Remcor OC2R Installation Manual

IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234 Telephone (800) 238-3600 Facsimile (763) 422-3246

Installation/Service Manual

OC2R/FLOOR MODEL POST-MIX DISPENSERS WITH V3+ FEATURES (W/REMOTE REFRIGERATION)

IMPORTANT:

TO THE INSTALLER. It is the responsibility of the

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

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

Part No. 569000119 June 12, 1997 Revised: February 16, 2000 Control Code A

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

IMI CORNELIUS INC; 1997–2000

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 DESCRIPTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

TWO–FLAVOR OVERCOUNTER (OC2R) UNIT 3. . . . . . . . . . . . . . . . . . . . . . . . . .

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

SYSTEM THEORY OF OPERATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEFROST SYSTEMS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL ELECTRIC DEFROST SYSTEM 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTOMATIC ELECTRIC DEFROST SYSTEM 6. . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘SLEEP’’ (SLEEP TIME) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘WAKE UP’’ (WAKE UP TIME) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

UNPACKING AND INSPECTION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION OF LOOSE-SHIPPED PARTS 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

SELECTING LOCATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TWO–FLAVOR OVERCOUNTER (OC2R) DISPENSER 10. . . . . . . . . . . . . . . . . . .

FOUR–FLAVOR FLOOR MODEL DISPENSER 11. . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE REFRIGERATION ASS’Y 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

INSTALLING TWO–FLAVOR OVERCOUNTER (OC2R) DISPENSER 11. . . . . . .

INSTALLING FOUR–FLAVOR FLOOR MODEL DISPENSER 12. . . . . . . . . . . . . .

INSTALLING DRIP TRAY DRAIN KIT 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING 24 VAC ELECTRICAL CIRCUIT FROM REMOTE

REFRIGERATION ASS’Y TO FCB DISPENSER 12. . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING REMOTE REFRIGERATION ASS’Y REFRIGERATION LINES

TO FCB OVERCOUNTER DISPENSER 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT

DRINK TANKS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING CITY PLAIN WATER SOURCE LINE TO UNIT 13. . . . . . . . . . . . .

INSTALLING PRIMARY CO2 REGULATOR ASS’Y ON CO2 CYLINDER 14. . . . .

CONNECTING CO2 SOURCE LINE TO UNIT CO2 INLET LINE 14. . . . . . . . . . . .

CONNECTING ELECTRICAL POWER CIRCUIT TO UNIT 14. . . . . . . . . . . . . . . . .

PREPARATION FOR OPERATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TURNING ON ELECTRICAL POWER TO REMOTE REFRIGERATION

ASSEMBLY(S) AND FCB DISPENSER 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TURNING ON CO2 SUPPLY TO THE UNIT 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING CO2 REGULATORS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING FCB AND ADJUSTING WATER-TO-SYRUP “RATIO” (BRIX) OF

DISPENSED PRODUCT 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FILLING FREEZE CYLINDERS WITH PRODUCT 17. . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS (cont’d)

CHECKING UNIT FOR SYRUP, CO2, OR PLAIN WATER LEAKS 17. . . . . . . . . .

PLACING UNIT IN OPERATING LOCATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE) 18. . . . . . . . . . . . . . . .

ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS, COMPONENTS “DIAGNOSE’’ (DIAGNOSTIC MODE), AND (‘‘TOTALS” DISPLAYED CYCLES AND

HOURS TOTALS) INTO UNIT 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY 19. . .

SETTING CLOCK (TIME OF DAY) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT 20. . . . . .

PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT 21. . . . . . . . . . . . . . . . . . . .

PROGRAMMING ‘‘WAKE UP’’ (WAKE UP TIME) INTO UNIT 21. . . . . . . . . . . . . . .

PROGRAMMING POINT OF SALE MESSAGE DISPLAY 22. . . . . . . . . . . . . . . . . .

ADJUSTING “VIS SET” (PRODUCT VISCOSITY) OF DISPENSED

PRODUCT 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CYLINDERS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON

OUTLET SENSORS TEMPERATURES. 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) 24. . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE)

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

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

ONTO MESSAGE DISPLAY 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT

ELECTRONICS 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT

ELECTRONICS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED ERROR CONDITIONS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING CONTROL BOX COVER AND BACK, SIDES, AND TOP PANELS

ON UNIT 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATOR’S INSTRUCTIONS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

CONTROL PANEL ASS’Y SWITCHES AND DISPLAYED MESSAGES 31. . . . . . .

CONTROL PANEL ASS’Y SWITCHES 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL ASSEMBLY DISPLAY MESSAGES 32. . . . . . . . . . . . . . . . . . . .

FREEZE CYLINDERS MANUAL OR AUTOMATIC ELECTRIC DEFROST

SYSTEMS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL ELECTRIC DEFROST SYSTEM 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTOMATIC ELECTRIC DEFROST SYSTEM 33. . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘SLEEP’’ (SLEEP TIME) OPERATION 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘WAKE UP’’ (WAKE UP TIME) 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FACEPLATE RELIEF VALVES 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT SAMPLE VALVES 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT SHUTOFF VALVES 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMARY CO2 REGULATOR 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY CO2 REGULATORS 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATED WATER FLOW REGULATORS 34. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP FLOW REGULATORS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS (cont’d)

DISPENSING VALVES 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT CONDITIONS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘OVERRUN’’, AS APPLIED TO FROZEN CARBONATED BEVERAGES 35. . . . .

OPERATING CHARACTERISTICS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING UNIT 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING SYRUP SUPPLY 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT FLAVOR CHANGE 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING CO2 SUPPLY 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE REFRIGERATION ASSEMBLY MAINTENANCE 38. . . . . . . . . . . . . . . . . .

LUBRICATION 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATED WATER FLOW RATE 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER-TO-SYRUP “RATIO” (BRIX) OF DISPENSED PRODUCT 38. . . . . . . . . .

CO2 REGULATORS 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING BEATERS MOTORS CURRENTS 38. . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY 38. .

SETTING ‘‘CLOCK’’ (TIME OF DAY) 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT 39. . . . .

PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT 39. . . . . . . . . . . . . . . . . . . .

PROGRAMMING ‘‘WAKE UP’’ (WAKE UP) TIME INTO UNIT 39. . . . . . . . . . . . . . .

PROGRAMMING POINT OF SALE MESSAGE DISPLAY 39. . . . . . . . . . . . . . . . . .

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

PRODUCT 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND

COMMON OUTLET SENSORS TEMPERATURES 39. . . . . . . . . . . . . . . . . . . . . . .

‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) 39. . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE)

INTO UNIT 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

ONTO MESSAGE DISPLAY 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT

ELECTRONICS 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPLAYED ERROR CONDITIONS 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE

MAINTENANCE 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CO2 GAS CHECK VALVES 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND MAINTENANCE 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING 41. . . . . . . . . .

PERIODIC INSPECTION 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL OF PANELS 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIP TRAY 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BACK PANEL 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

569000119

TABLE OF CONTENTS (cont’d)

SIDE PANELS 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOP PANEL 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOWER FRONT ACCESS PANEL 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPENING AND CLOSING FRONT ACCESS DOOR 41. . . . . . . . . . . . . . . . . . . . . . .

OPENING FRONT ACCESS DOOR 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLOSING FRONT ACCESS DOOR 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING PLAIN WATER PRESSURE REGULATOR 45. . . . . . . . . . . . . . . . . . .

ADJUSTING CARBONATED WATER FLOW RATE 45. . . . . . . . . . . . . . . . . . . . . . .

PRODUCT CARBONATION ADJUSTMENT 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE CYLINDERS

DRIVE SHAFT/ SEAL ASSEMBLIES 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICING DISPENSING VALVES CAGED O-RINGS. 47. . . . . . . . . . . . . . . . . . .

SERVICING FREEZE CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES. 48. . . .

CLEANING REMOTE REFRIGERATION ASS’Y CONDENSER COIL 51. . . . . . . . .

CLEANING AND SANITIZING 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING OF UNIT 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING SYRUP SYSTEMS 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YEARLY OR AFTER WATER SYSTEM DISRUPTION 55. . . . . . . . . . . . . . . . . . . . . .

SERVICING CARBONATOR WATER PUMP WATER STRAINER SCREEN 55. .

REPLACING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK

VALVE 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING CARBONATOR TANK LIQUID LEVEL 56. . . . . . . . . . . . . . . . . . . . . . . .

REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR 57. . . . . . . . . . . . . . . .

REPLENISHING SYRUP SUPPLY 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP TANKS SYSTEM 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BAG–IN–BOX SYSTEM 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CO2 SYSTEM GAS CHECK VALVES 62. . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP FLAVOR CHANGE 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT

MESSAGES 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING. 67. . . . . . . .

ALL CONTROL PANEL SWITCHES NOT OPERATING. 67. . . . . . . . . . . . . . . . . . .

CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED. 68. . . . . . . . . . . . .

PARTIAL MESSAGE OR DULL (POORLY ILLUMINATED) DISPLAY. 68. . . . . . . .

ONE OR MORE FAULT MESSAGES NOT OPERATING. 68. . . . . . . . . . . . . . . . . .

ALL FAULT MESSAGES NOT OPERATING. 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘‘CO2 OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. 69. . . . . . . . . .

‘‘H2O OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. 69. . . . . . . . . .

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

OPERATION. 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OPERATION. 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS (cont’d)

FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT OPERATE. 69

UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE. 69. . . . . . . . . . . . . .

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

SWITCH IS PRESSED. 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING ‘‘CANCEL

DEFROST ’’ SWITCH. 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR 70. . .

CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE. 70. . . . . . . . . . . .

CARBONATOR WATER PUMP WILL NOT SHUT OFF. 70. . . . . . . . . . . . . . . . . . . .

ERRATIC CARBONATOR WATER PUMP CYCLING. 70. . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING DISPENSED PRODUCT 71. . . . . . . . . . . . . . . . . . . . . . . . . . .

BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ TOO LOW. 71. . . . . . . . . . . . . . . . . . . . . . . . .

BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ TOO HIGH. 71. . . . . . . . . . . . . . . . . . . . . . . . .

IMPROPER PRODUCT DISPENSED. 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE, IN ONLY

SMALL AMOUNTS, OR ONLY LIQUID. 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN

DISPENSING. 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY. 71. . . . . . . . . . . .

CYLINDER FREEZE-UP. 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING REMOTE REFRIGERATION ASSEMBLY 72. . . . . . . . . . . .

FCB (OC2R) OVERCOUNTER POST-MIX DISPENSER WITH V3+ FEATURES

(ILLUSTRATED PARTS BREAKDOWN) 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

FCB FOUR–FLAVOR FLOOR MODEL POST-MIX DISPENSER WITH V3+ FEATURES

(ILLUSTRATED PARTS BREAKDOWN) 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF FIGURES

FIGURE 1. TWO–FLAVOR OVERCOUNTER (OC2R) UNIT 3. . . . . . . . . . . . . . . . .

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

FIGURE 3. FLOW DIAGRAM (TWO–FLAVOR OVERCOUNTER (OC2R) UNIT) 7

FIGURE 4. FLOW DIAGRAM (FOUR–FLAVOR FLOOR MODEL UNIT) 8. . . . . .

FIGURE 5. CONTROL PANEL 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. MASTER AND RELAY CIRCUIT BOARD 25. . . . . . . . . . . . . . . . . . . . . . .

FIGURE 7. OPERATING CONTROLS (FOUR-FLAVOR FLOOR MODEL UNIT) 42 FIGURE 8. PARTS IDENTIFICATION (FOUR-FLAVOR FLOOR MODEL UNIT) 43

FIGURE 9. OPERATING CONTROLS (TWO–FLAVOR OC2R UNIT) 44. . . . . . . . .

FIGURE 10. PARTS IDENTIFICATION (TWO–FLAVOR OC2R0 UNIT) 45. . . . . . .

FIGURE 11. SELF-CLOSING DISPENSING VALVE 47. . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 12. FREEZE CYLINDER CUTAWAY VIEW 50. . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 13. BEATERS AND SCRAPER BLADES INSTALLATION 51. . . . . . . . . . .

FIGURE 14. SERVICING BEATER MOTOR DRIVE SHAFT/SEAL ASSEMBLY 52 FIGURE 15. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE

(OVERCOUNTER (OC2R) UNIT) 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 16. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE

(FOUR–FLAVOR FLOOR MODEL UNIT) 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS (cont’d)

LIST OF FIGURES (CONT’D)

FIGURE 17. CARBONATOR LIQUID LEVEL CONTROL SWITCH

ADJUSTMENT 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 18. CO2 GAS CHECK VALVE 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 19. REFRIGERATION FLOW DIAGRAM 64. . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 20. WIRING DIAGRAM (OVERCOUNTER (OC2) UNIT) 65. . . . . . . . . . . .

FIGURE 21. WIRING DIAGRAM (FOUR–FLAVOR FLOOR MODEL UNIT) 66. . . .

FIGURE 22. OVERCOUNTER FCB POST-MIX DISPENSER ASSEMBLY 74. . . . .

FIGURE 23. OVERCOUNTER FCB POST-MIX DISPENSER ASSEMBLY 76. . . . .

FIGURE 24. BLENDER AND TUBING COMPONENTS 78. . . . . . . . . . . . . . . . . . . . .

FIGURE 25. SOLENOID AND FLOAT SWITCH COMPONENTS 78. . . . . . . . . . . . .

FIGURE 26. SOLENOID VALVE ASSEMBLY 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 27. WATER PUMP COMPONENTS 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 28. REGULATOR ASS’Y COMPONENTS 80. . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 29. TUBE ASSEMBLY (WATER PUMP TO CARBONATOR) 80. . . . . . . . .

FIGURE 30. CO2 REGULATOR ASSEMBLY 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 31. FACEPLATE ASSEMBLY 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 32. DISPENSING VALVE ASSEMBLY 82. . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 33. CARBONATOR TANK AND LINKAGE ASSEMBLY 83. . . . . . . . . . . . .

FIGURE 34. DOUBLE CHECK VALVE ASSEMBLY 83. . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 35. MANIFOLD AND TUBE ASSEMBLY 83. . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 36. TUBING ASSEMBLY 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 37. TUBING ASSEMBLY (SYRUP) 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 38. TUBING ASSEMBLY BLENDER TO FOAM PACK 84. . . . . . . . . . . . . .

FIGURE 39. TUBING ASSEMBLY (SYRUP AND WATER SOLENOID TO

BLENDER) 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 40. TUBING ASSEMBLY (REGULATOR TO BLENDER) 85. . . . . . . . . . . .

FIGURE 41. 4 FLAVOR FCB POST-MIX DISPENSER ASSEMBLY 87. . . . . . . . . . .

FIGURE 42. 4 FLAVOR FCB POST-MIX DISPENSER ASSEMBLY 89. . . . . . . . . . .

FIGURE 43. BLENDER AND TUBING COMPONENTS 91. . . . . . . . . . . . . . . . . . . . .

FIGURE 44. SOLENOID AND FLOAT SWITCH COMPONENTS 91. . . . . . . . . . . . .

FIGURE 45. ELECTRICAL BOX COMPONENTS 92. . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 46. CARBONATOR WITH PUMP AND MOTOTR COMPONENTS 92. . .

FIGURE 47. TUBE ASSEMBLY (WATER INLET) 92. . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 48. TUBING ASSEMBLY (CO2 REGULATOR TO CARBONATOR) 92. . .

FIGURE 49. TUBE ASSEMBLY (BLENDER TO FOAM PACK) 93. . . . . . . . . . . . . . .

FIGURE 50. TUBING ASSEMBLY (CO2 REGULATOR TO BLENDER) 93. . . . . . .

FIGURE 51. TUBING ASSEMBLY (CARBONATED WATER OUTLET) 93. . . . . . . .

FIGURE 52. PUMP AND MOTOR COMPONENTS 93. . . . . . . . . . . . . . . . . . . . . . . . .

569000119

TABLE OF CONTENTS (cont’d)

LIST OF TABLES

TABLE 1. DESIGN DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 2. ACCESSORIES AND TOOLS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 3. LOOSE-SHIPPED PARTS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 4. MAIN MENU SELECTIONS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 5. DIP SWITCH FUNCTIONS 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 6. MOTOR SELECT 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 7. POINT OF SALE DISPLAY MESSAGES 23. . . . . . . . . . . . . . . . . . . . . . . .

TABLE 8. “TOTALS” (DISPLAYED CYCLES AND HOURS TOTALS) MENU 27. . .

TABLE 9. DISPLAYED ERROR CONDITIONS 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii

569000119

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 this 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 temperature will cause residual water remaining inside the Unit to freeze resulting in damage to internal components of the Unit.

1 56000119

THIS PAGE LEFT BLANK INTENTIONALLY

569000119

GENERAL DESCRIPTION

This section gives the description, theory of operation, and design data for the FCB (OC2R) Overcounter Two– Flavor and the FCB Floor Model Four–Flavor Post-Mix Dispensers with V3+ Features (hereafter referred to as a Units).

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

This Unit must be installed by a qualified Service Person.This Unit contains no User serviceable parts.

Warranty Registration Date

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

Service Center:

UNIT DESCRIPTION

TWO–FLAVOR OVERCOUNTER (OC2R) UNIT

(see Figure 1) The Two–Flavor Overcounter (OC2R) Unit (see Figure 1) consists basically of two freeze cylinders each con-

taining an internal beater driven by an electric motor, one carbonator which feeds both carbonator-blender tanks, an electronically controlled automatic electric defrost system to defrost the freeze cylinders, and interconnecting tubing, components and fittings necessary to regulate, transfer and dispense product. The components are attached to a steel frame and are enclosed in a steel cabinet. The cabinet panels are easily removed to facilitate installation and service and maintenance. A transparent faceplate, with an integral relief valve and a removable self-closing dispensing valve, is mounted on front of each freeze cylinder. A removable drip tray, with a cup rest, is located directly below the dispensing valves.

IMPORTANT: The OC2R Post-Mix Dispenser (Evaporator Unit) must be used in con-junction with Remote Refrigeration Assembly P/N 4161170001 (60 HZ). The FCB OC2R Post-Mix Dispenser (Evaporator Unit) freeze cylinders evaporator coils are connected to and are refrigerated by the Remote Refrigeration Assembly.

FIGURE 1. TWO–FLAVOR OVER-

COUNTER (OC2R) UNIT

FIGURE 2. FOUR–FLAVOR FLOOR

MODEL UNIT

569000119

FOUR–FLAVOR FLOOR MODEL UNIT

(see Figure 2) The Four–Flavor Floor Model Unit (see Figure 2) consists basically of four freeze cylinders each containing an

internal beater driven by an electric motor, two carbonators which feeds all four carbonator-blender tanks, an electronically controlled automatic electric defrost system to defrost the freeze cylinders, and interconnecting tubing, components and fittings necessary to regulate, transfer and dispense product. The components are attached to a steel frame and are enclosed in a steel cabinet. The cabinet panels are easily removed to facilitate installation and service and maintenance. A transparent faceplate, with an integral relief valve and a removable self-closing dispensing valve, is mounted on front of each freeze cylinder. A removable drip tray, with a cup rest, is located directly below the dispensing valves.

IMPORTANT: The Four–Flavor Floor Model Dispenser (Evaporator Unit) must be used in con-junction with two Remote Refrigeration Assemblies P/N 4161170001 (60 HZ). The Four–Flavor Floor Model Dispenser (Evaporator Unit) freeze cylinders evaporator coils are connected to and are refrigerated by the Remote Refrigeration Assemblies.

CAUTION: Before shipping, storing, or relocating this 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 water in the Unit to freeze resulting in damage to internal components.

Table 1. Design Data

FCB (OC2R) OVERCOUNTER DISPENSER DATA

Unit Part Number:

230 VAC, 60 Hz 416116XXXX

Overall Dimensions:

Height 33-1/2 inches Width 19-1/8 inches Depth Without Drip Tray 35-1/4 inches Depth With Drip Tray 36 inches

Shipping Weight (approx.) 245 pounds

Refrigeration System:

Refrigerant Type and Charge See Unit Nameplate

Ambient Operating Temperature 40° F to 100° F

Electrical Requirements:

Operating Voltage See Unit Nameplate Current Draw See Unit Nameplate

569000119

Table 1. Design Data (cont’d)

FCB FLOOR MODEL FOUR–FLAVOR DISPENSER DATA

Unit Part Number:

230 VAC, 60 Hz 416216XXXX

Overall Dimensions:

Height 60–1/2 inches Width 32–1/2 inches Depth Without Drip Tray 32–1/2 inches Depth With Drip Tray 38 inches

Shipping Weight (approx.) 580 pounds

Refrigeration System:

Refrigerant Type and Charge See Unit Nameplate

Ambient Operating Temperature 40° F to 100° F

Electrical Requirements:

Operating Voltage See Unit Nameplate Current Draw See Unit Nameplate

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 Spanner Wrench, Dispensing Valve 322859000 Refractometer, 0-30 Scale 511004000 Wrench, Rear Seal Housing 2899 Tool, Drive/Coupler Adjustment Gauge 3810

SYSTEM THEOR Y OF OPERATION

(see applicable Figure 3 or 4 Flow Diagram) A CO2 cylinder delivers carbon dioxide (CO2) gas to an adjustable primary CO2 regulator assembly attached to

the cylinder. The primary CO2 regulator assembly in turn delivers CO2 gas to adjustable secondary CO2 regulators inside the Unit and also to the soft drink tanks. CO2 is delivered from the adjustable secondary CO2 regulators to the carbonator tank(s) and also to the product-blender tanks inside the Unit. CO2 gas pressure pushes

569000119

syrup out of soft drink tanks, through syrup sold-out float switches, through electrically-operated syrup solenoid valves, through adjustable syrup flow regulators, and on to product blender tanks. At the same time, plain water passes through water pressure regulator(s) and is pumped into the carbonator tank(s) by the water pump(s) and is carbonated by CO from carbonator tank(s), through electrically operated carbonated water solenoid valves through adjustable carbonated water flow regulators, and on to product blender tanks. Carbonated water and syrup enter the tanks properly proportioned (blended) for the desired BRIX of the dispensed product by adjustment of the syrup flow regulators. From product blender tanks, the product is pushed by CO 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 CO from the freeze cylinder to atmosphere when filling the cylinder with product. Electronic sensing on each freeze cylinder motor provides a means of adjusting the viscosity (consistency) of dispensed product to suit customer preference.

gas pressure also entering tank(s). Carbonated water is pushed by CO2 gas pressure

gas into the freeze cylinders. The beater

gas pressure

DEFROST SYSTEMS

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

MANUAL ELECTRIC DEFROST SYSTEM

The Manual electric defrost system may be activated at any time by pressing ‘‘DEFROST’’ switch on front of the Unit. Refrigeration compressor will operate for a short time, then both freeze cylinders will go into defrost and defrost for approximately 15-minutes. At end of manual defrost cycle, Unit will return to normal operation. Manual defrost may be cancelled at any time by pressing ‘‘CANCEL DEFROST’’ switch.

AUTOMATIC ELECTRIC DEFROST SYSTEM

The automatic electric 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 start of each automatic defrost cycle, refrigeration compressor will operate for a short time. No. 1 freeze cylinder only will go into defrost cycle and defrost for approximately 15-minutes, then will return to normal operation This ends automatic defrost cycle of No. 1 freeze cylinder. No. 2 freeze cylinder will defrost 30-minutes after the start of No. 1 freeze cylinder. The next automatic defrost cycle will occur according to time programmed into the Unit.

‘‘SLEEP’’ (SLEEP TIME)

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

‘‘WAKE UP’’ (WAKE UP TIME)

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

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

569000119

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

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

LINE LEGEND CO

PLAIN WATER CARB WATER SYRUP PRODUCT

CARBONATOR

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

VALVE

CYLINDER

WATER

PRESSURE

SWITCH

CARBONATOR

WATER PUMP

PRESSURE

SWITCH

CHECK

VALVE(3)

CHECK

VALVE

SOFT DRINK

TANK(2)

DOUBLE

LIQUID

CHECK

VALVE

SECONDARY CO2 REGULATORS

TO PRODUCT BLENDER

TANKS (60–PSI GAGE) (2)

SECONDARY CO2 REGULATOR

TO CARBONATOR TANK

(100-PSI GAGE)

FIGURE 3. FLOW DIAGRAM (TWO–FLAVOR OVERCOUNTER (OC2R) UNIT)

569000119

*WATER PRESSURE REGULATORS ARE FACTORY ADJUSTED TO 45-PSI AND SHOULD NOT BE READJUSTED.

CARBONATED WATER

VOLUME SAMPLE VALVE

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

CARBONATOR

TANK (2)

PRODUCT SAMPLE

VALVE (4))

PRODUCT BLENDER

TANK (4)

PRODUCT

SHUTOFF VALVE (4)

CARBONATED

WATER

SAMPLE VALVE (2)

FREEZE

CYLINDER (4)

SECONDARY CO2 REGULATORS

TO PRODUCT BLENDER

TANKS (60-PSI GAGES)

FREEZE CYLINDERS

OVERFLOW TUBE

SECONDARY CO2 REGULATORS

TO CARBONATOR TANKS

(100-PSI GAGES)

CARBONATED WATER

SOLENOID (4)

CO2 PRESSURE

SWITCH

LIQUID CHECK

VALVE (4)

CARBONATED WATER FLOW REGULATOR (4)

SYRUP FLOW

REGULATOR (4)

CYLINDER

LINE LEGEND CO

PLAIN WATER CARB WATER SYRUP PRODUCT

569000119

CO2 GAS

CHECK VALVE (5)

FIGURE 4. FLOW DIAGRAM (FOUR–FLAVOR FLOOR MODEL UNIT)

CO2 GAS

CHECK VALVE (2)

CO2 REGULATOR

121122

SYRUP TANK (4)

PLAIN WATER

PRIMARY

SHUTOFF VALVE

SOURCE

WATER PRESSURE

SWITCH

(2)

SYRUP

SOLENOID (4)

**SYRUP SOLD-OUT

SWITCH (4)

*WATER PRESSURE

REGULATOR (2)

DOUBLE LIQUID

CHECK VALVE (2)

CARBONATOR

WATER PUMP (2)

LIQUID CHECK

VALVE (4)

SYRUP FLOAT

SWITCH (4)

INSTALLATION

This section covers unpacking and inspection, selecting location, installing the FCB Post–Mix Dispenser, preparing for operation, and operation.

UNPACKING AND INSPECTION

NOTE: The FCB Post-Mix Dispenser 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. Unpack FCB Dispenser and remove all shipping tape and packing materials.

2. Unpack LOOSE-SHIPPED parts. Make sure all items are present and in good condition.

Table 3. Loose-Shipped Parts

Item

No. Part No. Name

1 178025100 Tapered Gasket, White 4 5 2 322859000 Spanner Wrench, Dispensing Valve 1 1 3 325216000 Cleaning Brush 1 1 4 311304000 Tapered Gasket, Black 1 5 5 317660000

325992000 6 325282 Thread Cutting Screw, Hex Hd.; No. 8 by 18 by 1/2-in. long 2 4 7 2738 Drip Tray Support, Left 1 X 8 2739 Drip Tray Support, Right 1 X 9 325986000 Drip Tray Support, (Both Left and Right Sides) X 2

10 317659029

325990039

11 326002000 Kit, Drip Tray Drain Hose 1 1 12 2899 Wrench, Rear Seal Housing 1 1 13 3810 Tool, Drive/Coupler Adjustment Gauge 1 1 14 324252000 Leveling Leg 4 X

Cup Rest Cup Rest

Drip Tray Drip Tray

2–Fl

Qty.

4–Fl

Qty.

15 3247 Spacer, White 2 X 16 3221 Front Access Panel 1 X 17 3108 Thread Cutting Screw, Phil Pan Hd; No. 10 by 32 by 1-in. long 2 X 18 3680 Seal Kit, Freeze Cylinder Drive Shaft 1 1 19 325018000 Caster Kit, 4–inch Dia. Casters X 1

IDENTIFICATION OF LOOSE-SHIPPED PARTS

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

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

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

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

5. DRIP TRAY SUPPORTS (item 7) and (item 8) to be installed on front of the Two–Flavor Overcounter Unit (See Figure 9) and secured with Thread Cutting SCREWS (item 6). and THREAD CUTTING SCREWS (Item 17).

6. CUP REST (item 5) to be installed in DRIP TRAY (item 10), then drip tray to be installed on drip tray supports.

7. DRIP TRAY DRAIN HOSE KIT (item 11) to be installed on drip tray as instructed in Instructions provided in the Kit.

8. WRENCH, REAR SEAL HOUSING (item 12) used to remove the drive shaft/seal assembly from inside the freeze cylinder.

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

10. LEVELING LEGS (item 14) are to be installed on bottom of the Unit.

11. FRONT ACCESS PANEL (item 16) to be installed on front of the Unit (See Figure 9) and secured with WHITE SPACERS (item 15) and THREAD CUTTING SCREWS (item 17). SPACERS TO BE INSTALLED BETWEEN THE FRONT PANEL AND THE UNIT FRAME.

12. SEAL KIT, FREEZE CYLINDER DRIVE SHAFT (item 18) is intended to replace seals on the freeze cylinder beater drive shaft assembly. Refer to SERVICE AND MAINTENANCE section of this manual for installation instructions.

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.

TWO–FLAVOR OVERCOUNTER (OC2R) DISPENSER

Locate the Dispenser so the following requirements are satisfied:

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

2. A properly grounded 208–230 VAC, 60Hz single-phase electrical circuit connected through a 15-amp minimum-rated disconnect switch (not provided) fused at 15-amps (slow-blow) or circuit connected through an equivalent HACR circuit breaker must be available to be connected to the electrical box located inside the Unit. ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES. MAKE SURE UNIT IS

PROPERLY GROUNDED.

3. The Unit must be placed in a location which will allow shortest possible refrigeration lines route (not to exceed 50–feet in length) from the Two–Flavor Overcounter Dispenser to the Remote Refrigeration Assembly.

IMPORTANT: Unit operating ambient temperature MUST NOT EXCEED 100° F. Several means are available to achieve proper ambient temperature and air circulation through the Unit which are wall air intake grilles and ceiling exhaust fans, air conditioning, etc. Consult local codes.

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

Circulating air, required to cool the beater drive motors, enters through louvers on back and sides of the Unit. Restricting air from entering the Unit will decrease cooling of the beater motors.

4. When placing Unit in operating location, do not allow wall or obstruction to block louvers on back and sides of the Unit. A minimum of 6-inches clearance must be allowed between back of Unit and wall or obstruction, 6-inches clearance on both sides of the Unit, and a minimum of 12-inches must be provided above the Unit for service and maintenance.

FOUR–FLAVOR FLOOR MODEL DISPENSER

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.

Locate the Dispenser so the following requirements are satisfied:

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

2. The Unit requires a properly grounded 208–230 VAC , 60 Hz single-phase electrical power circuit. The elec- trical power circuit may be connected through a (not provided) 50-amp minimum-rated disconnect switch fused at 50-amps or the power circuit may be connected through an equivalent HACR circuit breaker. ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES. MAKE SURE THE UNIT IS PROPERLY GROUNDED.

3. The Unit must be placed in a location which will allow the shortest possible refrigeration lines route (not to exceed 50–feet in length) from the Four–Flavor FCB Dispenser to the two Remote Refrigeration Assemblies.

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

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

REMOTE REFRIGERATION ASS’Y

(see Figure 19) The Remote Refrigeration Assembly(s) (one required for the Overcounter (OC2R) Dispenser and two required for

the Four–Flavor Floor Model Dispenser) must be located in a location which will allow shortest possible refrigeration lines route (not to exceed 50–feet in length) from the Refrigeration Assembly(s) to the FCB Post-Mix Dispenser. Refer to Installation Instructions provided with the Remote Refrigeration Assembly(s).

INSTALLATION

INSTALLING TWO–FLAVOR OVERCOUNTER (OC2R) DISPENSER

INSTALLING LEVELING LEGS Very carefully, tilt Unit up and install LEVELING LEGS (item 14) in four corners of the Unit base.

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PLACING UNIT IN OPERATING LOCATION

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

2. After Unit has been placed in operating location, make sure the Unit is sitting level by using a carpenters level and adjusting the four leveling legs installed on the Unit.

INSTALLING DRIP TRAY SUPPORTS AND DRIP TRAY

(see Figure 9)

1. Install DRIP TRAY SUPPORTS (items 7 and 8) on front of Unit and secure with THREAD CUTTING SCREWS (item 6).

2. Install DRIP TRAY (item 10) on drip tray supports.

INSTALLING FOUR–FLA VOR FLOOR MODEL DISPENSER

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

NOTE: An alternate to sealing the Unit base to the floor would be to install the CASTER KIT (item 19) provided with the Unit LOOSE–SHIPPED PARTS.

2. After Unit has been placed operating location, make sure it is sitting in a level position on a surface that provides adequate support and stability.

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

INSTALLING DRIP TRAY SUPPORTS, DRIP TRAY, AND CUP REST

1. Install DRIP TRAY SUPPORTS (item 9) on panel above lower front access panel on front of the Unit. Secure supports to panel with THREAD CUTTING SCREWS (item 6).

2. Place DRIP TRAY (item 10) in place on front of the Unit.

INSTALLING DRIP TRAY DRAIN KIT

1. Install DRIP TRAY DRAIN HOSE KIT (item 11) 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 5) in drip tray.

CONNECTING 24 VAC ELECTRICAL CIRCUIT FROM REMOTE REFRIGERATION ASS’Y TO FCB DISPENSER

OVERCOUNTER (OC2R) DISPENSER

1. Remove back, sides, and top panel from Unit as instructed in SERVICE AND MAINTENANCE section of this manual.

2. Route 24 VAC electrical circuit from Remote Refrigeration Assembly up through hole in Dispenser base to inside of the Dispenser.

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3. Connect 24 VAC power circuit grey and red electrical wires to labeled 24 Volt grey and red wires hanging down close to the electrical control box inside the Dispenser. Use wire nuts to secure connections.

FOUR–FLAVOR FLOOR MODEL DISPENSER

1. Remove back, sides, and top panel from Unit as instructed in SERVICE AND MAINTENANCE section of this manual.

2. Route 24 VAC electrical circuits (grey and red electrical wires) from both Remote Refrigeration Assemblies up through hole in Dispenser base to inside of the Dispenser.

3. Remove cover from the electrical control box.

4. Route Remote Refrigeration Assemblies 24 VAC electrical circuits through hole to inside of the electrical control box.

5. Refering to wiring diagram inside the electrical control box, connect the Refrigeration Assemblies 24 VAC electrical circuits grey and red electrical wires to labeled grey and red electrical wires located inside the electrical control box. Use wire nuts to secure connections.

CONNECTING REMOTE REFRIGERATION ASS’Y REFRIGERATION LINES TO FCB OVERCOUNTER DISPENSER

(see Figure 19)

OVERCOUNTER (OC2R) DISPENSER Connect refrigeration lines, routed from the Remote Refrigeration Assembly, to refrigeration connectors on bottom

of the Overcounter (OC2R) Dispenser.

FOUR–FLAVOR FLOOR MODEL DISPENSER Connect refrigeration lines, routed from the two Remote Refrigeration Assemblies, to refrigeration connectors on

back side of the Four–Flavor Floor Model Dispenser. Refer to refrigeration diagram on back side of Dispenser before making refrigeration lines connections.

PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT DRINK TANKS

(see applicable Figure 3 or 4)

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

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

DRINK TANKS AT THIS TIME.

CONNECTING CITY PLAIN WATER SOURCE LINE TO UNIT

(see applicable Figure 3 or 4)

NOTE: The Unit requires connection to a city plain water source line with a minimum water pressure of 12-psig. IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the City plain water source line (see Figure 3). A Cornelius Water Filter (P/N 313860000) and Quick Disconnect Set (P/N 313867000) are recommended.

1. Connect and route city plain water source line up to the Unit.

2. Before connecting the city plain water source line to the Unit, open shutoff valve in city plain water source line for a period of time to flush out any metal shavings, then close valve.

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

THIS TIME.

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INSTALLING PRIMARY CO2 REGULATOR ASS’Y ON CO2 CYLINDER

(see applicable Figure 3 or 4)

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, CO

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. Before installing primary CO2 regulator on CO2 cylinder, open CO2 cylinder valve slightly counterclockwise to blow away any dirt or dust from regulator outlet fitting, then close valve.

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

cylinder can cause serious personal injury.

CONNECTING CO2 SOURCE LINE TO UNIT CO2 INLET LINE

(see applicable Figure 3 or 4)

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). DO NOT TURN ON THE CO2 SOURCE AT THIS TIME.

CONNECTING ELECTRICAL POWER CIRCUIT TO UNIT

(see applicable Figure 20 or 21)

WARNING: Make sure Unit 15-amp minimum-rated disconnect switch (not provided) or equivalent HACR circuit breaker is in the ‘‘OFF’’ position.

1. Route 208–230 VAC, 60 Hz single-phase electrical power circuit (meeting requirements of SELECTING LOCATION) through Unit base to electrical control box inside the Unit.

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

the Unit.

2. Overcounter (OC2R) Dispenser–Connect electrical power circuit to to electrical wires inside the electrical control box as shown in wiring diagram (Figure 20), then install cover on the electrical control box. DO NOT

TURN ON ELECTRICAL POWER TO UNIT AT THIS TIME.

Four–Flavor Floor Model Dispenser–Connect electrical power circuit to electrical terminal block inside the electrical box as shown in wiring diagram (Figure 21), then install cover on the electrical control box. DO

NOT TURN ON ELECTRICAL POWER TO UNIT AT THIS TIME.

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PREPARATION FOR OPERATION

TURNING ON ELECTRICAL POWER TO REMOTE REFRIGERATION ASSEMBLY(S) AND FCB DISPENSER

1. Turn on electrical power to the Remote Refrigeration Assembly(s) at disconnect switch(s).

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

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

TURNING ON CO2 SUPPLY TO THE UNIT

Unit Connected to a CO2 Cylinder..

Open 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. The “CO

OUT” fault message on the Unit

control panel message display should have gone out.

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. to back seat the valve. Back-seating valve prevents leakage around valve shaft.The “CO

OUT” fault message on

the Unit control panel message display should have gone out.

ADJUSTING CO2 REGULATORS

(see applicable Figure 3 or 4)

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

Unit Connected to a Syrup Tanks Syrup Source System.

Adjust CO2 source (CO

cylinder or bulk CO

) primary CO

regulator to read not less then 80 psi.

regulator to read 80 to 100 psi.

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Adjusting Unit Secondary CO2 Regulators.

Product Blender Tanks Secondary CO Check and if necessary, adjust the Unit product blender tanks secondary CO

Regulators.

regulators with 60-psi gages at 25

to 30-psi for the best textured dispensed product.

IMPORTANT: The Carbonator secondary CO

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 CO2 regulator not adjusted high enough will cause decreased flow of carbonated water into the blender tanks which will increase BRIX of the dispensed product.

Carbonator Secondary CO2 Regulator.

Adjust the carbonated water tank secondary CO2 regulator with 100-psi gage to read 50 to 80-psi. Pull up on carbonator tank relief valve to purge air from the tank.

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

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

IMPORTANT: Product shutoff valves, located in lines leading from product blender tanks to freeze cylinders (see applicable Figure 3 or 4), must be closed at this time. Closing valves prevents product from filling freeze cylinders while checking BRIX of product in product blender tanks.

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

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

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

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

B. Second, disconnect CO2 quick disconnect from the soft drink tank. To connect soft drink tank into the Unit syrup system.

C. First, connect CO2 quick disconnect to the soft drink tank to pressurize the tank. D. Second, connect liquid quick disconnect to the soft drink tank.

3. Pressurize the soft drink tanks containing syrup, then connect the tanks into the Unit syrup systems.“OFF 1”, “OFF 2”, “SYRUP 1”, and “SYRUP 2” fault messages will continue to be displayed.

4. The following steps A through J are instructions for adjusting the Water-to-Syrup “Ratio” (Brix) of the dispensed product on on of the systems.

NOTE: The Unit control panel assembly is equipped with a hidden “SECURITY SWITCH” located between the “FILL 1” and the “ERROR RESET” control switches (see Figure 5). Pressing in and holding the “SECURITY SWITCH” for 3 seconds deactivates the control switches preventing tampering with the Unit normal operation. To reactivate the control switches, press in and hold the “SECURITY SWITCH” for 3 seconds.

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NOTE: The adjustable carbonated water flow regulators (see applicable Figure 3 or 4 and 15 or 16), located in their respective systems, control carbonated water flow rate to the product blender tanks. The water flow regulators are factory adjusted at 1.3  0.05 oz/sec and should not normally require adjustment. If adjustment is necessary, adjust as instructed in SERVICE AND MAINTENANCE section of this manual.

A. Press ‘‘FILL 1’’ switch to fill No. 1 syrup system sold-out float. ‘‘SYRUP 1’’ fault message will go out and

‘‘FILL 1’’ fault message will come on. ‘‘OFF 1’’, ‘‘OFF 2’’, and ‘‘SYRUP 2’’ fault messages will continue to

be displayed.

B. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 system product blender tank with product. ‘‘FILL 1’’ fault

message will go out when ‘‘AUTO BLEND 1’’ switch is pressed. When product blender tank is full, press ‘‘FILL 1’’ switch to prevent more product from entering tank. ‘‘OFF 1’’, ‘‘OFF 2’’, and ‘‘SYRUP 2’’ fault messages will continue to be displayed.

C. Open No. 1 product blender tank product sample valve (see applicable Figure 3 or 4) 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.

D. Check product BRIX with a temperature compensated hand-type refractometer. BRIX should read

13 ± 1. If BRIX is not within tolerance, adjust white syrup flow regulator for No. 1 syrup system as follows:

E. Turn regulator adjusting screw to the left (counterclockwise) no more than 1/8-turn at a time to reduce

syrup flow rate or turn screw to the right (clockwise) no more than 1/8-turn to increase flow rate.

F. Place container under No. 1 product sample valve. Open valve to purge product out of product blender

tank, line, and valve, then close valve. ‘‘OFF 1’’, ‘‘OFF 2’’, and ‘‘SYRUP 2’’ will continue to be displayed.

G. Press ‘‘AUTO BLEND 1’’ switch to run new batch of product into product blender tank. When product

blender tank is full, press ‘‘FILL 1’’ switch to prevent more product from entering product blender tank.

‘‘OFF 1’’, ‘‘OFF 2’’, and ‘‘SYRUP 2’’ fault messages will continue to be displayed. H. Repeat steps C and D preceding to check product sample for BRIX. I. Repeat steps F through H preceding until proper BRIX adjustment is achieved. J. Repeat steps A through I preceding to adjust BRIX of dispensed product on No. 2 system. After com-

pleting BRIX adjustment on No. 2 system, only the ‘‘OFF 1’’ and ‘‘OFF 2’’ fault messages should contin-

ue to be displayed.

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

FILLING FREEZE CYLINDERS WITH PRODUCT

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

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

CHECKING UNIT FOR SYRUP, CO2, OR PLAIN WATER LEAKS

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

2. Install the Unit back and side panels.

3. Install Unit front access panel (see Figure 9) and secure with THREAD CUTTING SCREWS (item 17) and WHITE SPACERS (ITEM 15).

4. Close front access door, then use a flat blade screwdriver to turn lock clockwise to lock the door.

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PLACING UNIT IN OPERATING LOCATION

1. Disconnect electrical power from Unit at the electrical power source disconnect switch.

IMPORTANT: When installing Unit in it’s operating position, do not allow obstructions to block sides, top, and front of the Unit which will block off cooling air intake to the inside of the Unit. Air flow through the Unit must be present to provide adequate cooling. Refer to SELECTING LOCATION and front clearances to be observed when placing Unit in operating position.

2. Referring to the preceding NOTE, very carefully, place the Unit in operating location.

3. Make sure the Unit is sitting level. The Unit may be leveled by using a carpenter’s level and adjusting the four leveling legs installed on the Unit during installation.

4. Restore Unit to operation by connecting electrical power at the electrical power source disconnect switch.

for sides, top,

ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE)

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

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. Adjust beater motor current (either side) as follows:

1. Using a flat blade screwdriver, turn lock counterclockwise to unlock the front access door, then open the door.

2. Remove four screws securing the upper electrical control box cover (control box located on back of the front access door). Remove cover for access to the master circuit board (see Figure 6 ).

3. Place No. 4 ‘‘BEATER MOTOR CURRENT READOUT’’ switch on DIP SWITCH assembly on master circuit board (see Figure 6) in ‘‘ON’’ position. Both freeze cylinders beater motors will start and operate and beaters motors current ratings will be displayed on message display.

4. Display should be adjusted to read A150 B150 ± 2 by adjusting MOTOR CURRENT ADJUSTMENTS located on No. 1 and No. 2 relay circuit boards (see Figure 6). These figures will fluctuate slightly with variations in line voltage and motor loads.

5. After completion of adjusting beater motor current to A150 B150 ± 2, make sure No. 5 ‘‘MOTOR CURRENT SELF-CALIBRATION’’ switch on DIP SWITCH assembly on master circuit board (see Figure 6) is in ‘‘OFF’’ position. No. 5 switch in ‘‘OFF’’ position allows the ‘‘MOTOR CURRENT’’ SELF-CALIBRATION’’ electronics to automatically self-calibrate the beaters motors currents at completion of each defrost cycle.

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

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

ANY TIME THE NO. 4 ‘‘BEATER MOTOR CURRENT READOUT’’ SWITCH ON DIP SWITCH ASSEMBLY IS PLACED IN ‘‘ON’’ POSITION, THE BEATER MOTOR CURRENT READINGS MUST BE READJUSTED TO A150 B150 ± 2 AS INSTRUCTED, THEN SWITCH MUST BE PLACED BACK IN THE ‘‘OFF’’ POSITION.

6. Close front access door, then use a flat blade screwdriver to turn lock clockwise to lock the door.

7. Install FRONT ACCESS PANEL (item 16) and SPACERS (item 15) and secure with THREAD CUTTING SCREWS (item 17). MAKE SURE SPACERS ARE INSTALLED BETWEEN THE FRONT ACCESS PANEL AND THE UNIT FRAME (see Figure 5).

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HIDDEN SECURITY

SWITCH

FIGURE 5. CONTROL PANEL

MESSAGE DISPLAY

ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS, COMPONENTS “DIAGNOSE’’ (DIAGNOSTIC MODE), AND (‘‘TOTALS” DISPLAYED CYCLES AND HOURS TOTALS) INTO UNIT

NOTE: The Unit control panel switches are as shown in Figure 5.

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

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

procedures can be performed on the Unit.

PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY

The MAIN MENU SELECTIONS (see Table 4) may be brought up on the message display as follows:

1. Press ‘‘AUTO 1’’, ‘‘WASH 1’’, and ‘‘BLEND 1’’ control switches (see Figure 5) at the same time and hold them pressed for a minimum of 1/2 second to bring up MAIN MENU SELECTIONS on message display. The word ‘‘CLOCK’’ will appear on display. You are now in the MAIN MENU SELECTIONS as shown in Table 4 To advance through the MENU SELECTIONS, repeatedly press the ‘‘CANCEL DEFROST’’ (ADVANCE) switch. Once you reach the desired selection, press the ‘‘DEFROST’’ (SELECT) switch to lock in on the selection.

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

SETTING CLOCK (TIME OF DAY)

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

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

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

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

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

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

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

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

The automatic defrost system may be programmed into the Unit to occur up to nine different times during a day with a minimum of two hours between defrost time settings. Program automatic defrost time settings into the Unit as follows:

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

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

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

MENU SELECTIONS

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

“DIAGNOSE” (DIAGNOSTIC MODE)

“TOTALS”

“MOTORS” (BEATER MOTOR MANUFACTURER) See Table 6

“REF TYPE” (REFRIGERANT TYPE)

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

See Programming Components Diagnose into Unit.

See Table 8 and programming “TOTALS” (DISPLAYED CYCLES AND HOURS TOTALS) into unit.

See PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS.

MESSAGE DISPLAY

(EXAMPLE READOUTS)

TABLE 4. MAIN MENU SELECTIONS

5. Press ‘‘DEFROST’’ (SELECT) switch, then repeat steps 2, 3, and 4 to program in next defrost time setting. MAKE SURE A MINIMUM OF TWO HOURS IS MAINTAINED BETWEEN DEFROST TIME SETTINGS. IF A TIME SETTING OF LESS THAN TWO HOURS IS PROGRAMMED INTO THE UNIT, A MOMENTARY

‘‘ERROR’’ MESSAGE WILL APPEAR ON THE MESSAGE DISPLAY WHEN OPERATOR TRIES TO EXIT ‘‘DEFROST’’. THE PROGRAM WILL NOT ALLOW THE OPERATOR TO EXIT THE DEFROST SETTING

UNTIL THE LESS THAN 2-HOUR DEFROST TIME IS CORRECTED. THE OPERATOR MUST PRESS ‘‘CANCEL DEFROST’’ (ADVANCE) SWITCH, THEN REPEAT STEPS 2, 3, and 4 TO PROGRAM CORRECTED DEFROST TIME INTO UNIT.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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SWITCH

NO. FUNCTION

1 POINT OF SALE MESSAGE SELECT See Table 7 2 POINT OF SALE MESSAGE SELECT See Table 7 3 See NOTE. 4 BEATER MOTOR CURRENT READOUT ON- Display current readout.

OFF- No displayed current readout.

5 MOT OR CURRENT SELF-CALIBRATION ON- Disabled.

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

OFF- Electric.

10 SERVICE USE

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

TABLE 5. DIP SWITCH FUNCTIONS

PROGRAMMING POINT OF SALE MESSAGE DISPLAY

(see Figure 6 and Table 7)

NOTE: Point of sale display messages may be turned off by placing No. 1 DIP SWITCH on master circuit board in “OFF” position and No. 2 DIP SWITCH in “ON” position (see Figure 6 and 5 and Table 7).

Three point of sales display messages are available and the desired one may be programmed in to appear on the message display by placing No. 1 and No. 2 switches (see Figure 6, 5, and Table 7) on the DIP SWITCH ASSEMBLY in the appropriate positions.

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 6. MOTOR SELECT

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DIP SWITCH

NO. 1

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

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

*For special messages, contact your local sales representative.

DIP SWITCH

NO. 2 *MESSAGE

TABLE 7. POINT OF SALE DISPLAY MESSAGES

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES.

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

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

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

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

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

‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT)

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

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

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

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

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

‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) may be programmed into the Unit to check certain components for operation. Program ‘‘DIAGNOSE’’ into Unit and check components for proper operation as follows:

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

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

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

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

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

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

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

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

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

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

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

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REFRIGERATION COMMON OUTLET TEMPERATURES

NO. 1 AND NO. 2 EVAPORATOR COILS

NO. 2 EVAPORATOR REFRIGERATION

COIL INLET TEMPERATURE

NO. 1 EVAPORATOR REFRIGERATION

COIL INLET TEMPERATURE

RELAY CIRCUIT

BOARD NO. 1

MASTER CIRCUIT

BOARD

RELAY CIRCUIT

BOARD NO. 2

MOTOR CURRENT

ADJUSTMENT

DIP SWITCH

ASS’Y

1 2

3 4 5 6 7

8 9

POINT OF SALE MESSAGE DISPLA Y SELECT

}

SEE NOTE

BEATER MOTORS CURRENT READOUT (SEE Note in Table 5)

MOTOR CURRENT SELF-CALIBRATION (SEE Table 5)

NOT USED

}

APPLICABLE ELECTRIC OR GAS DEFROST (SEE 5)

SERVICE USE ONLY

(SEE Table 5)

FIGURE 6. MASTER AND RELAY CIRCUIT BOARD

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(see Table 4 and Table 8).

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

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

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

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

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

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

7. Use CANCEL DEFROST (ADVANCE) switch to advance through remaining ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTAL MENU) see Table 8. Press ‘‘DEFROST’’ (SELECT) switch to obtain message display readings of the individual menu selections.

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

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TOTALS MENU COMMANDS DESCRIPTION

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

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

BRIX “A”

11.0 0.1358

11.5 0.1420

12.0 0.1481

12.5 0.1543

13.0 0.1605

13.5 0.1667

14.0 0.1728

14.5 0.1790

15.0 0.1852

15.5 0.1914

16.0 0.1975

GALLONS = “A” x SYRUP MINUTES

Note: “A” numbers are based upon a

4.4 to 1 water to syrup “ratio”.

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

TABLE 8. “TOTALS” (DISPLAYED CYCLES AND HOURS TOTALS) MENU

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MESSAGE

DISPLAYED ERROR

Motor 1 Low Current, < 109,

Sensed on motor one

ITEMS AFFECTED BY ERROR

BEATER

MOTOR 1

OFF OFF

BEATER

MOTOR 2

REFRIG 1 REFRIG 2

Motor 2 Low Current, < 109,

Sensed on motor two

Motor 1 High current > 255,

Sensed on motor one

Motor 2 High current > 255,

Sensed on motor two

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

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

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

OFF OFF

** 25 minutes on Standard System, 30 minutes on Remote System. *** Unit will complete a defrost cycle before beater motors will shut down.

TABLE 9. DISPLAYED ERROR CONDITIONS

PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT ELECTRONICS

IMPORTANT: Note in Table 6 “MOTOR SELECT” the number of freeze cylinders beater motors Manufacturers that are listed. Your Unit was manufactured and equipped with motors from one of these Manufacturers. A replacement freeze cylinder beater motor is also manufactured by one of these Manufacturers listed. DURING NEW UNIT INSTALLATION, OR WHEN REPLACING ONE OF THE BEATER MOTORS, NOTE THE MANUFACTURER’S NAME ON THE MOTOR(S). THE BEATER MOTOR(S) MANUFACTURER’S NAME(S) MUST BE PROGRAMMED INTO THE UNIT WHICH WILL MATCH THE MOTOR(S) TO THE UNIT ELECTRONICS. Proceed as follows to program the beater motors into the Unit electronics.

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

2. Press The “DEFROST” (SELECT) switch again. A motor Manufacturer’s name (see Table 6) will appear on the message display and will be non-blinking.

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

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

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

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

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

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

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

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS

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

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

A. “R404A2HP”

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

B. “R404A3HP”

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

C. “R502”

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

D. “R402B5OH”

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

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

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

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

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

DISPLAYED ERROR CONDITIONS

Displayed error conditions, associated errors, and items affected by the errors are found in Table 9 DISPLAYED ERROR CONDITIONS.

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

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

2. Install back, sides, and top panels on Unit by reversing removal procedure.

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THIS PAGE LEFT BLANK INTENTIONALLY

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OPERATOR’S INSTRUCTIONS

This section describes operating controls and indicators, dispensed product conditions, operating characteristics, Unit operation, replenishing syrup supply, product flavor change, checking CO2 supply, 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.

NOTE: Four–Flavor floor model Unit– The No. 1 freeze cylinder (see Figure 7) is the left–hand cylinder facing the front of the Unit. The other three freeze cylinders, to the right of No. 1 freeze cylinder, are labeled 2, 11, and 22.

Two–Flavor (OC2R) Unit–The No. 1 freeze cylinder (see Figure 9) 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.

CONTROL PANEL ASS’Y SWITCHES AND DISPLAYED MESSAGES

CONTROL PANEL ASS’Y SWITCHES

(see Figure 5)

NOTE: The Unit control panel assembly is equipped with a hidden “SECURITY SWITCH” located between “FILL 1” and “ERROR RESET” control switches (see Figure 9). Pressing in and holding “SECURITY SWITCH” for 3 seconds deactivates the control switches preventing tampering with Unit normal operation. To reactivate the control switches, press in and hold the “SECURITY SWITCH” for 3 seconds.

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

‘‘FILL 1’’ and ‘‘FILL 2’’ control switches, located on control panel assembly, are touch-type switches and require

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

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

‘‘AUTO BLEND 1’’ and ‘‘AUTO BLEND 2’’ control switches, located on control panel assembly, are touch-type

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

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

‘‘WASH 1’’ and ‘‘WASH 2’’ control switches, located on control panel assembly, are touch-type switches and re-

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

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“AUTO 1” and ‘‘AUTO 2” Control Switches.

‘‘AUTO 1’’ and ‘‘AUTO 2’’ control switches, located on control panel assembly, are touch-type switches and re-

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

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

‘‘OFF 1’’ and ‘‘OFF 2’’ control switches, located on control panel, are touch-type switches and require only

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

‘‘ERROR RESET’’ Control Switch.

‘‘ERROR RESET’’ control switch, located on control panel assembly, is a touch-type switch and requires only

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

‘‘SECURITY SWITCH.’’

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

CONTROL PANEL ASSEMBLY DISPLAY MESSAGES

(see Figure 5)

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

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

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

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

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

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

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

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

operating.

‘‘H2O OUT’’ Fault Message.

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

569000119 32

‘‘CO

OUT’’ Fault Message.

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

‘‘CO2 OUT’’ fault message.

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

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

Unit or product tanks are empty. Syrup systems syrup float switches must be filled with syrup to extinguish

‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages.

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

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

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

‘‘POINT OF SALE’’ Display Message.

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

Common Outlet Temperatures.

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

FREEZE CYLINDERS MANUAL OR AUTOMATIC ELECTRIC DEFROST SYSTEMS

The Unit is equipped with both manual and automatic electrical 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 ELECTRIC DEFROST SYSTEM

AUTOMATIC ELECTRIC DEFROST SYSTEM

The automatic electric 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 start of each automatic defrost cycle, refrigeration compressor will operate for a short time. No.1 freeze cylinder only will go into defrost cycle and defrost for approximately 15-minutes, then will return to normal operation This ends automatic defrost cycle of No. 1 freeze cylinder. No. 2 freeze cylinder will defrost 30-minutes after the start of No.1 freeze cylinder. The next automatic defrost cycle will occur according to time programmed into the Unit.

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‘‘SLEEP’’ (SLEEP TIME) OPERATION

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

‘‘WAKE UP’’ (WAKE UP TIME)

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

FACEPLATE RELIEF VALVES

The faceplate relief valves (see Figure 12), located in each freeze cylinder faceplate, are spring-loaded valves that protect freeze cylinders from accidental over-pressure. The relief valve is also used to manually bleed CO gas from freeze cylinder to atmosphere during filling with product and if gas pockets form in cylinder during operation.

PRODUCT SAMPLE VALVES

The product sample valves, located behind the front access door (see applicable Figure 3 or 4), are manually operated lever-type ball valves used to check product BRIX.Turn valve lever to line up with attached line to open valve and at a 90 degree angle with the line to close the valve.

PRODUCT SHUTOFF VALVES

The two product shutoff valves, located in lines leading from the product blender tanks to the freeze cylinders (see applicable Figure 3 or 4), are manually operated lever-type ball valves and are used to prevent product from entering and filling freeze cylinders while adjusting BRIX of dispensed product. Shutoff valves may also be used to shut off product to individual freeze cylinder for service and maintenance without disrupting operation of other freeze cylinder.

PRIMARY CO2 REGULATOR

The primary CO2 regulator (see applicable Figure 3 or 4) controls CO2 pressure to the soft drink tanks and the Unit secondary CO2 regulators located behind the lower front access panel. If necessary to adjust the primary CO2 regulator, adjust as instructed in the SERVICE AND MAINTENANCE section.

SECONDARY CO2 REGULATORS

The secondary CO2 regulators, located behind the lower front access panel (see applicable Figure 3 or 4), control CO2 pressure to the carbonator and the product blender tanks. If necessary to adjust the secondary CO regulators, adjust as instructed in the SERVICE AND MAINTENANCE section.

CARBONATED WATER FLOW REGULATORS

The adjustable carbonated water flow regulators, (see applicable Figure 3 or 4 and 15 or 16) located behind the front access panel, control carbonated water flow rate to the product blender tanks. The water flow regulators are factory adjusted at 1.3 0.05 oz/sec and should not normally require adjustment. If adjustment is necessary, adjust as instructed in the SERVICE AND MAINTENANCE section.

569000119 34

SYRUP FLOW REGULATORS

The syrup flow regulators located behind the front access door (see applicable Figure 3 or 4 and 15 or 16), are adjustable regulators that control syrup flow rate to the product blender tanks for desired BRIX of dispensed product. Adjust syrup flow regulators for desired BRIX as instructed in the SERVICE AND MAINTENANCE section.

DISPENSING VALVES

Self-closing dispensing valves (see Figure 12), located on faceplates on front of Unit, are operated one at a time or simultaneously to deliver product to the customer.

DISPENSED PRODUCT CONDITIONS

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

Overrun Defined.

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

breakout and secondary by freezing.

Overrun is a Variable.

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

adjusts product texture from very wet to light.

Specific Product Ingredients Affect Overrun.

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

sorb 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.

DRAWING 1

DRAWING 2

DRAWING 3

56900011935

Low Dispensing Volume Affects Overrun.

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

The result is these casual drinks have less overrun than drinks dispensed during peakĆuse periods.

Carbonation Level in Liquid Product Affects Overrun.

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

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

Freezing Affects Overrun.

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

OPERATING CHARACTERISTICS

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

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

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

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

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

OPERATING UNIT

Two–Flavor (OC2R) Unit–The No. 1 freeze cylinder (see Figure 9) 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 message display. This indicates no water supply to Unit.

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

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

569000119 36

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

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

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

REPLENISHING SYRUP SUPPLY

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

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

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

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

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

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

Syrup supply should be checked daily and if necessary, replenished as instructed in SERVICE AND MAINTENANCE section of this manual.

PRODUCT FLAVOR CHANGE

Perform syrup flavor change as instructed as instructed in SERVICE AND MAINTENANCE section of this manual.

CHECKING CO2 SUPPLY

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

Make sure CO2 cylinder shutoff valve is fully opened and regulator assembly 1800-psi gage indicator is not in shaded (‘‘change CO2 cylinder’’) portion of dial. If so, CO2 cylinder is almost empty and must be replaced as instructed in SERVICE AND MAINTENANCE section of this manual.

CLEANING AND SANITIZING

DAILY CLEANING

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

SANITIZING

The Unit syrup systems should be sanitized as instructed every 90–days and before and after storage periods following parent company requirements and sanitizer manufacturers recommendations. Sanitize syrup systems as instructed in SERVICE AND MAINTENANCE section of this manual.

56900011937

REMOTE REFRIGERATION ASSEMBLY MAINTENANCE

The Remote Refrigeration Assembly(s) connected to the FCB Dispenser is equipped with a condenser coil that must be cleaned every 30-days. Refer to manual provided with the Remote Refrigeration Assembly for condenser coil cleaning instructions.

LUBRICATION

Carbonator pump motor must be lubricated as instructed on the motor.

ADJUSTMENTS

CARBONATED WATER FLOW RATE

The carbonated water flow regulators (see applicable Figure 3 or 4 and 15 or 16), which control carbonated water flow rate into product blender tanks, are factory adjusted and normally do not require further adjustment. If adjustment should become necessary, adjust as instructed in the SERVICE AND MAINTENANCE section of this manual.

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

Water-To-Syrup “Ratio” (BRIX) is the water-to-syrup “ratio” of the dispensed product. Adjust BRIX as instructed in the INSTALLATION section of this manual.

CO2 REGULATORS

Primary CO2 Regulator.

The primary CO2 regulator (see applicable Figure 3 or 4 ) regulates CO2 pressure to the soft drink tanks (also to the bag-in-box syrup system if used) and also to the secondary CO2 regulators located inside the Unit. If necessary to adjust the primary CO2 regulator, adjust as instructed in the INSTALLATION section of this manual.

Secondary CO2 Regulators.

The secondary CO2 regulators (see applicable Figure 3 or 4 ) regulate CO2 pressure to the carbonator and product blender tanks. If necessary to adjust secondary CO2 regulators, adjust as instructed in the INSTALLATION section of this manual.

ADJUSTING BEATERS MOTORS CURRENTS

Beaters motors currents must be adjusted as instructed in THE INSTALLATION section of this manual.

PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY

The MAIN MENU SELECTIONS (see Table 4) may be brought up on the message display as instructed in the INSTALLATION section of this manual.

SETTING ‘‘CLOCK’’ (TIME OF DAY)

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

569000119 38

Program ‘‘CLOCK’’ (TIME OF DAY) into Unit as instructed in the INSTALLATION section of this manual.

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

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

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

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

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

PROGRAMMING POINT OF SALE MESSAGE DISPLAY

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

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

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

DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES

Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be displayed on the message display as instructed in the INSTALLATION section of this manual.

‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT)

Displayed voltage readout may be displayed on message display as instructed in INSTALLATION section of this manual.

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

56900011939

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

‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS) may be displayed on the message display as instructed in the INSTALLATION section of this manual.

PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS

DISPLAYED ERROR CONDITIONS

Displayed error conditions, associated errors, and items affected by the errors are found in Table 9 DISPLAYED ERROR CONDITIONS.

W ATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE MAINTENANCE

(see applicable Figure 3 or 4 and 15 or 16)

WARNING: The carbonator water pump water strainer screen and double liquid check valve must be inspected and serviced after any disruptions (plumbing work, earthquake, etc.) to

the water supply system, and at least once a year under normal circumstances. Water pump with no screen or defective screen in strainer would allow foreign particles to foul the double liquid check valve. CO2 gas could then back flow into water system and create health hazard in system.

Service water strainer screen and double liquid check valve as instructed in the SERVICE AND MAINTENANCE section of this manual.

CLEANING CO2 GAS CHECK VALVES

(see applicable Figure 3 or 4 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 as instructed in the SERVICE AND MAINTENANCE section of this manual.

569000119 40

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. Make sure the Remote Refrigeration Assembly condenser coil is free from debris. Restricting air circulation through the condenser coil will decrease the refrigeration systems cooling efficiency.

REMOVAL OF PANELS

(see applicable Figure 7 or 9)

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.

OPENING AND CLOSING FRONT ACCESS DOOR

(see applicable Figure 7 or 9)

OPENING FRONT ACCESS DOOR

Using a flat-blade screwdriver, turn lock counterclockwise to unlock the front access door to unlock, then open the door.

569000119

TOP PANEL RETAINING SCREW (2)

MASTER CIRCUIT BOARD

CONTROL PANEL

FACEPLATE RELIEF VALVE (4)

CONTROL PANEL

TOP PANEL

HIDDEN “SECURITY SWITCH”

UPPER CONTROL BOX

FAULT MESSAGE DISPLAY

RELAY CIRCUIT BOARD NO. 1

RELAY CIRCUIT BOARD NO. 2

FRONT ACCESS DOOR

LOWER FRONT ACCESS PANEL

CUP REST

DRIP TRAY

CONDENSER COIL ACCESS PANEL

NOTE: 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 No. 1 freeze cylinder, are labeled 2, 11, and 22.

BACK PANEL

FACEPLATE (4)

DISPENSING VALVE (4)

SIDE PANEL (2)

VENTILATION LOUVERS

SIDE PANEL RETAINING SCREW

FIGURE 7. OPERATING CONTROLS (FOUR-FLAVOR FLOOR MODEL UNIT)

569000119 42

PRODUCT BLENDER

UPPER CONTROL BOX

TANK (4)

FREEZE

CYLINDER (4)

SECONDARY CO

REGULATOR ASS’Y

BEATER DRIVE

MOTOTR (4)

WATER PUMP

MOTOR

(4)

REFRIGERATION

CONNECTORS

ELECTRICAL

CONTROL BOX

FIGURE 8. PARTS IDENTIFICATION (FOUR-FLAVOR FLOOR MODEL UNIT)

569000119

HIDDEN SECURITY

CONTROL PANEL

TOP PANEL

RETAINING SCREW (2)

SWITCH

TOP PANEL

FAULT MESSAGE DISPLAY

FRONT ACCESS DOOR

CONTROL PANEL

FACEPLATE

RELIEF VALVE (2)

LOWER FRONT

ACCESS PANEL

CUP REST

DRIP TRAY

FACEPLATE (2)

DISPENSING VALVE

BACK PANEL

SIDE PANEL (2)

VENTILATION LOUVERS

SIDE PANEL

RETAING SCREW

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

FIGURE 9. OPERATING CONTROLS (TWO–FLAVOR OC2R UNIT)

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RELIEF VALVE (2 )

PRODUCT BLENDER

TANK (2)

CARBONATED WATER FLOW REGULATOR (2)

SYRUP FLOW

REGULATOR (2)

CARBONATOR

TANK

SECONDARY CO

REGULATOR (3)

FREEZE CYLINDER (2)

BEATER DRIVE

MOTOR (2)

FIGURE 10. PARTS IDENTIFICATION (TWO–FLAVOR OC2R UNIT)

CLOSING FRONT ACCESS DOOR

Close front access door, then use a flat-blade screwdriver to turn lock clockwise to lock the door.

ADJUSTMENTS

ADJUSTING PLAIN WA TER PRESSURE REGULATOR

(see applicable Figure 3 or 4 and 15 or 16) The carbonator 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 3 or 4 and 15 or 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:

569000119

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.

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 CO2 regulator, with 60-psi gage, adjusting screw in (clockwise) until gage registers pressure noted in step 7 preceding.

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

18. 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 3 or 4) Carbonation of dispensed product can also be varied to suit consumer preference by adjusting Unit carbonator

secondary CO2 regulator 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.

569000119 46

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 CO2 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.

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

SERVICING DISPENSING VALVES CAGED O-RINGS.

(see Figure 11)

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 12.

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

RETAINING

SCREW(2)

HOLD-DOWN

PLATE(2)

VALVE

LEVER

SLEEVE

SPRING

KNOB

FIGURE 11. SELF-CLOSING DISPENSING VALVE

569000119

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 11) as follows: A. Remove two screws and hold-down plates securing spring housing to dispensing valve body, then re-

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

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

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 (item 14) 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.

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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 14) to set the shaft end at 1.542-inches out of the plastic housing. Make sure Allen-Head set screw in each bearing is securely tightened and properly seated on the shaft flat surface.

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

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

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

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

15. Position SCRAPER BLADES (item 2) on BEATER (item 13) as shown in Figure 13. Slide beater into freeze cylinder so slotted hooks engage DRIVE PIN (item 17) on DRIVE SHAFT (item 19) as shown in Figure 12. 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.

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15 16

21 22 23

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

4 Relief V alve Port 5 O-Ring 6 Flatwasher (4)

7 Hex Nut (4) 8 Faceplate 9 Relief V alve

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

20 Beater Drive Motor 21 Drive Shaft Assembly 22 Viscosity Sensor

23 Spinner 24 Spring

25 Shaft Release 26 Bearing 27 Bearing Housing

10 11

121314

FIGURE 12. FREEZE CYLINDER CUTAWAY VIEW

KEY ON END

OF POST

BEATER

KEY ON END

OF POST

KEY SLOT

ON BLADE

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

FIGURE 13. BEATERS AND SCRAPER BLADES INSTALLATION

CLEANING REMOTE REFRIGERATION ASS’Y CONDENSER COIL

The Remote Refrigeration Assembly (see Figure 19) connected to the FCB Dispenser (Evaporator Assembly) is equipped with a condenser coil that must be cleaned every 30-days. Refer to manual provided with the Remote Refrigeration Assembly for condenser coil cleaning instructions.

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

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 90-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 90-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:

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BEATER

DRIVE MOT OR

DRIVE SHAFT/SEAL ASS’Y

BEATER DRIVE

MOTOR SHAFT

COUPLING

ALLEN-HEAD

SET SCREW

PLASTIC

COUPLER

ALLEN-HEAD

SET SCREW

COUPLING

DRIVE SHAFT

COUPLER

DRIVE

BEATER

DRIVE

COUPLER

LOCK RING

BEARING

GAUGE, DRIVE/COUPLER

PLASTIC

HOUSING

O-RING

ALLEN-HEAD

SET SCREW (2)

DRIVE SHAFT/ SEAL ASSEMBL Y

FIGURE 14. SERVICING BEATER MOTOR DRIVE SHAFT/SEAL ASSEMBLY

(ITEM 13)

SHAFT

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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.

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.

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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.

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.

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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.

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

(see applicable Figure 3 or 4 and 15 or 16)

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.

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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).

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 3 or 4 and 15 or 16)

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.

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

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

8. Connect electrical power to Unit.

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

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

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 3 or 4).

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.

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

REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR

(see Figure 14)

IMPORTANT: Note in TABLE 6. 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 may have a screw in the vent hole on top of the gear box that must be removed before the motor is put into operation.

8. If the new beater motor has a vent hole screw in the vent hole on top of the beater drive motor gear box as noted in previous CAUTION note, remove the screw from the vent hole. BE CAREFUL NOT TO LAY THE

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.

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REPLENISHING SYRUP SUPPLY

SYRUP TANKS SYSTEM

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 tank is empty.

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

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

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

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

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

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

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DOUBLE LIQUID

CHECK VALVE ASS’Y

WATER PRESSURE

SWITCH

WATER STRAINER

WATER PUMP

AND MOTOR

WATER PRESSURE

REGULATOR

SYRUP SOLENOID

VALVE (2)

LIQUID CHECK

VALVE (4)

SYRUP FLOW

REGULATOR (2)

CARBONATED WATER

FLOW REGULATOR (2)

SYRUP SOLD-OUT FLOAT S W I T C H ( 2 )

CARBONATED WATER

SOLENOID VALVE (2)

FIGURE 15. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE

(OVERCOUNTER (OC2R) UNIT)

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SCREEN (P/N 315348000)

SCREEN RETAINER

O-RING (P/N 315349000)

DOUBLE LIQUID

CHECK VALVE ASS’Y

WATER PUMP MOTOR

CARB WATER

FLOW REGULATOR

SYRUP FLOW

REGULATOR

WHITE TAPERED

GASKET

WATER PRESSURE SWITCH

WATER PRESSURE

REGULATOR

WATER PUMP

SYRUP SOLD-OUT FLOAT S W I T C H ( 2 )

CARB WATER

FLOW REGULATOR

SYRUP FLOW

REGULATOR

LIQUID CHECK

VALVE (4)

CARBONATED WATER

SOLENOID VALVE (2)

FIGURE 16. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE

SYRUP SOLENOID

VALVE (2)

(FOUR–FLAVOR FLOOR MODEL UNIT)

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LEVEL CONTROL

SWITCHES(2)

RELIEF VALVE

CARBONATED

WATER TANK

SWITCHES

ACTUATOR BRACKET

ADJUSTMENT SCREW

FIGURE 17. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT

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

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

11. Rinse syrup outlet tube in warm water.

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

the container.

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

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

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

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16. If freeze cylinder is not full of product, repeatedly pull and release the faceplate relief valve to slowly bleed 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.

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.

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.

1. Fully close (clockwise) CO2 cylinder valve.

2. Slowly loosen the primary CO2 regulator assembly coupling nut allowing CO2 pressure to escape, then remove regulator assembly from empty CO2 cylinder.

3. Unfasten safety chain and remove empty CO2 cylinder.

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

WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder in 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.

CLEANING CO2 SYSTEM GAS CHECK VALVES

(see applicable Figure 3 or 4 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

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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.

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REMOTE REFRIGERATION ASS’Y

(P/N 4161170001)

MUST NOT BE INSTALLED MORE

THAN 10–FEET BELOW DISPENSER

(EVAPORATOR ASSEMBLY)

PROCESS LINE(2)

REFRIGERATION LINE SET AVAILABLE IN 25 AND 50–FOOT LENGTHS. LINE LENGTH NOT TO EXCEED 50–FEET.

INLET SENSOR

COMMON

SENSOR

FREEZE CYLINDER(2)

ELECTRONIC

EXPANSION VALVE(2)

INLET SENSOR

OUTLET

EVAPORATOR

NOTE: THIS REFRIGERATION FLOW DIAGRAM REPRESENTS ONE REMOTE REFRIGERATION ASSEMBY REFRIGERATING TWO FREEZE CYLI N D E R S ( A T W O –FLAVOR UNIT). THE FOUR–FLA VOR MODEL UNIT, WOULD BE REPRESENTED BY TWO OF THESE FLOW DIAGRAMS WHICH REQUIRES TWO REMOTE REFRIGERATION ASSEMBLIES TO REFRIGERATE FOUR FREEZE CYLINDERS.

FIGURE 19. REFRIGERATION FLOW DIAGRAM

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FIGURE 20. WIRING DIAGRAM (OVERCOUNTER (OC2) UNIT)

569000119

FIGURE 21. WIRING DIAGRAM (FOUR–FLAVOR FLOOR MODEL UNIT)

TROUBLESHOOTING

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

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

system, stop dispensing, shut off the CO

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

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

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

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

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

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

supply, then relieve the

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

TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES

Trouble Probable Cause Remedy

ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING.

A. Flat cable not properly

connected to control switch module or master circuit

A. Properly connect flat cable to

control switch module or master circuit board.

board.

B. Flat cable connected between

control switch module and master circuit board pinched

B. Check cable for pinched or

broken wire condition and repair

or replace as necessary. and shorted out or broken wire in cable.

C. Inoperable switch(s) on control

panel switch module.

D. Master circuit board not

C. Replace control panel switch

module.

D. Replace master circuit board.

operating properly.

ALL CONTROL PANEL SWITCHES NOT OPERATING.

A. Electric power disconnected

from Unit.

B. ‘‘SECURITY SWITCH’’ has

not been pressed to activate control panel switches.

A. Restore electric power to Unit.

B. Press and hold ‘‘SECURITY

SWITCH’’ for 3 seconds to

restore control panel switches to

operation.

C. ‘‘SECURITY SWITCH’’

inoperable (control switches deactivated).

D. Flat cable not properly

connected to control switch module or master circuit board.

C. Replace control panel switch

module.

D. Properly connect flat cable to

control switch module or master

circuit board.

569000119

Trouble RemedyProbable Cause

ALL CONTROL PANEL SWITCHES NOT OPERATING. (cont’d)

CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED.

PARTIAL MESSAGE OR DULL (POORLY ILLUMINATED) DISPLAY.

ONE OR MORE FAULT MESSAGES NOT OPERATING.

E. Flat cable connected between

control switch module and master circuit board pinched and shorted out or broken wire in cable.

F. Master circuit board not

operating properly.

A. Not pressing and holding

‘‘SECURITY SWITCH’’ for 3 seconds to deactivate control switches.

B. ‘‘SECURITY SWITCH’’

inoperable.

A. Extremely low voltage. A. Upgrade 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.

E. Check cable for pinched or

broken wire condition and repair or replace as necessary.

F. Replace master circuit board.

A. Press and hold ‘‘SECURITY

SWITCH’’ for 3 seconds to deactivate control switches.

B. Replace control panel switch

module.

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.

ALL FAULT MESSAGES NOT OPERATING.

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.

F. Master circuit board not

operating properly.

G. Fault message display

module not operating properly.

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 board.

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. Replace master circuit board.

G. Replace fault message display

module.

B. Properly connect flat cable to fault

message module or master circuit board.

C. Flat cable connected between

fault message module and master circuit board pinched and shorted out or broken wire in cable.

68569000119

C. Check cable for pinched or

broken wire condition and repair or replace as necessary.

Trouble RemedyProbable Cause

ALL FAULT MESSAGE NOT OPERATING (cont’d)

OUT’’ FAULT MESSAGE

‘‘CO

GOES ON DURING OPERATION.

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

D. Master circuit board not

operating.

E. Fault message display module

not operating properly.

A. CO2 supply turned off or

exhausted.

B. Primary CO2 regulator set too

low.

C. Inoperable CO2 pressure

switch.

A. Water supply turned off or

water pressure inadequate.

B. Plugged water filter or water

pump strainer screen.

C. Inoperative water pressure

switch.

D. Replace master circuit board.

E. Replace fault message display

module.

A. Open CO2 cylinder shutoff valve

or replenish CO2 supply as

instructed.

B. Adjust primary CO2 regulator as

instructed.

C. Replace CO2 pressure switch.

A. Turn on water supply or check

water supply line pressure.

B. Change water filter or clean water

pump strainer screen as

instructed.

C. Replace water pressure switch.

‘‘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.

UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE.

MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN ‘‘DEFROST’’ SWITCH IS PRESSED.

A. Soft drink tank empty. A. Replenish syrup supply as

instructed.

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.

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 ‘‘DEFROST’’ switch

on control panel switch

C. Replace control panel switch

module. module.

D. Loose or broken wire. D. Repair wire.

569000119

Trouble RemedyProbable Cause

MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN ‘‘DEFROST’’ SWITCH IS PRESSED. (cont’d)

DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING ‘‘CANCEL DEFROST ’’ SWITCH.

TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR

CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE.

E. Master circuit board not

operating properly.

A. Flat cable not properly

connected to control switch module or master circuit board.

B. Flat cable connected between

control switch module and master circuit board pinched and shorted out or broken wire in cable.

C. Inoperable ‘‘CANCEL

DEFROST’’ switch on control panel switch module.

D. Master circuit board not

operating properly.

A. No electrical power to Unit. A. Connect electrical power to Unit.

E. Replace master circuit board.

A. Properly connect flat cable to

B. Check cable for pinched or

C. Replace control panel switch

D. Replace master circuit board.

control switch module or master circuit board.

broken wire condition and repair or replace as necessary.

module.

Check power source.

CARBONATOR WATER PUMP WILL NOT SHUT OFF.

B. ‘‘AUTO BLEND 1’’ or ‘‘AUTO

BLEND 2’’ switches have not been pressed.

C. ‘‘H2O OUT’’ fault message is

on.

D. ‘‘CO2 OUT’’ fault message is

on.

E. Loose or broken electrical

wires.

F. Overheated water pump motor

cut off by overload protector.

G. Inoperative water pump/motor

assembly.

H. Inoperative carbonated water

tank level control switches.

I. Binding, damaged, or dirty

carbonated water tank balance mechanism.

A. Binding, damaged, or dirty

carbonated water tank balance mechanism.

B. Press ‘‘AUTO BLEND 1’’ or

‘‘AUTO BLEND 2’’ switch.

C. Restore water supply to Unit.

D. Replenish CO2 supply as

instructed.

E. Tighten connections or replace

wires.

F. Check for proper line voltage.

Check restricted pump discharge.

G. Replace water pump/motor

assembly.

H. Replace level control switches.

I. Clean, repair, or replace balance

mechanism.

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.

70569000119

A. Increase water inlet supply line

pressure. Water inlet supply line must have large enough I.D.

Trouble RemedyProbable Cause

TROUBLESHOOTING DISPENSED PRODUCT

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

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

A. Quick disconnect not secure

A. Secure tank quick disconnect.

on soft drink tank.

B. Syrup flow regulator set too

low.

C. Water flow regulator set too

high.

B. Adjust BRIX of dispensed product

as instructed.

C. Water flow regulator must be set

at 1.3 ± 0.05 oz/sec.

D. Syrup flow regulators stuck. D. Clean syrup flow regulators. E. Restriction in syrup line. E. Sanitize Unit as instructed. F. Syrup Baume not in proper

range.

A. Syrup flow regulators set too

high.

B. Water flow regulator set too

low.

F. Change syrup supply as

instructed.

A. Adjust BRIX of dispensed product

as instructed.

B. Water flow regulator must be set

for 1.3 ± 0.05 oz/sec.

C. Water flow regulator stuck. C. Clean regulator. D. Syrup Baume not in proper

range.

D. Change syrup supply as

instructed.

E. Restricted water filter. E. Replace water filter.

IMPROPER PRODUCT DISPENSED.

PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE, IN ONLY SMALL AMOUNTS, OR ONLY LIQUID.

FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING.

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.

B. Cylinder freeze-up. B. Refer to CYLINDER FREEZE-UP. A. ‘‘AUTO BLEND 1’’ or ‘‘AUTO

BLEND 2’’ switch not pressed.

B. Carbonator water pump not

operating.

A. Press ‘‘AUTO BLEND 1’’ or

‘‘AUTO BLEND 2’’ switch.

B. Check carbonator and restore to

operation.

C. Lines restricted. C. Sanitize Unit as instructed.

FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY.

A. Dispensed product BRIX

varying because:

a Syrup and/or water flow

regulator sticking.

b Primary CO2 regulator

pressure insufficient.

A. See below.

a. Clean regulator(s).

b. Primary CO2 regulator must be

adjusted from 80 to 100-psi.

569000119

Trouble RemedyProbable Cause

FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY (cont’d)

CYLINDER FREEZE-UP. A. Dispensed product BRIX too

Trouble Probable Cause Remedy

TROUBLESHOOTING REMOTE REFRIGERATION ASSEMBLY NOTE: Refer to manual provided with the Remote Refrigeration Assembly for troubleshooting

refrigeration assembly.

B. Cylinder freeze-up causing

ice formation in center of cylinder and liquid product channels around ice formation.

NOTE: DEFROST AFFECTED FREEZE CYLINDER AS INSTRUCTED.

low.

B. Viscosity of dispensed product

not properly adjusted.

B. Refer to CYLINDER

FREEZE-UP.

A. Refer to BRIX (Water-to-Syrup)

‘‘Ratio’’ too low.

B. Adjust dispensed product

viscosity as instructed.

72569000119

FCB (OC2R) OVERCOUNTER POST-MIX DISPENSER WITH V3+ FEATURES (illustrated parts breakdown)

UNIT PART NO:

416216XXXX

ILLUSTRATED PARTS BREAKDOWN

73 569000119

1 42 43

7 8

FIGURE 22. OVERCOUNTER FCB POST-MIX DISPENSER ASSEMBLY

74569000119

Item

No.

Part No. Name

1 319941000 Thread Rolling Screw, Hex Washer Hd.,

No. 8-32 By 3/8-In. Long

2 325282000 Self-Drilling Screw, Hex Washer Hd., No.

8-18 By 1/2-In. Long 3 200498003 Hex Nut, No. 8-32 4 320389000 Snap Bushing, .875 Dia. 5 343304000 W asher, .204 I.D. 6 4806 Frame 7 326071000 Expansion Valve 8 309338011 Clip, Sensor, Small 9 309338012 Clip, Sensor, Large (Not Shown)

10 560000929 Utility Box 11 321811000 Hex Nut, No. 10-32 12 3231 Strain Relief 13 560000930 Cover, Utility Box 14 4475 Wire Harness, Input (Not Shown) 15 3108 Thread Cutting Screw, Phil Pan Hd., No.

10-32 By 1-In. Long

16 4866 Panel, Top

5088 Panel, Top, Stainless Steel

17 4865 Panel, Back

5089 Panel, Back, Stainless Steel

18 4864 Panel, Side

5090 Panel, Side, Stainless Steel 19 320754000 Tube, Drain 20 320776000 Strap, Drain 21 317660000 Cup Rest 22 317659029 Drip Tray 23 3184 Leg 24 3221 Panel, Splash

Item

No.

Part No. Name

25 2739 Bracket, Drip Tray, Right-Hand

2738 Bracket, Drip Tray, Left-Hand 26 170413000 Fitting, Drain 27 151281000 Washer, .640 I.D. 28 170423000 Hex Nut, 5/8-32 29 140133000 Clamp, Drain Tube 30 3129 Fitting, Adaptor Kit 31 315865000 Tube, .625 I.D. By 75-In. Long 32 2704 Panel, Back, Display 33 2763 Housing, Display 34 325962040 Touch Switch 35 2897 Hinge, Display 36 325981069 Holder, Flavor tab 37 325925000 Support, P.C. Board 38 324136000 P.C. Board 39 324138000 P.C. Board, Motor No. 2 40 324137000 P.C. Board, Motor No. 1 41 4984 Wire Harness, Circuit Board (Not

Shown)

42 312251000 Thread Rolling Screw, Phil Pan Hd., No.

10-24 By 3/8-In. Long 43 2651 Control Box, Upper 44 0150 Fan 45 2895 Latch Ass’y 46 326078000 Circuit Board Display 47 326079000 Cable, Ribbon 48 320271000 Thread Cutting Screw, Phil Pan Hd., No.

6-32 By 3/8-In. Long 49 330181000 Hex Nut, No. 6-32 50 319739000 Transformer, 240V 50/60HZ 24V

75 569000119

51 5

FIGURE 23. OVERCOUNTER FCB POST-MIX DISPENSER ASSEMBLY

76569000119

Item

No.

Part No. Name

1 319941000 Thread Rolling Screw, Hex Washer Hd.,

No. 8-32 By 3/8-In. Long

2 320940000 Self-Drilling Screw, Hex Washer Hd., No.

10-16 By 5/8-In. Long 3 189429000 Hex Nut, 1/4-20 4 166146000 Hex Nut, 5/16-18 5 178025100 Tapered Gasket, White 6 200498003 Hex Nut, No. 8-32 7 309854000 Clamp, For .395 O.D. T ube 8 360688000 Snap Bushing, 1-In. Dia. 9 311304000 Tapered Gasket, Black

10 343304000 Washer, No. 10 11 316963000 Snap Bushing, 2-In. Dia. 12 4806 Frame 13 325701000 Extension, Foam Pack 14 560005379 Foam Pack 15 324213000 Coupling, 3/8 (Not Shown) 16 309919000 Flange, 3/8 (Not Shown) 17 309920000 Flange, 1/2 (Not Shown) 18 4988 Coupling, 1/2 (Not Shown) 19 4798 Tube Ass’y, CO2 Inlet to Regulator (See

Figure 36)

20 560000854 Tube Ass’y , Syrup Inlet (See Figure 37) 21 5081 Switch, Soldout 22 176272396 Tube Ass’y , Water Inlet (See Figure 36) 23 4491 Rod, Blender Support 24 318035000 Carbonator Ass’y (See Figure 33) 25 4432 Bracket, Spacing, Blender 26 4488 Manifold and Tube Ass’y (See Figure 35)

Item

No.

Part No. Name

27 2360 O-Ring, 1.86 I.D. By .139 C.S. 28 2583 Retaing Ring 29 3787 Coupling 30 4405 Plate, Motor 31 343313000 Washer, .332 I.D. 32 320940000 Self-Drilling Screw, Hex Washer Hd., No.

10-16 By 5/8-In. Long 33 3471 Motor, 1/4H.P. 220V 60HZ 120RPM 34 2463 Bearing, Shaft 35 2591 Housing, Shaft 36 2731 O-Ring, .671 I.D. By .139 C.S. 37 3156 Drive Shaft Ass’y 38 318418000 Washer, .312 I.D. 39 176193000 Fitting, 7/16-20 40 326106000 Door Ass’y, Freeze Cylinder (See Figure

31) 41 320916000 Washer, .450 I.D. 42 320553001 Hex Nut, 7/16-14 43 2392 Bushing, Split 44 3432 Body, B e a t e r 45 325457000 Blade, Scraper 46 317974000 Deflector, Relief Valve 47 320767000 Machine Screw, Phil Pan Hd., No. 10-24

By 3/8-In. Long

48 Regulator Ass’y Components (See

Figure 28)

49 Blender and Tubing Components (See

Figure 24)

50 Pump, Water Components (See Figure

27) 51 Solenoid and Float Switch Components

(See Figure 25)

77 569000119

Item

No.

Part No. Name

Blender and Tubing Components 1 315931000 O-Ring, .364 I.D. By .070 C.S. 2 315925000 O-Ring, 1.60 I.D. By .139 C.S. 3 324047000 Tank, Blender 4 311751000 Machine Screw, Sl Hex Hd., No. 4-40 By

1/4-In. Long 5 311743000 Retainer 6 326105000 Relief Valve 7 325288000 Float Switch Ass’y 8 324048000 Holder, Float Switch 9 324116000 W asher, .625 I.D.

10 324115000 Retaining Ring 11 186570000 Strain Relief 12 183008000 O-Ring, .489 I.D. By .070 C.S. 13 325576000 Tube, Syphon 14 560000125 Tube Ass’y , Blender to Foam Pack (See

Figure 38)

15 4487 Tube Ass’y , Syrup and Water Regulators

to Blender (See Figure 39)

16 4490 Tube Ass’y, CO2 Regulator to Blender

(See Figure 40)

12 12 13 15

12 12 13 14

12 13

8 2 9

FIGURE 24. BLENDER AND TUBING COMPONENTS

Item

No. Part No. Name

Solenoid and Float Switch Components 1 319941000 Thread Rolling Screw, Hex Washer Hd.,

No. 8-32 By 3/8-In. Long 2 315931000 O-Ring, .364 I.D. By .070 C.S. 3 315925000 O-Ring, 1.60 I.D. By .139 C.S. 4 311764001 Check Valve Ass’y (See Figure 34) 5 2487 Solenoid V alve Ass’y, Syrup (See Figure

26) 6 2469 Retainer 7 343487000 Machine Screw, Phil Pan Hd., No. 8-32

By 1/2-In. Long

8 2486 Solenoid V alve Ass’y, Water (See Figure

26) 9 317015000 O-Ring, .239 I.D. By .070 C.S.

10 2462 Connector, Solenoid 11 183008000 O-Ring, .489 I.D. By .070 C.S. 12 315915000 Body, Float Switch 13 325170000 Float Switch Ass’y 14 315916000 Cover, Float Switch 15 4437 Bracket, Solenoid and Float Switch 16 186150000 Machine Screw, Phil Pan Hd., No. 8-32

By 3/8-In. Long

17 560000187 Tube Ass’y , Water Solenoid Valve (See

Figure 29)

FIGURE 25. SOLENOID AND FLOAT SWITCH COMPONENTS

78569000119

Item

No.

Part No. Name

2486 Solenoid Valve Ass’y, Water

2487 Solenoid Valve Ass’y, Syrup 1 2356 Block, V alve 2 1319 Body, Valve 3 0837 Thread Rolling Screw , Phil Pan Hd., No.

6-32 By 5/8-In. Long

4 310754011 Piston, Water

310480011 Piston, Syrup 5 317431011 Cylinder 6 310482000 Spring 7 317816000 O-Ring, .676 I.D. By .070 C.S. 8 310632001 Adjusting Screw 9 1318 Flow Control, Top

10 180025000 O-Ring, .364 I.D. By .070 C.S. 11 1545 Retainer, Flow Control 12 1081 Thread Cutting Screw, Hex Washer Hd.,

No. 8-16 By 1/2-In. Long 13 0024 Solenoid, 24V. 14 187188000 Machine Screw, Phil Pan Hd., No. 8-32

By 1/4-In. Long 15 317579000 Arm, Solenoid 16 0854 Spring 17 311355000 Inlet Valve

FIGURE 26. SOLENOID VALVE ASSEMBLY

Item

No. Part No. Name

Water Pump Components

1 4480 Fitting, .375 I.D. By 3/8-FPT 2 4481 Fitting, .375 I.D. By 3/8-MPT 3 3253 Double Check V alve Ass’y 4 311035000 W ater Strainer 5 325794000 Tube Ass’y, Water Pump to Carbonator

(See Figure 29)

6 4420 Tube, 3/8 O.D. By 2-In. Long 7 560002424 Fitting, 3/4 I.D. By 1/4-MPT 8 3149 Pump and Motor , 230V 50/60HZ

9 3159 Pressure Switch, Water 10 183047000 Fitting, 1/4-MPT 11 0784 Regulator, Water 300-PSI 12 312062000 Fitting, 1/4-MPT By 5/8-18

FIGURE 27. WATER PUMP COMPONENTS

2 6 7

4 12

79 569000119

Item

No.

Part No. Name

Regulator Ass’y Components 1 178025100 Tapered Gasket, White 2 186182000 T ube, .312 I.D. By 16-In. Long 3 325776 Pressure Switch, 50-75 PSI 4 326097001 Regulator Ass’y (See Figure 30) 5 324218000 T ube, .156 I.D. By 3-In. Long 6 317528000 Fitting, Tee, 1/8-Barb 7 560000186 T ube, .156 I.D. By 20-In. Long 8 300393000 Fitting, Tee, 1/8-Barb By 3/8-Barb 9 324219000 T ube, .156 I.D. By 1-In. Long

10 187968000 Tube, .312 I.D. By 20-In. Long

FIGURE 28. REGULATOR ASS’Y COMPONENTS

Item

No. Part No. Name

325794000 Tube Ass’y, Water Pump to Carbonator 560000187 Tube Ass’y, Water Solenoid Valve 2495 Tube Ass’y, Water Pump to Carbonator

1 174103001 T ube, .250 I.D. By 20-In. Long

174103001 Tube, .250 I.D. By 24-In. Long

174103001 Tube, .250 I.D. By 21-In. Long 2 176001000 Ferrule, For .395 O.D. T ube 3 77040100 Fitting, Elbow, Swivel, 716-20

77050100 Fitting, Elbow, 1/4-Barb

FIGURE 29. TUBE ASSEMBLY (WATER PUMP TO CARBONATOR)

80569000119

FIGURE 30. CO2 REGULATOR ASSEMBLY

Item

No. Part No. Name

326097001 CO2 Regulator Ass’y and Bracket,

Secondary

1 183287000 Gage, 60 PSI

183286000 Gage, 100 PSI

2 183412000 CO2 Regulator Ass’y, 100 PSI, Gold

(Includes 3-18)

183449000 CO2 Regulator Ass’y, 30 PSI, Blue

(Includes 3-18)

3 183040000 Machine Screw, Phil Fill Hd., No. 10-32

By 7/8-In. Long

4 183233059 Cover Kit (Includes Nonremovable

Adjusting Screw) 5 183021000 Retainer, Spring 6 183020000 Adjusting Spring, 100 PSI

315424000 Adjusting Spring, 30 PSI 7 130174000 Diaphram Ass’y 8 183011047 Baffle 9 130167000 Guide

10 183010000 Gasket 11 183009007 Retainer, Seat 12 183008000 O-Ring, .489 I.D. By .070 C.S. 13 183007000 Filter Screen

Item

No. Part No. Name

14 183006000 Spring, Poppet 15 130170000 Valve, Poppet 16 130168000 Reducing Valve Seat 17 183003000 Gasket, Seat 18 183001015 Body 19 183057000 Fitting, 1/4-NPT 20 187485000 Fitting, Elbow, 1/4-NPT By 7/16-20 21 183068000 Fitting, Elbow, 1/4-NPT 22 183301100 Check Valve Ass’y with Adapter

(Includes 23-29) 23 183300001 Adapter 24 183320100 Check Valve Ass’y (Includes 25-29) 25 183294000 Quad Ring, .145 I.D. By .070 C.S. 26 183296000 Ball 27 183297000 Spring 28 183298000 Retainer 29 183295100 Body 30 324211000 Fitting, 1/16-NPT By 5/32-Barb

313808001 Fitting, No. 10-32 By 1/8-Barb 31 183317000 Bracket, Regulator (Not Shown) 32 321811000 Hex Nut, No. 10-32 (Not Shown)

81 569000119

Item

No.

Part No. Name

326106000 Door, Freeze Cylinder Ass’y (Cornelius) 560004156 Door, Freeze Cylinder Ass’y (Lancer)

1 325918000 Door, Freeze Cylinder (Cornelius)

560004155 Door, Freeze Cylinder (Lancer) 2 325954088 Relief Valve Ass’y 3 320678000 O-Ring, 4.60 I.D. By .210 C.S. 4 1557 V alve Head Ass’y, Cornelius (See Figure

32)

560003974 Valve Head Ass’y, Lancer 5 321652000 Shank Nut 6 325936000 Spacer 7 321269001 Spinner 8 322441000 Sensor 9 2361 Shaft

10 2358 Pin, Beater Bar 11 560004154 Adapter (Lancer; Not Shown) 12 560004161 Retaining Ring (Lancer; Not Shown) 13 321653000 O-Ring, .862 I.D. (Lancer; Not Shown)

FIGURE 31. FACEPLATE ASSEMBLY

Item

No. Part No. Name

1557 Dispensing Valve Ass’y 1 1556 Body and Shank 2 1554 Valve 3 1576 Housing 4 1575 Fitting 5 325305000 Spring 6 321651000 Lever, Valve 7 1555 Knob 8 325647000 Plate 9 317784000 Thread Cutting Screw, Phil Truss Hd.,

Stainless Steel, No. 8-32 By 3/8-In. long

10 2818 O-Ring, Caged, .562 I.D. By

.210 C.S. 11 321653000 O-Ring, .862 I.D. By .103 C.S. 12 1544 Spring 13 1543 Shaft Release

3 5

FIGURE 32. DISPENSING VALVE ASSEMBLY

82569000119

Item

No.

Part No. Name

318035000 Carbonator Tank and Linkage Ass’y

(OC2R)

326136000 Carbonator Tank and Linkage Ass’y

(4-Flavor Remote)

1 318034000 Tank, Carbonator (OC2R)

326135000 Tank, Carbonator (4-Flavor Remote) 2 317746000 Link, Pivot 3 317772000 Pin 4 318036000 Push-on Nut 5 317747000 Pivot Housing 6 317752000 Spring 7 318037000 Insulation, Switch 8 317771000 Level Control Switch 9 315961000 Machine Screw, Sl. Rd. Hd., No. 4-40 By

1-1/8-In. Long 10 318123000 Switch, Actuator 11 342663000 Thread Cutting Screw, Phil Pan Hd.,

Sems, No. 8-32 By 3/8-In. Long 12 318362000 Relief Valve

FIGURE 33. CARBONATOR TANK AND LINKAGE ASSEMBLY

Item

No. Part No. Name

311765001 Double Check Valve Ass’y

1 311764001 Single Check Valve Ass’y

(Includes 2-7)

2 317965000 Retainer 3 312196000 Spring 4 312419000 Ball 5 312415000 W asher, .300 I.D. 6 312418000 Quad Ring, .329 I.D. 7 317963000 Receptacle

FIGURE 34. DOUBLE CHECK VALVE ASSEMBLY

Item

No. Part No. Name

4488 Manifold and Tube Ass’y 1 3942 Manifold 2 311908000 Clamp, For .395 O.D. T ube 3 174103000 T ube, .250 I.D. By 13 1/2-In. Long 4 174103000 T ube, .250 I.D. By 46-In. Long 5 176001000 Ferrule, For .375 O.D. T ube 6 325012000 Shutoff Valve

1234

FIGURE 35. MANIFOLD AND TUBE ASSEMBLY

83 569000119

Item

No.

Part No. Name

176272396 Tube Ass’y, Water Inlet 4798 Tube Ass’y, CO2 Inlet to Regulator 174061196 Tube Ass’y

1 174292000 T ube, .375 I.D. By 96-In. Long

174478000 Tube, .265 I.D. By 120-In. Long 174478000 Tube, .265 I.D. By 96-In. Long

2 176204000 Ferrule, For .640 O.D. T ube

176000000 Ferrule, For .500 O.D. Tube

3 176205000 Nipple, For .375 I.D. T ube

77010400 Nipple, For .265 I.D. Tube

4 311242000 Nut, Swivel, 5/8-18

176017000 Nut, Swivel, 7/16-20

Item

No. Part No. Name

560000854 Tube Ass’y, Syrup 1 176017000 Nut, Swivel, 7/16-20 2 77010400 Nipple, For .265 I.D. Tube 3 176000000 Ferrule, For .500 O.D. T ube 4 174478000 T ube, .265 I.D. By 92-In. Long

174478000 Tube, .265 I.D. By 3-In. Long 5 5083 Fitting, Tee, Barb 6 176271000 Nipple, For .265 I.D. T ube 7 311242000 Nut, Swivel, 5/8-18

FIGURE 36. TUBING ASSEMBLY

FIGURE 37. TUBING ASSEMBLY (SYRUP)

Item

No. Part No. Name

560000125 Tube Ass’y, Blender to Foam Pack 1 174103000 T ube, .250 I.D. By 1 3/4-In. Long

174103000 Tube, .250 I.D. By 2 1/2-In. Long

174103000 Tube, .250 I.D. By 46-In. Long 2 176001000 Ferrule, For .395 O.D. T ube 3 174103001 T ube, .250 I.D. By 16-In. Long 4 770461000 Fitting, Elbow, Swivel, 1/2-16 By

1/4-Barb 5 1561 Connector, 1/4-Barb By 5/16-Barb 6 325012000 Shutoff Valve 7 77060100 Fitting, Tee, 1/4-Barb

FIGURE 38. TUBING ASSEMBLY BLENDER TO FOAM PACK

7 2

84569000119

Item

No.

Part No. Name

4487 Tube Ass’y, Solenoid Valves to Blender

2491 Tube Ass’y, Solenoid Valves to Blender 1 311742000 Connector, Barb 2 176001000 Ferrule, For .375 O.D. T ube 3 174103001 T ube, .250 I.D. By 1 3/4-In. Long

174103001 Tube, .250 I.D. By 1 13/16-In. Long

174103001 Tube, .250 I.D. By 3 3/8-In. Long

174103001 Tube, .250 I.D. By 1 3/4-In. Long 4 311908000 Clamp, For .395 O.D. T ube 5 77900500 Turnaround, Barb 6 77010400 Nipple, .250 I.D. Tube 7 176017000 Nut, Swivel, 7/16-20

FIGURE 39. TUBING ASSEMBLY (SYRUP AND WATER SOLENOID TO BLENDER)

Item

No. Part No. Name

4490 Tube Ass’y, Regulator to Blender 1 174103000 T ube, .250 I.D. 24-In. Long 2 176001000 Ferrule, .375 O.D. T ube 3 311741000 Connector, Barb

FIGURE 40. TUBING ASSEMBLY (REGULATOR TO BLENDER)

85 569000119

FCB FOUR–FLAVOR FLOOR MODEL POST-MIX DISPENSER WITH V3+ FEATURES (illustrated parts breakdown)

UNIT PART NO:

4162160680

ILLUSTRATED PARTS BREAKDOWN

86569000119

57 62 56 58

26 51 60

54 53

1 10

33 2

38 39 40 41 42 43

FIGURE 41. 4 FLAVOR FCB POST-MIX DISPENSER ASSEMBLY

6 45 44

87 569000119

Item

No.

Part No. Name

1 319941000 Thread Rolling Screw, Hex Washer Hd.,

No. 8-32 By 3/8-In. Long

2 325282000 Self-Drilling Screw, Hex Washer Hd., No.

8-18 By 1/2-In. Long 3 200498003 Hex Nut, No. 8-32 4 320389000 Snap Bushing, .875 Dia. 5 343304000 W asher, .204 I.D. 6 3797 Frame 7 326071000 Expansion Valve 8 309919000 Flange, Mounting, 3/8 9 309920000 Flange, Mounting, 1/2

10 560005099 Bracket, Connector 11 309913011 Coupling Fitting, 3/8 By 1 1/16-In. Long 12 4988 Coupling Fitting, 5/8 By 1 1/16-In. Long 13 309338011 Clip, Sensor, Small 14 309338012 Clip, Sensor, Large (Not Shown) 15 319739000 Transformer, 230V 50/60HZ-24V 16 188346000 Washer, .192 I.D. 17 320106000 Thread Rolling Screw, Phil Pan Hd, No.

6-32 By 1-In. Long

18 326026068 Panel, Top 19 326031000 Cover, P.C. Board 20 560004710 Panel, Back 21 3108 Thread Cutting Screw, Phil Pan Hd., No.

10-32 By 1-In. Long

22 0157 Panel, Side, Right-Hand 23 320754000 Tube, Drain 24 320776000 Strap, Drain 25 0156 Panel, Side, Left-Hand 26 325992000 Cup Rest 27 325990039 Drip Tray 28 2999 Panel, Splash 29 325985000 Support, Drip Tray 30 322967000 Washer, .142 I.D.

Item

No.

Part No. Name

31 325991000 Frame, Drip Tray 32 3000 Panel, Front Lower 33 326028068 Trim, Front Lower 34 3001 Panel, Drip Tray 35 316753000 Push-On Nut 36 321503000 Catch Bullet 37 150918000 Machine Screw, Sl Truss Hd, No. 8-32

By 3/8-In. Long 38 170413000 Fitting, Drain 39 151281000 Washer, .640 I.D. 40 170423000 Hex Nut, 5/8-32 41 140133000 Clamp, Drain Tube 42 3129 Fitting, Adaptor Kit 43 315865000 Tube, .625 I.D. By 75-In. Long 44 322028000 Caster, 4-In. 45 323185000 Washer, .641 I.D. 46 316963000 Bushing, Snap 47 326037073 Panel, Back, Display 48 326081000 Housing, Display 49 325962040 Touch Switch 50 326082069 Holder, Flavor tab 51 325957000 Support, P.C. Board 52 324136000 P.C. Board 53 324138000 P.C. Board, Motor No. 2 54 324137000 P.C. Board, Motor No. 1 55 4984 Wire Harness, Circuit Board (Not

Shown) 56 312251000 Thread Rolling Screw, Phil Pan Hd., No.

10-24 By 3/8-In. Long 57 0642 Control Box, Upper 58 0150 Fan 59 325998000 Cable, Ribbon 60 326078000 Circuit Board Display 61 326079000 Cable, Ribbon 62 325925000 Support, P.C. Board

88569000119

41 42

21 37 36

12 1

2 3

5 6

3 5

FIGURE 42. 4 FLAVOR FCB POST-MIX DISPENSER ASSEMBLY

89 569000119

Remcor OC2R Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual