.

See “How to Check Air/CO2 Pressure” on page 64 and “How to Check Plain Water Pressure” on page 66

3. Coil excess tubing and secure with tie straps.

Drain

See “Drain Connections” on page 14

4. Route drain line (minimum 1” ID) to drain, maintaining a 2” (51 mm) air gap. Cut to proper length if needed (do not leave loops in drain).

7. The touch screen should energize and inform the user to perform Zone 2 & 3 cleaning before the unit can be put into operation. See “Start-up & Cleaning” on page 17

Important

Do not add product to the machine until cleaning and sanitizing are complete.

16 Part Number 9294938 07/29/2016

Section 2 Installation

STARTUP & CLEANING

Checklist

Review before proceeding with Start-Up & Cleaning.

All internal packing has been removed?

Set Flavors & Mixers

9. Installer must also choose the number of flavors and mixers to be configured before being granted access to the user interface.

Have all of the electrical, water and CO2 connections been made?

Is there proper clearance around the machine for air circulation?

Is the machine grounded / polarity correct?

Has the machine been installed where the incoming water temperature will remain in the range of 40°F / 90°F (4°C / 32°C)?

Have the regulators been properly set?

Have the blender door(s) sensor position(s) been checked?

Has the Power switch been turned to the ON position?

Serial Number

8. During the first start-up of the machine the installer will be asked to input the unit’s 13 digit serial number.

A. Enter the serial number.

B. Press the green check to continue.

NOTE: These can be changed later through the Manager’s Menu if needed.

Tune-Up Reminder

10. The Tune-Up reminder screen will appear during initial installation, press the green check to continue.

11. The red wrench at the top of the screen and reminder will periodically popup until the installation date is set in the Managers Menu.

NOTE: This will be done once Start-Up and Cleaning have been completed.

Part Number 9294938 07/29/2016 17

Installation Section 2

12. Press the Back Arrow in the lower left corner to access the Main Menu.

13. Select the Cleaning Icon.

14. Select Zone 2, Clean and sanitize the Blend-In-Cup machine by following the on screen instructions.

NOTE: During the cleaning process is an ideal time to verify pressure regulator settings during flowing conditions. See

“Regulator Settings & Location” on page 14

D. Ice bin manually filled with ice. See “Manual Fill Ice” on

page 23 .

E. Product bags retrieved from walk-in cooler, installed into

the product bins and placed into their proper location in the cabinet. See “Procedure to Install a Product Bag” on page 51 & “Assigning Flavors” on page 40.

F. All product lines primed and ready for use.

Label

15. Add labels to product bins, put labels in correct place.

16. Add labels anywhere else on the unit required.

Software

17. Load recipes. See “Recipe Loading Procedure” on page

45.

18. Verify correct drinks and flavors are available.

NOTE: See “Weekly Cleaning - Zone 2” on page 28. By doing so, the following will have been completed:

A. All beverage lines, ice bin, dispense area, and blender

chambers, cleaned and sanitized.

B. Water run through the drain to verify it is draining properly.

C. Verify all regulators are set correctly during

cleaning.

(Drink choices will vary depending on loaded recipe file)

Drink Selection Screen

18 Part Number 9294938 07/29/2016

Section 2 Installation

Calibrate

See “Calibration Procedure” on page 41

19. Product calibration can be performed once operating temperature has been reached. Once completed, the Blend-In-Cup machine is ready for use.

20. Reinstall all side panels.

21. Push the BIC unit into place.

22. Verify the unit is level and shim if necessary.

Demonstrate

23. Demonstrate using the Interface. See “Touch Screens” on page 31.

24. Demonstrate how to make drink. See “Procedure to Make a Drink” on page 33.

25. Demonstrate Manager Menu options, using the default password. (The password can be changed.) See “Manager’s Menu Screen” on page 35.

26. Set date and time to activate warranty.

27. Complete start-up form, sign, and have store manager sign form. (Fax to number on form.)

POST INSTALLATION CHECKLIST

Has the machine been properly sanitized?

Has each flavor been installed and primed?

Has ice been added to the bin?

Have the all regulators been correctly set during flowing conditions?

Is the machine cycling ON/OFF on the temperature control?

Has the owner/operator been instructed regarding maintenance procedures?

Has the owner/operator completed the warranty registration card?

Part Number 9294938 07/29/2016 19

Installation Section 2

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20 Part Number 9294938 07/29/2016

Section 3

Operation

Sequence of Operation

Dual Blend Chamber

without

Cup Dispenser

Drink Selection screen appears after power-up of the unit. Operator presses one of the drink type buttons on the Drink Selection screen, and the Flavor Options screen appears. Once a flavor is selected, the Size screen appears. See “Procedure to Make a Drink” on page 33.

Next the drink preparation sequence commences. If add-ins are required for the drink, the user will be prompted. Here, according to the drink size selected and when initiated through the touch screen, the machine dispenses product and ice into the cup in the dispense area. The cup is then placed into an available blend chamber.

With the blend chamber door closed and after “Start Mixer” is selected on the touch screen, the machine blends the drink for the correct time at the proper blender speed. If add-ins are required for the drink after blending, the user will be prompted.

After the drink is removed and the operator closes the blend chamber door, the automatic rinse of the blender initiates. The Drink Selection screen re-appears.

Dual Blend Chamber

with Top Mount Cup

Dispenser

Product Dispense Operation

The sequence varies according to the recipe. Some recipes will use one ingredient, others will use multiple ingredients. The sequence below uses one ingredient to simplify the sequence.

Prerequisites:

• Line voltage must be supplied

• CO2 pressure is supplied and regulated to the correct pressure

• Product is inserted in cabinet and correctly connected to adapter/tubing

• Ice is available

• Water is supplied at the correct pressure

• A recipe has been developed in MenuConnect and transferred to the control board with a USB drive.

OPERATION

Selecting a drink from the touch screen will energize the following components for the time specified by the recipe:

A. The ice dispense wheel turns to add ice.

B. The water inlet valve opens to dispense water.

C. The solenoid valve opens and supplies CO2 to the

product pump.

D. The product pump energizes and pumps the

product into the cup.

The cup is then transferred to a blending station.

Part Number 9294938 07/29/2016 21

Operation Section 3

Refrigerated Cabinet Operation

Default temperature set point = 2.2°C / 36° F with a 2.2°C / 4° F Differential.

Parameter Default

Setting

Set-point (°F) 36 32 38

Differential (°F) 4 1 6

Minimum Off Time

(Min)

Defrost Run Time

(Min)

Defrost Temperature

(°F)

Defrost Time (Min) 15 10 20

Defrost Initiation

Temperature (°F) Default On Time (Min) 12 10 20 Default Off Time (Min) 3 2 5

3 2 5

180 120 240

43 35 50

5 0 12

Minimum

Setting

Maximum

Setting

NORMAL OPERATIONS

The microprocessor control board controls the cabinet temperature based on the input received from the cabinet temperature thermistor. The thermistor value is compared to the control board set point. When the reach-in temperature is equal or greater than the set point (plus half the differential), the compressor relay closes, provided the following conditions are satisfied:

• Power has been uninterrupted to the control board for a 3 minute period.

• The 3 minute compressor time delay has expired. The delay period starts after the compressor has run and then cycles off.

The compressor relay opens when the reach-in temperature is less than the set point (minus half the differential).

OPERATION IN THE CLEAN/SANITIZE CYCLE

During the weekly cleaning/sanitize cycle, the evaporator fan motor relay and the condenser fan motor/compressor relay remain energized.

ADAPTIVE DEFROST

After 3 hours of cumulative compressor run time, the compressor will be de-energized for fifteen (15) minutes.

HIGH TEMP ALARM

High temp alarm will display when product thermistor is above 5.5°C / 42°F for 30 minutes and the following conditions are satisfied:

• 3 hours since power is applied

• 1 hour since cleaning cycle

Error display will reset when the temperature reaches 5°C / 41°F or below.

THERMISTOR FAILURE

If the microprocessor control board receives an open or shorted cabinet thermistor signal, the following will happen:

1. A fault is displayed on the LCD screen

- Cabinet sensor open

- Cabinet sensor shorted

2. The microprocessor will initiate a default sequence for the refrigeration system - 12 minutes on, 3 minutes off.

3. The default cycle continues until the fault is corrected or power is disconnected. See “Temperature Thermistor

- Nozzle, Cabinet or Defrost” on page 125.

EVAPORATOR & CONDENSER FAN MOTOR OPERATION

The condenser fan motor and compressor share the same relay. The evaporator fan motor relay is energized continuously and the evaporator fan runs continuously.

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Section 3 Operation

Other Operations

RECOMMENDED CUPS

The following are cup general guidelines. Cups outside these parameters may work - testing in the machine with the product will be necessary.

- Cup heights between 4.25" (10.8 cm) and 7.00" (17.8 cm).

- Cup opening diameter greater than 3.50" (8.9 cm) and less than 4.18" (10.6 cm).

- Cup base diameter greater than 2.38" (6.0 cm) and less than 2.62" (6.6 cm).

CHANGING THE CUP DISPENSER SIZE

Turn the inner dial so that the notch sets at 1, 2, 3 or 4. Setting 1 will hold the smallest cup and 4 the largest cup. When the dial moves from 1 to 2, the dispenser fingers retract and allow for a larger cup to be inserted.

MANUAL FILL ICE

Procedure to add ice to the Ice bin.

1. Remove lid from ice bin and set aside.

2. Using a clean/sanitized container transfer ice from the back room ice machine to the ice bin.

3. Pour the ice from the transfer container into the ice bin until it is full; do not overfill.

4. Replace ice bin lid and verify lid seats in place.

5. The lid must fit in place to activate the ice bin lid switch

Position 1

Position 3

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Position 2

Position 4

Operation Section 3

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24 Part Number 9294938 07/29/2016

General Maintenance

Section 4

Maintenance

This section covers common unit components and their care. The chart below is an overview of the maintenance that the end user and service technician should perform, and the frequency. These figures are the minimum required. (X = End User, S = Service Company)

DAILY, WEEKLY, MONTHLY

Maintenance Daily Weekly Monthly

Blender / Dispense Area

Cleaning/ Sanitizing

(Zone 1 Cleaning)

Product Line Cleaning &

Sanitizing (Zone 2 Cleaning)

Drain Cleaning X

Clean Condenser Coil

QUARTERLY & BIANNUAL

Maintenance 3 Months 6 Months

Blender / Dispense Area

Cleaning/ Sanitizing

(Zone 1 Cleaning)

Product Line Cleaning &

Sanitizing

(Zone 2 Cleaning)

Drain Cleaning

Clean Condenser Coil X

ANNUAL, SHUTDOWN & STARTUP

Maintenance Annual After

Prolonged Shutdown

Blender / Dispense Area

Cleaning/ Sanitizing

(Zone 1 Cleaning)

Product Line Cleaning &

Sanitizing

(Zone 2 Cleaning)

Drain Cleaning X

Clean Condenser Coil X

X S

At Start-

Important

If the machine going to be shutdown for any length of time it is recommended to go through the Zone 2 Weekly Cleaning both prior to turning off the unit and when returned to use.

If the unit is turned off, the product will no longer be kept cool in the refrigeration cabinet, remove all product bags and keep refrigerated to prevent spoilage.

DOOR GASKET MAINTENANCE

Door gaskets require regular cleaning to prevent mold and mildew buildup and also to retain the elasticity of the gasket. Gasket cleaning can be done with the use of warm soapy water. Avoid full strength cleaning products on gaskets as this can cause them to become brittle and crack. Never use sharp tools or knives to scrape or clean the gasket. Gaskets can be easily replaced and do not require the use of tools or an authorized service person. The gaskets are “Dart” style and can be pulled out of the groove in the door and new gaskets can be “pressed” back into place.

DRAIN MAINTENANCE  INSIDE LOWER CABINET

Each unit has a drain located inside the unit that removes the condensation from the evaporator coil and routes it to an external condensate evaporator pan. Each drain can become loose or disconnected during normal use. If you notice water accumulation on the inside of the unit, be sure the drain tube is connected to the evaporator drain pan. If water is collecting underneath the unit, make sure the end of the drain tube is in the condensate evaporator in the machine compartment. The leveling of the unit is important as the units are designed to drain properly when level. Be sure all drain lines are free of obstructions.

Warning

Disconnect power to the unit before performing any service or maintenance functions.

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Maintenance Section 4

REFRIGERATOR

Caution

Warning

Do not damage the refrigeration circuit when installing, maintaining or servicing the unit.

The interior and exterior can be cleaned using soap and warm water. If this isn’t sufficient, try ammonia and water or a nonabrasive liquid cleaner. When cleaning the exterior, always rub with the “grain” of the stainless steel to avoid marring the finish. Do not use an abrasive cleaner because it will scratch the stainless steel and can damage the breaker strips and gaskets.

STAINLESS STEEL CARE & CLEANING

To prevent discoloration or rust on stainless steel, several important steps need to be taken. First, we need to understand the properties of stainless steel. Stainless steel contains 70-80% iron, which will rust. It also contains 1230% chromium, which forms an invisible passive film over the steel’s surface, which acts as a shield against corrosion. As long as the protective layer is intact, the metal is still stainless. If the film is broken or contaminated, outside elements can begin to break down the steel and begin to form discoloration or rust. Proper cleaning of stainless steel requires soft cloths or plastic scouring pads.

Important

Never Use Steel Pads, Wire Brushes or Scrapers!

Never use a high-pressure water wash for this cleaning procedure as water can damage the electrical components located near or at the condenser coil.

DOORS/HINGES

Over time and with heavy use, doors and hinges may become loose. If this happens, tighten the screws that mount the hinge brackets to the frame of the unit. Loose or sagging doors can cause the hinges to pull out of the frame, which may damage both the doors and the hinges. In some cases this may require trained & qualified service agents or maintenance personnel to perform repairs.

NOTE: Do not place hot pans on/against the blue ABS liner. Do not throw items into the storage area. Failure to follow these recommendations could result in damage to the interior of the cabinet or to the blower coil. Overloading the storage area, restricting the airflow, and continuous opening and closing of the doors and drawers will hamper the unit’s ability to maintain operational temperature.

PREVENTING CORROSION

Immediately wipe up all spills.

CLEANING KITS

Cleaning solutions need to be alkaline based or nonchloride cleaners. Any cleaner containing chlorides will damage the protective film of the stainless steel. Chlorides are also commonly found in hard water, salts, and household and industrial cleaners. If cleaners containing chlorides are used, be sure to rinse repeatedly and dry thoroughly. Routine cleaning of stainless steel can be done with soap and water. Extreme stains or grease should be cleaned with a non-abrasive cleaner and plastic scrub pad. Always rub with the grain of the steel. There are stainless steel cleaners available which can restore and preserve the finish of the steel’s protective layer. Early signs of stainless steel breakdown are small pits and cracks. If this has begun, clean thoroughly and start to apply stainless steel cleaners in attempt to restore the passivity of the steel.

Caution

Never use an acid based cleaning solution! Many food products have an acidic content, which can deteriorate the finish. Be sure to clean the stainless steel surfaces of ALL food products. Common items include: tomatoes, peppers and other vegetables.

Complete cleaning kits are available (part number 000-BIC001Q). These kits include the following:

• (3) three 5 gallon buckets

• Bucket labels for Wash, Rinse, & Sanitizing

• Red & Blue Cups for blender cleaning

• Squeeze Bottle

• Dispense Area Shield

• Tubing Manifold for product line cleaning

26 Part Number 9294938 07/29/2016

Section 4 Maintenance

OTHER MONTHLY TASKS

Cleaning the Condenser Coil

In order to maintain proper refrigeration performance, the condenser fins must be cleaned of dust, dirt and grease regularly. It is recommended that this be done at least every three months. If conditions are such that the condenser is totally blocked in three months, the frequency of cleaning should be increased. Clean the condenser with a vacuum cleaner or stiff brush. If extremely dirty, a commercially available condenser cleaner may be required.

Failure to maintain a clean condenser coil can initially cause high temperatures and excessive run times. Continuous operation with a dirty or clogged condenser coil can result in compressor failure. Neglecting the condenser coil cleaning procedures will void any warranties associated with the compressor and cost to replace the compressor.

Caution

Never use a high-pressure water wash for this cleaning procedure as water can damage the electrical components located near or at the condenser coil.

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Maintenance Section 4

Daily Cleaning - Zone 1

Zone 1 cleaning is accessed through the cleaning icon on the touch screen. It covers the basic components of the BIC that will need cleaned on a daily basis.

NOTE: The on-screen instructions can vary depending on the recipe that was created with the MenuConnect program. All Zone 1 cleaning steps are covered in the Installation Operation & Maintenance manual that ships with the unit.

• Time to complete - 15 minutes

1. Cycle touch screen to the Main Menu and select the Cleaning icon.

2. In the Cleaning screen select the ZONE 1 icon.

Weekly Cleaning - Zone 2

Zone 2 cleaning is accessed through the cleaning icon on the touch screen. It covers all the steps that will need to be performed to complete the weekly cleaning.

NOTE: The on-screen instructions can vary depending on the recipe that was created with the MenuConnect program or options chosen in the Managers Menu. All Zone 2 cleaning steps are covered in the Installation Operation & Maintenance manual that ships with the unit.

• Time to complete - 90 Minutes

NOTE: An additional 1 hour 45 minutes will be needed if the Sanitizing Ice bin option is enabled in the Managers Menu.

1. Cycle touch screen to the Main Menu and select the Cleaning icon.

Exterior Cleaning

Remove dust and dirt from the exterior surfaces with a mild household dish washing detergent and warm water. Wipe dry with a clean, soft cloth.

Use cleaners designed for use with stainless steel products.

Heavy stains should be removed with stainless steel wool. Never use plain steel wool or abrasive pads. They will scratch the panels.

Plastic exterior panels and UI (User Interface) Screen should be cleaned with a mild household dish washing detergent and warm water on a damp cloth. Wipe dry with a clean, soft cloth.

2. In the Cleaning screen select the ZONE 2 icon.

NOTE: Failure to complete the weekly cleaning sequence entirely will not reset the weekly cleaning timer and will require the process to be repeated.

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Section 4 Maintenance

Product Line Flush

The Product Line Flush procedure allows a user to choose which lines to flush instead of being forced to flush every product line in the unit.

Product Line Flush is accessed through the cleaning icon on the touch screen. It covers all the steps that will need to be performed to complete Product Line Flushing.

NOTE: The on-screen instructions can vary depending on the recipe that was created with the MenuConnect program or options chosen in the Managers Menu. All Product Line Flush steps are covered in the Installation Operation & Maintenance manual that ships with the unit.

1. Cycle touch screen to the Main Menu and select the Cleaning icon.

Annual Planned Maintenance

The following parts are recommended for annual planned maintenance replacement to ensure optimum unit performance and minimize downtime:

• Refrigerator door gasket (cleaning may be sufficient)

• Two (2) #6 O-rings for the water and CO2/air quick connect lines

• Nine (9) LMS valves

• (1 Or 2) Mixer assemblies

• Ice Dispense Wheel

• Blender Shaft Assemblies

NOTE: All planned maintenance must be done by an approved, certified Manitowoc Field Service Technician.

2. In the Cleaning screen select the PRODUCT LINE FLUSH icon.

NOTE: Performing the product line flush through this interface procedure will not reset the Zone 2 cleaning countdown timer, Zone 2 cleaning will need to be performed in its entirety in order to reset the counter.

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Maintenance Section 4

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