Service Manual FCB Overcounter V3Plus with R404A

Service Manual
FCB
OVERCOUNTER
POST-MIX DISPENSER
WITH
V3+FEATURES
(R-404A REFRIGERANT)
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.
Publication Number: 312028000
Revision Date: May 06, 2014
Revision: E
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Service Manual must be read and understood before starting to install or operate this equipment.
© CORNELIUS INC; 1994-2014
Printed in U.S.A.
TABLE OF CONTENTS
Page
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
DEFROST SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
MANUAL DEFROST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
AUTOMATIC DEFROST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
‘‘SLEEP’’ (SLEEP TIME) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
‘‘WAKE UP’’ (WAKE UP TIME) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
IDENTIFICATION OF LOOSE-SHIPPED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
ELECTRICAL POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
60 HZ UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
50 HZ UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
SELECTING LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
INSTALLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
INSTALLING LEVELING LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
INSTALLING DRIP TRAY SUPPORTS (ITEM 7) AND (ITEM 8) . . . . . . . . . .
9
INSTALLING DRIP TRAY DRAIN HOSE KIT (ITEM 10) . . . . . . . . . . . . . . . . .
9
PREPARING UNIT FOR CONNECTION TO SYRUP, CO2, AND CITY PLAIN
WATER SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
INSTALLING PRIMARY CO2 REGULATOR ASSEMBLY ON CO2
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
CONNECTING SOFT DRINK TANKS CO2 LINES TO PRIMARY CO2
REGULATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT
DRINK TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
CONNECTING CO2 SOURCE LINE TO UNIT CO2 INLET LINE . . . . . . . . .
10
CONNECTING CITY PLAIN WATER SOURCE LINE TO UNIT . . . . . . . . . .
11
CONNECTING ELECTRICAL POWER CIRCUIT TO THE UNIT . . . . . . . . .
11
PREPARATION FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
TURNING ON ELECTRICAL POWER TO UNIT . . . . . . . . . . . . . . . . . . . . . . .
12
TURNING ON CO2 SUPPLY TO THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
ADJUSTING PRIMARY CO2 REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
ADJUSTING PRODUCT BLENDER TANKS SECONDARY CO2 . . . . . . . . .
12
ADJUSTING CARBONATOR SECONDARY CO2 REGULATOR . . . . . . . . .
12
STARTING FCB AND ADJUSTING WATER-TO-SYRUP “RATIO” (BRIX) OF
DISPENSED PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
FILLING FREEZE CYLINDERS WITH PRODUCT . . . . . . . . . . . . . . . . . . . . .
14
CHECKING UNIT FOR SYRUP, CO2, OR PLAIN WATER LEAKS . . . . . . .
14
PLACING UNIT IN OPERATING LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . .
15
ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE) . . . . . . . . . . . . .
15
TABLE OF CONTENTS (cont’d)
Page
ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS, COMPONENTS
“DIAGNOSE’’ (DIAGNOSTIC MODE), AND ‘‘TOTALS”(DISPLAYED CYCLES AND
HOURS TOTALS) INTO UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY
16
SETTING CLOCK (TIME OF DAY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT . . .
17
PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT . . . . . . . . . . . . . . . . .
18
PROGRAMMING ‘‘WAKE UP’’ (WAKE UP TIME) INTO UNIT . . . . . . . . . . . .
19
PROGRAMMING POINT OF SALE MESSAGE DISPLAY . . . . . . . . . . . . . . .
19
ADJUSTING “VIS SET” (PRODUCT VISCOSITY) OF DISPENSED
PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
‘‘VIS READ’’ (ACTUAL VISCOSITY READOUT) OF PRODUCT IN FREEZE
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON
OUTLET SENSORS TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) . . . . . . . . . . . . . . . . . . . . . .
22
PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE)
INTO UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
DISPLAYING ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS)
ONTO MESSAGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT
ELECTRONICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT
ELECTRONICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
DISPLAYED ERROR CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
OPERATOR’S INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
CONTROL PANEL ASS’Y SWITCHES AND DISPLAYED MESSAGES . . . . . . .
27
CONTROL PANEL ASS’Y SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
CONTROL PANEL ASSEMBLY DISPLAY MESSAGES . . . . . . . . . . . . . . . . .
28
FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS . . . . .
29
MANUAL DEFROST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
AUTOMATIC DEFROST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
‘‘SLEEP’’ (SLEEP TIME) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
‘‘WAKE UP’’ (WAKE UP TIME) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
FACEPLATE RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
PRODUCT SAMPLE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
PRODUCT SHUTOFF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
PRIMARY CO2 REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
SECONDARY CO2 REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
CARBONATED WATER FLOW REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
SYRUP FLOW REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
DISPENSING VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
DISPENSED PRODUCT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
‘‘OVERRUN’’, AS APPLIED TO FROZEN CARBONATED BEVERAGES . .
31
OPERATING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
OPERATING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
TABLE OF CONTENTS (cont’d)
Page
REPLENISHING SYRUP SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
PRODUCT FLAVOR CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
CHECKING CO2 SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
CLEANING AND SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
DAILY CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
CLEANING CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
CARBONATED WATER FLOW RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
WATER-TO-SYRUP “RATIO” (BRIX) OF DISPENSED PRODUCT . . . . . . .
34
CO2 REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
ADJUSTING BEATERS MOTORS CURRENTS . . . . . . . . . . . . . . . . . . . . . . .
34
PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY
34
SETTING ‘‘CLOCK’’ (TIME OF DAY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT . .
34
PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT . . . . . . . . . . . . . . . . .
35
PROGRAMMING ‘‘WAKE UP’’ (WAKE UP) TIME INTO UNIT . . . . . . . . . . . .
35
PROGRAMMING POINT OF SALE MESSAGE DISPLAY . . . . . . . . . . . . . . .
35
ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED
PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
“VIS READ” (ACTUAL VISCOSITY READOUT) OF PRODUCT IN
FREEZE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND
COMMON OUTLET SENSORS TEMPERATURES . . . . . . . . . . . . . . . . . . . .
35
‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) . . . . . . . . . . . . . . . . . . . . . .
35
PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE)
INTO UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
DISPLAYING ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS)
ONTO MESSAGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT
ELECTRONICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
DISPLAYED ERROR CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT
ELECTRONICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
CLEANING CO2 GAS CHECK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING . . . . . . . . . .
37
PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
REMOVAL OF TOP PANEL, BACK PANEL, SIDE PANELS, AND FRONT
ACCESS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
TOP PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
BACK PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
TABLE OF CONTENTS (cont’d)
Page
SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
FRONT ACCESS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
OPENING AND CLOSING FRONT ACCESS DOOR . . . . . . . . . . . . . . . . . . . . . . .
38
OPENING FRONT ACCESS DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
CLOSING FRONT ACCESS DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
CARBONATOR WATER PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE
CYLINDERS DRIVE SHAFT/ SEAL ASSEMBLIES . . . . . . . . . . . . . . . . . . . . .
38
CLEANING CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
ADJUSTING PLAIN WATER PRESSURE REGULATOR . . . . . . . . . . . . . . . .
43
ADJUSTING CARBONATED WATER
FLOW RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
ADJUSTING CO2 REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
ADJUSTING BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ OF DISPENSED
PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
PRODUCT CARBONATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .
49
CLEANING AND SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
DAILY CLEANING OF UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
SANITIZING SYRUP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
YEARLY OR AFTER WATER SYSTEM DISRUPTION . . . . . . . . . . . . . . . . . . . . . .
52
SERVICING CARBONATOR WATER PUMP WATER STRAINER SCREEN
52
SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
REPLENISHING SYRUP SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
REPLENISHING CO2 SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
SYRUP FLAVOR CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
CLEANING CO2 GAS CHECK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR . . . . . . . . . . . . . . . .
57
ADJUSTING CARBONATOR TANK LIQUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . .
58
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT
MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING. . . . . .
63
ALL CONTROL PANEL SWITCHES NOT OPERATING. . . . . . . . . . . . . . . . .
63
CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED. . . . . . . . . . .
64
PARTIAL MESSAGE OR DULL (POORLY ILLUMINATED) DISPLAY. . . . . .
64
ONE OR MORE FAULT MESSAGES NOT OPERATING. . . . . . . . . . . . . . . .
64
ALL FAULT MESSAGES NOT OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . .
64
‘‘CO2 OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. . . . . . . .
65
‘‘H2O OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. . . . . . . .
65
‘‘SYRUP 1’’ OR ‘‘SYRUP 2’’ FAULT MESSAGE GOES ON DURING
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
‘‘ERROR 1’’ OR ‘‘ERROR 2’’ FAULT MESSAGE GOES ON DURING
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
TABLE OF CONTENTS (cont’d)
Page
FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT
OPERATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE. . . . . . . . . . . .
65
MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN ‘‘DEFROST’’
SWITCH IS PRESSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN ‘‘DEFROST’’
SWITCH IS PRESSED. (CONT’D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING ‘‘CANCEL
DEFROST ’’ SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR . . .
66
CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE. . . . . . . . . .
66
CARBONATOR WATER PUMP WILL NOT SHUT OFF. . . . . . . . . . . . . . . . . .
67
ERRATIC CARBONATOR WATER PUMP CYCLING. . . . . . . . . . . . . . . . . . .
67
TROUBLESHOOTING DISPENSED PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ TOO LOW. . . . . . . . . . . . . . . . . . . . . . .
67
BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ TOO HIGH. . . . . . . . . . . . . . . . . . . . . . .
67
IMPROPER PRODUCT DISPENSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE, IN ONLY
SMALL AMOUNTS, OR ONLY LIQUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN
DISPENSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY. . . . . . . . . .
68
CYLINDER FREEZE-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
LIST OF FIGURES
FIGURE 1. FCB OVERCOUNTER POST-MIX DISPENSER . . . . . . . . . . . . . . . . .
3
FIGURE 2. FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
FIGURE 3. CONTROL PANEL ASS’Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
FIGURE 4. MASTER AND RELAY CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . .
21
FIGURE 5. OPERATING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
FIGURE 6. UNIT INTERNAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
FIGURE 7. SELF-CLOSING DISPENSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . .
41
FIGURE 8. FREEZE CYLINDER CUTAWAY VIEW . . . . . . . . . . . . . . . . . . . . . . . . .
44
FIGURE 9. SERVICING BEATER MOTOR DRIVE SHAFT/SEAL ASSEMBLY .
45
FIGURE 10. BEATERS AND SCRAPER BLADES INSTALLATION . . . . . . . . . . .
46
FIGURE 11. LIQUID CHECK VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
53
FIGURE 12. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
FIGURE 13. CO2 GAS CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
FIGURE 14. CARBONATOR LIQUID LEVEL CONTROL SWITCH
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
FIGURE 15. REFRIGERATION FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . .
60
FIGURE 16. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
FIGURE 17. OVERCOUNTER FCB POST-MIX DISPENSER . . . . . . . . . . . . . . . .
70
FIGURE 18. SECONDARY CO2 REGULATOR COMPONENTS . . . . . . . . . . . . .
73
TABLE OF CONTENTS (cont’d)
Page
LIST OF FIGURES (CONT’D)
FIGURE 19. CONTROL BOX COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
FIGURE 20. SECONDARY CO2 REGULATOR ASS’Y . . . . . . . . . . . . . . . . . . . . . .
74
FIGURE 21. TUBE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
FIGURE 22. TUBE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
FIGURE 23. CO2 REGULATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
FIGURE 24. CHECK VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
FIGURE 25. BLENDER AND TUBING COMPONENTS . . . . . . . . . . . . . . . . . . . . .
76
FIGURE 26. TUBING ASSEMBLY (CARB WATER) . . . . . . . . . . . . . . . . . . . . . . . .
77
FIGURE 27. TUBING ASSEMBLY (SYRUP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
FIGURE 28. TUBING ASSEMBLY (BLENDER TO FREEZE CYLINDER) . . . . . .
77
FIGURE 29. TUBING ASSEMBLY (WATER SOLENOID TO BLENDER) . . . . . .
78
FIGURE 30. TUBING ASSEMBLY (REGULATOR TO BLENDER) . . . . . . . . . . . .
78
FIGURE 31. DOUBLE CHECK VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
78
FIGURE 32. SOLENOID VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
FIGURE 33. BLENDER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
FIGURE 34. CONTROL BOX AND DISPLAY PANEL COMPONENTS . . . . . . . .
81
FIGURE 35. FACEPLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
FIGURE 36. DISPENSING VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
FIGURE 37. CARBONATOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
FIGURE 38. TUBING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
FIGURE 39. DRIP TRAY DRAIN KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
FIGURE 40. CARBONATOR TANK AND LINKAGE ASSEMBLY . . . . . . . . . . . . .
85
FIGURE 41. PUMP AND MOTOR ASS’Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
FIGURE 42. BEATER MOTOR DRIVE SHAFT/SEAL ASS’Y . . . . . . . . . . . . . . . . .
87
LIST OF TABLES
TABLE 1. DESIGN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
TABLE 2. ACCESSORIES AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
TABLE 3. LOOSE-SHIPPED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
TABLE 4. MAIN MENU SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
TABLE 5. DIP SWITCH FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
TABLE 6. MOTOR SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
TABLE 7. POINT OF SALE DISPLAY MESSAGES . . . . . . . . . . . . . . . . . . . . . . . .
19
TABLE 8 “TOTALS” (DISPLAYED CYCLES AND HOURS TOTALS) MENU . . . .
24
TABLE 9 DISPLAYED ERROR CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
GENERAL DESCRIPTION
IMPORTANT: To the user of this manual – This manual is a guide for installing, operating, and maintaining
this equipment. Refer to Table of Contents for page location of information pertaining to questions that arise
during installation, operation, service and maintenance, or troubleshoo musting this equipment.
These Units must be installed and serviced by a qualified Service Person. These Units contain no User serviceable
parts.
Warranty Registration Date
(to be filled out by customer)
Model Number:
Serial Number:
Install Date:
Local Authorized
Service Center:
GENERAL DESCRIPTION
This section gives the description, theory of operation, and design data for the FCB (Frozen Carbonated
Beverage) Overcounter Post-Mix Dispenser with V3+ Features (hereafter referred to as a Unit).
UNIT DESCRIPTION
The Unit (see Figure 1) consists basically of two freeze cylinders each containing an internal beater driven by an electric motor, one refrigeration system with a 2-horsepower compressor, one carbonator which feeds both carbonatorblender tanks, a timer-controlled automatic hot-gas defrost system to defrost the freeze cylinders, and interconnecting
tubing, components, and fittings necessary to regulate, transfer, and dispense product.
The components are attached to a steel frame and are enclosed in a steel cabinet. The cabinet sides and back panels are easily removed and the front access door may be opened 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 drip tray, with cup rest, is located directly below the dispensing valves.
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.
Table 1. Design Data
Unit Part Numbers:
60 HZ Unit
50 HZ Unit
416136XXXX
496136XXXX
Overall Dimensions:
Height
Width
Depth W/O Drip Tray
Depth W/Drip Tray
32 inches
19 inches
31 1/8 inches
36 inches
Shipping Weight (approx)
420 pounds
1
312028000
Table 1. Design Data (cont’d)
Refrigeration System:
Compressor Horsepower
Refrigerant Type And Charge
2 H.P.
See Unit Nameplate
Ambient Operating Temperature
40° F to 100° F
Electrical Requirements:
Operating Voltage
See Unit
Nameplate
See Unit
Nameplate
Operating Current
Table 2. Accessories and Tools
ACCESSORIES
Installation kits
Cup Holder
Cup Holder
CO2 Changeover Kit
1155
511005000
511006000
511035000
GENERIC FLAVOR TABS
Cola
Cherry
Orange
Grape
Lemon-Lime
Strawberry
Banana
1085
1086
1087
1088
1089
1090
1091
SERVICE TOOLS
3-gallon Sanitizing Tank
Spanner Wrench, Dispensing Valve
Refractometer, 0-30 Scale
Wrench, Rear Seal Housing
Tool, Drive/Coupler Adjustment Gauge
281884000
322859000
511004000
2899
3810
THEORY OF OPERATION
(see Figure 2)
A CO2 cylinder delivers carbon dioxide (CO2) gas to an adjustable primary CO2 regulator assembly which is 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 two soft drink tanks. CO2 is delivered from the adjustable secondary CO2 regulators to the
carbonator tank and also to product-blender tanks inside the Unit. CO2 gas pressure pushes syrup out of the soft
drink tanks through the syrup sold-out switches, through adjustable syrup flow regulators, through electrically operated syrup solenoid valves, and on to the product blender tanks. At the same time, plain water passes through the
water pressure regulator and is pumped into the carbonated water tank by the water pump and is carbonated by CO2
gas pressure also entering the tank. Carbonated water is pushed by CO2 gas pressure from the carbonated water
tank, through adjustable carbonated water flow regulators, through electrically operated carbonated water solenoid
valves, and on to the product blender tanks. Carbonated water and syrup enter the tanks properly proportioned
(blended) for desired BRIX of dispensed product by adjustment of the syrup flow regulators.
From product blender tanks, product is pushed by the CO2 gas into the freeze cylinders. The beater in each freeze
cylinder is driven by an electric motor. Scraper blades, attached to the beaters, scrape product from the cylinder walls
as product enters the freeze cylinders and is frozen.
312028000
2
Transparent faceplate, attached to the front of each freeze cylinder, includes a self-closing dispensing valve and a
spring-loaded relief valve that protects freeze cylinder from accidental over pressure. The relief valve is also used to
bleed CO2 gas pressure from the freeze cylinder to atmosphere when filling the cylinder with product. Electronic sensing on each freeze cylinder motor provides a means of adjusting viscosity (consistency) of the dispensed product to
suit customer preference.
FIGURE 1. FCB OVERCOUNTER POST-MIX
DISPENSER
DEFROST SYSTEMS
The Unit is equipped with both manual and automatic hot-gas defrost systems. The automatic defrost system may be
programmed into the Unit to occur up to nine different times a day with a minimum of two hours between defrost time
settings or the system may be completely turned off.
MANUAL DEFROST SYSTEM
The Manual hot-gas defrost system may be activated at any time by pressing the ‘‘DEFROST’’ switch on front of the
Unit. Refrigeration compressor will operate for a short time, then both freeze cylinders will go into defrost for approximately 60 seconds. At the end of the manual defrost cycle, the Unit will return to normal operation. Manual defrost
may be cancelled at any time by pressing the ‘‘CANCEL DEFROST’’ switch.
AUTOMATIC DEFROST SYSTEM
The automatic hot-gas defrost system may be programmed into the Unit to occur up to nine different times a day with
a minimum of two hours between defrost settings. At the start of each automatic defrost cycle, refrigeration compressor will operate for 30 seconds to pump freon out of the freeze cylinders evaporator coils.
After freon has been pumped out of the freeze cylinders evaporator coils, No. 1 freeze cylinders only will go into defrost cycle for approximately 7 minutes, then will return to normal operation. This ends the automatic defrost cycle of
the No. 1 freeze cylinder. No. 2 freeze cylinder will defrost 30 minutes after the start of No. 1 freeze cylinder. The next
automatic defrost cycle will occur according to the time programmed into the Unit. Automatic defrost may be cancelled at any time by pressing the ‘‘CANCEL DEFROST’’ switch.
3
312028000
‘‘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
for 60 seconds. After No. 1 freeze cylinder has defrosted, No. 2 freeze cylinder will go into defrost for 60 seconds. At
the 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.
312028000
4
FIGURE 2. FLOW DIAGRAM
5
312028000
THIS PAGE LEFT BLANK INTENTIONALLY
312028000
6
INSTALLATION
This section covers unpacking and inspection, installing Loose-Shipped Parts, selecting location, installing Unit,
preparing for operation, and operation.
UNPACKING AND INSPECTION
(see Figure 5)
NOTE: The Unit was thoroughly inspected before leaving the factory and the carrier has accepted and
signed for it. Any damage or irregularities should be noted at time of delivery (or not later than 15
daysfrom date of delivery) and immediately reported to the delivering carrier. Request a written
inspectionreport from a Claims Inspector to substantiate any necessary claim. File claim with the
delivering carri- er, not with Cornelius Inc.
1. After Unit has been unpacked, remove shipping tape and other packing material.
2. Remove Unit sides and back panels as instructed.
3. Remove shipping bolts that secure Unit to skid, then remove skid.
4. Unpack Loose-Shipped Parts. Make sure all items are present and in good condition.
Table 3. Loose-Shipped Parts
Item
No.
Part No.
1
178025100
Tapered Gasket, White
4
2
322859000
Spanner Wrench, Dispensing Valve
1
3
325216000
Cleaning Brush
1
4
311304000
Tapered Gasket, Black
1
5
317660000
Cup Rest
1
6
325282000
Thread Cutting Screw, Hex Hd.; No. 8 by 18 by 1/2-in. long
2
7
2738
Drip Tray Support, Left
1
8
2739
Drip Tray Support, Right
1
9
317659029
Drip Tray
1
10
326002000
Kit, Drip Tray Drain Hose
1
11
2899
Wrench, Rear Seal Housing
1
12
3810
Tool, Drive/Coupler Adjustment Gauge
1
13
324252000
Leveling Leg
4
14
3247
Spacer, White
2
15
3221
Front Access Panel
1
16
3108
Thread Cutting Screw, Phil Pan Hd; No. 10 by 32 by 1-in. long
2
Name
Qty.
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.
312028000
7
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) are to be installed on front of Unit (See Figure 5) and secured with
thread cutting screws (item 6) and thread cutting screw (item 16).
6. Cup rest (item 5) is to be installed in drip tray (item 9), then drip tray is to be installed on drip tray supports.
7. Drip tray drain hose kit (item 10) is to be installed on drip tray as instructed in Instructions provided in the
Kit.
8. Wrench, rear seal housing (item 11) is used to remove the drive shaft/seal assembly from inside the freeze
cylinder.
9. Tool, drive/coupler adjustment gauge (item 12) is used for servicing the beater motor drive shaft/ seal assembly (See Figure 9).
10. Leveling legs (item 13) are to be installed on bottom of the Unit.
11. Front access panel (item 15) is to be installed on front of the Unit (See Figure 5) and secured with white
spacers (item 14) and screws (item 16). Spacers are to be installed between the front panel and the unit
frame.
ELECTRICAL POWER REQUIREMENTS
IMPORTANT: Before connecting electrical power to the Unit, refer to nameplate and note if Unit is to be
operated with 50 or 60 Hz power source.
60 HZ UNIT
IMPORTANT: Power circuit voltage across L1 and L2 terminals on contactor inside lower electrical
control box, with refrigeration compressor operating, must be in range of 198-253 VAC, 60 Hz
single-phase for proper operation.
A properly grounded 198-253 VAC, 60 Hz single-phase electrical circuit connected through a 30-amp minimumrated disconnect switch (not provided) fused at 30-amps (slow-blow) or circuit connected through an equivalent
HACR circuit breaker must be available to be connected to the electrical box located in lower back side of the
Unit. ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES. MAKE SURE UNIT IS PROPERLY
GROUNDED.
50 HZ UNIT
DANGER: To avoid possible fatal electrical shock or serious injury to the Operator, it is
required that an ELCB (earth leakage circuit breaker) be installed in the electrical power
circuit for all 50-Hz Units.
IMPORTANT: Power circuit voltage across L1 and L2 terminals on contactor inside lower control box,
with refrigeration compressor operating, must be in range of 209-253 VAC, 50 Hz single-phase for
proper operation.
A properly grounded 209-253 VAC, 50 Hz single-phase electrical circuit connected through a 30-amp minimumrated disconnect switch (not provided) fused at 30-amps (slow-blow) must be available to be connected to the
electrical box located in the lower back side of the Unit.
SELECTING LOCATION
IMPORTANT: Unit operating ambient temperature MUST NOT EXCEED 100°F. Operating ambient in
excess of 100°F will automatically void the factory warranty and will eventually result in Unit failure.
Several means are available to achieve proper ambient temperature and air circulation around the Unit,
which are wall air intake grilles and ceiling exhaust fans, air conditioning, etc. Consult local codes.
312028000
8
Locate the Unit so the following requirements are satisfied.
1. Close to a filtered plain water inlet supply line with a minimum water pressure of 12-psig.
NOTE: The FCB Dispenser refrigeration system is equipped with a condenser coil that is cooled by two
condenser coil fans. Circulating air, required to cool the refrigeration system’s condenser coil, is drawn
in through the grilled panel on the right-hand side and is exhausted out through the opposite side
grilled panel. Restricting air circulation through the Unit will decrease its cooling efficiency.
2. 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 for the refrigeration system.
CAUTION: Do not place or store anything on top of the Unit.
Locate the Unit to provide the following clearances:
Top of Unit
Back side
Sides
Front
Open (24-inches min.)
0-inches
6-inches (min)
Open
INSTALLING UNIT
CAUTION: This Unit is intended for indoor installation only. Do not install this Unit in an
outdoor environment which would expose it to the outside elements.
IMPORTANT: After Unit has been placed in operating position, make sure it is sitting in a level position
on a surface that provides adequate support and stability.
INSTALLING LEVELING LEGS
Very carefully, tilt Unit up and install LEVELING LEGS (item 13) on four corners of the Unit base.
INSTALLING DRIP TRAY SUPPORTS (ITEM 7) AND (ITEM 8)
1. Install DRIP TRAY SUPPORT, LEFT (item 7) and DRIP TRAY SUPPORT, RIGHT (item 8) on front of the
Unit and secure with SCREWS (item 6). See Figure 5.
2. Place DRIP TRAY (item 9) on drip tray supports.
3. Place CUP REST (item 5) in drip tray.
INSTALLING DRIP TRAY DRAIN HOSE KIT (ITEM 10)
Install DRIP TRAY DRAIN HOSE KIT (item 10) on Unit as instructed in Installation Instructions provided with
the Kit.
PREPARING UNIT FOR CONNECTION TO SYRUP, CO2, AND CITY PLAIN WATER
SOURCES
Route coiled up syrup, CO2, and plain water lines out through the hole provided in the Unit base.
312028000
9
INSTALLING PRIMARY CO2 REGULATOR ASSEMBLY ON CO2 CYLINDER
(see Figure 2)
WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder in
upright position with a safety chain to prevent it from falling over. Should the valve become
accidentally damaged or broken off, CO2 cylinder can cause serious
personal injury.
WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of
CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is
suspected, particularly in a small area, immediately ventilate the contaminated area before
attempting to repair the leak. Personnel exposed to high concentration of CO2 gas will experience
tremors which are followed rapidly by loss of consciousness and suffocation.
1. Unscrew protector cap (with chain attached) from CO2 cylinder valve. Open CO2 cylinder valve slightly
counterclockwise to blow any dirt or dust from outlet fitting before installing primary CO2 regulator, then
close valve.
2. Remove shipping plug from primary CO2 regulator assembly coupling nut 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.
CONNECTING SOFT DRINK TANKS CO2 LINES TO PRIMARY CO2 REGULATOR
ASSEMBLY
(see Figure 2)
1. Connect soft drink tanks CO2 lines to primary CO2 regulator manifold assembly as shown in Figure 2.
2. Install gas quick disconnects on ends of soft drink tanks CO2 lines. DO NOT CONNECT CO2 LINES TO
TANKS AT THIS TIME.
PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT DRINK TANKS
(see Figure 2)
1. Route Unit syrup inlet lines labeled No. 1 and No. 2 to soft drink tanks location.
2. Install liquid quick disconnects on ends of Unit syrup inlet lines. DO NOT CONNECT SYRUP LINES TO
SOFT DRINK TANKS AT THIS TIME.
CONNECTING CO2 SOURCE LINE TO UNIT CO2 INLET LINE
(see Figure 2)
1. Connect and route a CO2 source line from the primary CO2 regulator up to the Unit.
312028000
10
2. Connect the CO2 source line to the Unit CO2 inlet line. DO NOT TURN ON THE CO2 SOURCE AT THIS
TIME.
CONNECTING CITY PLAIN WATER SOURCE LINE TO UNIT
NOTE: The Units require connection to a city plain water source line with a minimum water pressure of
12-psig. Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the City
plain water source line (see Figure 2). 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 source line support valve at this time.
CONNECTING ELECTRICAL POWER CIRCUIT TO THE UNIT
(see Figure 16)
WARNING: Make sure Unit 30-amp (60 Hz Unit) or 50-amp (50 Hz Unit) minimum-rated
disconnect switch (not provided) or equivalent HACR circuit breaker is in ‘‘OFF’’ position.
60 HZ Unit.
IMPORTANT: Power circuit voltage across L1 and L2 terminals on the contactor inside the lower electrical
control box, with refrigeration compressor operating, must be in the range of 198-253 VAC, 60 Hz
single-phase for proper operation. Use No. 10 AWG copper wire, or larger, depending upon line length,
in suitable conduit or BX sheath. POWER CIRCUIT TO UNIT MUST BE MADE UP OF COPPER
CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES.
50 HZ Unit.
IMPORTANT: Power circuit voltage across L1 and L2 terminals on the contactor inside the lower electrical
control box, with refrigeration compressor operating, must be in the operating range of 209-253 VAC, 50
Hz single-phase for proper operation.
1. Remove cover from electrical box located in lower back side of the Unit.
WARNING: The Unit must be electrically grounded to avoid possible fatal electrical shock
or serious injury to the operator. A green screw, with lock washer, is provided inside the
electrical box to connect power circuit ground wire, which will electrically ground the Unit.
2. Connect electrical power circuit from a 30-amp (60 Hz Unit) or 30-amps (50 Hz Unit) minimum-rated disconnect switch (not provided) fused at 30-amps (60 Hz Unit) or 30-amps (50 Hz Unit) (slow-blow) or through an
equivalent HACR circuit breaker to electrical wires inside the electrical control box. Secure the connections
with red wire nuts. MAKE SURE GROUND WIRE IS CONNECTED TO GREEN GROUND SCREW INSIDE
THE ELECTRICAL BOX.
3. Install the electrical box cover and secure with screws.
11
312028000
PREPARATION FOR OPERATION
TURNING ON ELECTRICAL POWER TO UNIT
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
1. Open CO2 cylinder valve slightly to allow lines to slowly fill with gas, then open valve fully to backseat valve.
Back-seating valve prevents leakage around valve shaft.
ADJUSTING PRIMARY CO2 REGULATOR
IMPORTANT: If bag-in-box syrup supply system will be connected to the Unit instead of soft drink tanks,
primary CO2 regulator (see Figure 2) must be adjusted to no less than 80-psi.
1. Adjust primary CO2 regulator (see Figure 2) by turning regulator adjusting screw to the right (clockwise) until
regulator pressure reads 80 to 100-psig.“OUT OF CO2 ” warning light on control panel message display
should have gone out.
2. Using a flat blade screwdriver, turn lock counterclockwise to unlock the front access door (see Figure 5),
then open the door for access to the product blender tanks relief valves
(see Figure 6).
3. Pull up on product blender tanks relief valves (see Figure 6) to purge air from tanks.
ADJUSTING PRODUCT BLENDER TANKS SECONDARY CO2
Check product blender tanks secondary CO2 regulators with 60-psi gages (see Figures 2 and 6) for pressure setting which should be set at 25 to 30-psi for best textured product. If further adjustment is necessary, adjust as
instructed.
ADJUSTING CARBONATOR SECONDARY CO2 REGULATOR
IMPORTANT: The carbonator secondary CO2 regulator must be adjusted 25-psi higher or more above the
product blender tanks secondary CO2 regulators pressure settings. Carbonated water and syrup
pressures must be able to overcome and vent product blender tanks head pressures while tanks are
filling with carbonated water and syrup. 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.
1. Adjust carbonator secondary CO2 regulator, with 100-psi gage, by turning regulator adjusting screw to the
right (clockwise) until gage reads 50 to 60-psi.
2. Pull up on carbonator tank relief valve plastic cover to purge air from tank.
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12
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 Figure 2 and 6), 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 product blender tanks to freeze cylinders, to prevent product from entering cylinders.
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:
FIGURE 3. CONTROL PANEL ASS’Y
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.
To connect soft drink tank into Unit syrup
system.
A.
First, connect CO2 quick disconnect to soft drink tank to pressurize the tank.
B.
Second, connect liquid quick disconnect to the soft drink tank.
3. Pressurize soft drink tanks containing syrup, then connect tanks into 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 one of the systems.
NOTE: The Unit control panel assembly is equipped with a hidden “SECURITY SWITCH” located between “FILL 1” and “ERROR RESET” control switches (see Figure 3). Pressing in and holding the
“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.
NOTE: The adjustable carbonated water flow regulators (see Figure 2 and 12) 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/second and should not normally require adjustment. If adjustment is
necessary, adjust as instructed.
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.
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312028000
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 Figure 2 and 6) and take 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 completing BRIX adjustment on No. 2 system, only the ‘‘OFF 1’’ and ‘‘OFF 2’’ fault messages should continue 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 5) and secure with THREAD CUTTING SCREWS (item 16) and
WHITE SPACERS (ITEM 14).
4. Close front access door, then use a flat blade screwdriver to turn lock clockwise to lock the door.
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14
PLACING UNIT IN OPERATING LOCATION
IMPORTANT NOTICE
The FCB Dispensers manufactured prior to the models documented in this manual were
elevated in the front (dispensing valve side) 1/4 to 3/8-inch higher than the back when placing
the Unit in operating position to eliminate gas pockets being trapped inside the freeze
cylinders. Due to a redesign of the foam pack in the models documented in this manual,
elevating the front of the Dispenser is no longer required. The Dispenser must be leveled at
time of placing 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 for the refrigeration system. Refer to SELECTING
LOCATION for sides, top, 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.
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.
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 (see Figure 5),
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 4).
3. Place No. 4 ‘‘BEATER MOTOR CURRENT READOUT’’ switch on DIP SWITCH assembly on master circuit
board (see Figure 4) in ‘‘ON’’ position. Both freeze cylinders beater motors will 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 4). 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 4) 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.
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312028000
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,
the beater motor current has just been reset at A155 B145. Operating the FCB Dispenser at these
current readings may have serious effects on its operation.
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 RE-ADJUSTED 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 15) and SPACERS (item 14) and secure with THREAD CUTTING
SCREWS (item 16). MAKE SURE SPACERS ARE INSTALLED BETWEEN THE FRONT ACCESS PANEL
AND THE UNIT FRAME (SEE FIGURE 5).
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 3.
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 3) 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 4To 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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16
MESSAGE DISPLAY
(EXAMPLE READOUTS)
MENU SELECTIONS
“CLOCK” (TIME OF DAY)
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)
See Programming Components Diagnose into
Unit.
“TOTALS”
See Table 7 and programming “TOTALS”
(DISPLAYED CYCLES AND HOURS TOTALS)
into unit.
“MOTORS” (BEATER MOTOR MANUFACTURER)
See Table 6
“REF TYPE” (REFRIGERANT TYPE)
See PROGRAMMING PROPER
REFRIGERANT TYPE INTO UNIT
ELECTRONICS
see note below
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.
TABLE 4. MAIN MENU SELECTIONS
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.
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 ‘‘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 TWO 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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312028000
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.
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 minutes (time of day) on display.
5. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.
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
MOTOR CURRENT SELF-CALIBRATION
ON- Disabled.
OFF- Operating.
6
NOT USED
7
NOT USED
8
NOT USED
9
DEFROST
10
SERVICE USE
ON- Hot gas.
OFF- Electric.
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
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18
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
DIP SWITCH
NO. 1
DIP SWITCH
NO. 2
OFF
OFF
“ENJOY A FROZEN BEVERAGE”
OFF
ON
NOT USED - BLANK
ON
OFF
“HAVE A NICE DAY”
ON
ON
“DISFRUTE UNA BEBIDA CONGELADA CARBONATADA”
*MESSAGE
*For special messages, contact your local sales representative.
TABLE 7. POINT OF SALE DISPLAY MESSAGES
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.
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 minutes (time of day) on display.
5. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.
PROGRAMMING POINT OF SALE MESSAGE DISPLAY
(see Figure 4 and 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 4 and 5 and 7).
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312028000
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 4, 5, and 7) on the DIP SWITCH ASSEMBLY in
the appropriate positions.
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.
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.
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DIP SWITCH
ASS’Y
10
9
8
7
6
5
4
3
2
1
}
SERVICE USE ONLY
APPLICABLE ELECTRIC OR GAS DEFROST (See Table 5)
NOT USED
MOTOR CURRENT SELF-CALIBRATION (See Table 5)
BEATER MOTORS CURRENT READOUT (See Table 5)
MESSAGE DISPLAY SELECT
} POINT OF SALE(See
Table 7)
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 Units with mechanical
expansion valves.
MOTOR CURRENT
ADJUSTMENT
RELAY CIRCUIT
BOARD NO. 2
MASTER CIRCUIT
BOARD
RELAY CIRCUIT
BOARD NO. 1
NO. 2 EVAPORATOR REFRIGERATION
COIL INLET TEMPERATURE
NO. 1 EVAPORATOR REFRIGERATION
COIL INLET TEMPERATURE
NO. 1 AND NO. 2 EVAPORATOR COILS
REFRIGERATION COMMON OUTLET TEMPERATURES
FIGURE 4. MASTER AND RELAY CIRCUIT BOARD
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‘‘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.
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 ‘‘H2O 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:
A.
Refer to PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY and bring up the
word ‘‘CLOCK’’ on message display.
B.
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.
C.
Press and hold ‘‘DEFROST’’ (SELECT) switch. Compressor run hours will appear on message display.
D.
Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘COMP CYC’’ on message
display.
E.
Press and hold ‘‘DEFROST’’ (SELECT) switch. Compressor cycles x 100 will appear on message display.
F.
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.
G.
Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.
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 “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 “DEFROST” (SELECT) switch again. A motor manufacturer’s name (see Table 6) will appear on the
mesage display and will be non-blinking.
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TOTALS MENU COMMANDS
DESCRIPTION
COMP HRS
COMPRESSOR RUN HOURS
COMP CYC
COMPRESSOR CYCLES X100
DFSTYC1
DEFROST SIDE 1 CYCLE
DFSTYC2
DEFROST SIDE 2 CYCLES
BLDRCYC1
BLENDER SIDE 1 CYCLE X100
BLDRCYC2
BLENDER SIDE 2 CYCLES X100
SOLDOUT 1
SOLDOUT SYRUP SIDE 1
SOLDOUT 2
SOLDOUT SYRUP SIDE 2
BMTRHRS1
BEATER MOTOR 1 HOUR
BMTRHRS2
BEATER MOTOR 2 HOURS
PWR ON
POWER ON HOURS
AUTO ON 1
AUTO SIDE 1 HOUR
AUTO ON 2
AUTO SIDE 2 HOURS
ERR HRS 1
ERROR SIDE 1 HOUR
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 to the left, choose the “A” number that
corresponds to your BRIX. 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
ITEMS AFFECTED BY ERROR
BEATER
BEATER
MOTOR 1
MOTOR 2 REFRIG 1 REFRIG 2
ERROR
Motor 1
Low Current, < 109,
Sensed on Motor One
OFF
OFF
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
SYRUP 1
Syrup Out Side One
SYRUP 2
Syrup Out Side Two
CO2 OUT
CO2 Out
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
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
* The refrigeration system and carbonator shall continue to operate for 1.5 minutes after a water pressure loss
has been detected. If water pressure loss continues beyond 1.5 minutes, the refrigeration system and carbonator
will stop.
** 25 minutes on Standard System, 30 minutes on Remote System.
TABLE 9 DISPLAYED ERROR CONDITIONS
3. Press “CANCEL DEFROST” (ADVANCE) switch. The motor manufacturer’s name will start blinking.
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 manufacturer’s name of the No. 1
freeze cylinder beater motor (new Unit installation) or the new installed replacement motor.
6. After the applicable beater motor manufacturer’s name has been selected, press “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 “DEFROST” (SELECT) switch to return to “MOT_MFG1”.
8. Press “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.
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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 “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 “DEFROST” (SELECT) switch to lock in on the selection. This programs the proper refrigerant pulse
rate into the Dispenser electronics.
5. Press “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.
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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.
CAUTION: Do not place or store anything on top of the Unit.
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: The No. 1 freeze cylinder (see Figure 5) is the left-hand cylinder facing the front of the Unit. No.
2 freeze cylinder is to the right of No. 1 freeze cylinder.
CONTROL PANEL ASS’Y SWITCHES AND DISPLAYED MESSAGES
CONTROL PANEL ASS’Y SWITCHES
(see Figure 3)
NOTE: The Unit control panel assembly is equipped with a hidden “SECURITY SWITCH” located between “FILL 1” and “ERROR RESET” control switches (see Figure 3). 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 that 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
sold-out floats have been filled, ‘‘FILL 1’’ and ‘‘FILL 2’’ switches may be used to prevent more product entering
product blender tanks during 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
sold-out 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
require 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
require 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 normal operation. To reactivate control
switches, press in and hold ‘‘SECURITY SWITCH’’ for 3 seconds.
CONTROL PANEL ASSEMBLY DISPLAY MESSAGES
(see Figure 3)
‘‘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
developed 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, it will cause ‘‘H2O OUT’’ fault message to appear on message display.
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.
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‘‘CO2 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 control
panel message display as instructed.
FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS
The Unit is equipped with both manual and automatic hot-gas defrost systems. The automatic defrost system
may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours
between defrost time settings or the system may be completely turned off.
MANUAL DEFROST SYSTEM
The manual hot-gas 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 60-seconds. 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 DEFROST SYSTEM
The automatic hot-gas defrost system may be programmed into the Unit to occur up to nine different times a
day with a minimum of two hours between defrost settings. At start of each automatic defrost cycle, refrigeration
compressor will operate for 30 seconds to pump freon out of freeze cylinders evaporator coils. After freon has
been pumped out of freeze cylinders evaporator coils, No. 1 freeze cylinder only will go into defrost for approximately 7 minutes and 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 60-seconds. After No.1 freeze cylinder has defrosted, No. 2 freeze
cylinder will go into 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.
FACEPLATE RELIEF VALVES
The faceplate relief valves (see Figure 5), 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 CO2
gas from freeze cylinder to atmosphere during filling with product and if gas pockets form in cylinder during operation.
PRODUCT SAMPLE VALVES
The two product sample valves are located behind the lower front access panel (see Figure 2 and Figure 6)
and 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 90° angle with line to close valve.
PRODUCT SHUTOFF VALVES
The two product shutoff valves, located in lines leading from the product blender tanks to the freeze cylinders
(see Figure 2 and 6), 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 cylinders.
PRIMARY CO2 REGULATOR
The primary CO2 regulator (see Figure 2) 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 Figure 2 and 6), control CO2
pressure to the carbonator and the product blender tanks. If necessary to adjust the secondary CO2 regulators,
adjust as instructed in the SERVICE AND MAINTENANCE section.
CARBONATED WATER FLOW REGULATORS
The adjustable carbonated water flow regulators, (see Figure 2 and 12) 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.
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SYRUP FLOW REGULATORS
The syrup flow regulators located behind the front access door (see Figure 2 and Figure 12), 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 5)), 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
absorb carbonation and the way it will release carbonation.
BRIX Affects Overrun.
Sugar in carbonated drinks is like anti-freeze 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
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.
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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 drinks. The degree of
freezing is limited because the finished drink is intended to be sipped through a straw. This is not possible if the
product is too ‘‘solid’’.
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 the drink dispensed. The dispensed product will have a normal variance due to the
following conditions:
1. If some time has elapsed since last drink was drawn from particular freeze cylinder and 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
NOTE: The No. 1 freeze cylinder (see Figure 5) is the left-hand cylinder facing the front of the Unit. No.
2 freeze cylinder is to the right of 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.
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:
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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.
B.
Second, connect liquid quick disconnect to soft drink tank.
Syrup supply should be checked daily and if necessary, replenished as instructed.
PRODUCT FLAVOR CHANGE
Perform syrup flavor change as instructed.
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
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.
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.
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 120-days and before and after storage periods
following parent company requirements and sanitizer manufacturers recommendations. Sanitize syrup systems
as instructed.
CLEANING CONDENSER COIL
The FCB Dispenser refrigeration system is equipped with a condenser coil (see Figure 6) that is cooled by two
condenser coil fans. Circulating air, required to cool the refrigeration system’s condenser coil, is drawn in
through a grilled panel on the right-hand side and is exhausted out through the opposite side and back grilled
panels. Restricting air circulation through the Unit will decrease its cooling efficiency. THE CONDENSER COIL
MUST BE CLEANED PERIODICALLY AS INSTRUCTED IN the SERVICE AND MAINTENANCE section.
LUBRICATION
Carbonator pump motor must be lubricated as instructed on the motor.
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ADJUSTMENTS
CARBONATED WATER FLOW RATE
The carbonated water flow regulators (see Figure 2 and 12), 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.
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 SERVICE AND MAINTENANCE section.
CO2 REGULATORS
Primary CO2 Regulator.
The primary CO2 regulator (see Figure 2 and 6) 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 SERVICE AND MAINTENANCE section.
Secondary CO2 Regulators.
The secondary CO2 regulators (see Figure 2 and 6) regulate CO2 pressure to the carbonator and product
blender tanks. If necessary to adjust secondary CO2 regulators, adjust as instructed in the SERVICE AND
MAINTENANCE section.
ADJUSTING BEATERS MOTORS CURRENTS
Beaters motors currents must be adjusted as instructed in the INSTALLATION section.
PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY
The MAIN MENU SELECTIONS (see Table 4) may be brought up on message display as instructed in the
INSTALLATION section.
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.
Program ‘‘CLOCK’’ (TIME OF DAY) into Unit as instructed in the INSTALLATION section.
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 instructed in the INSTALLATION section.
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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.
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
INSTALLATION section.
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.
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.
“VIS READ” (ACTUAL VISCOSITY READOUT) OF PRODUCT IN FREEZE CYLINDERS
“VIS READ” (actual viscosity readout) may be brought up on the message display to actually read the viscosity
(product consistency) of product in the freeze cylinders while the Unit is in operation as instructed in the
INSTALLATION section.
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 display as instructed in the INSTALLATION section.
‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT)
Displayed voltage readout may be displayed on message display as instructed in the INSTALLATION section.
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 the Unit and check components for proper operation as instructed in the
INSTALLATION section.
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.
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PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT ELECTRONICS
Note in Table 6 “MOTOR SELECT” the number of freeze cylinders beater motors manufacturer’s that are listed.
Your Unit was manufactured and equipped with motors from one of these manufacturer’s. A replacement freeze
cylinder beater motor is also manufactured by one of these manufacturer’s listed. 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 as instructed in the INSTALLATION section.
DISPLAYED ERROR CONDITIONS
Displayed error conditions, associated errors, and items affected by the errors are found in Table 9
DISPLAYED ERROR CONDITIONS.
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 to the INSTALLATION section for programming
instructions.
WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE
MAINTENANCE
(see Figures 2 and 12)
WARNING: The carbonator water pump water strainer screen and the 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 a defective screen in the strainer would allow foreign particles to
foul the double liquid check valve. CO2 gas could then back flow into the water system and create
a health hazard in the system.
Service water strainer screen and double liquid check valve as instructed in the SERVICE AND MAINTENANCE section.
CLEANING CO2 GAS CHECK VALVES
(see Figure 2 and 13)
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.
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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. Make sure CO2 cylinder valve is fully opened and primary CO2 cylinder 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.
2. Make sure soft drink tanks contain sufficient amount of syrup for Unit operation.
3. The FCB Dispenser refrigeration system is equipped with a condenser coil (see Figure 6) that is cooled by
two condenser coil fans. Circulating air, required to cool the refrigeration system’s condenser coil, is drawn
in through a grilled panel on the right-hand side and is exhausted out through the opposite side and back
grilled panels. Restricting air circulation through the Unit will decrease its cooling efficiency. THE CONDENSER COIL MUST BE CLEANED PERIODICALLY AS INSTRUCTED IN THE SERVICE AND MAINTENANCE SECTION.
REMOVAL OF TOP PANEL, BACK PANEL, SIDE PANELS, AND FRONT
ACCESS PANEL
(see Figure 5)
TOP PANEL
Remove two screws securing the top panel, then lift panel up off Unit.
BACK PANEL
Remove one screw securing back panel, then lift panel straight up to remove.
SIDE PANELS
Remove screw securing side panel, then lift panel straight up to remove.
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FRONT ACCESS PANEL
Remove two screws securing front access panel, then remove panel and plastic spacers from the Unit. MAKE
SURE WHEN REINSTALLING THE FRONT ACCESS PANEL, TO REINSTALL THE PLASTIC SPACERS IN
BETWEEN THE PANEL AND THE UNIT FRAME.
OPENING AND CLOSING FRONT ACCESS DOOR
OPENING FRONT ACCESS DOOR
Using a flat blade screwdriver, turn lock counterclockwise to unlock the front access door (see Figure 5), then
open the door.
CLOSING FRONT ACCESS DOOR
Close front access door, then use a flat blade screwdriver to turn lock clockwise to lock the door.
LUBRICATION
CARBONATOR WATER PUMP MOTOR
(see Figure 12)
Carbonator water pump motor bearings must be lubricated periodically. Refer to oiling instructions on motor. DO
NOT OVER OIL.
SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE CYLINDERS DRIVE
SHAFT/ SEAL ASSEMBLIES
Servicing Dispensing Valves Caged O-Rings.
(see Figure 7)
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 8.
2. Remove HEX NUTS (item 7) and FLATWASHERS (item 6) securing FACEPLATE (item 8) to freeze cylinder, then remove faceplate from
cylinder.
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FIGURE 5. OPERATING CONTROLS
39
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REFRIGERATION
COMPRESSOR
CONDENSER COIL
RELIEF VALVE (2)
PRODUCT BLENDER
TANK (2)
FREEZE CYLINDER (2)
BEATER DRIVE
MOTOR (2)
ACCUMULATOR
SECONDARY CO2
REGULATOR (3)
FIGURE 6. UNIT INTERNAL COMPONENTS
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40
RETAINING
SCREW(2)
SPRING HOUSING
TORSION SPRING
HOLD-DOWN
PLATE(2)
SPRING FITTING
DISPENSING
VALVE BODY
CAGED O-RING
VALVE
LEVER
SLEEVE
SPRING
KNOB
FIGURE 7. SELF-CLOSING DISPENSING VALVE
3. Carefully remove large O-RING (item 5) from FACEPLATE (item 8).
4. Unscrew RELIEF VALVE (item 9) from FACEPLATE (item 8).
5. Disassemble dispensing valve (see Figure 7) as follows:
A.
Remove two screws and hold-down plates securing spring housing to dispensing valve body, then remove housing.
B.
Remove torsion spring from dispensing valve.
C.
Remove knob, spring, sleeve, and lever from dispensing valve.
D.
Remove spring fitting from dispensing valve.
E.
Press valve, with caged O-ring, down and out of dispensing valve body.
F.
Carefully remove caged O-ring from valve.
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 (item 3, Table 3) to clean faceplates relief valve passages.
7. Submerge all parts in 4 percent solution of approved sanitizing agent for time recommended by 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 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.
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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 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 Beater Motor Drive Shaft/Seal Assemblies.
Servicing Freeze Cylinders Drive Shaft/Seal Assemblies.
(see Figure 9)
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 11, LOOSE-SHIPPED PARTS), 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-Ring seals and two outer O-Ring
seals from the plastic housing. Discard the old O-Ring seals.
NOTE: If old lubricant cannot be removed from the plastic housing by washing, use a nylon ‘‘pot and
pan’’ scrubber (3M Company ‘‘Scotchbrite’’, or equivalent) to remove the residue. Do not scrape plastic
housing. Replace any housing that has rough edges in O-Ring sealing areas.
7. Remove old lubricant from the plastic housing with paper towel. DO NOT SCRAPE THE PLASTIC HOUSING. Wash the housing and the back of the freeze cylinder with warm water.
8. Lubricate two new drive shaft O-Ring seals with a generous amount of special light-grade silicone grease,
then install O-Rings inside the plastic housing.
9. Inspect the drive shaft and both bearings. Replace the drive shaft if worn and bearing(s) if found to be
rough.
10. Reassemble the drive shaft/seal assembly. Using TOOL, DRIVE/COUPLER ADJUSTMENT GAUGE (item
12), insert “DRIVE” end of adjustment gauge between drive-pin and housing (see Figure 9) 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.
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15. Position SCRAPER BLADES (item 2) on BEATER (item 13) as shown in Figure 8. Slide beater into freeze
cylinder so slotted hooks engage DRIVE PIN (item 17) on DRIVE SHAFT (item 19). 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, then return Unit to operation.
CLEANING CONDENSER COIL
(see Figure 6)
NOTE: The FCB Dispenser refrigeration system is equipped with a condenser coil (see Figure 6) that is
cooled by two condenser coil fans. Circulating air, required to cool the refrigeration system’s condenser coil, is drawn in through grilled panel on the right-hand side and is exhausted out through the opposite side and back grilled panels. Restricting air circulation through the Unit will decrease its cooling
efficiency. THE CONDENSER COIL MUST BE CLEANED PERIODICALLY AS INSTRUCTED.
Periodically clean condenser coil as follows:
1. Press ‘‘OFF 1’’ and ‘‘OFF 2’’ switches on Unit control panel to stop refrigeration system and beaters motors.
2. Remove Unit right-side panel as instructed.
3. Clean condenser coil with vacuum cleaner, low pressure compressed air, or a soft brush.
4. Install Unit right-side panel as instructed.
5. Press ‘‘AUTO 1’’ and ‘‘AUTO 2’’ switches on Unit control panel to start refrigeration system and beaters
motors.
ADJUSTMENTS
ADJUSTING PLAIN WATER PRESSURE REGULATOR
(see Figure 2 and 12)
Carbonator(s) plain water inlet adjustable water pressure regulator is factory adjusted to 45-psi and should not
be readjusted.
ADJUSTING CARBONATED WATER
FLOW RATE
The carbonated water flow regulators (see Figure 2 and 12), 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:
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15
21
1
17
16
22
23
5
6
7
8
9
25
19
18
10
11
24
26
20
14
27
2
13
3
4
12
44
1
2
3
4
5
6
7
8
9
Product Inlet Fitting
Scraper Blade (2)
Evaporator Coil
Relief Valve Port
O-Ring
Flatwasher (4)
Hex Nut (4)
Faceplate
Relief Valve
10
11
12
13
14
15
16
17
18
19
Valve Lever
Knob
Dispensing Valve
Beater
Allen Head Setscrew
Beater Shaft Coupling
Drive Pin
Bearing Housing Locking Tab (4)
Bearing Retainer
Beater Motor Drive Shaft
FIGURE 8. FREEZE CYLINDER CUTAWAY VIEW
20
21
22
23
24
25
26
Beater Drive Motor
Drive Shaft Assembly
Viscosity Sensor
Spinner
spring
Shaft Release
Bearing
27
Bearing Housing
BEATER
DRIVE MOTOR
DRIVE SHAFT/SEAL ASS’Y
BEATER DRIVE
MOTOR SHAFT
BEATER
ALLEN-HEAD
SET SCREW
COUPLING
PLASTIC
COUPLER
PIN
ALLEN-HEAD
SET SCREW
COUPLING
DRIVE
COUPLER
DRIVE
COUPLER
DRIVE SHAFT
GAUGE, DRIVE/COUPLER
(ITEM 14)
PLASTIC
HOUSING
LOCK RING
O-RING
BEARING
O-RING
SHAFT
ALLEN-HEAD
SET SCREW (2)
DRIVE SHAFT/ SEAL ASSEMBLY
FIGURE 9. SERVICING BEATER MOTOR DRIVE SHAFT/SEAL ASSEMBLY
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BEATER
Key on End
of Post
Key on End of
Post
Key Slot
on Blade
Scraper blades must be mounted to the beater body as
shown using the perforated edge as the leading edge.
Line up key on end of posts with key slot in scraper
blades.
FIGURE 10. BEATERS AND SCRAPER BLADES INSTALLATION
1. Press applicable ‘‘OFF 1’’ or ‘‘OFF 2’’ switch to prevent more product from entering the applicable product
blender tank.
2. Disconnect Unit syrup inlet line from the applicable soft drink tank.
3. Using a flat blade screwdriver, turn lock counterclockwise to unlock the front access door (see Figure 5),
then open the door.
4.
Remove lower front access panel as instructed for access to the applicable carbonated water flow regulator, product shutoff valve, and the product sample valve.
5. Close applicable product shutoff valve to prevent more product from entering the freeze cylinder.
6. 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.
7. Note pressure setting on the applicable secondary CO2 regulator with 60-psi gauge for the applicable product blender tank. Turn regulator adjusting screw out (counterclockwise) until gauge 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.
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46
11. Press applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch to activate the electrically operated carbonated water solenoid.
12. When a 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 ‘‘FILL 1’’ or ‘‘FILL 2’’ 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 gauge, adjusting screw in (clockwise) until gauge
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. Connect Unit syrup inlet line to the soft drink tank.
19. Press the applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch to fill the product blender tank with
product.
20. Open the product shutoff valve that was closed in step 4 preceding.
21. Close front access door, then use a flat blade screwdriver to turn lock clockwise to lock the door.
22. Install the lower front access panel by reversing the removal procedure.
ADJUSTING CO2 REGULATORS
NOTE: To readjust CO2 regulator to a lower setting, loosen the adjusting screw lock nut, then turn the
screw to the left (counterclockwise) until the pressure gauge reads 5-psi lower than the new setting will
be. Turn the adjusting screw to the right (clockwise) until the gauge registers a new setting, then tighten the lock nut.
Primary CO2 Regulator.
(see Figure 2)
Adjust the primary CO2 regulator by turning the regulator adjusting screw to the right (clockwise) until the regulator pressure reads 80 to 100-psig.
Product Blender Tanks Secondary CO2 Regulators.
(see Figures 2 and 6)
1. Remove the Unit lower front access panel as instructed for access to the product blender tanks secondary
CO2 regulators.
2. Adjust the product blender tanks secondary CO2 regulators, with 60-psi gauges, by turning their regulator
adjusting screws to the right (clockwise) until their gauges read 25 to 30-psig for best textured product.
3. Install the lower front access panel by reversing the removal procedure.
47
312028000
Carbonator Secondary CO2 Regulator.
(see Figure 2 and 6)
1. Remove the Unit lower front access panel as instructed for access to the carbonator(s) secondary CO2
regulator(s).
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. Carbonator tank secondary CO2 regulator
not adjusted high enough will cause a decreased flow of carbonated water into the blender tanks,
which will increase brix of the dispensed product.
2. Adjust carbonator(s) secondary CO2 regulator(s), with 100-psi gauge(s), by turning regulator(s) adjusting
screw(s) to the right (clockwise) until gauge(s) reads 50 to 60-psig.
3. Install the lower front access panel by reversing the removal procedure.
ADJUSTING BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ OF DISPENSED PRODUCT
(see Figures 2 and 6)
1. Remove Unit lower front access panel as instructed for access to product blender tanks secondary CO2
regulators and product sample valves.
2. Check product blender tanks secondary CO2 regulators, with 60-psi gauges, for proper pressure settings
which is set at 25 to 30-psi for best textured dispensed product. If adjustment is necessary, adjust as
instructed.
3. Remove both Unit side panels as instructed for access to product shutoff valves located close to product
blender tanks.
4. Close product shutoff valve in line between applicable product blender tank and associated freeze cylinder
brix adjustment will be performed on.
5. Press applicable ‘‘FILL 1’’ or ‘‘FILL 2’’ switch to prevent more product from filling product blender tank.
6. Open applicable product blender tank product sample valve and take sample (approximately 6-ounces) of
product in cup.
NOTE: Temperature compensated hand-type refractometers (P/N 511004000) are available from the Cornelius Company.
7. Observe pressure setting on carbonator secondary CO2 regulator gauge.
8. Press applicable ‘‘AUTO BLEND 1‘’ or ‘‘AUTO BLEND 2’’ switch to fill product blender tank 1/4-full of new
batch of product. When product blender tank is 1/4-full of product, press applicable ‘‘FILL 1’’ or ‘‘FILL 2’’
switch to prevent more product from entering product blender tank.
9. Repeat steps 6 and 7 preceding to check product sample for brix.
10. Repeat steps 7 through 10 preceding until proper brix adjustment is achieved.
11. Open product shutoff valve in line between product blender tank and freeze cylinder.
12. Press applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch.
13. Install Unit side panels and lower front access panel by reversing removal procedures.
312028000
48
PRODUCT CARBONATION ADJUSTMENT
(see Figures 2 and 6)
Carbonation of dispensed product can also be varied to suit consumer preference by adjusting Unit carbonator
secondary CO2 regulator as follows:
IMPORTANT: Carbonator tank secondary CO2 regulator must be adjusted 25-psi higher or more above
product blender tanks secondary CO2 regulator pressure settings. Carbonated water and syrup
pressures must be able to overcome and vent product blender tanks head pressures while tanks are
filling with carbonated water and syrup. Carbonator tank secondary CO2 regulator not adjusted high
enough will cause decreased flow of carbonated water into blender tanks, which will increase brix of
dispensed product.
1. Remove Unit lower front access panel as instructed for access to carbonator secondary CO2 regulator
with 100-psi gauge.
2. Observe pressure setting on carbonator secondary CO2 regulator gauge.
3. To lower CO2 pressure, loosen regulator adjusting screw lock nut. Turn adjusting screw to the left (counterclockwise) until pressure gauge reads 15-psi below desired reading, then turn screw to the right (clockwise)
until gauge 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. Observe pressure setting on carbonator secondary CO2 regulator gauge.
5. To raise CO2 pressure, turn regulator adjusting screw to the right (clockwise) until gauge reads desired
pressure. DO NOT SET PRESSURE HIGHER THAN 60-PSI. Make sure primary CO2 regulator on CO2
cylinder is set at 80 to 100-psi. Tighten adjusting screw lock nut after each adjustment.
6. Install lower front access panel on Unit.
CLEANING AND SANITIZING
DAILY CLEANING OF UNIT
Daily, or more often if necessary, wash all external surfaces of Unit with a mild soap solution. Rinse with clean
water, then wipe dry with a clean soft cloth. DO NOT USE ABRASIVE CLEANERS. Remove and wash drip tray
in mild soap solution, rinse with clean water, then install drip tray on Unit.
SANITIZING SYRUP SYSTEMS
NOTE: The Unit should be sanitized every 120 days following Sanitizer Manufacturer’s recommendation. Use Chlor-Tergent (Oakite Products, Inc.) or equivalent sanitizer.
The Unit should be sanitized every 120 days and before and after storage periods following parent company
requirements and sanitizer manufacturer’s recommendations. One or both syrup systems may be sanitized at
one time for routine 120 days sanitizing requirements. The following sanitizing instructions use No. 1 syrup system as an example. No. 2 syrup system sanitizing instructions are identical to No. 1 syrup system with the exception of using applicable system switches. Proceed as follows:
1. Press ‘‘OFF 2’’ 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 ‘‘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 ‘‘AUTO 2’’ control switch to restart beater in No. 2 freeze cylinder. Refrigeration in No. 2
cylinder will not be operating.
49
312028000
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.
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:
6. To disconnect soft drink tank from Unit syrup system.
A. Disconnect liquid disconnect 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 adjustments.
B.
Second, disconnect CO2 quick disconnect from soft drink tank.
7. 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.
8. Disconnect soft drink tank containing syrup from No. 1 syrup system.
9. Connect clean empty soft drink tank into No. 1 syrup system.
10. Place waste container under No. 1 cylinder dispensing valve nozzle. Open dispensing valve and dispense
all product from cylinder. As product level lowers in cylinder, partially close valve to avoid spurting.
11. Remove Unit lower front access panel as instructed for access to No. 1 product blender tank product sample valve.
12. Place waste container under No. 1 product blender tank product sample valve. Slowly open valve and
purge remaining product out of tank, then close valve.
13. Disconnect empty soft drink tank from No. 1 syrup system.
14. Refer to SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE CYLINDERS DRIVE
SHAFT/SEAL ASSEMBLIES under LUBRICATION and perform procedure to lubricate dispensing valve
caged O-ring and drive shaft seal assembly.
WARNING: To avoid possible injury or property damage, do not attempt to remove soft
drink tank cover until CO2 pressure has been released from tank.
15. Pull up on empty soft drink tank cover relief valve to release CO2 pressure from tank.
WARNING: If powder type sanitizer is used, it must be thoroughly dissolved with water
prior to adding to soft drink tank.
NOTE: Sanitizing solution is used in a more concentrated form because it will be diluted approximately
four-to-one in product blender tank.
16. Using clean empty soft drink tank, prepare full tank 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 product blender tank
after carbonated water has been mixed with sanitizing solution.
17. Shake sanitizing solution tank to thoroughly mix solution, then connect tank into No. 1 syrup
system.
18. Press ‘‘FILL 1’’ switch to fill No. 1 syrup system syrup float switch with sanitizing solution. ‘‘SYRUP 1’’ fault
message on message display will go out indicating syrup float switch has been filled with sanitizing solution.
312028000
50
19. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 product blender tank with sanitizing solution. Carbonator water
pump will start and begin pumping carbonated water into product blender tank, which will dilute sanitizing
solution also entering tank.
20. After carbonator water pump cycles off, completely fill No. 1 freeze cylinder with sanitizing solution by repeatedly pulling and releasing relief valve knob on freeze cylinder faceplate and until sanitizing solution
comes out of relief valve port. Open dispensing valve until sanitizing solution flows from valve, then close
valve. Open product blender tank sample valve until sanitizing solution flows from valve, then close valve.
21. Press ‘‘WASH 1’’ switch to start No. 1 freeze cylinder beater. Allow sanitizing solution to remain in freeze
cylinder for no less than 10 and no more than 15 minutes (max) contact time.
22. When sanitizing solution contact time has elapsed, press ‘‘OFF 1’’ switch to stop No. 1 freeze cylinder
beater.
23. Hold appropriate container under dispensing valve and dispense until soft drink tank containing sanitizing
solution is empty and all sanitizing solution has been dispensed from freeze cylinder. As sanitizing solution
level lowers in freeze cylinder, partially close valve to avoid spurting. Dispose of sanitizing solution in a safe
way.
24. Place waste container under No. 1 system product sample valve. Slowly open valve and purge remaining
sanitizing solution out of product blender tank, then close valve.
25. Disconnect empty sanitizing solution tank from No. 1 syrup system.
26. Connect soft drink tank containing syrup into No. 1 syrup system.
WARNING: Flush residual sanitizing solution from syrup system as instructed. Residual
solution left in system could create a health hazard.
27. Press ‘‘FILL 1’’ switch to fill No. 1 syrup system syrup float switch with syrup. ‘‘SYRUP 1’’ fault message on
message display will go out indicating syrup float switch has been filled with syrup.
28. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 product blender tank with product. Carbonator water pump will
start and begin pumping carbonated water into product blender tank along with syrup to make product.
29. After carbonator water pump cycles off, completely fill No. 1 freeze cylinder with product by repeatedly pulling and releasing faceplate relief valve and until product comes out of relief valve port. Open dispensing
valve until product flows from valve, then close valve. Open No. 1 system product sample valve until product flows from valve, then close valve.
30. Press ‘‘WASH 1’’ switch to start No. 1 freeze cylinder beater. Allow beater to operate for five minutes, then
press ‘‘OFF 1’’ switch to stop beater.
31. Disconnect soft drink tank containing syrup from No. 1 syrup system.
32. Connect clean empty soft drink tank into No. 1 syrup system.
33. Hold appropriate container under dispensing valve and dispense until all product has been dispensed from
freeze cylinder. As product level lowers in freeze cylinder, partially close valve to avoid spurting.
34. Place waste container under No. 1 system product sample valve. Slowly open valve and purge remaining
product out of product blender tank.
35. Disconnect empty soft drink tank from No. 1 syrup system and install tank containing syrup.
36. Press ‘‘FILL 1’’ switch to fill No. 1 syrup system syrup float switch with syrup. ‘‘SYRUP 1’’ fault message on
message display will go out indicating syrup float switch has been filled with syrup.
37. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 product blender tank with product. Carbonator water pump will
start and begin pumping carbonated water into product blender tank along with syrup to make product.
CAUTION: Do not relieve freeze cylinder pressure too fast or product will foam excessively
in cylinder and lose carbonation.
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312028000
38. After carbonator water pump cycles off, intermittently pull and release No. 1 freeze cylinder faceplate relief
valve. This bleeds CO2 from freeze cylinder and allows product to enter and fill cylinder.
39. Open No. 2 product blender tank product shutoff valve.
40. Press both ‘‘AUTO 1’’ and ‘‘AUTO 2‘’ switches to start both freeze cylinders beaters and refrigeration system. Product will be ready for dispensing in approximately 10 minutes.
41. Install right-hand side panel and lower front access panel by reversing removal procedure.
42. Service water pump water strainer screen before servicing water pump double liquid check valve.
43. Disconnect carbonator tank water line from double liquid check valve assembly outlet.
YEARLY OR AFTER WATER SYSTEM DISRUPTION
WARNING: The carbonator water pump water strainer screen and the 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 strainer screen or a defective screen would allow foreign particles to foul the
double liquid check valve. 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 Figure 2 and 12)
1. Press ‘‘OFF 1’’ and ‘‘OFF 2’’ switches to stop freeze cylinders beaters and refrigeration systems.
2. Disconnect electrical power from Unit.
3. Close CO2 cylinder and water inlet supply line shutoff valve.
4. Using a flat blade screwdriver, turn lock counterclockwise to unlock the front access door (see Figure 5),
then open the door.
5.
Remove back panel as instructed for access to the water pump water strainer screen.
6. Pull up on carbonator tank relief valve plastic cover to release CO2 pressure from tank.
7. Loosen screen retainer in water pump port, then remove screen retainer and strainer screen from the port.
8. Pull strainer screen from the screen retainer. Clean any sediment from the screen retainer and the water
pump port.
9. Inspect strainer screen for holes, restrictions, corrosion, and other damage. Discard damaged strainer
screen.
10. Check O-ring on screen retainer. Replace worn or damaged O-ring (P/N 315349000).
Note: A strainer screen should always be used, otherwise particles could foul the double liquid check
valve.
11. Install good or new strainer screen (P/N 315348000) in screen retainer, then screw retainer into water
pump port and tighten securely.
12. Proceed to SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE.
312028000
52
1
3
2
4
5
6
Index
No
Part
No
1
317965000
Retainer
2
312196000
Spring
3
312419000
Ball
4
312415000
Washer, .300 I.D.
5
312418000
Quad Ring
6
317963000
Body
Name
*Install new ball seat each servicing.
FIGURE 11. LIQUID CHECK VALVE ASSEMBLY
SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE
(see Figures 2 and 12)
1. Service water pump water strainer screen before servicing the water pump double liquid check valve.
2. Disconnet carbonator water line from double liquid check valve assembly outlet.
3. Remove double liquid check valve assembly from elbow in water pump outlet port. Retain white tapered
gasket inside (female) end of double liquid check valve.
4. Disassemble each check valve as shown in Figure 11.
5. Wipe each part with a clean lint-free cloth. Inspect each part, especially ball for burrs, nicks, corrosion,
deterioration, and other damage. Discard ball seat and any damaged or suspicious parts and replace with
new parts during reassemble.
6. Reassemble liquid check valves as shown in Figure 11. ALWAYS INSTALL NEW BALL SEAT (QUAD
RING) P/N 312418000.
NOTE: Make sure when assembling check valves together, check to ensure the valve female end (with
white tapered gasket inside) is on inlet side of double liquid check valve assembly.
7. Assemble check valves together. DO NOT OVERTIGHTEN.
8. Make sure white tapered gasket is in place inside female end of double liquid check valve assembly, then
install check valve assembly on elbow in water pump outlet port.
9. Connect carbonator tank water line to double liquid check valve assembly outlet. DO NOT OVERTIGHTEN.
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312028000
10. Open CO2 cylinder and water inlet supply lines shutoff valves. Check for water leaks and tighten any loose
connections.
11. Close front access door, then use a flat blade screwdriver to turn lock clockwise to lock the door.
12. Install back panel by reversing the removal procedure.
13. Connect electrical power to Unit.
14. Press both ‘‘AUTO BLEND 1’’ and ‘‘AUTO BLEND 2’’ switches.
15. Press both ‘‘AUTO 1’’ and ‘‘AUTO 2’’ switches to start freeze cylinders beaters and refrigeration system.
REPLENISHING SYRUP SUPPLY
NOTE: Sugar-free diet syrup cannot be used with this Unit.
Although syrup replenishing can be done anytime, syrup supply must be replenished when either ‘‘SYRUP 1’’ or
‘‘SYRUP 2’’ fault messages are displayed on message display indicating either No. 1 or No. 2 syrup system soft
drink tank is empty.
NOTE: The following instructions are applicable only when replenishing syrup supply. Refer to SYRUP
FLAVOR CHANGE when changing syrup flavors.
1. Remove double liquid check valve assembly from elbow in water pump outlet port. Retain white tapered
gasket inside inlet (female) end of double liquid check valve.
2. Press applicable ‘‘OFF 1’’ or ‘‘OFF 2’’ switch to stop applicable freeze cylinder beater and refrigeration system.
IMPORTANT: The following CO2 and liquid disconnect and connecting procedure for soft drink tank
replacement or filling soft drink tank in place must be performed in order as follows:
3. 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.
4. 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.
5. Disconnect inlet (CO2) and outlet (syrup) lines from empty soft drink tank.
6. Check soft drink tank quick disconnects for sticky or restricted operation. Rinse disconnects in warm water.
7. First, pressurize full soft drink tank by connecting CO2 line to tank, then connect Unit syrup inlet line to
tank.
8. Press applicable ‘‘FILL 1’’ or ‘‘FILL 2’’ switch to fill applicable No. 1 or No. 2 syrup system syrup float switch
with syrup.
9. Press applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch to fill applicable No. 1 or No. 2 system
product blender tank with product.
10. Press applicable ‘‘AUTO 1’’ or ‘‘AUTO 2’’ switch to start refrigeration system and beater in applicable No. 1
or No. 2 freeze cylinder.
11. If freeze cylinder is not full of product, repeatedly pull and release faceplate relief valve to slowly bleed CO2
from freeze cylinder and allow product to fill cylinder. Do not relieve freeze cylinder pressure too fast or
product will foam excessively in cylinder and lose carbonation.
312028000
54
REPLENISHING CO2 SUPPLY
WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of
CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is
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.
NOTE: When indicator on primary CO2 cylinder regulator assembly 1800-psi gauge 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 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
upright position with safety chain to prevent it from falling over. Should valve become
accidentally damaged or broken off, CO2 cylinder can cause serious personal injury.
5. Make sure gasket is in place inside CO2 regulator coupling nut, then install regulator on CO2 cylinder.
6. Open (counterclockwise) CO2 cylinder valve slightly to allow lines to slowly fill with gas, then open valve
fully to back-seat valve. (Back-seating valve prevents leakage around valve shaft).
7. Check CO2 connections for leaks. Tighten loose connections.
SYRUP FLAVOR CHANGE
One or both syrup flavors can be changed at the same time. Perform flavor change on one system as follows:
1. Perform sanitizing procedure on syrup system. Syrup flavor change will be made as instructed in the
SERVICE AND MAINTENANCE SECTION.
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:
2. To disconnect soft drink tank from Unit syrup system.
A. Disconnect liquid disconnect from soft drink tank. NOTE - Disconnecting liquid 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.
3. 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.
4. First, pressurize soft drink tank containing new flavor syrup by connecting CO2 line to tank, then connect
Unit syrup inlet line to tank.
55
312028000
O-RING (P/N 315349000)
DOUBLE LIQUID
CHECK VALVE ASS’Y
SCREEN RETAINER
SCREEN (P/N 315348000)
WHITE TAPERED
GASKET
WATER PUMP MOTOR
WATER PUMP
WATER PRESSURE
REGULATOR
WATER PRESSURE SWITCH
CARBONATED WATER
FLOW REGULATOR (2)
SYRUP FLOW
REGULATOR (2)
LIQUID CHECK
VALVE (4)
CARBONATED WATER
SOLENOID VALVE (2)
SYRUP SOLENOID
VALVE (2)
SYRUP SOLD-OUT
FLOAT SWITCH (2)
312028000
FIGURE 12. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE
56
5. Press applicable ‘‘FILL 1’’ or ‘‘FILL 2’’ switch to fill applicable No. 1 or No. 2 syrup system syrup float switch
with syrup.
6. Press applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch to fill applicable No. 1 or No. 2 system
product blender tank with product.
7. Press applicable ‘‘AUTO 1’’ or ‘‘AUTO 2’’ switch to start refrigeration system and beater in applicable No. 1
or No. 2 freeze cylinder.
CAUTION: Do not relieve freeze cylinder pressure too fast or product will foam excessively
in freeze cylinder and lose carbonation.
8. After carbonator water pump cycles off, intermittently pull and release applicable No. 1 or No. 2 freeze cylinder faceplate relief valve. This bleeds CO2 from freeze cylinder and allows product to enter and fill cylinder.
9. If necessary, adjust BRIX, product viscosity (product consistency), and product carbonation of dispensed
product as instructed.
CLEANING CO2 GAS CHECK VALVES
(see applicable Figures 2 and 13)
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
183294000
BALL
183296000
SPRING
183297000
RETAINER
183298000
BODY
183295100
QUAD RING SEAL MUST BE REPLACED
EACH TIME CHECK VALVE IS SERVICED.
FIGURE 13. CO2 GAS CHECK VALVE
REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR
(see Figures 5 and 9)
IMPORTANT: Note in 6 “MOTOR SELECT” the number of freeze cylinder beater drive motors
manufacturers that are listed. Your Unit was manufactured and equipped with freeze cylinder 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.
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312028000
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 Unit back and both side panels as instructed.
4. Remove one bolt and two hex nuts and two lockwashers securing motor to Unit frame.
5. Very carefully, pull motor back off two mounting studs and disengauge motor shaft and plastic coupler from
freeze cylinder drive shaft.
6. Lower motor down to Unit bottom platform, then turn motor for access to it’s electrical wiring
cover plate.
7. Remove two screws securing the electrical wiring cover plate, then remove plate for access to electrical
terminals.
8. Tag beater drive motor electrical wiring for identification, then disconnect wiring from terminals.
9. Remove old beater drive motor from inside Unit.
10. Remove plastic coupler from the old beater drive motor shaft and install on the new motor shaft. MAKE
SURE THE ALLEN-HEAD SET SCREWS ARE SECURELY TIGHTENED AND PROPERLY SEATED ON
THE SHAFT FLAT SURFACE.
11. Install new beater drive motor in the Unit by reversing removal procedure.
CAUTION: The new beater drive motor has a screw in the vent hole on top of the gear box
that must be removed before the motor is put into operation.
12. Remove screw from the vent hole on top of the beater drive motor gear box.
13. Install Unit back and both side panels by reversing removal procedures.
14. Restore the Unit to operation.
15. Refer to “PROGRAMMING FREEZE CYLINDER BEATER MOTORS INTO UNIT ELECTRONICS” in the
INSTALLATION section to program the new replacement beater motor into the Unit to match the Unit electronics.
ADJUSTING CARBONATOR TANK LIQUID LEVEL
The carbonator tank liquid level (pump cut-in and cut-out) 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 Figure 6 and 14).
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 14 ) and move actuator bracket up slightly. If more than 58 ounces, maximum of
carbonated water was dispensed, move actuator bracket down, then tighten screw. MAKE ADJUSTMENTS IN SMALL INCREMENTS.
5. Connect electrical power to Unit and allow carbonator tank to fill with water until water pump cycles off.
6. Repeat steps 2 through 5 preceding as many times as necessary until correct carbonated water volume
adjustment is achieved.
312028000
58
RELIEF VALVE
CARBONATED
WATER TANK
SWITCHES
ACTUATOR BRACKET
LEVEL CONTROL
SWITCHES(2)
ACTUATOR BRACKET
ADJUSTMENT SCREW
FIGURE 14. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT
59
312028000
ELECTRONIC
EXPANSION VALVE (2)
HOT-GAS DEFROST
SOLENOID VALVE
ASS’Y (2)
CONDENSER COIL
FAN ASS’Y
FREEZE CYLINDER (2)
EVAPORATOR
STRAINER/DRYER
COMPRESSOR
RECEIVER TANK
ACCUMULATOR
FIGURE 15. REFRIGERATION FLOW DIAGRAM
312028000
60
61
312028000
FIGURE 16. WIRING DIAGRAM
THIS PAGE LEFT BLANK INTENTIONALLY
312028000
62
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 CO2 system, stop dispensing, shut off the CO2 supply, then relieve the
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.
B.
Second, connect liquid quick disconnect to soft drink tank.
TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES
Trouble
ONE OR MORE CONTROL
PANEL SWITCHES NOT
OPERATING.
Probable Cause
Remedy
A.
Flat cable not properly
connected to control switch
module or master circuit
board.
A.
Properly connect flat cable 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.
B.
Check cable for pinched or
broken wire condition and repair
or replace as necessary.
C.
Inoperable switch(s) on control
panel switch module.
C.
Replace control panel switch
module.
D.
Master circuit board not
operating properly.
D.
Replace master circuit board.
ALL CONTROL PANEL
A.
SWITCHES NOT OPERATING.
Electric power disconnected
from Unit.
A.
Restore electric power to Unit.
B.
‘‘SECURITY SWITCH’’ has
not been pressed to activate
control panel switches.
B.
Press and hold ‘‘SECURITY
SWITCH’’ for 3 seconds to
restore control panel switches to
operation.
C.
‘‘SECURITY SWITCH’’
inoperable (control switches
deactivated).
C.
Replace control panel switch
module.
D.
Flat cable not properly
connected to control switch
module or master circuit
board.
D.
Properly connect flat cable to
control switch module or master
circuit board.
63
312028000
Trouble
Probable Cause
ALL CONTROL PANEL
E.
SWITCHES NOT OPERATING.
(cont’d)
Remedy
Flat cable connected between
control switch 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.
Master circuit board not
operating properly.
F.
Replace master circuit board.
A.
Not pressing and holding
‘‘SECURITY SWITCH’’ for 3
seconds to deactivate control
switches.
A.
Press and hold ‘‘SECURITY
SWITCH’’ for 3 seconds to
deactivate control switches.
B.
‘‘SECURITY SWITCH’’
inoperable.
B.
Replace control panel switch
module.
PARTIAL MESSAGE OR DULL
(POORLY ILLUMINATED)
DISPLAY.
A.
Extremely low voltage.
A.
Upgrade voltage.
ONE OR MORE FAULT
MESSAGES NOT
OPERATING.
A.
Flat cable not properly
connected to fault message
module or master circuit
board.
A.
Properly connect flat cable 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.
B.
Check cable for pinched or
broken wire condition and repair
or replace as necessary.
C.
External sensing device failing
to signal master circuit board
which in turn signals fault
message display.
C.
Replace or repair external sensing
device.
D.
External sensing devices cable
connectors not securely
connected to master circuit
board connectors.
D.
Make sure external sensing
devices cable connectors are
securely connected to master
circuit board connectors.
E.
Disconnected or broken wire
between master circuit board
connector and external
sensing device.
E.
Connect or repair wire between
master circuit board connector
and external sensing device.
F.
Master circuit board not
operating properly.
F.
Replace master circuit board.
G.
Fault message display
module not operating properly.
G.
Replace fault message display
module.
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.
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.
64
C.
Check cable for pinched or
broken wire condition and repair
or replace as necessary.
CONTROL PANEL SWITCHES
CANNOT BE DEACTIVATED.
ALL FAULT MESSAGES NOT
OPERATING.
312028000
Trouble
ALL FAULT MESSAGE NOT
OPERATING (cont’d)
Probable Cause
Remedy
D.
Master circuit board not
operating.
D.
Replace master circuit board.
E.
Fault message display module
not operating properly.
E.
Replace fault message display
module.
A.
CO2 supply turned off or
exhausted.
A.
Open CO2 cylinder shutoff valve
or replenish CO2 supply as
instructed.
B.
Primary CO2 regulator set too
low.
B.
Adjust primary CO2 regulator as
instructed.
C.
Inoperable CO2 pressure
switch.
C.
Replace CO2 pressure switch.
A.
Water supply turned off or
water pressure inadequate.
A.
Turn on water supply or check
water supply line pressure.
B.
Plugged water filter or water
pump strainer screen.
B.
Change water filter or clean water
pump strainer screen as
instructed.
C.
Inoperative water pressure
switch.
C.
Replace water pressure switch.
‘‘SYRUP 1’’ OR ‘‘SYRUP 2’’
FAULT MESSAGE GOES ON
DURING OPERATION.
A.
Soft drink tank empty.
A.
Replenish syrup supply as
instructed.
‘‘ERROR 1’’ OR ‘‘ERROR 2’’
FAULT MESSAGE GOES ON
DURING OPERATION.
A.
Error within Unit has
developed interrupting normal
operation.
A.
Locate and correct error, then
press ‘‘ERROR RESET’’ switch to
restore normal operation.
FREEZE CYLINDER
AUTOMATIC DEFROST
CYCLE DOES NOT
OPERATE.
A.
Loose or broken electrical
wires.
A.
Repair electrical wires.
B.
Inoperable automatic defrost
timer.
B.
Replace master circuit board.
UNIT DOES NOT GO OFF
AUTOMATIC DEFROST
CYCLE.
A.
Automatic defrost timer stuck
in automatic defrost cycle.
A.
Replace master circuit board.
MANUAL DEFROST CYCLE
DOES NOT OPERATE WHEN
‘‘DEFROST’’ SWITCH IS
PRESSED.
A.
Flat cable not properly
connected to control switch
module or master circuit
board.
A.
Properly connect flat cable 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.
B.
Check cable for pinched or
broken wire condition and repair
or replace as necessary.
C.
Inoperable ‘‘DEFROST’’ switch
on control panel switch
module.
C.
Replace control panel switch
module.
D.
Loose or broken wire.
D.
Repair wire.
‘‘CO2 OUT’’ FAULT MESSAGE
GOES ON DURING
OPERATION.
‘‘H2O OUT’’ FAULT MESSAGE
GOES ON DURING
OPERATION.
65
312028000
Trouble
Probable Cause
Remedy
MANUAL DEFROST CYCLE
DOES NOT OPERATE WHEN
‘‘DEFROST’’ SWITCH IS
PRESSED. (cont’d)
E.
Master circuit board not
operating properly.
E.
Replace master circuit board.
DEFROST CYCLE DOES NOT
CANCEL AFTER PRESSING
‘‘CANCEL DEFROST ’’
SWITCH.
A.
Flat cable not properly
connected to control switch
module or master circuit
board.
A.
Properly connect flat cable 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.
B.
Check cable for pinched or
broken wire condition and repair
or replace as necessary.
C.
Inoperable ‘‘CANCEL
DEFROST’’ switch on control
panel switch module.
C.
Replace control panel switch
module.
D.
Master circuit board not
operating properly.
D.
Replace master circuit board.
TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR
CARBONATOR WATER PUMP
MOTOR WILL NOT OPERATE.
312028000
A.
No electrical power to Unit.
A.
Connect electrical power to Unit.
Check power source.
B.
‘‘AUTO BLEND 1’’ or ‘‘AUTO
BLEND 2’’ switches have not
been pressed.
B.
Press ‘‘AUTO BLEND 1’’ or
‘‘AUTO BLEND 2’’ switch.
C.
‘‘H2O OUT’’ fault message is
on.
C.
Restore water supply to Unit.
D.
‘‘CO2 OUT’’ fault message is
on.
D.
Replenish CO2 supply as
instructed.
E.
Loose or broken electrical
wires.
E.
Tighten connections or replace
wires.
F.
Overheated water pump motor
cut off by overload protector.
F.
Check for proper line voltage.
Check restricted pump discharge.
G.
Binding water pump (new or
replacement pump only).
G.
Remove water pump from motor.
Rotate pump coupling shaft 180
degrees, then reinstall pump.
H.
Inoperative water pump and/or
motor.
H.
Replace pump and/or motor.
I.
Inoperative carbonated water
tank level control switches.
I.
Replace level control switches.
J.
Binding, damaged, or dirty
carbonated water tank balance
mechanism.
J.
Clean, repair, or replace balance
mechanism.
K.
Inoperative water pump and/or
motor.
K.
Replace water pump and/or
motor.
66
Trouble
Probable Cause
Remedy
CARBONATOR WATER PUMP
WILL NOT SHUT OFF.
A.
Binding, damaged, or dirty
carbonated water tank 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.
A.
Increase water inlet supply line
pressure. Water inlet supply line
must have large enough I.D.
B.
Water filter restricted.
B.
Replace water filter.
TROUBLESHOOTING DISPENSED PRODUCT
BRIX (WATER-TO-SYRUP)
‘‘RATIO’’ TOO LOW.
BRIX (WATER-TO-SYRUP)
‘‘RATIO’’ TOO HIGH.
IMPROPER PRODUCT
DISPENSED.
A.
Quick disconnect not secure
on soft drink tank.
A.
Secure tank quick disconnect.
B.
Syrup flow regulator set too
low.
B.
Adjust BRIX of dispensed product
as instructed.
C.
Water flow regulator set too
high.
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.
F.
Change syrup supply as
instructed.
A.
Syrup flow regulators set too
high.
A.
Adjust BRIX of dispensed product
as instructed.
B.
Water flow regulator set too
low.
B.
Water flow regulator must be set
for 1.3 ± 0.05 oz/sec.
C.
Water flow regulator stuck.
C.
Clean regulator.
D.
Syrup Baume not in proper
range.
D.
Change syrup supply as
instructed.
E.
Restricted water filter.
E.
Replace water filter.
A.
Secondary CO2 regulators not
properly adjusted.
A.
Adjust secondary CO2 regulators
as instructed.
B.
Dirty CO2 supply. CO2 must
be clean and free of water, oil,
and dirt. Water will not absorb
dirty CO2 gas in same way as
clean gas. This can also cause
off-taste problems.
B.
Replace CO2 supply as
instructed.
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.
A.
Cylinder freeze-up.
‘‘AUTO BLEND 1’’ or ‘‘AUTO
BLEND 2’’ switch not pressed.
B.
A.
Refer to CYLINDER FREEZE-UP.
Press ‘‘AUTO BLEND 1’’ or
‘‘AUTO BLEND 2’’ switch.
B.
Carbonator water pump not
operating.
B.
Check carbonator and restore to
operation.
PRODUCT WILL NOT
A.
DISPENSE OUT OF
DISPENSING VALVE, IN ONLY
SMALL AMOUNTS, OR ONLY
LIQUID.
FREEZE CYLINDER DOES
NOT REFILL AT ALL TIMES
WHEN DISPENSING.
67
312028000
Trouble
Probable Cause
FREEZE CYLINDER DOES
NOT REFILL AT ALL TIMES
WHEN DISPENSING. (cont’d)
C.
Lines restricted.
FROZEN PRODUCT
CONSISTENCY VARIES
EXCESSIVELY.
A.
Dispensed product BRIX
varying because:
B.
CYLINDER FREEZE-UP.
A.
B.
312028000
Remedy
C.
Sanitize Unit as instructed.
Syrup and/or water flow
regulator sticking.
a. Clean regulator(s).
Primary CO2 regulator
pressure insufficient.
b. Primary CO2 regulator must be
adjusted from 80 to 100-psi.
Cylinder freeze-up causing
ice formation in center of
cylinder and liquid product
channels around ice
formation.
B.
Refer to CYLINDER
FREEZE-UP.
NOTE: DEFROST AFFECTED FREEZE CYLINDER
AS INSTRUCTED.
Dispensed product BRIX too
A. Refer to BRIX (Water-to-Syrup)
low.
‘‘Ratio’’ too low.
Viscosity of dispensed product
not properly adjusted.
68
B.
Adjust dispensed product
viscosity as instructed.
FCB
OVERCOUNTER
POST-MIX DISPENSER
WITH
V3+FEATURES
(R-404A REFRIGERANT)
UNIT PART NUMBERS:
416136xxxx
496136xxxx
ILLUSTRATED PARTS BREAKDOWN
69
312028000
24
19
36
59
56
42
22
54
71
35
56
36
19
55
20
42
39
52
24
59
44
38
48
23
37
43
18
32
66
81
60
38
78
8
81
82
36
80
19
79
25
14
34
26
28
82
85
73
91
84
76
82
69
93
94
36
61
86
48
11
68
74
2
47
83
82
21
63
9
49
31
65
1
17
41
32
64
37
72
37
6
53
46
88
37
45
37
37
37
4
29
37
51
27
62
10
89
67
33
37
40
13
12
16
5
30
FIGURE 17. OVERCOUNTER FCB POST-MIX DISPENSER
312028000
77
38
70
90
7
38
19
81
38
37
50
84
70
15
4
75
92
FCB POST-MIX DISPENSER
Item
No.
Part No.
Item
No.
Name
Part No.
Name
1
325457000
Blade, Scraper
35
320539000
Washer, .191 I.D.
2
3432
Body, Beater
36
343304000
Washer, .204 I.D.
3
326002000
Tube Kit, Drain Tube (Not Shown; See
Figure 39)
37
319941000
Thread Rolling Screw, Hex Washer Hd.,
No. 8-32 By 3/8-In. Long
4
2613
Bracket, Receiver and Accumulator
38
325282000
Secondary CO2 Regulator Components
(See Figure 18)
Machine Screw, Hex Washer Hd., No.
8-18 By 1/2-In. Long
39
2685
Panel, Top
3104
Panel, Top, Stainless Steel
40
3221
Panel, Splash
41
2604
Frame
42
186770000
Machine Screw, Phil Rd. Hd., No. 10-24
By 5/8-In. Long
43
2671
Panel, Side, Right-Side
3102
Panel, Side, Right-Side, Stainless Steel
2670
Panel, Side, Left-Side
3101
Panel, Side, Left-Side, Stainless Steel
45
320754000
Tube, Drain, 2-1/4-In. Long, Stainless
Steel
46
320776000
Strap, Tube
47
325701000
Extension, Foam Pack
48
0831
Retainer, Syrup Lines
49
326106000
Door Ass’y, Freeze Cylinder
(See Figure 35)
50
320553001
Hex Nut, 7/16-14
51
320916000
Washer, .450 I.D.
52
2621
Shroud, Condenser
53
3409
Foam Pack
54
309316000
Motor, Fan, 230V 60Hz 35W (Domestic)
300835000
Motor, Fan, 230V 50Hz 35W (Export)
55
3113
Fan, 5-Blade
56
2944
Bracket, Fan Motor
57
560001286
Wire Harness, Input (Not Shown)
58
560001288
Wire Harness, Output (Not Shown)
59
186154000
Machine Screw, Phil Pan Hd., No. 8-36
By 3/8-In. Long
60
2580
Condenser Coil
5
6
7
Control Box Components (See Figure
19)
1317
8
Filter, Solenoid
Blender and Tubing Components (See
Figure 25)
9
2392
Bushing, Flange, .501 I.D.
10
178025100
Tapered Gasket, White
11
Control Box and Display Panel
Components (See Figure 34)
44
12
317660000
Cup Rest
13
317659029
Drip Tray
14
2623
Base, Compressor
15
150777000
Hex Nut, 3/8-16
16
186147000
Washer, .375 I.D.
17
3247
Spacer, Splash Panel
18
3038
Shield, Wire
19
3108
Thread Cutting Screw, Phil Pan Hd., No.
10-32 By 1-In. Long
20
187394000
Silencer, Fan
21
343606000
Electrical Box
22
321484000
Grommet, Condenser Fan Motor Bracket
23
3173
Shield, Side
24
120227000
Washer, .194 I.D.
25
3234
Plate, Beater Motor, Left-Side (Klauber)
3236
Plate, Beater Motor, Left-Side (Emerson)
3235
Plate, Beater Motor, Right-Side (Klauber)
3237
Plate, Beater Motor, Right-Side
(Emerson)
27
3184
Leg
28
319739000
Transformer, 240V. 50/60Hz
29
2738
Bracket, Drip Tray, Left-Side
30
2739
Bracket, Drip Tray, Right-Side
31
313102000
Cover, Electrical Box
32
189429000
Hex Nut, 1/4-20
33
200498003
Hex Nut, No. 8-32
34
3193
Drive Shaft/Seal Ass’y (See Figure 42)
26
61
71
Carbonator Components (See Figure 37)
62
325776000
Pressure Switch, CO2
63
325644000
Lug, Ground
64
325145000
Washer, .205 I.D.
312028000
FCB POST-MIX DISPENSER (cont’d)
Item
No.
Part No.
Item
No.
Name
65
325069000
Machine Screw, Sl Truss Hd., No. 10-24
By 1/2-In. Long
66
3898
Compressor Kit, 2HP 230V 60Hz
(Domestic)
3899
67
Part No.
Name
78
186148000
Washer, .319 I.D.
79
3609
Grommet, Compressor
80
3608
Spacer, Compressor
Compressor Kit, 2HP 230V 50Hz
(Export)
81
186146000
Hex Nut, 5/16-18
82
318418000
Washer, .312 I.D.
3832
Cover, Control Box
83
176272396
68
311304000
Tapered Gasket, Black
Tube Ass’y, .375 I.D. By 96-In. Long,
Water Inlet (See Figure 38)
69
3557
Dryer
84
325673000
Washer, .384 I.D.
70
326071000
Expansion Valve, Refrigeration
85
3787
Coupling
71
2672
Panel, Back
86
325579000
Solenoid, 208/240V 50/60Hz
3103
Panel, Back, Stainless Steel
87
560001290
Wire Harness, Hot Gas (Not Shown)
72
2582
Receiver
88
309524011
Service Cord, Compressor
73
309338011
Clip, Sensor, Expansion Valve
89
2581
Accumulator
74
309338012
Clip, Sensor, Thermostat
90
326073012
Sensor, Thermostat
75
320940000
Machine Screw, Hex Washer Hd., No.
10-16 By 5/8-In. Long
91
324171000
Relay, 230V 50/60Hz 10Amp (Klauber
Only)
76
3238
Bracket, Beater Motor
92
320106000
Thread Rolling Screw, Phil Pan Hd., No.
6-32 By 1-In. Long (Klauber Only)
77
324120000
Motor, 1/4H.P. 220V 60Hz (Klauber)
93
3879
Cover, Motor
2472
Motor, 1/4H.P. 220/240V 50Hz (Klauber)
94
300200000
Clamp
3471
Motor, 1/8H.P. 208/240V 50/60Hz
(Emerson)
312028000
72
Item
No.
9
Part No.
Name
12
Secondary CO2 Regulator
Components
1
324218000
Tube, .156 I.D. By 3-In. Long
2
324219000
Tube, .156 I.D. By 1-In. Long
3
324220000
Tube, .156 I.D. By 11-In. Long
4
317528000
Fitting, Tee, 1/8-Barb
5
300393000
Fitting, Tee, 1/8-Barb By 3/8-Barb
6
178025100
Tapered Gasket, White
7
187462000
Tube, .312 I.D. By 20-In. Long
8
321811000
Hex Nut, No. 10-32
9
176193000
Fitting, 7/16-20
10
3049
Secondary Regulator Ass’y (See
Figure 20)
11
2684
Bracket, Regulator
12
174061196
Tube Ass’y, Secondary CO2
Regulator (See Figure 21)
13
2827
Tube Ass’y, Secondary CO2
Regulator (See Figure 22)
14
324221000
Tube, .312 I.D. By 6-In. Long
8
11
7
10
6
5
14
3
4
2
1
6
13
FIGURE 18. SECONDARY CO2 REGULATOR COMPONENTS
Item
No.
Part No.
Name
5
Control Box Components
1
3310
7
Jump Cord, Control Box
to Electrical Box
2
325192000
Snap Bushing, 1.093 Dia.
3
40285
Relay, Start
4
40284
Capacitor, Start
5
325518000
Capacitor, Run (Domestic)
3617
Capacitor, Run (Export)
6
320620000
Relay
7
187552000
Machine Screw, Phil Rd. Hd., No.
8-32 By 1/4-In. Long
8
3831
Control Box, Lower
9
319941000
Thread Rolling Screw, Hex Washer
Hd., No. 8-32 By 3/8-In. long
10
3595
Strap, Capacitor
10
4
2
9
3
6
2
8
1
FIGURE 19. CONTROL BOX COMPONENTS
73
312028000
Item
No.
Part No.
3049
Secondary CO2 Regulator Ass’y
1
183287000
Gage, 60-PSI
2
183449000
Regulator Ass’y, 30-PSI (See Figure
23)
1
6
Name
5
2
1
5
3
183412000
Regulator Ass’y, 100-PSI (See
Figure 23)
4
183286000
Gage, 100-PSI
5
183047000
Fitting, 1/4-NPT
6
130066ooo
Fitting, Plug, 1/4-NPT
7
183061000
Fitting, 1/4-NPT By 7/16-20
8
183301100
Check Valve Ass’y (See Figure 24)
9
183068000
Fitting, Elbow, 1/4-NPT
10
324211000
Fitting, 5/32-Barb By 1/16-NPT
11
183045000
Fitting, 1/4-MPT By 1/4-FPT
4
2
7
3
10
10
9
8
9
11
8
FIGURE 20. SECONDARY CO2 REGULATOR ASS’Y
Item
No.
Part No.
174061196
Name
Tube Ass’y, Secondary CO2
Regulator
1
174478000
Tube, .265 I.D. By 96-In. Long
2
176000000
Ferrule, For .465 O.D. Tube
3
770104000
Nipple, For .265 I.D. Tube
3
4
4
176017000
2
1
4
Swivel Nut, 7/16-20
2
3
FIGURE 21. TUBE ASSEMBLY
Item
No.
Part No.
Name
2827
Tube Ass’y, Secondary CO2
Regulator
309379000
Tube Ass’y, Pump to Carb
174103001
Tube, .250 I.D. By 60-In. Long
174103001
Tube, .250 I.D. By 22-In. Long
2
176001000
Ferrule, For .425 O.D. Tube
3
770104000
Nipple, For .250 I.D. Tube
4
176017000
Swivel Nut, 7/16-20
1
1
4
3
FIGURE 22. TUBE ASSEMBLY
312028000
2
74
10
15
14
13
12
9
11
16
8
7
6
5
4
1
Item
No.
17
Part No.
2
3
Item
No.
Name
183449000
CO2 Regulator Ass’y, 60-PSI,
Orange (Includes 1-16)
183412000
CO2 Regulator Ass’y, 100-PSI, Gold
(Includes 1-16)
1
183040000
2
Part No.
Name
7
130167000
Guide
8
183010000
Gasket
9
183009007
Retainer, Seat
Machine Screw, Phil Fill Hd., No.
10-32 By 7/8-In. Long
10
183008000
O-Ring, .489 I.D. By .070 C.S.
11
183007000
Filter Screen
183233059
Cover Kit (Includes Nonremovable
Adjusting Screw)
12
183006000
Spring, Poppet
3
183021000
Retainer, Spring
13
130170000
Valve, Poppet
4
315424000
Adjusting Spring, 60-PSI
14
130168000
Reducing Valve Seat
183020000
Adjusting Spring, 100-PSI
15
183003000
Gasket, Seat
5
130174000
Diaphram Ass’y
16
183001015
Body
6
183011047
Baffle
17
324211000
Fitting, 1/16-NPT By 5/32-Barb
FIGURE 23. CO2 REGULATOR ASSEMBLY
Item
No.
Part No.
Name
1
183301001
Check Valve Ass’y with Adapter
1
183300001
Adapter
3
2
183320100
Check Valve Ass’y (Includes 3-7)
4
3
183294000
Quad Ring, .145 I.D. By .070 C.S.
5
4
183296000
Ball
6
5
183297000
Spring
7
6
183298000
Retainer
7
183295100
Body
2
FIGURE 24. CHECK VALVE ASSEMBLY
75
312028000
18
10
20
17
19
7
18
18
15
4
11
24
16
9
12
14
6
13
11
23
20
5
3
10
21
8
22
1
25
26
6
18
4
8
14
16
11
7
15
18
19
24
11
12
13
2
9
23
22
8
6
3
21
1
25
18
8
FIGURE 25. BLENDER AND TUBING COMPONENTS
Item
No.
Part No.
Item
No.
Name
Blender and Tubing Components
Part No.
Name
14
2487
Solenoid Valve Ass’y, Syrup (See
Figure 32)
15
2781
Tube Ass’y, Product, Blender to
Freeze Cylinder (See Figure 28)
16
2779
Tube Ass’y, Water and Syrup
Solenoid to Blender (See Figure 29)
1
31701500
O-Ring, .239 I.D. By .070 C.S.
2
2657
Base
3
316963000
Bushing, 2-In. Dia.
4
2469
Retainer, Module
5
200498003
Hex Nut, No. 8-32
17
326098000
Tube Ass’y, CO2 Regulator to
Blender (See Figure 30)
6
319941000
Thread Rolling Screw, Hex Washer
Hd., No. 8-32 By 3/8-In. Long
18
183008000
O-Ring, .489 I.D. By .070 C.S.
7
2780
Tube Ass’y, Carb. Water Outlet (See
Figure 26)
19
325576000
Tube, Syphon, 12-In. Long
20
2486
8
560000855
Tube Ass’y, Syrup Source to Syrup
Solenoid (See Figure 27)
Solenoid Valve Ass’y, Water (See
Figure 32)
21
2680
Bracket, Module
9
5081
Soldout Switch, Syrup
22
315915000
Body, Float Switch
10
311764001
Check Valve Ass’y (See Figure 31)
23
325170000
Switch, Float
11
343487000
Machine Screw, Phil Pan Hd., No.
8-32 By 1/2-In. Long
24
315916000
Cover, Float Switch
12
315925000
O-Ring, 1.609 I.D. By .139 C.S.
25
2462
Fitting, Module
13
315931000
O-Ring, .364 I.D. By .070 C.S.
312028000
26
76
Blender Components (See Figure
33)
Item
No.
3
Part No.
2780
Name
5
Tube Ass’y, Carb Water Outlet
1
77060200
Fitting, Cross, 1/4-Barb
2
77050100
Fitting, Elbow, Valve
3
325012000
Shut-Off Valve
4
174103000
Tube, .250 I.D. By 3-In. Long
174103000
Tube, .250 I.D. By 10-In. Long
174103000
Tube, .250 I.D. By 22-In. Long
6
4
5
5
1
5
4
5
176001000
Ferrule, .425 O.D. Tube
6
174103001
Tube, .250 I.D. By 40-In. Long
4
5
2
5
2
FIGURE 26. TUBING ASSEMBLY (CARB WATER)
Item
No.
Part No.
Name
560000855
Tube Ass’y, Syrup
1
176017000
Nut, Swivel, 7/16-20
2
770104000
Nipple, .265 I.D. Tube
3
176000000
Ferrule, .500 O.D. Tube
4
174478000
Tube, .265 I.D. By 92-In. Long
174478000
Tube, .265 I.D. By 3-In. Long
5
5083
Fitting, Tee, Barb
6
770460000
Fitting, Elbow, Swivel, 5/8-18
6
4
3
3
5
4
2
1
3
3
FIGURE 27. TUBING ASSEMBLY (SYRUP)
Item
No.
Part No.
2781
1
174103000
174103000
5
Name
2
1
2
Tube Ass’y, Blender to Freeze
Cylinder
7
Tube, .250 I.D. By 3-In. Long
2
2
Tube, .250 I.D. By 22-In. Long
1
6
174103000
Tube, .250 I.D. By 38-In. Long
2
176001000
Ferrule, For .375 O.D. Tube
3
176016000
Nut, Swivel, 1/2-16
4
770204000
Nipple, For .250 I.D. Tube
5
1561
Connector, Barb
6
325012000
Shut-Off Valve
7
770601000
Fitting, Tee, 1/4-Barb
2
1
6
1
2
2
3
4
FIGURE 28. TUBING ASSEMBLY (BLENDER TO FREEZE CYLINDER)
77
312028000
Item
No.
1
Part No.
2779
2
Name
5
Tube Ass’y, Water Solenoid to
Blender
1
311742000
Connector, Barb
2
176001000
Ferrule, .375 O.D. Tube
3
174103000
Tube, .250 I.D. By 11-In. Long
4
309854000
Clamp, .400 O.D. Tube
5
77900500
Turnaround, Barb
6
77040100
Fitting, Elbow, Swivel, 7/16-20
3
2
4
3
2
6
FIGURE 29. TUBING ASSEMBLY (WATER SOLENOID TO BLENDER)
Item
No.
1
5
2
Part No.
Name
326098000
Tube Ass’y, Regulator to Blender
174103000
Tube, .250 I.D. 48-In. Long
2
176001000
Ferrule, .375 O.D. Tube
3
176017000
Nut, Swivel, 7/16-20
4
770104000
Nipple, .250 I.D. Tube
5
311741000
Connector, Barb
1
2
3
4
FIGURE 30. TUBING ASSEMBLY (REGULATOR TO BLENDER)
Item
No.
Part No.
Name
311764001
Single Check Valve Ass’y
1
317965000
Retainer
2
312196000
Spring
3
312419000
Ball
4
312415000
Washer, .300 I.D.
5
312418000
Quad Ring, .329 I.D.
6
317963000
Receptacle
6
5
4
3
2
1
FIGURE 31. DOUBLE CHECK VALVE ASSEMBLY
312028000
78
9
15
12
7
11
8
17
10
2
6
16
4
13
5
1
7
14
3
FIGURE 32. SOLENOID VALVE ASSEMBLY
Item
No.
Part No.
Item
No.
Name
Part No.
Name
2486
Solenoid Valve Ass’y, Water
8
310632001
Adjusting Screw
2487
Solenoid Valve Ass’y, Syrup
9
1318
Flow Control, Top
1
2356
Block, Valve
10
180025000
O-Ring, .364 I.D. By .070 C.S.
2
1319
Body, Valve
11
1545
Retainer, Flow Control
3
0837
Thread Rolling Screw, Phil Pan Hd.,
No. 6-32 By 5/8-In. Long
12
1081
Thread Cutting Screw, Hex Washer
Hd., No. 8-16 By 1/2-In. Long
4
310754011
Piston, Water
13
0024
Solenoid, 24V.
310480011
Piston, Syrup
14
187188000
5
317431011
Cylinder
Machine Screw, Phil Pan Hd., No.
8-32 By 1/4-In. Long
6
310482000
Spring
15
317579000
Arm, Solenoid
7
317816000
O-Ring, .676 I.D. By .070 C.S.
16
0854
Spring
17
311355000
Inlet Valve
79
312028000
12
11
13
2
8
1
7
2
9
4
6
3
10
5
FIGURE 33. BLENDER COMPONENTS
Item
No.
Part No.
Item
No.
Name
Part No.
Name
Blender Components
7
315931000
O-Ring, .364 I.D. By .070 C.S.
1
2625
Support, Blender
8
325288000
Float Switch Ass’y
2
188206000
Thread Rolling Screw, Phil Truss
Hd., No. 10-24 By 3/4-In. Long
9
324048000
Holder, Float Switch
10
324115000
Retaining Ring
3
324116000
Washer, .625 I.D.
11
311743000
Retainer, Tube
4
324047000
Tank, Blender
12
311751000
5
186570000
Strain Relief
Machine Screw, Sl Hex Washer Hd.,
No. 4-40 By 1/4-In. Long
6
315925000
O-Ring, 1.609 I.D. By .139 C.S.
13
326105000
Relief Valve Ass’y
312028000
80
1
16
10
19
15
17
7
12
11
7
7
8
4
18
20
16
6
14
13
1
9
3
5
2
FIGURE 34. CONTROL BOX AND DISPLAY PANEL COMPONENTS
Item
No.
Part No.
Item
No.
Name
Control Box and Display Panel
Components
Part No.
Name
10
325981069
Holder, Flavor Tab
11
2716
Cover, Control Box
12
312251000
Thread Rolling Screw, Phil Pan Hd.,
No. 10-24 By 3/8-In. Long
1
326079000
Cable, Ribbon
2
326078000
P.C. Board, Display
3
2763
Housing, Display
13
2651
Control Box
4
2897
Hinge, Display
14
0150
Fan, Cage, 230V 9W
5
2895
Latch, Display
15
324136000
P.C. Board, Main
6
2704
Panel, Back, Display
16
325998000
Cable, Ribbon
7
319941000
Thread Rolling Screw, Hex Washer
Hd., No. 8-32 By 3/8-In. Long
17
325925000
Support, P.C. Board
18
326076000
P.C. Board, Motor No. 1
8
189955000
Rivet
19
326077000
P.C. Board, Motor No. 2
9
325962040
Switch, Touch
20
320389000
Bushing, .875 Dia.
21
560001291
Wire Harness (Not Shown)
81
312028000
10
8
7
9
3
5
1
2
6
4
FIGURE 35. FACEPLATE ASSEMBLY
Item
No.
Part No.
Item
No.
Name
Part No.
Name
326106000
Door, Freeze Cylinder Ass’y
5
321652000
Shank Nut
1
325918000
Door, Freeze Cylinder
6
325936000
Spacer
2
325954088
Relief Valve Ass’y
7
321269001
Spinner
3
320678000
O-Ring, 4.60 I.D. By .210 C.S.
8
322441000
Sensor
4
1557
Valve Head Ass’y (See Figure 36)
9
2361
Shaft
10
2358
Pin, Beater Bar
312028000
82
9
8
11
3
5
4
1
10
2
6
13
12
7
FIGURE 36. DISPENSING VALVE ASSEMBLY
Item
No.
Part No.
Item
No.
Name
Part No.
Name
1557
Dispensing Valve Ass’y
8
325647000
Plate
1
1556
Body and Shank
9
317784000
2
1554
Valve
Thread Cutting Screw, Phil Truss
Hd., Stainless Steel, No. 8-32 By
3/8-In. long
3
1576
Housing
10
2818
4
1575
Fitting
O-Ring, Caged, .562 I.D. By
.210 C.S.
5
325305000
Spring
11
321653000
O-Ring, .862 I.D. By .103 C.S.
6
321651000
Lever, Valve
12
1544
Spring
7
1555
Knob
13
1543
Shaft Release
83
312028000
Item
No.
2
Part No.
10
Name
1
Carbonator Components
1
2682
Bracket, Motor
2
320767000
Machine Screw, Phil Pan Hd., No.
10-24 By 3/8-In. Long
3
309854000
Clamp, .409 O.D. Tube
4
326136000
Carbonator Tank Ass’y (See Figure
40)
5
3159
Switch, Pressure
6
2833
Pump and Motor Ass’y, Domestic
(See Figure 41)
2814
Pump and Motor Ass’y, Export (See
Figure 41)
7
318976000
Machine Screw, Sl Hex Washer Hd.,
1/4-20 By 1/2-In. Long
8
311855000
J-Nut, 1/4-20
9
317974000
Deflector, Relief Valve
10
309379000
Tube Ass’y (See Figure 22)
7
9
3
8
6
5
4
FIGURE 37. CARBONATOR COMPONENTS
Item
No.
Part No.
Name
176272396
Tube Ass’y, .375 I.D. By 96-In. Long
1
174292000
Tube, .375 I.D. By 96-In. Long
2
176204000
Ferrule, .640 O.D. Tube
3
176205000
Nipple, .375 I.D. Tube
4
311242000
3
4
2
Nut, Swivel, 5/8-18
1
4
3
FIGURE 38. TUBING ASSEMBLY
Item
No.
Part No.
4
Name
326002000
Drain Kit, Drip Tray
2
1
170423000
Hex Nut, 5/8-32
1
2
151281000
Washer, .640 I.D.
3
3
140133000
Clamp, .687 O.D.
4
170413000
Fitting,
5
315865
Tube, .625 I.D. By 75-In. Long
5
FIGURE 39. DRIP TRAY DRAIN KIT
312028000
84
2
12
1
3
2
4
10
11
6
5
9
7
8
7
FIGURE 40. CARBONATOR TANK AND LINKAGE ASSEMBLY
Item
No.
Name
Item
No.
326136000
Carbonator Tank and Linkage Ass’y
7
318037000
Insulation, Switch
1
326135000
Tank, Carbonator
8
317771000
Level Control Switch
2
317746000
Link, Pivot
9
315961000
3
317772000
Pin
Machine Screw, Sl. Rd. Hd., No.
4-40 By 1-1/8-In. Long
4
318036000
Push-on Nut
10
318123000
Switch, Actuator
5
317747000
Pivot Housing
11
342663000
Thread Cutting Screw, Phil Pan Hd.,
Sems, No. 8-32 By 3/8-In. Long
6
317752000
Spring
12
318362000
Relief Valve
Part No.
85
Part No.
Name
312028000
7
1
4
6
2
3
5
5
10
11
9
8
9
FIGURE 41. PUMP AND MOTOR ASS’Y
Item
No.
Part No.
Item
No.
Name
2833
Pump and Motor Ass’y, 230/220V.
60/50HZ (Domestic)
2814
Pump and Motor Ass’y, 230V. 50HZ
(Export)
320626000
Motor, 230/220V. 60/50HZ
(Domestic)
199020000
2
Part No.
Name
5
187502000
Fitting, Elbow, 3/8-MPT By 7\16-20
6
311765001
Double Check Valve Ass’y (See
Figure 31)
7
311855000
J-Nut, 1/4-20
8
183047000
Fitting, 1/4-NPT
Motor, 230V 50HZ (Export)
9
312062000
Fitting, 1/4-NPT By 5/8-18
312996000
Pump, Water, 90GPH
10
320640000
Fitting, 1/4-NPT By 7/16-20
3
178025100
Tapered Gasket, White
11
0784
Regulator, Water Pressure
4
187483000
Clamp, Pump to Motor
1
312028000
86
4
2
3
2
6
5
1
FIGURE 42. BEATER MOTOR DRIVE SHAFT/SEAL ASS’Y
Item
No.
Part No.
Item
No.
Name
Part No.
Name
3193
Rear Seal Ass’y
3
2360
O-Ring, 1.86 I.D. By .139 C.S.
1
3156
Drive Shaft
4
2583
Retaining Ring
2
2463
Bearing with Setscrews
5
2731
O-Ring, .671 I.D. By .139 C.S.
6
2591
Housing
87
312028000
THIS PAGE LEFT BLANK INTENTIONALLY
89
312028000
CORNELIUS INC.
CORPORATE HEADQUARTERS:
One Cornelius Place
Anoka, Minnesota 55303-6234
(612) 421-6120
(800) 238-3600