FRLB2 and FRLB2-S
Installation and Operation Guide
Revision S-L
Rev. S-N
Rev. S-N
All Rights Reserved
Table of Contents
Limited Warranty ..................................................................................................... 3
Freezer Temperature Requirements ...................................................................... 4
User Safety Notices ................................................................................................. 5
Blender Installation .............................................................................................. 6-8
Blender Operation ................................................................................................... 9
Daily Cleaning and Sanitizing ............................................................................... 10
Preventive Maintenance ................................................................................... 11-12
System Descriptions ........................................................................................ 13-16
Electrical Schematic ......................................................................................... 17-18
Troubleshooting ............................................................................................... 19-37
Warranty Procedure .............................................................................................. 38
Rev. S-N
2
Limited Warranty
This product is warranted to be free from defects in
material and/or workmanship for a period of one year
from date of installation, not to exceed fifteen months
from date of shipment from our factory. Any part or
component which proves to be faulty in material and/or
workmanship within warranty period may be returned
to f’REAL! for warranty credit. All labor for in-market
repairs will be furnished by qualified technicians
provided by customer at customer expense, not
f’REAL! expense, unless otherwise agreed to in writing
at time of blender purchase. Major repairs determined
by f’REAL! to require removal of product from market
for repair by a factory authorized representative will be
performed at no cost to customer.
This warranty is subject to the following exceptions/
conditions:
•
Any use of non-genuine f'REAL! spare parts may,
at f’REAL!’s discretion, void this warranty.
•
Damage caused by carelessness, neglect, improper
cleaning or maintenance and/or abuse (e.g., dropping. tampering or altering parts, equipment damaged in shipment, by fire, flood or an act of God) is
not covered under this warranty
In no event shall f’REAL! Foods, LLC be liable for any other damages or losses including,
but not limited to, lost sales, lost profits, cost of down time, loss of use of equipment, cost
of substitute equipment, claims of Buyer’s customers, or any other special, incidental or
consequential damages.
Rev.
Rev. S-N
S-N
33
Check Freezer Temperature Before Blender Installation
Check Freezer Temperature Before Beginning Blender Installation!
A potential cause of difficulties with the f’REAL! Blender is the display freezer
for frozen cups not being within the required 0 ºF to +6 ºF temperature range.
0 to +6 ºF is the ideal temperature for frozen f’REAL! cups at time of blending.
If freezer is equipped with a digital thermometer, without opening the freezer
door, check to see that temperature of freezer is near the ideal temperature of
0 to +6 ºF. (Note - If freezer is not equipped with a thermometer that can be
seen with the door closed, it is best to check the freezer temperature by
sticking a temperature probe directly into a frozen cup, with the heat sealed lid
still on. The air temperature can change rapidly when the freezer door is
opened but the product in the frozen cups will take a minute or more to change
temperature.)
If freezer is too cold or warm, adjust accordingly, ensuring that temperature
stabilizes in desired range. It is best to make an adjustment, and then come
back at least 1 hour later to see what the new, stabilized temperature of the
freezer is. (Note - If freezer temperature is unexpectedly warm, freezer may be
in defrost mode, which takes about one half hour to complete. Check again
later to see if temperature comes back down to ideal range. If temperature is
still unexpectedly warm, confirm proper installation of freezer baffles below
freezer, as instructed by freezer instructions. Also be sure freezer dust filter is
not clogged.)
If temperature is not in correct range, continue on with installation, but be sure
to get temperature corrected or the f’REAL! frozen drinks will not be of
optimum quality. If frozen cups are warmer than ideal temperature, the blender
may not blend them. Extra cold cups will cause the blender to take longer to
blend them and will eventually shorten blender life if left uncorrected.
If freezer is by Silver King, the best setting to start with is “nine o’clock” on the
freezer temperature control located in the back upper-right corner of the
freezer. If this does not result in the correct temperature after one hour, adjust
accordingly. Counterclockwise makes freezer warmer.
Note: The 0ºF to +6 ºF temperature range applies to the display/serving
freezer, not the longer term storage freezer. It is best to store frozen cups at
0ºF or colder if they are going to be held for more than a few days.
Rev. S-N
4
User Safety Notice
Carefully read and follow all notices in this manual and on the equipment. All labels on the equipment
should be kept in good condition. Replace any unreadable or damaged labels.
Care should be taken to read and fully understand this Installation and Operation Guide before installing
the blender. Failure to comply risks equipment damage, injury, fire, or shock hazard. All installation and
maintenance work performed on blender must be performed by a qualified technician.
It is the sole responsibility of the Buyer and Installer to ensure that this blender is installed in accordance
with the “National Electric Code”, “Basic Plumbing Code of Building Officials”, and/or any other local electrical and plumbing codes as they apply.
WARNING
•
•
•
•
•
•
•
Connect filtered water supply to blender before connecting to power source.
Blender has an electric water heater that begins heating as soon as blender power is turned on.
Use only a properly protected electrical circuit capable of the rated load of 15.0 amps at 120V.
Follow all applicable national/local electrical and plumbing codes.
Read the entire Installation and Blender Operation sections of this manual before using product.
Moving components rotate inside blending chamber during blending cycle. Never touch moving components or cup lid when blender is operating.
Only use f’REAL! Foods approved sanitizers on blender. Do not use chlorine based sanitizers on
blender. Use only iodine or quaternary based sanitizers to avoid corrosion of stainless steel blender
components. Unapproved use of sanitizers will void blender warranty.
Rev. S-N
5
Blender Installation
Prepare f'REAL! Blender for Installation:
Plug-in display freezer 1 hour before putting frozen product in the display freezer.
Hoses required to complete installation of blender:
1. 1/4” ID braided hose for water line from filtered water supply, with shutoff valve. (Not Included)
2. 5/8” ID hose able to reach desired drain location in accordance with local ordinances. (Included)
Unpack blender from its packing carton. Blender can then be lifted off carton base and placed in
convenient location. Lift blender by placing one hand underneath blender cup holder and your other arm
around back of blender in a hugging position.
7 Items are packed with blender. They are:
1. Cup lid - A five pound round cup lid shaped like the liberty bell.
2. Blending assembly including three sided lower shaft section - To screw onto bottom of blending shaft.
3. Female quick-connect fitting with a 1/4” barbed end - For use in water line connection.
4. Plastic 1/2” male pipe thread x 5/8” barb fitting - For use in drain line connection.
5. 10’ of 5/8” ID anti-microbial hose - For use in drain line connection.
6. Sanitizer kit for daily sanitizing - Including 2 Sanitizer cups, 4 brushes, Iodophor sanitizer bottle, test
strips and sanitizing instructions.
7. Large bottle of Ecolab Oasis 146 sanitizer - To be used to fill sanitizing rinse reservoir.
Open front access door of blender by pulling forward on small metal tab located under lower right corner
of front access door. This will open blending chamber for access to blending shaft.
Slide cup lid up onto blending shaft, directing shaft down through hole in its center. When properly
oriented, the cup lid looks like the liberty bell. (Note: See page 16 of this manual for visual reference.)
While holding cup lid up on shaft, thread lower spindle and blending assembly into bottom of blending
shaft and hand tighten it hard. Metal Slider should move freely side-to-side.
Close front access door by pushing it closed on its right side until you hear/feel it fully close.
Fill sanitizing rinse reservoir by pulling straight out on blue front of sanitizing rinse reservoir, located just
to left and behind shiny silver cup holder. Pull until tether prevents further travel. Remove front cap of
sanitizer reservoir and fill reservoir to nearly full with Ecolab Oasis 146 sanitizer, and then slide reservoir
back into position behind cup holder.
Rev. S-N
6
Installation - continued
Prepare Power, Water, and Drainage:
Power requirement
The f’REAL! blender requires 15 Amps of 120 Volt power, in compliance with local electrical code. (Note:
Extension cords are not acceptable and may void warranty due to improper power supply.)
Water line connection
The f’REAL! blender requires 25psi from a filtered, non-carbonated water source. Ensure water connection complies with local code. The blender is equipped with a male quick-connect fitting at lower back of
blender to attach water line to. Connect the included female quick-connect fitting to a braided, flexible 1/4”
ID water line from filtered water source using barbed end of fitting.
(Note: Purge air out of main water line before connecting female quick-connect to blender.)
Drain line connection
The f’REAL! blender is equipped with a 1/2” female pipe-threaded fitting at lower back of blender to attach
drain line to. Ensure drain connection complies with local code. Thread included barbed tubing adapter
into drain fitting on blender. Use included 5/8” ID anti-microbial drain line to route rinse/waste water from
blender fitting to drain taking care to slope drain line downward all the way to drain to provide for free flow
of rinse water. This 5/8” ID line is important because it helps to prevent microbial activity, which keeps line
free of buildup over time. When tightening barbed hose fitting into female pipe-threaded fitting, do not
over tighten plastic fittings.
Install and Connect Blender:
Place blender in desired location.
Attach included anti-microbial drain line and route drain line tubing for free flow of rinse water.
Attach water line by pressing female quick-connect fitting, attached to 1/4” water line as previously
described, onto male fitting on blender. Be sure not to damage o-ring on male fitting when connecting
female quick-connect. Turn on water pressure to blender.
Plug power cord into 120 Volt circuit capable of supplying at least 15 Amps of power. (Note: Do not plug
blender and sales floor freezer in the same outlet or power supply.)
Rev. S-N
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Installation - continued
Turn On Blender:
Open front access door of blender by pulling forward on small metal tab located under lower right corner
of front access door. Turn on blender power using red switch in upper left corner of blender.
Upon power up, the new blender will purge water from the top water supply orifice inside the blending
chamber for 10 seconds for the first 20 blending cycles. This is used to purge all air out of water supply
line and water heater.
Close front access door. Blender will begin heating water in hot water heater. Display will show
temperature set point of 135ºF and actual water temperature. Water takes about three minutes to heat to
set point. When water temperature reaches set point, blender is ready for use.
Confirm Normal Blender Operation:
Blue LED lights will begin flashing through their cycle, one at a time, and blender display will begin cycling
through instructions for operation of blender.
Place empty f’REAL! blender cup in cup holder. If no empty cup is available, use sanitizer cup provided
with blender for this startup procedure.
With empty cup in cup holder, confirm that cycling of blue lights has stopped and the three green push
buttons (Less Thick, Regular Thickness, and More Thick) are all lighted up. (If this is not the case see
troubleshooting section in the back of this guide).
Then press and hold center “Regular Thickness” button for ten seconds. This will start blender running
through a full blending cycle in the empty cup. (Note, if center button is released too soon while an empty
cup is in the blender, blender will stop its cycle and send the cup back down to its home position, and
display will read “To Use Blender, Cup Must Contain Hard Frozen Product.” This is a safety feature to
prevent people from using the wrong cup in blender as well as to prevent people from sending their cups
through a second time, as this is potentially unsanitary.)
When cycle is complete, remove cup from blender. Check to see that there is 1 and 1/8 inches of warm
water in bottom of cup, as measured by placing cup on a flat counter and measuring up from counter to
water’s surface as faintly seen through cup side wall. This is the amount of water that is added during a
regular thickness blending cycle.
It’s time to make a delicious f’REAL! Frozen Beverage!
Rev. S-N
8
Blender Operation
f’REAL! Blender Operation:
Operation of the f’REAL! Blender has been designed to be entirely self-serve, and therefore, instructions
are provided in several forms on the blender as well as on the f’REAL! frozen cups.
The Simple Operating Instructions are:
1. Remove your favorite frozen cup from freezer.
2. Remove lid from cup.
3. Place cup in cup holder.
4. Press green button with your preferred thickness.
5. When blender is through, remove your frozen blended drink and enjoy!
Potential Mistakes by Customer, and What Happens:
If customer does not remove lid, blender will sense this when the blending disc hits the foil lid and blender
will reverse itself and bring cup back down to the home position.
If customer uses wrong cup, blender will not run (for most cups). The blender senses for the correct
height of cup using an infra-red (IR) sensor. The blender will only run when it senses the correct height
cup in cup holder. The green buttons will not light up and they will not activate blender if IR sensor does
not sense correct height cup.
If customer uses wrong cup, but it is right height to trigger IR sensor, green buttons will light up, and
blender can be activated, raising cup up into blending chamber and beginning to spin blending disc.
However, as soon as blender senses that there is not the expected resistance of frozen product cup, it will
stop and reverse itself, bringing cup back down to the home position. A message on the display will
appear “To Use Blender, Cup Must Contain Hard Frozen Product.”
If customer places a previously blended cup back into blender, blender can also be activated, raising cup
up into blending chamber and beginning to spin blending disc. However, as soon as blender senses that
there is not the expected resistance of frozen product cup, it will stop and reverse itself, bringing cup back
down to the home position. A message on the display will appear “To Use Blender, Cup Must Contain
Hard Frozen Product.”
Rev. S-N
9
Daily Cleaning and Sanitizing
f’REAL! Blender must be cleaned and sanitized every 24 hours as follows:
1.
Gather: f’REAL! Sanitizing Cup, a clean f’REAL! Brush in good condition*, dishwashing liquid, and BTF Iodophor
Sanitizer bottle or equivalent quaternary sanitizer approved by f’REAL! .
2. Thoroughly wash hands with soap and warm water.
3. Put 2 – 3 squirts of dishwashing liquid into f’REAL! Sanitizing Cup and fill cup about half way with hot water.
4. Open blender front door to access blending chamber by pulling on metal tab located under right corner of door. (Do not
turn blender power off. Power must remain on for blender to recognize cleaning has been done properly).
5. Using clean f’REAL! Brush dipped frequently in Sanitizing Cup with prepared dishwashing solution, thoroughly clean in
the following order:
a. First, the top and underside of metal cup lid. (Lift lid up along shaft to thoroughly clean underside of lid. This is the
most important step in the entire process, so be sure to do it thoroughly every time.);
b. Then the top & bottom of blending disc and slider. (Lift lid to access blending disc. Beware of sharp edges.);
c. Then the blending shaft;
d. Then the gray plastic blending chamber walls and front door liner;
e. Then the clear plastic flip-up doors—top and bottom, taking care not to press them fully open without supporting
them, as this can cause their return springs to break off;
f. And last, the interior bottom area of the gray plastic blending chamber. (Do this step last to avoid possible spreading
of drain area material onto other cleaned surfaces.)
6. Close front door firmly. Blender will automatically rinse off cleaned components.
7. Rinse out f'REAL! Blender Sanitizing Cup with room temperature water and fill with room temperature water to Fill Line on
Sanitizing Cup. Then add 4 -6 drops of BTF Iodophor Sanitizer to room temperature water in Sanitizing Cup. (Or
substitute approved quaternary sanitizer diluted to 200 ppm in cup.) 4 -6 drops from spout of BTF Iodophor Sanitizer
bottle is all that is needed to reach proper concentration. Sanitizing solution is still nearly clear when properly prepared.
**
8. Run 2-minute sanitize cycle:
Place Sanitizing Cup with properly prepared sanitizing solution in blender cup holder;
Press and hold both “Less Thick” & “More Thick” buttons for 5 seconds to begin sanitize cycle.
Note: Do not use chlorine based sanitizers on blender. Chlorine sanitizers can cause serious damage to
f’REAL! blender disc and shaft, and will void warranty. Quaternary sanitizers may be acceptable if approved by
f’REAL! Foods. Call our Customer Support Center at 800-483-3218 for more information.
9. While 2 minute sanitize cycle timer counts down, clean f’REAL! Brush and hands again with dishwashing liquid to ensure
they are as clean as possible for Step 11, and then thoroughly rinse with warm water.
10. When sanitize cycle ends, remove Sanitizing Cup from cup holder, and open front door of blender again.
11. Use cleaned f’REAL! Brush dipped frequently in Iodophor sanitizer solution from Sanitizing Cup to thoroughly apply
sanitizing solution to:
a. First, the underside of metal cup lid. (Lift lid up along shaft to thoroughly apply sanitizer to underside of lid.);
b. And then, the top of metal cup lid. Be sure to apply solution to area touched when lifting the
cup lid in prior step.
12. Pour remaining sanitizing solution down blender’s internal drain located in gray plastic blending chamber.
13. Close front door firmly. Blender will automatically rinse off sanitized components.
14. Rinse f’REAL! Brush and Sanitizing Cup thoroughly with hot water. Allow to dry and save for next day’s use.
* Notice: To avoid compromising f’REAL! Blender cleaning and sanitizing, do not use f’REAL! Sanitizing Cup or
f’REAL! Brush on equipment other than f’REAL! Blenders. Replace sanitizing brush every three (3) weeks with new
f’REAL! Brush provided in kit to be sure brush is in good condition. Order replacement sanitizing kit as necessary by
calling f’REAL! Customer Support at 800-483-3218.
** To confirm Iodophor sanitizing solution is properly prepared, test strips are provided in vial with all sanitizer kits
available from f’REAL!. To use test strips:
• Remove test strip from vial using dry fingers.
• Dip test strip into prepared Iodophor sanitizing solution for 60 seconds without agitating, and then remove.
• Compare color of test strip to color comparison chart provided in vial.
Colors in range from 12.5 ppm to 25 ppm confirm proper sanitizer concentration.
Rev. S-N
10
Preventative Maintenance
Preventative Maintenance Recommendations
The f’REAL! Blender is designed to be virtually maintenance free. We do recommend these simple maintenance
steps be taken to ensure trouble-free operation.
Blender
Refill automatic sanitizer reservoir monthly. The f’REAL! FRLB2-S Blender automatically performs a sanitizing
rinse of its blending components after each blending cycle. A sanitizer reservoir in the blender provides
concentrated sanitizer for this sanitizing rinse. Pull forward on blue plastic front of sanitizer reservoir, located just to
left and behind the silver cup holder, until tether prevents further movement forward. Remove reservoir cap and
refill with Ecolab Oasis 146 sanitizer. If reservoir is more than half full, refilling every other month or less frequently
is acceptable. Sanitizer is available from Ecolab or from f’REAL! Foods Customer Support Center at 800-483-3218.
Check water shot quantity after first month and then semi-annually. The f’REAL! Blender adds a shot of warm
water to the frozen cup as it blends. It is important that the proper amount of water be added to get the right
thickness of frozen beverage. The proper water shot for a regular thickness beverage is 75 milliliters. See page 13
step #3 for further instructions on setting and testing water shot. This should be done after the first month of operation of blender, and then semi-annually thereafter.
Change fluorescent bulbs annually. The three fluorescent bulbs behind the backlit panel should be changed
once each year even if they are still working. One year is their design life and they will go out soon afterward if they
are not changed. Remove the plastic backlit panel and change out all three bulbs with F6T5 bulbs available from
the f’REAL! Customer Support Center 800-483-3218.
Freezer
Clean freezer filter monthly. Follow instructions provided with freezer to clean dust filter. For the f’REAL! freezer
by Silver King, filter is accessed from front bottom left of freezer. Remove filter monthly and clean by running water
through it until all dust is washed off.
Blow off freezer condenser coils annually. The condenser coils slowly collect dust. They should be blown off
once each year with compressed air. Remove the panel on the back of the freezer to access the coils and blow
them off once each year.
Recommended Preventative Maintenance Schedule Summary
Monthly
Semi-Annually
Annually
Clean Freezer Filter
Blow Off Condenser Coils
Check Water Shot
At end of 1st Month
And
Change Fluorescent Bulbs
Refill Sanitizer Reservoir
Rev. S-N
11
Preventative Maintenance - continued
Programming Water Shot Setting
This water shot calibration is to be performed semi-annually during regular preventative maintenance and
when replacing the main control board on blender.
Procedure to Check and Set Water Shot Quantity:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Open front door and turn off power to unit by switching off red power switch at upper left.
Press and hold all three green buttons on front door (Less Thick, Regular Thick, More Thick).
Turn power back on while still pressing and holding the three green buttons.
Continue to hold the three green buttons until you see the display reading “Sec” on top row, and
“LESS TEST MORE” on the bottom row.
Note: Front door must remain open while making water shot adjustments.
Press the middle “TEST” button and immediately catch the water coming from the water injecting hole
located just to the right side of the top of the blending shaft using the f’REAL! Water Measuring
Cylinder - Part number (01-0011) from the f’REAL! Customer Support Center.
Water shot quantity should be 75-77 milliliters (grams). If a measuring cylinder is not available, it is
possible to catch the water shot in an empty f’REAL! cup. After capturing water in cup, place cup on a
flat surface and measure 1 1/8” from flat surface to top of water, which is slightly visible through sidewall of cup. To improve visibility of top of water, shine light down into cup as you measure. Height
should be exactly 1 1/8” to top of water from surface cup is resting on. A slight difference makes a
significant difference in thickness of frozen beverages, so measure carefully.
Adjust “Sec” for water shot timing by pressing corresponding green button on the front door display for
“MORE” or “LESS” water to be dispensed. Adjustment range is from 3.0 – 9.8 seconds. The higher
the number of seconds, the more water will be dispensed. Note: If you need to adjust water shot to
more than 6.0 seconds there may be a water restriction/clog in the pressure regulator or water valve
which needs to be cleared up.
Press “TEST” (Regular Thick Button) and immediately catch water shot to check your changes.
Make additional adjustments to water level as needed to obtain 75-77 milliliters. When water shot is
properly set, close front door and press green button (Less Thick) corresponding to “SAVE” your
setting. If you do not press “SAVE”, blender will return to setting from before you initiated changes
without saving your new setting.
Note: There is a program timer that will exit this programming mode without saving your new setting if no
green buttons are pressed for 25 seconds.
Rev. S-N
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System Operation Descriptions
f'REAL! Blender Systems - Overview:
The f’REAL! Blender begins with real ingredients, such as real ice cream and milk for milkshakes, which
are pre-frozen in a patented blending/serving cup. The cup is placed in the blender’s cup holder.
Customer chooses a thickness by selecting one of green user buttons on the front panel. The blender
raises the cup up to its shaving/whipping components in the blending chamber and shaves through the
hard frozen product while adding hot water to the frozen shavings. The blending disc then accelerates to
high-speed and makes multiple passes up and down through the product, blending and whipping the
combined mixture into delicious frozen beverages like real ice cream milkshakes. When the blending
cycle is complete, the serving cup returns back down to the home position where it may be removed and
enjoyed. The blender then automatically rinses and sanitizes the blending components and blending
chamber to be ready for the next customer.
System Descriptions and Functions:
Backlit Panel
If not already in place, a backlit panel should be placed in blender by directing tabs on panel’s edges into
slots at edges of blender’s opening for the backlit panel. Press panel fully into position.
Water System
The blender has a hot water system to add hot water to frozen beverages during blending and also to
rinse blending components and blending chamber with sanitizing water after each blending cycle.
A filtered water line is attached to the blender using a barbed female quick-connect fitting.
This fitting is engaged with a male fitting on the utility panel at the bottom back of the blender.
Following the flow of water inside the blender from the connection point there are:
1. A pressure switch to ensure there is adequate water pressure to the blender. If water pressure
drops below 25 psi., the display reads “Water Pressure Too Low” and the blender will not operate
until water pressure is restored.
2. A pressure regulator which reduces the water pressure to 25 psi.
3. A water heater to heat the water to 135ºF. The heater also has a manually re-settable high
temperature cutoff attached as a safety feature.
4. A blending water valve to direct water flow into frozen beverages during blending via a hose
leading to an orifice in top of blending chamber, just to the right of blending shaft.
5. A sanitizing water valve to direct rinse water flow via a hose leading to the sanitizer injector, where
sanitizer fluid is mixed into rinse water, and then to two sanitizing rinse nozzles located in blending
chamber’s left side.
Rev. S-N
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System Operation Descriptions - continued
Motors and Motion System
The blender has two motors with associated positioning and blending mechanisms:
The position motor, mounted near the bottom of the blender, drives the cup holder up and down via a
toothed belt and positioning screw.
The spindle motor, mounted near the top of the blender, drives the main blending shaft via a toothed belt.
System Controls - Control Board
The blender has a custom logic and motor control board which controls all blender functions and provides
safety and diagnostic functionality.
Off-Board Safety Override Controls
There are four safety controls that are off the control board so they function independently from the control
board in case of a control board failure.
Off-board safety override controls are:
1. Manually re-settable 180ºF thermal overload protection on the hot water heater.
2. Manual In-line fuse for thermal overload protection on the position motor.
3. Automatically resetting thermal overload protection on the blending motor.
4. Safety door circuit, which passes through four safety switches, all of which have to be closed to allow
power to reach the main motor switching relay. If this safety door circuit is broken, power is cut off to
motor switching relay which immediately cuts power to both motors, stopping the blender. The four
switches in the circuit are as follows:
1.
2.
3.
4.
Rev. S-N
Door switch for front access door, just below door locking solenoid at top right of blender.
Switch on clip at back of left hand clear flip-up door
Switch on clip at back of right hand clear flip-up door
Actuator switch mounted next to blender position screw and linear slide, down near the bottom,
which overrides flip-up door switches when flip-up doors are opened by cup holder moving up
through them.
14
System Operation Descriptions - continued
Items monitored, controlled and/or powered by the control board:
1. LCD display is used to display operating instructions to the self-serve user as well as to display alert
and diagnostic messages for the operator.
2. Four blue LED lights light up in sequence during normal operation. They will also all flash
simultaneously to provide an error alert when the LCD display displays specific error messages, such
as when daily cleaning or sanitizing have not been done for 72 hours.
3. Three green buttons, each with internal LED light, start blender or allow for other operator input.
4. Infrared cup sensor senses presence of correct size cup. IR sensor and receiver are mounted on right
hand side of blender at height of cup holder, behind dark red lens.
5. Hot water heater to heat water to 135ºF. When blender is first turned on, temperature set point and
actual water temperature are displayed on display and blender will not function until water temperature
reaches set point of 135ºF. Once set point is reached first time, water temperature is not displayed
and blender function is not interrupted by water temperature again.
6. Two drive motors (position and spindle), including full time, closed loop monitoring of RPM and
amperage for comparison to expected values.
7. Bottom and top IR limit switches monitor cup holder movement. Bottom limit switch acts as home for
cup holder movement at end of each blending cycle. Upon power up of blender, blender will also
attempt to move cup holder down until this switch is mated in order to prepare for start of next
blending cycle. Top limit switch provides only a fault detection function, stopping blender and
triggering an error message display if cup holder rises too high during its programmed travel.
8. Safety switches for front access door and clear plastic flip-up doors ensure these doors are properly
closed during blender operation, protecting customers and employees from potential injury from
rotating components.
9. Safety interrupt for unexpected resistance during cup holder move up or down. While cup holder is
moving up from or down to its home position, blender monitors current draw of position motor, and if
an unexpected load is detected, cup holder reverses direction immediately. If cup holder was on the
way up, it comes back down to its home position. If cup holder was on the way down, it rises about
1/4” and stops. This safety feature protects against potential injury to customers or damage to blender
if an obstruction is placed in path of cup holder motion.
10. Daily cleaning and sanitizing cycles are required. If the front access door is not opened for 72 hours
to clean the blending chamber, a “Service Required, Notify Attendant” error message will appear on
the front display and attendant will be directed to an additional message, “Cleaning Inside Required
Daily” (which is not shown to the customer). Blender will lock out until front door is opened and
cleaning is performed. If sanitize cycle is not performed for 72 hours, “Service Required, Notify Attendant” error message will appear and attendant will be directed to an additional message, “Use Sanitize
Cup, Run Sanitizing Cycle.” Blender will lock out until full 2 minute sanitizing cycle is completed.
Rev. S-N
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System Operation Descriptions - continued
f'REAL! Blender Component Identification:
Component Identification is shown with parts
spatially oriented as they are found in the
blender, with replacement part numbers
indicated.
02-9023
CONFORMAL SLIDER
Rev. S-N
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Electrical Schematic
Rev. S-N
17
Electrical Schematic - continued
Dip Switch Descriptions
Four dip switches are located on the blender circuit board. The standard settings for the FRLB2-S
blender are - Off, Off, Off, On. That is, - Down, Down, Down, Up. Their functions are as follows:
Switch 1 - Automated Sanitizer Bypass. This switch is only set Up to On when the circuit board is used
with an model FRLB2 blender, which does not have the automated sanitizer feature. All
FRLB2-S blenders have the automated sanitizer feature, and this switch should be set Down to
Off.
Switch 2 - Infrared sensor monitoring. If switch 2 is set Up to On, display shows strength of signal being
received by infrared cup size sensor. When a standard size milkshake cup is present, the first
two sets of 000’s on top line should read 255 M 255, though they may read slightly lower
values. If either of these signals registers below 150 when a milkshake cup is present in cup
holder, sensor should be replaced. If this is happening, recalibration of infrared sensors may
be needed. See Calibration section below.
Switch 3 - Motor monitoring. If switch 3 is set Up to On, top display line monitors Position Motor and
bottom line monitors Spindle Motor. Farthest right digits, 00.00 measure motor Amps. Middle
digits, 0000 measure motor RPMs. Farthest left digits, 0000 on top line measure counts of the
rotating position screw as sensed by the Position Screw Sensor.
Switch 4 - Self-Serve speed. Blenders used in self-serve operations are designed to move cup holder up
and down from blending zone at slower speed by switching switch 4 Up to On. Switching to
Off is only for operator-assisted settings where operator is fully knowledgeable about blender
operations.
Calibrate - Infrared Sensor Recalibration is required if control board or infrared cup size sensor are replaced. To recalibrate, place any f'REAL! cup in cup holder and switch red blender power
switch off. Press and hold both Less Thick and More Thick green buttons while turning power
back on with red blender power switch. LCD screen will say “Cup IR Sensor Recalibrating”
and blender will automatically begin recalibrating. Release green buttons. When recalibrating
is complete, blender will say “IR Recalibrated SAVE or CANCEL.” Press green “SAVE” button (less thick) to save recalibration. Recalibration is complete. If “SAVE” button (less thick)
is not pressed to save recalibration, blender will not be recalibrated.
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Error Message Troubleshooting - Alphabetic List
f’REAL! operates a Customer Support Center. Our hours are 6:00am to 9:00pm CST
7 days a week. We are here to help you at 1-800-483-3218 option 1 or email
questions to callsupport@freal.com.
Note: If an error message displays on blender screen, first turn blender off and on and then try to run
another frozen f’REAL! product. This will either clear or validate the error message. If message continues,
find message below, listed alphabetically, for more troubleshooting/repair instructions.
Auto-Sanitizer Is Running Low. Refill Sanitizer Reservoir Located Behind Left Side of Cup Holder.
Use Ecolab Oasis 146 Sanitizer. Blender Will Run XXX More Cycles Before Lock-out if Not Refilled.
Push Less & More Again To Resume.
Situation:
When sensor recognizes sanitizer is low in sanitizer reservoir, the blender displays this warning message
during 2-minute sanitize cycle. You are allowed up to 350 more cycles before blender locks out making
blender inoperable.
Resolution:
1. Fill sanitizer reservoir with Oasis 146 Quaternary Sanitizer by pulling out sanitizer reservoir located to
left side of cup holder. Once filled, slide reservoir back in place. Sensor will recognize sanitizer level
in reservoir and reset blender. (Note: Use only Oasis 146 Quaternary Sanitizer in reservoir. Other
sanitizers will damage blender and could cause food safety risk.)
2. If problem continues, when facing front of blender, remove four screws from left side panel. Next to
sanitizer reservoir is a sensor mounted to a metal bracket. This sensor has a LED light that will illuminate orange when it senses liquid in the reservoir. If orange light is not on, then bend sensor bracket in
towards reservoir until sensor is touching reservoir. If orange LED still does not light up on sensor,
then replace sensor.
3. To temporarily by-pass the sanitizer sensor, locate the 4 dip switches on the control board at the back
of the blender. Turn on dip switch #1. As soon as the sensor is replaced, turn #1 off.
Auto Sanitizer Is Now Empty. Refill Sanitizer Reservoir Located Behind Left Side of Cup Holder.
Use Ecolab Oasis 146 Sanitizer. Blender Lockout Now In Effect. Refill Sanitizer To Reset Lockout.
Situation:
When sensor recognizes that sanitizer reservoir is empty, the blender displays this message. The blender
is now inoperable until sanitizer reservoir is filled up with Oasis 146 Quaternary Sanitizer.
Resolution:
1. Fill sanitizer reservoir with Oasis 146 Quaternary Sanitizer by pulling out sanitizer reservoir located to
left side of cup holder. Once filled, slide reservoir back in place. Sensor will recognize sanitizer level
in reservoir and reset blender. (Note: Use only Oasis 146 Quaternary Sanitizer in reservoir. Other
sanitizers will damage blender and could cause food safety risk.)
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Troubleshooting - continued
2. If problem continues, when facing front of blender, remove four screws from left side panel. Next to
sanitizer reservoir is a sensor mounted to a metal bracket. This sensor has a LED light that will
illuminate orange when it senses liquid in the reservoir. If orange light is not on, then bend sensor
bracket in towards reservoir until sensor is touching reservoir. If orange LED still does not light up on
sensor, then replace sensor.
3. To temporarily by-pass the sanitizer sensor, locate the 4 dip switches on the control board at the back
of the blender. Turn on dip switch #1. As soon as the sensor is replaced, turn #1 off.
Blade Failure – Call for Service.
Situation:
During blending process this message will display and shut blender down if spindle motor sees lower
resistance than expected. This may indicate a failed blending disc or frozen product that is too soft.
Open front door of blender and cycle power on and off. This will return cup holder to the home position so
blending disc can be inspected. Next, lift up cup lid to look at the round blending disc.
Resolution:
1. Inspect large (2” diameter) blending disc located inside the blending chamber. (See page 15)
2. Replace blending disc if cracked, broken or missing. (Note: If replacement is necessary, please call
f’REAL! Call Center immediately at 800-483-3218 to report the situation. This is a highly unusual
failure and one we take very seriously if it happens.)
3. Check the temperature of the freezer unit. Product must be kept between 0-6 degrees. If
temperature is not correct, adjust freezer unit.
4. In some instances this message will be displayed if frozen product in f’REAL! cups has air pocket in it
prior to blending. To check, cycle power to blender and run another frozen product to test blender. If
blender operates correctly, then the incident is isolated and blender is working properly. If you
encounter this issue and you still have the product that did not blend properly, please record that
product’s flavor and full date code located on side of cup and report this to f’REAL! Call Center.
Check Lower Limit Switch For Error – Service Required. Notify Attendant.
Situation:
With a f’REAL! cup placed in cup holder, press one of the green push buttons and message appears.
Resolution:
Locate lower limit switch by removing blender right side panel when facing front of blender. Looking inside
blender and towards the bottom you will see a 1-inch by 1-inch circuit board.
1. Wipe off two black posts (optical eyes) of the switch.
2. Verify the three-wire connector is securely fastened to circuit board.
3. Verify wire connection TB9 - Bottom Limit is securely fastened to main electronic control board.
4. Try lifting the cup holder up by hand. If you are able to then, the ZBX nut may be broken.
5. If problem persists, replace limit switch.
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Troubleshooting - continued
Check Top Limit Switch For Error – Service Required. Notify Attendant.
Situation:
While frozen product is being blended this error message is displayed and blender stops in mid-cycle.
Cup holder remains up inside blender.
Resolution:
Locate top limit switch by removing blender right side panel when facing front of blender. Looking inside
blender and towards the top you will see a 1-inch by 1-inch circuit board.
1. Wipe off two black posts (optical eyes) of the switch.
2. Verify the three-wire connector is securely fastened to circuit board. The white wire should be toward
front of blender with black wire toward back of blender.
3. Verify wire connection TB9 - Bottom Limit is securely fastened to main electronic control board.
4. If problem persists, replace limit switch.
Cup Obstruction During Move Down – Service Required Notify Attendant.
Symptom 1: Message Appears After Frozen Product Is Blended And Cup Holder Is Returning To Home
Position
If during the blending cycle, this message is displayed, an object or high resistance on the lead screw has
interfered with the cup holder lowering.
Cycle power to blender and close front door to bring cup holder to the home position.
Resolution:
1. Remove any object interfering with cup holder moving down.
2. If problem persist, apply Quinplex grease on the lead screw and rerun frozen product.
3. Check the position motor pulley to make sure it didn’t slide down the position motor shaft. If so, move
pulley up and re-tighten the set screws.
4. If problem still continues then realign the lower bearing. Call f’REAL! Customer Support Center for
instructions on completing this realignment.
Symptom 2: Message Displays Immediately After Pressing One Of The Green Push Buttons
Resolution:
1. Verify that the cup holder is not resting against the aluminum block located underneath the cup holder.
You should have at least a ¼ inch gap between cup holder and the aluminum block. If you do not have
the ¼ inch gap then raise cup holder up by turning the lead screw located on the top of the blender.
2. If problem persists, then replace electronic control board. The directional relay for position motor has
failed.
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Cup Obstruction During Move Up.
Symptom 1: Someone Grabs The Cup Holder While It Rises Up
While the cup holder moves up this error message appears when the position motor is seeing high current
when turning the lead screw.
This error message can occur while the cup holder is rising up and someone grabs the cup holder trying to
hold it in place or if an object is in the way of the cup holder and prevents the cup holder from raising.
Resolution:
1. Remove any obstruction from the path of the cup holder.
2. Open front door and cycle power to the blender by turning the power off and then back on. The power
switch is located in the upper left hand corner of the blender. After closing the front door the blender
will lower the cup holder to the home position.
Symptom 2: If Blender Makes Noise While Moving Up and This Error is Displayed
Resolution:
1. Use only Quinplex grease to lube the lead screw. Place an empty f’REAL! Sanitizer cup in the cup
holder and hold the “Regular Thickness” button for 10 seconds or place frozen product in the cup
holder and run the blender 2-3 times to work the lube in on the lead screw. Note: You may need to run
the blender more times until error message disappears.
2. Check the position motor pulley to make sure it didn’t slide down the position motor shaft. If so, move
pulley up and re-tighten the set screws.
Cycle Interrupted – Notify Attendant
Symptom #1: Cup Holder Travels Up and Just As It Gets to the Flip Up Doors It Stops.
Resolution:
1. The micro switch is sticking and will need replaced.
Symptom #2: After the Cup Starts to Blend This Error Displays
Resolution:
1. Remove the backlit panel from the front door – Marketing material displaying f’REAL! frozen products.
Locate the magnet in the upper right hand corner, inside the front door. Verify magnet is not broken
and still visible. Replace magnet if broken or missing.
2. Verify that the two black wires from the black magnetic reed switch going into a white connector are
securely connected.
3. The double door arms with springs are fastened to the backside of the flip-up doors, verify they are still
connected to the right and left flip-up doors and are making contact with the micro lever switch when
the flip-up doors are fully closed.
4. Replace flip-up door if double door arm does not fasten correctly to flip-up door.
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Troubleshooting - continued
Symptom #3: As the Cup Holder is Going Down This Error Displays
Resolution:
1. This happens because the flip up doors didn’t close like they should. They could be hanging up on the
blending chamber before they are closing.
2. Verify that the flip up doors operate without any binding or tightness.
Cups Too Cold Notify Attendant Blender Is Working Fine More Directions Will Show Here When
Attendant Opens Front Door. Front Door Open: Freezer Temp May Be Cold Run Cup That Is
Frozen Less Hard To Return To Normal Operation.
The blender measures the resistance of the frozen product in the cup. If the resistance of the frozen
product is too hard in the first ½ inch of the product, this error message appears.
Situation:
On the third consecutive Too Cold (-10 or colder) frozen product that is attempted, this error message
appears. The blender is working fine but gives a warning that the freezer thermostat may be set too cold
or product was taken out of walk-in freezer (-20 degrees) and put to the front of the display freezer shelf.
Resolution:
1. Remove the attempted blended cup and this error message clears.
2. Verify display freezer temperature is 0 to +6 degrees.
3. Run frozen product that is less frozen to reset counter. Product temperature should be 0 to +6 degrees
with thermometer in center of product.
4. Stores are to rotate product up from bottom shelving and fill bottom shelf with new frozen product to
allow time to thaw to 0 to +6 degrees.
Cups Too Warm Notify Attendant Blender Is Working Fine More Directions Will Show Here When
Attendant Opens Front Door. Front Door Open: To Use Blender Cup Must Contain Hard Frozen
Product. Freezer Temp May Be Too Warm Run Cup That Is Frozen Hard To Return To Normal
Operation.
Situation:
On the third consecutive frozen product that is attempted to blend this error message appears. The
blender is working fine but gives a warning that the freezer may not be working properly.
Resolution:
1. Remove attempted blended cup and this error message clears.
2. Verify display freezer temperature is 0 to +6 degrees.
3. Verify front door of freezer is closing fully and not being held open by frozen product.
4. Run frozen product that is hard frozen to reset counter.
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Troubleshooting - continued
Hi Mixer Current Check Blade/Cup Round Blade May Be Bent Down And Hitting Bottom – If SoReplace It
Situation:
During the blending process this message will display if the round blending disc has hit the bottom of the
cup holder and has bent or broken the blending disc.
Open the front door to the blender and lift up the cup lid weight to look at the round blending disc.
Resolution:
1. Verify if the blending disc is bent or broken and replace if broken or bent. (See Page 16)
2. Check the amount of water being added to cup and adjust if necessary. The correct amount of water
is 75-77 ml. (See page 11)
3. Verify that the freezer temperature is between 0 and +6 degrees. Adjust as necessary.
4. Run another shake, if cycle completes with no issue then monitor blender.
5. If issue continues or error will not clear, then replace control board.
Less Thick Button Is Stuck
This error message appears if the green Less Thick push button is stuck in.
Situation:
The Less Thick push button light is stuck ON, or when a customer places frozen product cup in cup holder
and the cup holder raises up automatically.
Resolution:
1. Massage the button left to right and up and down to work button free. This may take a few minutes. If
you can’t free up the button, replace.
2. If problem continues, see troubleshooting guide for Cup Obstructions on pages 21-22.
Mix Motor Cutout High Temperature – Service Required Notify Attendant
Mixer current is less than 0.1 amps for 5 seconds.
Situation:
When the cup holder raises up into the blending chamber, the blender stops and this error message is on
the blenders display.
Locate the spindle motor by removing the right side panel, then remove the back panel along with the top
blue panel. The spindle motor is the motor turning the upper pulleys that mixes the frozen products and is
located on the back and top portion of the blender.
Resolution:
1. Verify that the lead wires that come out the side of the spindle motor to a white connector is connected
securely. Make sure wires are fully seated into white connector. Tape this connection with electrical
tape.
2. Spin the spindle motor by hand. If motor makes noise or is hard to spin. Replace the spindle motor.
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Troubleshooting - continued
3. Verify display freezer temperature is 0 to +6 degrees.
4. Bend the front door switch forward.
5. If problem persist, then replace spindle motor.
Mix Motor Encoder Failure – Service Required Notify Attendant
The encoder doesn’t detect any movement from the mix motor for a period of 6 seconds.
Situation:
With a frozen product cup in the cup holder and one of the green buttons is selected, the cup holder raises
up into the blending chamber then this error message appears on the display.
Locate the spindle motor by removing the right side panel when facing the front of the blender, then
remove the back panel along with the top blue panel. The spindle motor is the motor turning the upper
pulleys that mixes the frozen product and is located on the back and top portion of the blender.
Resolution:
1. Verify that the lead wires that come out the side of the spindle motor, to a white connector, are
secure.
2. Verify that the wires for the encoder, connected to the bottom of the spindle motor, are connected
securely to the square connector and to the electronic control board located at the back of the blender.
Location TB12 ‘Mix Motor Sensor’.
3. Verify the operation of the mix motor by doing a rinse cycle. The spindle motor should spin during the
rinse cycle. If not then check the resistance of resistor R115 – this is the largest resistor located on
the lower left of the electronic control board. The resistance should be less than 1ohm. Typically, if this
resistor is blown, it will measure high resistance on your multi meter and the motor will not spin.
4. If R115 resistor is blown then replace electronic control board.
5. If green LED “MM Safety” does illuminate, then replace spindle motor.
More Thick Button Is Stuck
This error message appears if the More Thick push button is stuck in.
Situation:
The More Thick push button light is stuck ON, or when a customer places frozen product cup in cup holder
and the cup holder raises up automatically.
Resolution:
1. Massage the button left to right and up and down to work button free. This may take a few minutes. If
you can’t free up the button, replace.
2. If problem continues, see troubleshooting guide for Cup Obstructions on pages 21-22.
Rev. S-N
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Troubleshooting - continued
No Carriage Movement Sensed – Service Required Notify Attendant
Symptom 1: Cup Holder Raises Up Quickly But Comes Back Down
With a frozen product cup in the cup holder and one of the green push buttons is selected, the cup holder
raises up into the blending chamber quickly and this error message is displayed. The encoder for the lead
screw is not recognizing the lead screw rotating.
Locate the position motor encoder by removing the right side panel when facing the front of the blender,
then removing the top blue panel. The position motor encoder looks like a black plastic donut with a
round magnet in the middle located on the top and center of the blender, centered between two mixer
system pulleys.
1.
2.
3.
4.
5.
Resolution:
There are three wires coming off of the encoder (black/red/blue) and they run to a white square
connector. Verify that the wires are firmly in place on both sides of the connector.
Verify that the wire connection to the electronic control board, located on the backside of the blender,
is securely connected to TB13 ’Position Motor Sensor’ and that the wires are firmly in place in the
connector.
Flip up dipswitch #3. The LCD display will have changed to a line that has a ‘P’ at the beginning of
one it and an ‘M’ at the beginning of the next line. With a f’REAL! cup in the cup holder, press one of
the thickness buttons and watch the middle set of numbers on the ‘P’ line . As the cup holder moves
up, those numbers should change. If they do not the encoder is not detecting any movement,
proceed to the next step.
Remove the position motor encoder by removing the two screws. Make sure encoder sensor is not
dirty or that the magnet is not cracked or broken on the lead screw. Note: when replacing the encoder
make sure have even space around the magnet and encoder.
If problem still persist, replace encoder.
Symptom 2: Blender Clicks But Cup Holder Will Not Raise Up
With a frozen product in the cup holder and one of the green push button is selected, the front door
solenoid clicks and the cup holder does not raise up. The cup holder is resting on top of the aluminum
block underneath the cup holder. The cup holder needs to be manually raised to ¼ inch off the aluminum
block.
Locate the position motor encoder by removing the right side panel when facing the front of the blender,
then removing the top blue panel. The position motor encoder is a black plastic donut with a round magnet in the middle located on the top and center of the blender, centered between two mixer system
pulleys.
Resolution:
1. A slot is located on the shaft, take a flat-head screwdriver and turn the lead screw to raise the cup
holder a ¼ inch.
2. Check the position motor pulley to make sure it didn’t slide down the shaft of the motor. If it did,
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Troubleshooting - continued
3. Loosen the two set screws on the pulley, reposition the pulley and then tighten the two set screws.
4. Check the in-line fuse for the position motor.
5. If problem still persist, replace electronic control board.
Please Clean If Needed-Thank You Close Door When Ready To Go
Symptom 1: Front Door Switch
Front door is fully closed, the flip up doors are oriented right over left, and this message appears on the
display.
There are 4 switches (1-front door switch, 2-flip-up door micro lever switches, 1-actuator switch) that have
to be working properly for this message to go away.
Locate the front door switch by opening the front door of the blender and in the top right hand corner you
will see the reed switch with two black wires coming from it.
Resolution:
1. Remove the right side panel of the blender and locate the two black wires from the front door switch
going to a white connector. With a meter, check continuity of the front door switch side of the
connector by opening and closing the front door. Continuity should be present when the front door is
closed.
2. If no continuity is present, then check to make sure magnet located on the front door is still attached.
Remove the marketing overlay that covers the fluorescent lights on the front door. Located in the
upper right hand corner is the magnet that mates with the reed switch when the front door is closed.
Verify that the magnet is still attached to the front door and is not loose, cracked or broken.
3. If magnet on front door looks good then replace the front door switch and then retest continuity of the
front door switch.
4. If continuity is present on the front door switch, then go to Symptom 2.
Symptom 2: Flip-up Double Door Arms
Front door is fully closed and this message still appears on the display after checking the front door switch
continuity.
The double door arms are attached to the backside of the clear plastic flip-up doors. The double door arms
can be located by removing the 4 screws out of the right and left side blue panels. Attached to the end of
the flip-up doors are the double door arms with a spring attached to them. Each double door arm triggers a
separate micro lever switch.
Resolution:
1. If the double door arm is not attached to the flip-up door then the double door arm will not press
against the micro lever switch. Inspect the flip up door and double door arm for cracks or breaks.
Replace the flip-up door and reattach the double door arm clip. (Note: When attaching the double door
arm, the flat side should go against the blender wall.)
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Troubleshooting - continued
2. Verify wiring to micro lever switches is correct. Switch is wired N/O Normally Open.
3. With an ohmmeter check continuity of the micro lever switches . When the doors are closed there
should be continuity and when open the continuity should cease. Replace switch if working incorrectly.
If the right and left flip-up double door arms are attached and resting against the micro lever switch in the
closed position, then go to Symptom 3.
Symptom 3: Actuator Switch
Front door is fully closed and this message still appears on the display after checking the front door switch
continuity, and the right and left flip-up double door arms.
Find the actuator switch by removing the 4 screws on the right side panel. Locate the actuator micro
switch by measuring up from the bottom middle part of the blender 6 inches. You will notice a black and
blue wire going to a micro switch that is hidden behind the metal cup holder track.
Resolution:
1. Disconnect the white connector with the blue and black wire for the actuator and check continuity between the blue and black wires. This switch is wired N/C and no continuity should be present if the cup
holder is in the home position. If continuity is present, then check to make sure the switch is wired
correctly for N/C.
2. Check the micro switch button for proper operation. When the button is pressed in and released the
button should pop out immediately. If there is any type of delay, the micro switch must be replaced.
Regular Thickness Button Is Stuck
This error message appears if the green Regular Thick push button is stuck in.
Situation:
The Regular Thick push button light is stuck ON, or when a customer places a frozen product cup in the
cup holder and the cup holder raises up automatically.
Resolution:
1. Massage the button left to right and up and down to work button free. This may take a few minutes. If
you can’t free up the button, replace.
2. If problem continues, see troubleshooting guide for Cup Obstructions on pages 21-22.
Service Required Notify Attendant More Directions Will Show Here When Attendant Opens Front
Door Daily Clean & Sanitize Needed Clean First – Open Front Door Use Brush; Clean Shaft, Blade
and Top and Underside of Lid/Weight Then Run Sanitize Cycle Using Approved Sanitizer in Cup
Push/Hold Less and More Buttons When Cycle Ends, Empty & Save Cup To Return To Normal Operation.
Symptom 1: Blender shuts down and all 4 blue LED’s flash simultaneously.
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Troubleshooting - continued
Resolution:
1. Completely clean inside blending chamber. (Note: Power must remain on for blender to recognize
cleaning has been done properly). Then run complete sanitize cycle. Refer to f’REAL! Sanitizing
procedures for correct sanitizing Instructions.
Symptom 2: Blender shuts down and all 4 blue LED’s flash simultaneously and the blender will not allow
the 2-minute sanitizing to be performed.
One of the safety switches for the front door or the flip-up doors may be open.
Resolution:
1. Verify that the double door arms are attached to the right and left flip-up doors and making contact with
the micro lever switch.
2. Check the continuity of the front door switch when the front door is closed. Replace if continuity is not
made when the front door is closed.
3. Recalibrate the cup sensor. Place an f’REAL! sanitizer cup in the cup holder, open front door and in
the upper left hand corner turn the power switch off. With the front door still open, press and hold the
“Less” and “More” Thick buttons and turn the power back on. Keep pressing the buttons until the
display reads IR Sensor Recalibrating. Release the buttons When prompted, press “Save” or “Less”
Thick button.
To Use Blender Cup Must Contain Hard Frozen Product
The blender is looking for resistance from the frozen product in the cup. If the correct resistance of frozen
product is not found in the first ½ inch of the product this error message appears.
Symptom 1: Customer Uses A Cup Other Than A f’REAL! Frozen Product Cup
Some customers think by placing an empty cup (coffee or fountain) in the cup holder, that the blender will
dispense frozen product into the cup. When the customer places an empty cup in the cup holder and
presses any of the green push buttons the cup holder rises up but the blender will send it back down.
Resolution:
1. The cup sensor should not register other cups, but occasionally there are cups that can trigger the
sensor. If other cups are sent in to the blending the chamber the blender will simply check for
resistance of frozen product and if no product is present the cup holder will return to the home position.
Symptom 2: Frozen Product is Too Warm
When the frozen product is above 6+ degrees the blender may not blend the frozen product.
Resolution:
1. Check the temperature of the display freezer. The inside temperature should be between 0-6+
degrees. Adjust if necessary.
2. Make sure front door to display freezer is closing properly. Sometimes a frozen product cup can flip
forward holding the door open.
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Troubleshooting - continued
3. If the temperature is above 8+ degrees check to make sure the fan is running in the back of the
freezer. If fan has STOPPED then wait one hour and recheck temperature to make sure it’s fallen to 0
to +6 degrees. If fan has stopped and the lights are out inside the freezer then check power to freezer.
4. If unit is a Silver King, check the filter at the base of the unit. Clean if necessary.
5. If unit is still having issues, then contact the f’REAL! Customer Support Center.
Water Heater Not Full Of Water - Unplug Power and Connect Water
Situation:
Blenders display shows the water-heating screen upon power up and the temperature read out on the
lower left corner is erratically increasing by 5 degrees per second. The temperature read out should only
increase 1-2 degrees per second.
Resolution:
1. Verify that the water supply has been connected to the blender and that the water is turned on.
2. Check the thermal cutout switch on the back of the water heater. If the button will depress, then the
cutout has been tripped. Press button and then cycle power to the blender. If button trips again the go
to next check.
3. Verify that the two white wires located on TB7-H20 are connected on the electronic control board and
that the wires are firmly seated in the connector.
4. Check resistance of water heater probe. To check the resistance, unplug the connector with two white
wires located on TB7-H20 from the electronic control board. Use an ohm meter to check resistance
across the two wires. Resistance should be between 3K to 10K. If under 3k, replace thermistor.
5. If problem persist, replace water heater.
Water Heater Not Heating Properly - Service Required Notify Attendant
Situation:
Water inside of water heater is not heating at the correct temperature of 115-125 degrees within 180
seconds after water is dispensed. Main water supply to blender may have been shutoff during power up.
Resolution:
1. Verify that the main water supply valve is turned on to the blender.
2. Open the front door of the blender and check to see if water is continuously running from either the
rinse nozzles or the water shot opening. If so, replace either the water shot valve or the rinse valve.
3. Facing the front of the blender, remove the four screws holding the right side blue panel, then remove
the back panel. Locate the water heater thermal cutout switch on the backside and towards top of the
water heater. Push thermal cutout switch button in towards the water heater until you feel it click to
reset switch.
Rev. S-N
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Troubleshooting - continued
4. Check resistance of water heater probe. To check the resistance, unplug the connector with two
white wires located on TB7-H20 from the electronic control board. Use an ohm meter to check
resistance across the two wires. Resistance should be between 3K to 10K. If under 3k, replace
thermistor.
5. If problem persist, replace the water heater.
Water Pressure Too Low – Service Required Notify Attendant
Situation:
Blender will display this error message if water pressure falls below 25 psi going in to the blender.
Resolution:
1. Check to see if there is water pressure issue to the other equipment – fountain, coffee etc… If so,
water pressure to all of the store is low.
2. Verify that the main water supply valve to the blender is turned on.
3. Locate the female quick disconnect located on the lower left corner on the backside of the blender.
Verify that the female quick disconnect is securely fastened to the male quick disconnect on the
blender.
4. Verify that the inline water pressure to the blender is consistently at least 25psi, even when other
equipment is also using water.
5. Check to make sure the 25 psi pressure switch is securely connected.
6. Verify that there are no leaks in the blenders water system. Repair any leaks.
7. If problem persists, replace pressure switch.
Rev. S-N
31
Possible Issues and No Error Message is Displayed
Rev. S-N
•
Cup holder will not go up when button is pressed ........................................................... 33
•
Blender displays “Remove Drink and Enjoy” and will not clear ....................................... 33
•
Blender makes squealing noise while cup holder travels up and down .......................... 33
•
Blender makes a grinding noise coming from the position motor.................................... 34
•
Cup was damaged during the blending cycle ................................................................. 34
•
Blender makes a grinding noise while blending a drink .................................................. 34
•
There appears to be grease in the blending chamber .................................................... 35
•
Blue lights, on the front of the blender, will not work ....................................................... 35
•
LCD display is dark but the words are legible ................................................................. 35
•
LCD display is reading odd characters, or missing a line................................................ 35
•
Fluorescent lights are not working .................................................................................. 35
•
Water is not draining out of blending chamber ................................................................ 36
•
Product is not blending correctly ..................................................................................... 36
•
There is frozen product in the blending chamber ............................................................ 36
•
Water constantly sprays inside the blending chamber .................................................... 36
•
The power switch is on and no lights are lit on the blender ............................................ 37
•
Frozen drinks are too soft or too thick after blending ...................................................... 37
32
Troubleshooting — No Error Message is displayed
Cup Sensor Issues
Symptom 1: Blender not taking cup up
When a f’REAL! shake cup is placed in the cup holder and the thickness buttons do not light up and stay
lit.
This issue takes place when the cup sensor is not recognizing that a f’REAL! cup is in the cup holder.
Resolution
1. Recalibrate the cup sensor. Place a f’REAL! cup in the cup holder. Open the front door and turn the
power off. Press and hold the LESS thick and MORE thick buttons and turn the blender on at the
same time. Continue to hold the buttons in until your display reads CUP IR SENSOR
RECALIBRATING. Once this message appears release the buttons. Recalibration takes approximately 45 seconds. The message will ask you to SAVE or CANCEL. Press the SAVE button. (LESS
thick)
2. If problem persists, replace the cup sensor and software chip.
Symptom 2: Message on blender says Remove Cup and Enjoy after cup is removed
After shake is blended the cup sensor does not recognize that the cup has been removed.
Resolution
1. Make sure there are no objects to the left of the blender. (i.e. lid holder, marketing danglers etc) If
there are, move the objects back or out of the way.
2. Recalibrate the cup sensor using the double-cup method. Place a shake cup inside the f’REAL!
cleaning cup. Place in cup holder. Open the front door and turn the power off. Press and hold the
LESS thick and MORE thick buttons and turn the blender on at the same time. Continue to hold the
buttons in until your display reads CUP IR SENSOR RECALIBRATING. Once this message appears
take your fingers off of the buttons. Recalibration takes approximately 45 seconds. Then a message
will ask you to SAVE or CANCEL. Press the SAVE button. (LESS thick)
3. If problem persists, replace the cup sensor and software chip.
Lead Screw Issues
Situation:
Blender makes a squealing noise while moving up and down. This happens when the lead screw needs
lubricated.
1. Remove the right side panel of the blender and locate the lead screw. Apply a few drops of Quinplex
4023 lube to several points on the lead screw. It is important that only the Quinplex grease is used.
Other greases may damage the lead screw. Run 5 to 6 test cycles to work the grease across the lead
screw.
2. Remove the top panel of the blender and locate the top of the lead screw. It is between the two silver
pulleys. Manually turn the lead screw and see if it is hard to turn and feel for any ‘catching’ in the
bearing as it is being turned. Replace bearing if not easy to turn or if it is noisy.
Rev. S-N
33
Troubleshooting - continued
Position Motor Assembly
Situation:
During the blending process, the position motor makes a grinding or whining noise.
Resolution
1. Remove the side panels of the blender. Remove the top panel. Remove the drain and water inlet line.
Lay blender on it’s back and remove bottom access panel. Remove the position motor belt and spin
the lead screw. If the lead screw is hard to spin then the likely issue is the bearings.
2. Spin the position motor and listen for any noise and feel for smooth operation. If the motor makes
noise or if it doesn’t spin smoothly, then replace the position motor.
Mixer System
Symptom 1: Cups damaged during blending cycle
During the blending cycle the cup comes down and has been damaged.
Depending on where the damage is on the cup will depend on where to look on the blender.
Resolution:
1. If the damage is on the upper half of the cup, then the product may have been mishandled. Frozen
product should be handled carefully.
2. If the damage is in the lower half of the cup, then inspect the lower spindle assembly. Ensure the
conformal slider moves freely on top of the blending disc and that it doesn’t stick out any more than 3/8
of an inch past the edge of the blending disc.
3. If the damage is because the blending disc is hitting the bottom of the cup. Check to see if the blender
has a shim installed below the anti-rotational device. If it has one it can be removed to help the issue.
There are two Phillips head screws on the underside of the cup holder that will need removed to take
the shim out.
Symptom 2: Grinding noise while blending
As the mixer system starts to spin a grinding noise is heard.
Resolution:
1. Check the temperature of the freezer unit. The temperature for the product must be between 0 and 6
degrees.
2. Verify the amount of water added to each shake. The amount of water must be 75—77 ml of water.
Or roughly 3/4 of an inch if measured from the inside of the cup. Adjust water accordingly per the
instructions on page 11.
3. Check the pre-load on the mixer system. To do this, open the front door of the blender and pull down
on the upper spindle. You should be able to get 1/16 inch of travel. If you are not able to pull down,
then adjust the castle nut at the top of the upper spindle pulley.
4. Remove the mixer system belt. Spin the mix motor by hand. Checking for noise and smoothness. If
the motor does not spin smoothly or if it is noisy, the mix motor should be replaced.
Rev. S-N
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Troubleshooting - continued
Symptom 3: There appears to be grease in the blending chamber.
Resolution:
1. The u-cup seal is damaged and will need replaced.
Blue LEDs
Situation:
Blue LEDs will not illuminate.
Resolution:
1. Verify the power to the blender is plugged in and the power switch is turned on.
2. Check the connection at the control board. The connection for the LEDs is located on the right side of
the control board. Ensure that the connector is correctly attached to the control board and ribbon
cable is in good condition.
3. If issue continues, replace the LED.
LCD Display
Symptom 1: LCD display is dark, but the words are legible.
Resolution:
1. Check LCD for a grounding issue. Squeeze the display and check to see if the LCD back light
illuminates. If it does, then one or more of the ground tabs may need to be bent to make a better
connection.
2. Replace LCD if bending the ground tabs does not work.
Symptom 2: LCD display reading odd characters, missing characters, or missing line(s)
Resolution:
1. Verify that the ribbon cable running from the display to the control board is in good condition. Check
for exposed or broken traces.
2. Unplug the user button ribbon cable and see if the display starts working. If so, replace the user
button ribbon cable.
3. Check for water damage at the control board.
4. If the issue continues, replace the LCD display.
Fluorescent Lights
Situation:
Fluorescent light(s) not working
Resolution:
1. Check for broken or burnt out bulbs. Inspect the sockets for discoloration or burn marks. Replace
parts as needed.
2. Verify the ballast is in good working order. Check the output voltage for the ballast. Set the meter to
AC voltage. Carefully touch one probe to the metal in the socket and ground the other probe. Your
reading should be around 180 Vac.
Rev. S-N
35
Troubleshooting - continued
Clogged Drain
Situation:
Water not draining out of the gray blending chamber.
Resolution:
1. Remove the left side panel of the blender. Locate the drain hose. Remove the drain hose and clean,
then re-install.
2. If issue continues, clog is outside of the blender and will need to be investigated further.
Frozen Product not Blending Properly
Symptom #1: During the blending cycle the shakes come out like they have a hole drilled in the center or
they ‘explode’ in the blending chamber.
Resolution:
1. Using an empty f’REAL! cup, run a test cycle and then measure the water in the bottom of the cup.
There should be 3/4 inch of water in the bottom of the cup. If not, adjust the water shot. (See page
11)
2. Clean out the water shot orifice. The water shot opening is located inside the blending chamber. It is
to the right of the upper spindle.
3. Verify that the proper amount of voltage is getting to the water shot valve. The correct voltage is 33
Vdc.
4. Take apart the water shot valve and clean, then retest. If issue continues replace valve.
Rinse Nozzles Not Spraying
Situation:
During a rinse cycle, the rinse nozzles are not spraying any rinse water.
Resolution:
1. Verify that the rinse valve is supplied with the correct voltage. The correct voltage is 33 Vdc.
2. Take apart the rinse valve and clean, then retest.
3. If problem continues, replace the rinse valve.
Water Continues to Spray out of Water Shot Orifice
Situation:
Water continues to pour out of the water shot orifice to the right of the spindle.
Resolution:
1. If the blender or the control board is new, it will do a purge of the water system for 30 cycles. During
this time the water will spray from the water shot orifice during the rinse cycle.
2. Check to make sure that the water shot valve is not being energized. To do this simply shut off the
blender. If the water keeps running then the problem is in the water shot valve. If it stops then the
issue is electrical.
3. Take apart the water shot valve and clean.
4. Replace water shot valve if it continues to leak.
Rev. S-N
36
Troubleshooting - continued
Water Continues to Spray out of Rinse Nozzles
Situation:
Water is constantly being sprayed out of the rinse nozzles.
Resolution:
1. Check to make sure that the rinse valve is not being energized. To do this, shut off the blender. If the
water keeps spraying out of the rinse valves then the problem is the rinse valve. If it stops then the
control board is the issue.
2. Take apart the rinse valve and clean.
3. Replace the rinse valve if it continues to leak.
Power Issues
Situation:
No lights on the blender.
Resolution:
1. Open the front door of the blender and make sure the power switch is turned on.
2. Verify that the blender is plugged into a wall outlet. Is the outlet a GFI type outlet? Press the reset
button if so.
3. Check the circuit breaker assigned to the blender.
4. Check the incoming voltage. Blender requires 120 VAC.
5. Inspect the control board for burn marks or signs of damage. If so, the control board will need to be
replaced.
Freezer Issues
Situation:
Temperature for the shakes must be kept between 0 & 6 degrees.
Resolution:
1. Silver King freezers. Check the condenser filter. The filter is located at the bottom of the freezer unit.
Remove the front grill and then pull the filter screen pull tab to remove the filter. Rinse it off with
running water. Dry the screen by tapping it on the floor or counter.
2. To adjust the Siler King freezer temperature: The control knob is located inside the freezer unit,
against the back wall. Turn the knob to the right to make temperature colder.
3. To adjust the Minus Forty temperature: Locate the electronic control on the right of the front bottom
grill. The grill is secured by two Phillips screws half way down the front of the grill. Remove these two
screws and pull the grill off. Press and release the P button; the set temperature and SP1 are
displayed alternatively on the controller. Press the UP or DOWN buttons to adjust the set temperature. Press the P to store the adjusted value.
NOTE: The value on the Minus Forty display screen, during the programming mode, is not a degree
reading. It is a setting value.
Rev. S-N
37
Limited Blender Parts Warranty
f’REAL! Foods strives to continuously improve the quality of our products; therefore, the Limited Blender Parts
Warranty requires all parts to be returned to our Customer Support Center in order to receive credit. This ensures
our opportunity to analyze all parts returned in order to continue to make the best blender possible.
The Limited Blender Parts Warranty applies to blender parts only. Please refer to the f’REAL! Warranty Option Selection
Agreement for any labor contracts agreed upon at the time of blender purchase. The Limited Blender Parts Warranty is
valid for one year from the date of installation, not to exceed fifteen months from the date of shipment from our
factory. Additional parts purchased for warehouse or truck inventory are sold “as is” with no extended warranties.
f’REAL! Foods will invoice for all parts shipped to customers. In order to receive credit for parts under warranty,
customers (including those designated to be in a “test period”) must follow the parts warranty claim procedures
outlined below. Properly observing these procedures will expedite the processing of warranty claims and reduce
the number of claims that are denied.
-- Part Warranty Claim Procedures -1. Call for an RMA number. An RMA number is required for all part warranty claims. All part
claims are to be handled directly with f’REAL! Foods Customer Support Center. To request an
RMA number, contact the f’REAL! Foods Customer Support Center at 800-483-3218. To complete
the RMA process, f’REAL! Foods requires the blender serial number, part number, and contact
information. RMA numbers are valid for 30 days from date of issue. RMA’s received after 30 days of
issue may forfeit credit memo entitlement. Parts received without an RMA # will not be processed.
2. Send the part back to f’REAL! Foods. The outside of each part box sent from f’REAL! is
stamped with warranty claim information. Simply fill out the warranty information on the outside of
the box, place the defective part in the box, and send the part back to the f’REAL! Foods Customer
Support Center. Shipping charges for returning parts shall be the responsibility of the customer.
3. Credit memo issued. A determination will be made within 30 days of receipt of the part
whether the claim has been approved. If the claim is approved, a credit memo will be issued.
The RMA number will be referenced on the credit memo. Credit will be issued for the part and
applicable taxes. No credit will be given for shipping charges. Credits will be issued as “open
credits” which can be used toward any blender part orders. Credit for parts may not be used for
blender purchases or frozen product purchases.
In the event a customer terminates the f’REAL! Program, the customer must notify f’REAL! Foods Customer Support Center
in writing to receive money for outstanding credits. Any credits remaining in account will first be applied to outstanding
invoices. A check will then be issued for the remaining balance to the customer.
Any use of non-genuine f’REAL! Parts may, at f’REAL!’s discretion, void this warranty. Damage caused by carelessness,
neglect, improper cleaning or maintenance and/or abuse (e.g., dropping, tampering or altering parts, equipment damaged in
shipment, by fire, flood or act of God) is not covered under this warranty.
For questions, please call the f’REAL! Foods Customer Support Center at 800-483-3218.
Rev. S-N
38
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