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Service Manual FCB Overcounter V3Plus with R404A

1. PUR 25A LEFT LEFT LEET LEFT UNITS 1 2 5 1 2 LEFT 1 LEFT 2 SYRUP BLENDER soD ouT FEDATS FLOATS BEATER BEATER SWITCHES I RED YEL MOTOR MOTOR 1 5 x n es 9 LEFT 1 LEFT 42 5 A WIR PSI SIT NC N BLU CX ay Ek T o r QRN 8 1 GRAY I x g Ul zla s c Inc RED 3 1 FILTER FILTER BLK YEL MIR CURRENT BLK YEL xL 1251 9 RED YEL 1 et RED YEL RER MED E E SU 5 B ma 2 s L BOARD 05 2 8 1 167 o WAT 181 OR GRN YEL 122 1 MASTER BOARD 45 BOARD 13 CO2 PSI SWT 2 ra 1 19 MBN GRAY 8 112 152 r 167 1 LEFT LEFT 2 4d d rFB E ary 5 5 REFA 8 1 zz amp 501 soL ud 5 y y d H LEFT amp ec LET a ume hi I I Fd aati as m OOO DL I z WIR 2 gt SYRUP WTR Ep E mnm TSPLAY 5 SOL amp 2 0 SOL F 3 LBOARD dz Thee TT 9 TOUCH SWT S ge aus z 25 POWER SUPPLY 95 Sza RED YEL gay WHT af BLU 131 BLY GRAY OT RED YEL 4 m COND 0520 1 2 z 3 FAN
2. 12 TURNING ON ELECTRICAL POWER TO UNIT 12 TURNING CO2 SUPPLY TO THE UNIT 12 ADJUSTING PRIMARY REGULATOR 12 ADJUSTING PRODUCT BLENDER TANKS SECONDARY 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 put obruta tn ferto 16 PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY 16 SETTING CLOCK TIME OF 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 R
3. FREEZE CYLINDER 2 BEATER DRIVE MOTOR 2 ACCUMULATOR SECONDARY CO REGULATOR 3 FIGURE 6 UNIT INTERNAL COMPONENTS 312028000 40 RETAINING SPRING HOUSING SCREW 2 TORSION SPRING HOLD DOWN SPRING PLATE 2 DISPENSING 2 O VALVE BODY CAGED O RING c5 VALVE B LEVER ipm Cip SLEEVE SPRING KNOB NO 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 re move housing B Remove torsion spring from dispensing valve C Remove knob spring sleeve and lever from dispensing valve D Remove spring fitting from dispensing valve E Press valve with caged O ring down and out of dispensing valve body F Carefully remove caged O ring from valve 6 Wash all parts in warm water Remove all traces of syrup and lubricant especially from faceplate O rings and dispensing valve If parts are excessively coated wipe clean with paper towel to remove syrup and lubricant especially from caged O ring and dispensing valve Use BRUSH item 3 Table 3 to clean face plates relief valve passages 7 Submerge all parts in 4 percen
4. ADJUSTMENT SCREW pue FIGURE 14 CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT 59 312028000 i a ELECTRONIC e EXPANSION VALVE 2 c C Co eS C HOT GAS DEFROST SOLENOID VALVE Oct ASS Y 2 171 4 2 k ET CONDENSER COIL s FAN ASS Y f 1 FREEZE CYLINDER 2 eum D eu Gum EVAPORATOR ye al STRAINER DRYER COMPRESSOR RECEIVER TANK ACCUMULATOR FIGURE 15 REFRIGERATION FLOW DIAGRAM 312028000 60 9 000860 1 RED YEL
5. s 52 35 N mu aa ou Eo 55 09 c FEY Q N 5 ca 9 S 2 9 3 S 8 s i 8 o zr 55 E 9 m ux 2 a E 5 8 up we w eo g 5 ag 2 oc 5 ui 9 35 z lt oc z tc o SCREEN 56 FIGURE 12 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE 312028000 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 cyl inder faceplate relief valve This bleeds from freeze cylinder and allows product to enter and fill cylin der 9 If necessary adjust BRIX product viscosity product consistency and product carbonation of dispensed product as instructed CLEANING CO GAS CHECK VALVES see applicable Figures 2
6. UNIT PART NUMBERS 416136xxxx 496136xxxx ILLUSTRATED PARTS BREAKDOWN 312028000 FIGURE 17 OVERCOUNTER FCB POST MIX DISPENSER 70 312028000 FCB POST MIX DISPENSER 1 325457000 2 3432 3 326002000 Blade Scraper Body Beater Tube Kit Drain Tube Not Shown See Figure 39 2613 Bracket Receiver and Accumulator Secondary CO Regulator Components See Figure 18 Control Box Components See Figure 19 Filter Solenoid Blender and Tubing Components See Figure 25 2392 Bushing Flange 501 1 0 10 178025100 Tapered Gasket White 11 Control Box and Display Panel Components See Figure 34 Cup Rest Drip Tray 12 317660000 13 317659029 14 2623 15 150777000 16 186147000 3108 Thread Cutting Screw Phil Pan Hd No 10 32 By 1 In Long 2 3234 Plate Motor Left Side Klauber 120227000 N 3236 Plate Beater Motor Left Side Emerson N 3235 Plate Beater Motor Right Side Klauber 3237 Plate Beater Motor Right Side Emerson 33 200498003 Hex Nut No 8 32 34 3193 Drive Shaft Seal Ass y See Figure 42 j EE soe r s 2151 Um 71 35 36 37 320539000 343304000 319941000 Washer 191 1 0 Washer 204 1 0 Thread Rolling Screw Washer No 8 32 By 3 8 In
7. Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be dis played 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 35 312028000 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
8. H20 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 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 dis play 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 F
9. Regulators The secondary CO regulators see Figure 2 and 6 regulate CO pressure to the carbonator and product blender tanks If necessary to adjust secondary CO 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 312028000 34 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 opera tion until programmed WAK
10. 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 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 CO gas could then back flow into the water system and create a health hazard in the system WARNING The carbonator water pump water strainer screen and the double liquid check Service water strainer screen and double liquid check valve as instructed in the SERVICE AND MAINTE NANCE section CLEANING GAS CHECK VALVES see Figure 2 and 13 The CO gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO system as instructed in the SERV
11. Motor 1 4H P 220 240V 50Hz Klauber Motor 1 8H P 208 240V 50 60Hz Emerson 312028000 72 Washer 319 1 0 176272396 324171000 320106000 Grommet Compressor Spacer Compressor Hex Nut 5 16 18 Washer 312 I D Tube Ass y 375 1 0 By 96 In Long Water Inlet See Figure 38 Washer 384 1 0 Coupling Solenoid 208 240V 50 60Hz Wire Harness Hot Gas Not Shown Service Cord Compressor Accumulator Sensor Thermostat Relay 230V 50 60Hz 10Amp Klauber Only Thread Rolling Screw Phil Pan Hd No 6 32 By 1 In Long Klauber Only Secondary Regulator Components ze 324218000 Tube 156 1 0 By 3 In Long 2 324219000 Tube 156 1 0 By 1 In Long 3 324220000 Tube 156 1 0 11 In Long 3049 Secondary Regulator Ass y See Figure 20 2684 Bracket Regulator 12 174061196 Tube Ass y Secondary Regulator See Figure 21 13 2827 Tube Ass y Secondary Regulator See Figure 22 14 324221000 Tube 312 D By 6 In Long 4 317528000 Fitting Tee 1 8 Barb 5 300393000 Fitting Tee 1 8 Barb By 3 8 Barb Control Box Components to Electrical Box Capacitor Run Domestic Capacitor Run Export 187552000 Machine Screw Phil Rd Hd No 8 32 By 1 4 In Long 3831 Control Box Lower 319941000 Thread Rolling Screw Hex Washer Hd No 8 32 By 3 8 In long 10 3595 Strap Capacitor FIGURE 19 CONTROL BOX COMPONENTS 73 312028000 3049
12. X SYRUP MINUTES 11 0 0 1358 11 5 0 1420 NOTE A numbers are based upon a 4 4 to 1 water to syrup ratio 12 0 0 1481 12 5 0 1543 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 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 TABLE 8 TOTALS DISPLAYED CYCLES AND HOURS TOTALS MENU 312028000 24 ITEMS AFFECTED BY ERROR MESSAGE BEATER BEATER DISPLAYED ERROR MOTOR 1 MOTOR 2 Motor 1 Low Current lt 109 OFF OFF Sensed on Motor One Motor 2 Low Current lt 109 OFF OFF Sensed on Motor Two Motor 1 High Current gt 255 OFF OFF Sensed on Motor One Motor 2 High Current gt 255 OFF OFF Sensed on Motor Two _ smei __ 9 mon wo F r 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 manufac
13. 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 13 312028000 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 Open No 1 product blender tank product sample valve see Figure 2 and 6 and take sample approxi mately 6 ounces of product in a cup or glass NOTE Temperature compensated hand type refractometers P N 511004000 are available from The Cor nelius 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 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 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 Press A
14. Common Outlet 3 Press ERROR RESET switch two times to exit from MENU SELECTIONS 312028000 20 SERVICE USE ONLY APPLICABLE ELECTRIC OR GAS DEFROST See Table 5 1 0 9 8 7 6 5 4 3 2 1 USED DIP SWITCH MOTOR CURRENT SELF CALIBRATION See Table 5 ASS Y BEATER MOTORS CURRENT READOUT See Table 5 POINT OF SALE MESSAGE DISPLAY SELECT See Table 7 Note Switch No 3 must be in OFF position for standard Units with pulse expan sion valves Switch No 3 must be in ON position for Units with mechanical expansion valves MOTOR CURRENT ADJUSTMENT JO RELAY CIRCUIT BOARD NO 2 c DIII MASTER CIRCUIT BOARD RELAY CIRCUIT BOARD NO 1 L 31 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 21 312028000 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 Press DEFR
15. DISPENSE OUT OF DISPENSING VALVE IN ONLY SMALL AMOUNTS OR ONLY LIQUID B FREEZE CYLINDER DOES A NOT REFILL AT ALL TIMES WHEN DISPENSING B Quick disconnect not secure on soft drink tank Syrup flow regulator set too low Water flow regulator set too high Syrup flow regulators stuck Restriction in syrup line Syrup Baume not in proper range Syrup flow regulators set too high Water flow regulator set too low Water flow regulator stuck Syrup Baume not in proper range Restricted water filter Secondary CO regulators not properly adjusted Dirty supply CO must be clean and free of water oil and dirt Water will not absorb dirty CO gas in same way as clean gas This can also cause off taste problems Dispensing valve has ice particles in it Oylinder freeze up AUTO BLEND 1 or AUTO BLEND 2 switch not pressed Carbonator water pump not operating 67 Remedy Clean repair or replace balance mechanism Increase water inlet supply line pressure Water inlet supply line must have large enough I D Replace water filter Secure tank quick disconnect Adjust BRIX of dispensed product as instructed Water flow regulator must be set at 1 3 0 05 oz sec Clean syrup flow regulators Sanitize Unit as instructed Change syrup supply as instructed Adjust BRIX of dispensed product as instructed Water flow regulator must be set for 1 3 0 05
16. POORLY ILLUMINATED DISPLAY ONE OR MORE FAULT MESSAGES NOT OPERATING ALL FAULT MESSAGES NOT OPERATING 312028000 Probable Cause Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Master circuit board not operating properly Not pressing and holding SECURITY SWITCH for 3 seconds to deactivate control switches SECURITY SWITCH inoperable Extremely low voltage Flat cable not properly connected to fault message module or master circuit board Flat cable connected between fault message module and master circuit board pinched and shorted out or broken wire in cable External sensing device failing to signal master circuit board which in turn signals fault message display External sensing devices cable connectors not securely connected to master circuit board connectors Disconnected or broken wire between master circuit board connector and external sensing device Master circuit board not operating properly Fault message display module not operating properly No electrical power to Unit Flat cable not properly connected to fault message module or master circuit board Flat cable connected between fault message module and master circuit board pinched and shorted out or broken wire in cable 64 Remedy Check cable for pinched or broken wire condition and repair or replace as necessary
17. Replace master circuit board Press and hold SECURITY SWITCH for 3 seconds to deactivate control switches Replace control panel switch module Upgrade voltage Properly connect flat cable to fault message module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace or repair external sensing device Make sure external sensing devices cable connectors are securely connected to master circuit board connectors Connect or repair wire between master circuit board connector and external sensing device Replace master circuit board Replace fault message display module Connect electrical power to Unit Properly connect flat cable to fault message module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Trouble ALL FAULT MESSAGE NOT OPERATING cont d OUT FAULT MESSAGE GOES ON DURING OPERATION H20 OUT FAULT MESSAGE GOES ON DURING OPERATION SYRUP 1 OR SYRUP 2 FAULT MESSAGE GOES ON DURING OPERATION ERROR 1 OR ERROR 2 FAULT MESSAGE GOES ON DURING OPERATION FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT OPERATE UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN DEFROST SWITCH IS PRESSED Probable Cause Master circuit board not operating Fault message display m
18. can be varied by adjustment and secondary CO regulator setting from a high overrun light drink to a wet heavy drink The length of freezing cycle and amount of 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 lf 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 OUT fault message is not displayed
19. 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 cylin der then remove faceplate from cylinder 312028000 38 CANCEL 5 DEFROST SELECT ADVANCE FAULT MESSAGE DISPLAY CONTROL PANEL HIDDEN SECURITY SWITCH BACK PANEL SCREW 2 CONTROL PANEL FACEPLATE RELIEF VALVE 4 CUP REST f SRI 246267 _ T FRONT ACCESS DOOR LOCK Ss SIDE PANEL 2 SIDE PANEL RETAINING SCREW FACEPLATE 2 ACCESS PANEL SPACE ACCESS PANEL ITEM 14 RETAINING SCREW LOWER FRONT NOTE The No 1 freeze cylinder is the left hand ITEM 16 ACCESS PANEL cylinder facing the front of the Unit The No 2 freeze cylinder is to the right ofthe No 1 freeze cylinder FIGURE 5 OPERATING CONTROLS 39 312028000 REFRIGERATION COMPRESSOR CONDENSER COIL PRODUCT BLENDER TANK 2
20. turer 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 8 Press CANCEL DEFROST ADVANCE switch to go from MFG 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 re frigerant gas that has been installed then proceed as follows to program the Dispenser 25 312028000 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 o
21. 253 VAC 50 Hz single phase electrical circuit connected through a 30 amp minimum rated 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 pre
22. 3 4 12 10 Valve Lever 20 Beater Drive Motor 21 Drive Shaft Assembly va ve 22 Viscosity Sensor 13 Beater 23 Spi 14 Allen Head Setscrew 24 pinner 15 Beater Shaft Coupling Spring 16 Drive Pin 25 Shaft Release 17 Bearing Housing Locking Tab 4 25 Bearing 18 Bearing Retainer 27 Bearing Housing 19 Beater Motor Drive Shaft FIGURE 8 FREEZE CYLINDER CUTAWAY VIEW BEATER DRIVE MOTOR DRIVE SHAFT SEAL ASS Y m BEATER DRIVE BEATER MOTOR SHAFT ALLEN HEAD H ALLEN HEAD PIN SET SCREW MIT __ n e COUPLING COUPLING COUPLER DRIVE SHAFT tc H ul 8 o a gt o GAUGE DRIVE COUPLER ITEM 14 PLASTIC LOCK RING HOUSING O RING BEARING O RING SHAFT ALLEN HEAD SET SCREW 2 DRIVE SHAFT SEAL ASSEMBLY FIGURE 9 SERVICING BEATER MOTOR DRIVE SHAFT SEAL ASSEMBLY 45 312028000 10 BEATER Key on End of Post Key Slot on Blade Scraper blades must be mounted to the beater body as shown using the perforated edge as the leading edge Line up key on end of posts with key slot in scraper blades F
23. 319941000 Thread Rolling Screw Hex Washer Hd No 8 32 By 3 8 In Long 2780 Tube Ass y Carb Water Outlet See Figure 26 560000855 Tube Ass y Syrup Source to Syrup Solenoid See Figure 27 5081 Soldout Switch Syrup 311764001 Check Valve Ass y See Figure 31 343487000 Machine Screw Phil Pan Hd No 8 32 1 2 In Long 315925000 O O Ring 1 609 1D By 139 C S 1 609 I D By 139 C S 315931000 O Ring 364 I D By 070 C S 312028000 76 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 17 326098000 Tube Ass y CO Regulator to Blender See Figure 30 183008000 O Ring 489 I D By 070 C S 325576000 Tube Syphon 12 In Long 2486 Solenoid Valve Ass y Water See Figure 32 s wm p i Blender Components See Figure Essl m EN 2780 Tube Ass y Carb Water Outlet 4 6 da TE EF N RW j 4 174103000 Tube 250 1 0 By 3 In Long race 174103000 Tube 250 1 0 By 10 In Long AUT 4 ES 5 174103000 Tube 250 1 0 22 In Long 5 08 4 s 5 176001000 Ferrule 425 O D Tube 5 5 174103001 Tube 250 I D By 40 In Long FIGURE 26 TUBING ASSEMBLY CARB WATER 560000855 Tube Ass y Syrup 6 s Ww 1 176017000 Nut Swivel 7 16 20 PT e 3 2
24. 770104000 Nipple 265 I D Tube 5 p 176000000 Ferrule 500 O D Tube 4 Ss 4 174478000 Tube 265 I D By 92 In Long 1 2 54 174478000 Tube 265 1 0 3 In Long NS 52 5083 Fitting Barb 770460000 Fitting Elbow Swivel 5 8 18 5 sns 2 1 uc pet 2781 Tube Ass y Blender to Freeze A oe XO Cylinder 1 174103000 Tube 250 I D By 3 In Long 2 2 1 Pe Pt 6 174103000 Tube 250 1 0 By 22 In Long x 174103000 Tube 250 I D By 38 In Long aM ET vA 6 176001000 Ferrule For 375 Tube 176016000 Nut Swivel 1 2 16 Re Bu 79 770204000 Nipple For 250 I D Tube P i us 5 6 325012000 ShutOf Valve b 770601000 Fitting Tee 1 4 Barb FIGURE 28 TUBING ASSEMBLY BLENDER TO FREEZE CYLINDER 77 312028000 2779 Tube Ass y Water Solenoid to Blender s mous ring Eron ene nem FIGURE 30 TUBING ASSEMBLY REGULATOR BLENDER 311764001 Single Check Valve Ass y N s memo Quad Ring 329 1 0 6 817958000 Recenade FIGURE 31 DOUBLE CHECK VALVE ASSEMBLY 312028000 78 Solenoid Valve Ass y Water Solenoid Valve Ass y Syrup a es Lee No 6 32 By 5 8 In Long Piston Water Piston Syrup 317431011 Oylinder 317816000 O Ring 676 I D By 070 C S 79 Hd No 8 16 By 1 2 In Long 8 32 By 1 4 In Long 311355000 Inlet
25. AND MAINTENANCE enr 37 PREPARING UNIT FOR SHIPPING STORING OR RELOCATING 37 PERIODIC INSPECTION I aatia iei aia a 37 REMOVAL OF TOP PANEL BACK PANEL SIDE PANELS AND FRONT ACCESS E RDUM a 37 TOP DOR EINER aa hua dag 37 BACK PANEL ep kau PEERS LAE ERO 37 TABLE OF CONTENTS cont d Page SIDE PANELS exuere eU pag ku Bie lika 37 FRONT AGCESS PANEL aasan RES 38 OPENING AND CLOSING FRONT ACCESS DOOR 38 OPENING FRONT ACCESS DOOR 38 CLOSING FRONT ACCESS DOOR 38 EUBRICATIQON eben per i Bee eer desc Ere oper e ee 38 CARBONATOR WATER PUMP MOTOR 38 SERVICING DISPENSING VALVES CAGED O RINGS AND FREEZE CYLINDERS DRIVE SHAFT SEAL ASSEMBLIES 38 CLEANING CONDENSER COIL 43 ADJUST MEN ES rum acetate CER HORE DRE A EA e aUe RR ea 43 ADJUSTING PLAIN WATER PRESSURE REGULATOR 43 ADJUSTING CARBONATED WATER FLOW RATE sata maaa te ayuda 43 ADJUSTING CO2 REGULATORS 47 ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT x S Supayman ta qme hue Ua UOCE IRI CHER 48 PRODUCT CARBONATION ADJUSTMENT 4
26. 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 vis cosity 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 tem perature readings in degrees Fahrenheit Left Reading Refrigeration Coils Inlet No 1 Middle Reading Refrigeration Coils Inlet No 2 Right Reading
27. CO2 REGULATOR 30 SECONDARY CO2 REGULATORS 30 CARBONATED WATER FLOW REGULATORS 30 SYRUP FLOW REGUDATORS see e du 81 DISPENSING datis ha ex 81 DISPENSED PRODUCT CONDITIONS 81 OVERRUN AS APPLIED TO FROZEN CARBONATED BEVERAGES 31 OPERATING CHARACTERISTICS sa Males riot genial de t etn 32 OPERATING tte eet eed REX Re RE SEXE Rr acp ute 32 TABLE OF CONTENTS cont d Page REPLENISHING SYRUP SUPPLY 32 PRODUCT FLAVOR CHANGE 33 CHECKING COZ obit ehm cities Be Cape ale dat tma ted 33 CLEANING AND SANITIZING 33 DALY CLEAN IN G mas eter te es e Ces 33 SANLBEZING at sca tet Feu eed echa e denar 33 CLEANING CONDENSER COIL 33 LUBRICATION 33 ADJUSTMENTS nhau Canna E 34 CARBONATED WATER FLOW RATE 34 WATER TO SYRUP RATIO BRIX OF DISPENSED PRODUCT 34 CO2 REGULATORS kusa satu TR 34 ADJUSTING BEATERS MOTORS CURR
28. CONSISTENCY VARIES EXCESSIVELY 68 CYLINDER FREE Ze eer Ss ote EE da 68 LIST OF FIGURES FIGURE 1 FCB OVERCOUNTER POST MIX DISPENSER 3 FIGURE 2 FLOW DIAGRAM r e OR a t 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 cu 56 FIGURE 18 CO2 GAS CHECK VALVE 57 FIGURE 14 CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT tops As 59 FIGURE 15 REFRIGERATION FLOW 60 FIGURE 16 WIRING DIAGRAM a e 61 FIGURE 17 OVERCOUNTER FCB POST MIX DISPENSER 70 FIGURE 18 SECONDARY CO2 REGULATOR COMPONENTS 73 FIGURE 19 FIGURE 20 FIGURE 21 FIGURE 22 FIGURE 23 FIGURE 24 FIGURE 25 FIGURE 26 FIGURE 27
29. FAULT MESSAGE GOES ON DURING aa aid 65 ERROR 1 OR ERROR 2 FAULT MESSAGE GOES ON DURING OPERATION pO nag ahead REP Lor ahd 65 TABLE OF CONTENTS cont d Page FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT OPERATE esso NL A M AM ot mz 65 UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE 65 MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN DEFROST SWITCH IS PRESSED r r rnrn reren 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 Sua eere UAE La 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 67 FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING 5 E ceu tA 67 FROZEN PRODUCT
30. Figure 2 WARNING To avoid personal injury and or property damage always secure CO cylinder in upright position with a safety chain to prevent it from falling over Should the valve become accidentally damaged or broken off CO cylinder can cause serious personal injury WARNING CO displaces oxygen Strict attention must be observed in the prevention of carbon dioxide gas leaks in the entire and soft drink system If a 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 CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation 1 Unscrew protector with chain attached from cylinder valve Open CO cylinder valve slightly counterclockwise to blow any or dust from outlet fitting before installing primary regulator then close valve 2 Remove shipping plug from primary CO regulator assembly coupling nut and make sure gasket is in place inside nut Install regulator assembly on CO cylinder so gages can be easily read then tighten coupling nut DO NOT OPEN CYLINDER VALVE AT THIS TIME CONNECTING SOFT DRINK TANKS CO LINES TO PRIMARY CO REGULATOR ASSEMBLY see Figure 2 1 Connect soft drink tanks CO lines to primary CO regulator manifold assembly as shown in Figure 2 2 Install gas quick disco
31. Leveling Leg 14 Spacer White 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 inlet line to CO source 2 ES EX ES ES 6 EX _8_ 10 13 EE N 2 Spanner wrench dispensing valve item 2 is used to remove shank nuts securing dispensing valves to faceplates 312028000 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 as sembly 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 o
32. Switch Switch 315961000 Machine Screw SI Rd Hd No 4 40 1 1 8 In Long 318123000 Switch Actuator Actuator 342663000 Thread Cutting Screw Phil Pan Hd Sems No 8 32 ae 3 8 In Long 318362000 Relief Vave Valve 85 312028000 Pump and Motor Ass y 230 220V 187502000 Fitting Elbow 3 8 MPT By 16 20 60 50HZ Domestic 311765001 Double Check Valve Ass y See Pump and Motor Ass y 230V 50HZ Figure 31 Export 311855000 J Nut 1 4 20 320626000 Motor 230 220V 60 50HZ m Domestic 183047000 Fitting 1 4 199020000 Motor 230V 50HZ Export E 312062000 Fitting 1 4 NPT By 5 8 18 312996000 Pump Water 90GPH 320640000 Fitting 1 4 NPT By 7 16 20 178025100 Tapered Gasket White 0784 Regulator Water Pressure 187483000 Clamp Pump to Motor 312028000 86 FIGURE 42 BEATER MOTOR DRIVE SHAFT SEAL ASS Y O Ring 1 86 1 0 By 139 C S 2583 Retaining Ring 2731 O Ring 671 1 0 By 139 C S 87 312028000 THIS PAGE LEFT BLANK INTENTIONALLY 89 312028000 CORNELIUS INC iii CORPORATE HEADQUARTERS One Cornelius Place Anoka Minnesota 55303 6234 612 421 6120 800 238 3600
33. Valve 312028000 ke 12 5 5 FIGURE 33 BLENDER COMPONENTS 2625 Support Blender Blender Components 2 188206000 Thread Rolling Screw Phil Truss Hd No 10 24 By 3 4 In Long 324116000 Washer 625 I D 3 Tank Blender Strain Relief 6 315925000 O Ring 1 609 1 0 By 139 C S 312028000 80 315931000 O Ring 364 1 0 By 070 C S 325288000 Float Switch Ass y 324048000 Holder Float Switch 324115000 Retaining Ring 12 311751000 Machine Screw Sl Hex Washer Hd No 4 40 By 1 4 In Long 326105000 Relief Valve Ass y FIGURE 34 CONTROL BOX AND DISPLAY PANEL COMPONENTS Control Box and Display Panel 10 325981069 Holder Flavor Tab Components 11 2716 Cover Control Box 326079000 Cable Ribbon 12 312251000 Thread Rolling Screw Phil Pan Hd 326078000 P C Board Display No 10 24 By 3 8 In Long 2897 Hinge Display 14 10150 Fan 0806 230V 9W 2895 Latch Display 15 324136000 P C Board Main 2704 Panel Back Display 16 325998000 Cable Ribbon 319941000 Thread Rolling Screw Hex Washer 17 325925000 Support P C Board Hd No 8 32 By 3 8 In Long 18 326076000 P C Board Motor No 1 19 326077000 P C Board Motor No 2 325962040 Switch Touch 20 320389000 Bushing 875 Dia 21 560001291 Wire Harness Not Shown 81 312028000 FIGURE 35 FACEPLATE
34. and 13 The CO gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the system ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED QUAD RING 183294000 BALL pe 18270000 SPRING 183297000 8 5 RETAINER 183298000 3 BODY 183295100 QUAD RING SEAL MUST BE REPLACED EACH TIME CHECK VALVE IS SERVICED FIGURE 13 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 57 312028000 Qu 12 13 14 15 Press OFF 1 and OFF 2 control switches to stop the refrigeration system and the beater drive motors Disconnect electrical power to the Unit Remove Unit back and both side panels as instructed Remove one bolt and two hex nuts and two lockwashers s
35. 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 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 Disconnect empty sanitizing solution tank from No 1 syrup system Connect soft drink tank containing syrup into No 1 syrup system solution left in system could create a health hazard WARNING Flush residual sanitizing solution from syrup system as instructed Residual 27 28 29 30 31 32 99 34 35 36 37 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 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 After carbonator water pump cycles off completely fill No 1 freeze cylinder with product by repeatedly pull ing and releasing faceplate relief valve and until product comes out of relief valve port Open di
36. 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 CO 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 adjust ment 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 pr
37. flow regulator which may alter regulator adjustment B Second disconnect CO quick disconnect from soft drink tank To connect soft drink tank into Unit syrup system A First connect quick disconnect to soft drink tank to pressurize tank B Second connect liquid quick disconnect to soft drink tank Disconnect inlet CO gt and outlet syrup lines from empty soft drink tank Check soft drink tank quick disconnects for sticky or restricted operation Rinse disconnects in warm water First pressurize full soft drink tank by connecting CO line to tank then connect Unit syrup inlet line to tank Press applicable FILL 1 or FILL 2 switch to fill applicable No 1 or No 2 syrup system syrup float switch with syrup Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill applicable No 1 or No 2 system product blender tank with product Press applicable AUTO 1 or AUTO 2 switch to start refrigeration system and beater in applicable No 1 or No 2 freeze cylinder 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 SUPPLY WARNING CO displaces oxygen Strict attention must be observed in the prevention of CO carbon dio
38. ice Rien AQ 4 WAKE UP WAKE UP TIME M ntes 4 INSTALLATION a eoe te em oy pari ie onn 7 UNPACKING AND INSPECTION 7 IDENTIFICATION OF LOOSE SHIPPED PARTS 7 ELECTRICAL POWER REQUIREMENTS 8 60 FIZ aa asan apaun t tre Sene Ede nate rr voies 8 50 HZ NIT ou s u aq unu Rr e 8 SELEGTING LOGATION e Lever e dhe See Nal uska 8 INSTALLING UNIT l a up Susu RR RR RII mhil 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 ie Puke i 9 INSTALLING PRIMARY CO2 REGULATOR ASSEMBLY ON CO2 GYEINDERB pu yy tuni det 10 CONNECTING SOFT DRINK TANKS CO2 LINES TO PRIMARY CO2 REGULATOR ASSEMBLY 10 PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT 2 au 10 CONNECTING CO2 SOURCE LINE 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
39. 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 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 CO quick disconnect from soft drink tank 3 To connect soft drink tank into Unit syrup system A First connect 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 CO line to tank then connect Unit syrup inlet line to tank 55 312028000 DOUBLE LIQUID a CHECK VALVE ASS Y GASKET a ul t X m Fa cc EG ox us 2 gt 9 E Or I gt ac 5 a o gt z O00 s lt 59 r J 3492 39 9
40. mately 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 compres sor 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 de frost 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 can celled 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 cyl inders 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
41. position and No 2 DIP SWITCH in ON position see Figure 4 and 5 and 7 19 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 fol lows 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 lt gt 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 flash ing 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
42. 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 manu
43. 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 withi
44. the factory and should require no fur ther 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 To check carbonator tank total fill allow carbonator water pump motor to operate and fill tank with carbon ated water After pump cycles off disconnect electrical power from Unit 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 If total carbonated water dispensed is below 40 ounces loosen screw securing level control switches ac tuator 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 ADJUST MENTS IN SMALL INCREMENTS Connect electrical power to Unit and allow carbonator tank to fill with water until water pump cycles off Repeat steps 2 through 5 preceding as many times as necessary until correct carbonated water volume adjustment is achieved 312028000 58 RELIEF VALVE CARBONATED SWITCHES ACTUATOR BRACKET LEVEL CONTROL SWITCHES 2 C b
45. valve to avoid spurting 11 Remove Unit lower front access panel as instructed for access to No 1 product blender tank product sam ple 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 pressure has been released from tank 15 Pull up on empty soft drink tank cover relief valve to release CO pressure from tank prior to adding to soft drink tank WARNING If powder type sanitizer is used it must be thoroughly dissolved with water 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 Prod uct 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 insid
46. 1 and No 2 relay circuit boards see Figure 4 These figures will fluctuate slightly with varia tions 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 15 312028000 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 CAUTION IF NO 4 BEATER MOTOR CURRENT READOUT SWITCH ON DIP SWITCH 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 BE
47. 11 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to activate the electrically operated car bonated water solenoid 12 When a steady stream of water is flowing from the added length of line catch carbonated water in a con tainer graduated in ounces for exactly 10 seconds Press applicable FILL 1 or FILL 2 switch to deacti vate 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 counter clockwise 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 car bonated water line disconnected from the carbonated water flow regulator in step 8 preceding to the regu lator outlet 16 Turn the product blender tanks CO 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 pr
48. 9 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 VANE RCNH 58 REPLENISHING SYRUP SUPPLY 54 REPLENISHING SUPPLY raras 55 SYRUP FLAVOR CHANGE 55 CLEANING GAS CHECK VALVES 57 REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR 57 ADJUSTING CARBONATOR TANK LIQUID LEVEL 58 TROUBLESHOOTING ed d HA widens 63 TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES rii relira n auia verc tat t dated aha aute edges 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 2 OUT FAULT MESSAGE GOES ON DURING OPERATION 65 SYRUP 1 OR SYRUP 2
49. ASSEMBLY a 326106000 Door Freeze Oylinder Ass y 321652000 Shank Nut 325918000 Door Freeze Oylinder 325936000 325954088 Relief Valve Ass y 320678000 O Ring 4 60 I D By 210 C S 1557 Valve Head Ass y See Figure 36 312028000 82 11 FIGURE 36 DISPENSING VALVE ASSEMBLY 317784000 Thread Cutting Screw Phil Truss Hd Stainless Steel No 8 32 By 3 8 In long 1 83 312028000 Carbonator Components 320767000 Machine Screw Phil Pan Hd No 10 24 By 3 8 In Long 309854000 Clamp 409 O D Tube 326136000 Carbonator Tank Ass y See Figure 40 3159 Switch Pressure 2833 Pump and Motor Ass y Domestic See Figure 41 N 2814 Pump and Motor Ass y Export See Figure 41 7 318976000 Machine Screw SI Hex Washer Hd 1 4 20 By 1 2 In Long 311855000 J Nut 1 4 20 317974000 Deflector Relief Valve 309379000 Tube Ass y See Figure 22 10 FIGURE 37 CARBONATOR COMPONENTS i s _ 176272806 SY 174292000 3 221 82 65 A 3 FIGURE 38 TUBING ASSEMBLY 2 2 326002000 Drain Kit Drip Tray 2 1 170423000 Hex Nut 5 8 32 a 151281000 Washer 640 1 0 eset 140133000 Clamp 687 O D 315865 Tube 625 1 0 By 75 In Long FIGURE 39 DRIP TRAY DRAIN KIT 312028000 84 essen canonar Tan ana usage er EH 318037000 RN Switch Ex 317771000 Level Level Control
50. CO 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 312028000 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 mes sages 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 pre vent product from entering cylinders IMPORTANT The following 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 HIDDEN SECURITY MESSAGE DISPLAY DEFROST SELECT 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 dr
51. E 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 re turn to normal operation after sleep time has occurred Program WAKE 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
52. EADOUT PRODUCT IN 20 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 20 VOLTAGE DISPLAYED VOLTAGE 22 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE NTO UNIT MESS to td a GN ae 22 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY 23 PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT BOE da 23 PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT 1 e TER curses 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 aa eee 30 FACEPLATE RELIEF VALVES pao t de eet eee te ea 30 PRODUCT SAMPLE VALVES qur 30 PRODUCT SHUTOFF VALVES onus 30 PRIMARY
53. ENTS 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 85 ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT Za eMe eC MMC MOULE TUR I MP A IN 85 VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT IN FREEZE CYLINDERS 22245554 Awe ia a Dd bea need 35 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 85 VOLTAGE DISPLAYED VOLTAGE 85 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE Gq Ub 35 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY oe oce ea 35 PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS siap 36 DISPLAYED ERROR CONDITIONS 36 PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS a RUP e Ud Seu tus 36 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE MAINTENANCE not talons Ceuta cubat Ida 36 CLEANING GAS CHECK VALVES 36 SERVICE
54. FIGURE 28 FIGURE 29 FIGURE 30 FIGURE 31 FIGURE 32 FIGURE 33 FIGURE 34 FIGURE 35 FIGURE 36 FIGURE 37 FIGURE 38 FIGURE 39 FIGURE 40 FIGURE 41 FIGURE 42 TABLE 1 DESIGN DATA TABLE 2 ACCESSORIES AND TOOLS TABLE 3 LOOSE SHIPPED PARTS TABLE 4 MAIN MENU SELECTIONS TABLE 5 DIP SWITCH FUNCTIONS TABLE 6 MOTOR SELECT TABLE 7 POINT OF SALE DISPLAY MESSAGES TABLE 8 TOTALS DISPLAYED CYCLES AND HOURS TOTALS MENU TABLE 9 DISPLAYED ERROR CONDITIONS TABLE OF CONTENTS cont d LIST OF FIGURES CONT D CONTROL BOX COMPONENTS SECONDARY CO2 REGULATOR ASS Y TUBE ASSEMBDLY DO TERR e Ree TUBE ASSEMBLY CO2 REGULATOR ASSEMBLY CHECK VALVE ASSEMBLY BLENDER AND TUBING COMPONENTS TUBING ASSEMBLY CARB WATER TUBING ASSEMBLY SYRUP TUBING ASSEMBLY BLENDER TO FREEZE CYLINDER TUBING ASSEMBLY WATER SOLENOID TO BLENDER TUBING ASSEMBLY REGULATOR TO BLENDER DOUBLE CHECK VALVE ASSEMBLY SOLENOID VALVE ASSEMBLY BLENDER COMPONENTS CONTROL BOX AND DISPLAY PANEL COMPONENTS FACEPLATE ASSEMBLY DISPENSING VALVE ASSEMBLY CARBONATOR COMPONE
55. Figure 2 must be adjusted to no less than 80 psi 1 Adjust primary CO regulator see Figure 2 by turning regulator adjusting screw to the right clockwise until regulator pressure reads 80 to 100 psig OUT OF 602 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 CO Check product blender tanks secondary CO regulators with 60 psi gages see Figures 2 and 6 for pressure set ting which should be set at 25 to 30 psi for best textured product If further adjustment is necessary adjust as instructed ADJUSTING CARBONATOR SECONDARY CO REGULATOR IMPORTANT The carbonator secondary regulator must be adjusted 25 psi higher or more above the product blender tanks secondary CO 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 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
56. ICE AND MAINTENANCE section 312028000 36 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 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 CO cylinder valve is fully opened and primary CO cylinder regulator assembly 1800 psi gage indicator is not in shaded change CO cylinder portion of dial If so CO 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 panel
57. IGURE 10 BEATERS AND SCRAPER BLADES INSTALLATION Press applicable OFF 1 or OFF 2 switch to prevent more product from entering the applicable product blender tank Disconnect Unit syrup inlet line from the applicable soft drink tank Using a flat blade screwdriver turn lock counterclockwise to unlock the front access door see Figure 5 then open the door Remove lower front access panel as instructed for access to the applicable carbonated water flow regula tor product shutoff valve and the product sample valve Close applicable product shutoff valve to prevent more product from entering the freeze cylinder 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 Note pressure setting on the applicable secondary CO regulator with 60 psi gauge for the applicable prod uct blender tank Turn regulator adjusting screw out counterclockwise until gauge reads 0 Pull up on the applicable product blender tank relief valve to release CO pressure from the tank Disconnect carbonated water line from the outlet side of the applicable carbonated water flow regulator 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 Place end of the carbonated water line routed to the outside of the Unit in the container 312028000 46
58. Long Machine Screw Hex Washer Hd No 8 18 By 1 2 In Long 38 325282000 39 2685 Panel Top 3104 Panel Top Stainless Steel 40 3221 Panel Splash 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 44 2670 Panel Side Left Side 3101 Panel Side Left Side Stainless Steel 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 309316000 Motor Fan 230V 60Hz 35W Domestic 300835000 Motor Fan 230V 50Hz 35W Export 3113 Fan 5 Blade 45 50 51 52 53 a 55 56 57 58 59 186154000 8 By 3 8 In Long 62 63 64 325776000 325644000 325145000 312028000 FCB POST MIX DISPENSER cont d Machine Screw SI Truss Hd No 10 24 By 1 2 In Long 3898 Compressor Kit 2HP 230V 60Hz Domestic 3899 Compressor Kit 2HP 230V 50Hz Export ra 3832 Cover Control Box ES 311304000 Tapered Gasket Black ass 326071000 Expansion Valve Refrigeration Panel Back 71 2672 3103 i Serer Panel Back Stainless Steel 309338012 320940000 Clip Sensor Thermostat Machine Screw Hex Washer Hd No 10 16 By 5 8 In Long Bracket Beater Motor Motor 1 4H P 220V 60Hz Klauber ES 3238
59. NGLE PHASE LINE WIRING FOR 3 PHASE COMPRESSOR ONLY 2 FLAVOR SHOWN Z SINGLE PHASE LINE 4476 REV A THIS PAGE LEFT BLANK INTENTIONALLY 312028000 62 TROUBLESHOOTING IMPORTANT Only qualified personnel should service internal components or electrical wiring the applicable product tank then relieve the system pressure before proceeding If repairs WARNING If repairs are to be made to a product system remove quick disconnects from are to be made to the CO system stop dispensing shut off the CO 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 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 CO quick disconnect from soft drink tank 2 To connect soft drink tank into Unit syrup system A First connect CO quick disconnect to soft drink tank to pressurize tank B Second connect liquid quick disconnect to soft drink
60. NTS TUBING ASSEMBLY DRIP TRAY DRAIN KIT seeeeess RII CARBONATOR TANK AND LINKAGE ASSEMBLY PUMP AND MOTOR ASS Y BEATER MOTOR DRIVE SHAFT SEAL ASS Y LIST OF TABLES Page 73 74 74 74 75 75 76 77 77 77 78 78 78 79 80 81 82 83 84 84 84 85 86 87 17 18 19 19 24 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 mustbe 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 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 elec tric motor one refrigeration system with a 2 horsepower compressor one carbonator which feeds both carbonator blender tanks a timer controlled automatic hot gas def
61. O 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 CO 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 CO quick disconnect from soft drink tank 7 To connect soft drink tank into Unit syrup system A First connect 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
62. OL 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 be tween 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 spe cial light grade silicone grease 13 Reinstall the drive shaft seal assembly in the freeze cylinder 14 Push 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 312028000 42 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 FACE PLATE item 8 Inst
63. ONATOR TANK 1100 PSI GAGF1 FIGURE 2 FLOW DIAGRAM 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 1 Tapered Gasket White Spanner Wrench Dispensing Valve 3 Cleaning Brush 4 Tapered Gasket Black 5 Cup Rest Thread Cutting Screw Hex Hd No 8 by 18 by 1 2 in long 7 Drip Tray Support Left Drip Tray Support Right Drip Tray 10 Kit Drip Tray Drain Hose Wrench Rear Seal Housing Tool Drive Coupler Adjustment Gauge 13
64. OST SELECT switch to bring up voltage readout on message display 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 opera tion Program DIAGNOSE into Unit and check components for proper operation as follows 1 10 11 12 13 14 15 16 17 18 19 20 21 312028000 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up the word CLOCK on display 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 Press DEFROST SELECT switch No 1 beater motor will start and operate while switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up the word MOTOR 2 on message display Press DEFROST SELECT switch No 2 beater motor will start and operate while switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up DEFROST 1 on message dis play Press DEFROST SELECT switch No 1 defrost relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up DEFROST 2 on message dis play Press DEFROST SELECT switch No 2 defrost relay will click when switch is pressed Pr
65. OZEN BEVERAGE NOT USED BLANK OFF HAVE A NICE DAY DISFRUTE UNA BEBIDA CONGELADA CARBONATADA 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 DE FROST 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
66. P 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 swi
67. REEZE 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 MO TORS 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 23 312028000 PWR ON 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 GALLONS A
68. RELAY 3 S 3 8 MOTOR 1 15 1 WHT eg 1 5 1 x BRN 1 z mua O 212 w i c mi le 9 2 FLAVOR UNITS o 1 ELECTRONICS a m COOLING E FAN gt G BLK 5 saa START CAPAC s CAPAC 1 ege COMPRESSOR LEFT Qo 1 1 1 I KLAUBER 1 2 1 520 BEATER BEATER RELA MOTOR 10 a o D I D z z 5 J 5 J BRN 9 BRN m L 2 nm HrPREssuRE i US RELAY l RELAY l I RED WHT ID 2 3 2 5 1 g1 01 m 1 WIRING FOR WATER COOLED UNIT ONLY 2 FLAVOR SHOWN CONDENSER FAN WIRES REMOVED BRN RED BLU FIGURE 16 WIRING DIAGRAM z 5 3 a 55 88 z g 5 22552 888 444381 45 88585885 EEEEEEEE gazaz EEEEE BLU eriLte eT2L2e 51 gt NOTE WILD LEG NOT TO BE ON SI
69. Secondary Regulator Ass y 1 183287000 Gage 60 PSI 2 183449000 Regulator Ass y 30 PSI See Figure 23 183412000 Regulator Ass y 100 PSI See Figure 23 s emo mesveer Fitting Plug 1 4 2 174061196 Tube Ass y Secondary Regulator Tube Ass y Secondary Regulator 309379000 Tube Ass y Pump to Carb 174103001 Tube 250 1 0 By 60 In Long 174103001 Tube 250 1 0 By 22 In Long 2 176001000 Ferrule For 425 O D Tube 770104000 Nipple For 250 1 0 Tube 4 176017000 Swivel Nut 7 16 20 FIGURE 22 TUBE ASSEMBLY 312028000 74 183449000 CO Regulator Ass y 60 PSI 130167000 Orange Includes 1 16 183412000 CO Regulator Ass y 100 PSI Gold EN Machine Screw Phil Fill Hd No 10 183008000 O Ring 489 I D By 070 C S 2 183233059 Cover Kit Includes Nonremovable 12 183006000 Spring Poppet ________ Adjusting Screw 12 183006000 Spring Poppet Tp 183021000 Retainer Spring 3017 0900 valve Poppet 315424000 _ Adjusting Spring 60 PSI 4 183020000 Adjusting Spring 100 PSI 93003000 130174000 Diaphram Ass y 83001015 ody 324211000 Fitting 1 16 NPT By 5 32 Barb FIGURE 23 CO REGULATOR ASSEMBLY s 3 _ 5 1223 s smo mmm 2000 FIGURE 24 CHECK VALVE ASSEMBLY 75 312028000
70. 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 22 2 an approved vacuum breaker 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 cs Eun res eum Om ey pese eese ose 1 THEORY OF OPERATION 2 DEFROST SYSTEMS a in q amuki q ERROR 3 MANUAL DEFROST SYSTEM 3 AUTOMATIC DEFROST SYSTEM 3 SLEEP SLEEP TIME ca ert eei
71. TTING 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 312028000 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 duri
72. TWEEN 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 DIAG NOSE DIAGNOSTIC MODE and TOTALS DISPLAYED CYCLES AND HOURS TOTALS into the Unit NOTE Plain water CO and syrup supplies to Unit must be satisfied to turn off OUT CO 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 ad vance 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 RE SET switch Pr
73. UTO 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 Repeat steps C and D preceding to check product sample for BRIX Repeat steps F through H preceding until proper BRIX adjustment is achieved Repeat steps A through l preceding to adjust BRIX of dispensed product on No 2 system After com pleting BRIX adjustment on No 2 system only the OFF 1 and OFF 2 fault messages should contin ue to be displayed NOTE Syrup systems may be sanitized at this time as instructed FILLING FREEZE CYLINDERS WITH PRODUCT 1 Open product shutoff valves located in lines leading from product blender tanks to freeze cylinders 2 Press AUTO BLEND 1 and AUTO BLEND 2 switches to begin filling freeze cylinders Open freeze cylin ders 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 CO OR PLAIN WATER LEAKS 1 Inspect the entire Unit and the entire system for syrup 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 CU
74. al 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 approxi mately 7 minutes and then will return to normal operation This ends automatic defrost cycle of No 1 freeze cyl inder 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 29 312028000 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
75. all 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 condens er coil is drawn in through grilled panel on the right hand side and is exhausted out through the oppo site 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 mo tors 2 Remove Unit right side panel a
76. ckwise to lock the door Install back panel by reversing the removal procedure Connect electrical power to Unit Press both AUTO BLEND 1 and AUTO BLEND 2 switches 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 Press applicable OFF 1 or OFF 2 switch to stop applicable freeze cylinder beater and refrigeration sys tem IMPORTANT The following 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 10 11 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
77. djusted 25 psi higher or more above product blender tanks secondary CO 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 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 CO regulator with 100 psi gauge 2 Observe pressure setting on carbonator secondary CO regulator gauge 3 To lower CO pressure loosen regulator adjusting screw lock nut Turn adjusting screw to the left counter clockwise until pressure gauge reads 15 psi below desired reading then turn screw to the right clockwise until gauge reads desired pressure DO NOT SET REGULATOR PRESSURE BELOW 25 PSI HIGH ER THAN PRODUCT BLENDER TANKS REGULATORS ARE ADJUSTED TO SEE PRECEDING IMPORTANT NOTE Tighten adjusting screw lock nut after each adjustment 4 Observe pressure setting on carbonator secondary CO regulator gauge 5 To raise CO 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 CO regulator on cylinder is set at 80 to 100 psi Tighten adjusting screw lock nut after each adjustm
78. 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 cou pling 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 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 HOUS ING 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 TO
79. e 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 33 312028000 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 REGULATORS Primary CO Regulator The primary CO regulator see Figure 2 and 6 regulates CO pressure to the soft drink tanks also to the bag in box syrup system if used and also to the secondary CO regulators located inside the Unit If necessary to adjust the primary CO regulator adjust as instructed in the SERVICE AND MAINTENANCE section Secondary
80. e 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 solu tion 312028000 50 20 21 22 23 24 25 26 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 After carbonator water pump cycles off completely fill No 1 freeze cylinder with sanitizing solution by re peatedly 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 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 When sanitizing solution contact time has elapsed press OFF 1 switch to stop No 1 freeze cylinder beater Hold
81. ecuring motor to Unit frame Very carefully pull motor back off two mounting studs and disengauge motor shaft and plastic coupler from freeze cylinder drive shaft Lower motor down to Unit bottom platform then turn motor for access to it s electrical wiring cover plate Remove two screws securing the electrical wiring cover plate then remove plate for access to electrical terminals Tag beater drive motor electrical wiring for identification then disconnect wiring from terminals Remove old beater drive motor from inside Unit 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 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 Remove screw from the vent hole on top of the beater drive motor gear box Install Unit back and both side panels by reversing removal procedures Restore the Unit to operation 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 elec tronics ADJUSTING CARBONATOR TANK LIQUID LEVEL The carbonator tank liquid level pump cut in and cut out was adjusted at
82. ent 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 recommenda tion 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 sys tem as an example No 2 syrup system sanitizing instructions are identical to No 1 syrup system with the ex ception 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 de frosted 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 ap pear on message display as long as defrost cycle is in progress 3 Immediately press AUT
83. ess 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 312028000 16 Fr DISPLAY v R Io N Im iO fim fie Jit o I 1 Too fue 15 Io gt jio gt gt IN N ln TIN IO 0 N DIAGNOSE DIAGNOSTIC e Programming Components Diagnose into See Table 7 and programming TOTALS TOTALS DISPLAYED CYCLES AND HOURS TOTALS into unit MOTORS BEATER MOTOR MANUFACTURER See Table 6 See PROGRAMMING PROPER REF TYPE REFRIGERANT TYPE REFRIGERANT TYPE INTO UNIT ELECTRONICS NOTE The CLOCK TIME OF DAY must be programmed into the Unit before DEFROST AUTO MATIC SLEEP SLEEP TIME and WAKE U
84. ess CANCEL DEFROST ADVANCE switch to advance and bring up SYRUP 1 on message display Press DEFROST SELECT switch No 1 syrup solenoid relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up SYRUP 2 on message display Press DEFROST SELECT switch No 2 syrup solenoid relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up WATER 1 message display Press DEFROST SELECT switch No 1 carbonated water solenoid relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up WATER 2 on message display Press DEFROST SELECT switch No 2 carbonated water solenoid relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up RF SOL 1 on message display Press DEFROST SELECT switch Refrigeration relay clicks when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up RF SOL 2 on message display Press DEFROST SELECT switch No 2 refrigeration solenoid clicks when switch is pressed 22 22 Press CANCEL DEFROST ADVANCE switch to advance and bring up COMPRESS on message dis play 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
85. f 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 L4 and 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 minimum rated disconnect switch not provided fused at 30 amps slow blow or circuit connected through an equivalent HACR circuit breaker must be available to 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 L4 and L 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
86. 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 de sired time When programmed wake up time is reached an alarm will sound for a short duration then Unit will re sume normal operation NOTE Automatic defrost sleep time and wake up time may be used in any combination together or sepa rately 312028000 4 WATER PRESSURE REGULATOR IS m w FACTORY ADJUSTED TO 45 PSI AND SHOULD NOT BE READJUSTED ud VALVE 2 SYRUP SOLD OUT SWITCHES ARE FACTORY ADJUSTED AND SHOULD NOT BE READJUSTED CARB WATER END SL PRODUCT T CARBONATOR TANK PLAIN WATER PRODUCT BLENDER TANK 2 PRODUCT SHUTOFF VALVE 2 FREEZE CYLINDER 2 CARBONATED WATER VOLUME SAMPLE VALVE a CARBONATED WATER SOLENOID VALVE 2 CARBONATED WATER FLOW REGULATOR 2 SYRUP SOLENOID 2 PRIMARY CO REGULATOR ASS Y SYRUP SOLD OUT FLOAT SWITCH 2 SYRUP SOLD OUT SWITCH eX oF g meg m INS PRESS RE ru TANKS 60 PSI GAGE 2 CO CHECK SECONDARY CO2 REGULATOR VALVE 3 TO CARB
87. hut off product to individual freeze cylinder for service and maintenance without disrupting operation of other freeze cylinders PRIMARY REGULATOR The primary regulator see Figure 2 controls pressure to the soft drink tanks and the Unit secondary regulators located behind the lower front access panel If necessary to adjust the primary CO regulator adjust as instructed in the SERVICE AND MAINTENANCE section SECONDARY REGULATORS The secondary CO regulators located behind the lower front access panel see Figure 2 and 6 control pressure to the carbonator and the product blender tanks If necessary to adjust the secondary CO regulators adjust as instructed in the SERVICE AND MAINTENANCE section CARBONATED WATER FLOW REGULATORS The adjustable carbonated water flow regulators see 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 9 0 05 oz sec and should not normally require adjustment If adjustment is necessary adjust as instructed in the SERVICE AND MAINTENANCE section 312028000 30 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
88. ink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment B Second disconnect CO quick disconnect from soft drink tank To connect soft drink tank into Unit syrup system A First connect 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 be tween 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
89. it or 30 amps 50 Hz Unit minimum rated discon nect 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 inter vals 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 CO OUT No CO 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 SUPPLY TO the UNIT 1 Open CO 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 CO REGULATOR IMPORTANT If bag in box syrup supply system will be connected to the Unit instead of soft drink tanks primary regulator see
90. justment of the syrup flow regulators From product blender tanks product is pushed by the CO 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 CO gas pressure from the freeze cylinder to atmosphere when filling the cylinder with product Electronic sens ing 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 approxi
91. n 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 H P Copeland Compressor and R 404A refrigerant C R502 and V3 Dispensers using Bristol or Tecumseh Compressor R502 refrigerant D R402B5OH V3 and V3 Dispensers using a Bristol Compressor and R 402B refrigerant 2 Referto 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 refriger ant 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 312028000 26 OPERATOR S INSTRUCTIONS This section describes operating controls and indicators dispensed product conditions operating characteris tics Unit operation replenishing syrup supply product flavor change checking supply opera
92. n 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 H20 OUT fault message to appear on message display Unit will continue to operate for 1 1 2 minutes after 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 312028000 28 OUT Fault Message COs OUT fault message will appear on message display when CO supply to Unit has been turned off or if CO pressure drops below 50 psi A minimum CO pressure of 75 psi must be available to Unit to extinguish CO OUT fault message SYRUP 1 or SYRUP 2 Fault Messages SYRUP 1 or SYRUP 2 fault messages will appear on message display if
93. ng 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 lo cated on No
94. nnects on ends of soft drink tanks lines DO NOT CONNECT CO 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 CO SOURCE LINE TO UNIT INLET LINE see Figure 2 1 Connect and route a CO source line from the primary CO regulator up to the Unit 312028000 10 2 Connect the CO source line to the Unit inlet DO NOT TURN ON THE 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 gas ket black i
95. oduct 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 lt 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 CO gas in the system takes a set When first few drinks are drawn off after an idle period CO gas has less tendency to break out as drink is dispensed The result is these casual drinks have less overrun than drinks dispensed during peak use periods 31 312028000 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 CO 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
96. oduct 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 Cor nelius Company 7 Observe pressure setting on carbonator secondary CO 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 regulator as follows IMPORTANT Carbonator tank secondary CO regulator must be a
97. oduct 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 CO REGULATORS NOTE To readjust 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 tight en the lock nut Primary CO Regulator see Figure 2 Adjust the primary CO regulator by turning the regulator adjusting screw to the right clockwise until the regu lator pressure reads 80 to 100 psig Product Blender Tanks Secondary Regulators see Figures 2 and 6 1 Remove the Unit lower front access panel as instructed for access to the product blender tanks secondary CO regulators 2 Adjust the product blender tanks secondary CO 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 CO Regulator see Figure 2 and 6 1 Remove the Unit lower front access panel as instructed for access to the carbonator s
98. odule not operating properly supply turned off or exhausted Primary regulator set too low Inoperable CO pressure switch Water supply turned off or water pressure inadequate Plugged water filter or water pump strainer screen Inoperative water pressure switch Soft drink tank empty Error within Unit has developed interrupting normal operation Loose or broken electrical wires Inoperable automatic defrost timer Automatic defrost timer stuck in automatic defrost cycle Flat cable not properly connected to control switch module or master circuit board Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Inoperable DEFROST switch on control panel switch module Loose or broken wire 65 Remedy Replace master circuit board Replace fault message display module Open CO cylinder shutoff valve or replenish supply as instructed Adjust primary CO regulator as instructed Replace CO pressure switch Turn on water supply or check water supply line pressure Change water filter or clean water pump strainer screen as instructed Replace water pressure switch Replenish syrup supply as instructed Locate and correct error then press ERROR RESET switch to restore normal operation Repair electrical wires Replace master circuit board Replace master circ
99. 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 POINT OF SALE MESSAGE SELECT See Table 7 POINT OF SALE MESSAGE SELECT See Table 7 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 NOTUSED NOT USED 8 NOTUSED DEFROST ON Hot gas OFF Electric SERVICE USE NOTE Switch No 3 must be in OFF position for standard Units with pulse expansion valves Switch No 3 must be in ON position for older Units with mechanical expansion valves TABLE 5 DIP SWITCH FUNCTIONS 312028000 18 Ksa aaa Fasc oo gear boc wtr a Fasea waerenga agendi 1 FASGWR o cw 60 Sandal gear boc vag alge oe wks few 60 Sandan deme soon 60 mre 60 000 TABLE 6 MOTOR SELECT DIP SWITCH DIP SWITCH NO 1 NO 2 MESSAGE OFF OFF ENJOY A FR
100. on message display This indicates no water supply to Unit 2 Make sure COs OUT fault message is not displayed on message display This indicates CO 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 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 312028000 32 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 CO quick disconnect from soft drink tank 2 To connect soft drink tank into Unit syrup system A First connect CO 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 necessa
101. oz sec Clean regulator Change syrup supply as instructed Replace water filter Adjust secondary CO regulators as instructed Replace CO supply as instructed 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 Refer to CYLINDER FREEZE UP Press AUTO BLEND 1 or AUTO BLEND 2 switch Check carbonator and restore to operation 312028000 Trouble FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING cont d FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY CYLINDER FREEZE UP 312028000 Probable Cause Remedy Lines restricted C Sanitize Unit as instructed Dispensed product BRIX varying because Syrup and or water flow a Clean regulator s regulator sticking Primary regulator b Primary regulator must be pressure insufficient adjusted from 80 to 100 psi Cylinder freeze up causing B Refer to CYLINDER ice formation in center of FREEZE UP cylinder and liquid product channels around ice formation 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 Adjust dispensed product not properly adjusted viscosity as instructed 68 FCB OVERCOUNTER POST MIX DISPENSER WITH V3 FEATURES R 404A REFRIGERANT
102. perating Current See Unit __ ____ _______ __ U 3 p C E nstallation kits 115 51100500 51100600 51103500 ee 22 108 108 108 108 108 109 anana 109 _ O 28188400 32285900 51100400 289 381 THEORY OF OPERATION see Figure 2 A CO cylinder delivers carbon dioxide gas to an adjustable primary CO regulator assembly which is attached to the cylinder The primary CO regulator assembly in turn delivers gas to adjustable secondary CO regulators inside the Unit and also to two soft drink tanks CO is delivered from the adjustable secondary CO regulators to the carbonator tank and also to product blender tanks inside the Unit gas pressure pushes syrup out of the soft drink tanks through the syrup sold out switches through adjustable syrup flow regulators through electrically oper ated 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 gas pressure also entering the tank Carbonated water is pushed by 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 ad
103. 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 27 312028000 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
104. rative water pump and or motor 66 D B Remedy Replace master circuit board Properly connect flat cable to control switch module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace control panel switch module Replace master circuit board Connect electrical power to Unit Check power source Press AUTO BLEND 1 or AUTO BLEND 2 switch Restore water supply to Unit Replenish supply as instructed Tighten connections or replace wires Check for proper line voltage Check restricted pump discharge Remove water pump from motor Rotate pump coupling shaft 180 degrees then reinstall pump Replace pump and or motor Replace level control switches Clean repair or replace balance mechanism Replace water pump and or motor Trouble CARBONATOR WATER PUMP A WILL NOT SHUT OFF ERRATIC CARBONATOR A WATER PUMP CYCLING B Probable Cause Binding damaged or dirty carbonated water tank balance mechanism Insufficient water supply pressure OUT fault message goes on and off intermittently and water pump cycles on and off during carbonator tank fill cycle Water filter restricted TROUBLESHOOTING DISPENSED PRODUCT BRIX WATER TO SYRUP A RATIO TOO LOW BRIX WATER TO SYRUP A RATIO TOO HIGH B C D E IMPROPER PRODUCT DISPENSED B PRODUCT WILL NOT A
105. re servicing the water pump double liquid check valve Disconnet carbonator water line from double liquid check valve assembly outlet 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 Disassemble each check valve as shown in Figure 11 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 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 T 8 Assemble check valves together DO NOT OVERTIGHTEN 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 Connect carbonator tank water line to double liquid check valve assembly outlet DO NOT OVERTIGH TEN 53 312028000 10 11 12 13 14 15 Open CO cylinder and water inlet supply lines shutoff valves Check for water leaks and tighten any loose connections Close front access door then use a flat blade screwdriver to turn lock clo
106. rmittently pull and release No 1 freeze cylinder faceplate relief valve This bleeds 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 sys tem 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 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 gas could then back flow into the water system and create a health hazard in the water system WARNING The carbonator water pump water strainer screen and the double liquid check 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 CO cylinder and wa
107. rost 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 pan els are easily removed and the front access door may be opened to facilitate installation and service and mainte nance 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 nit Part Numbers 60 HZ Unit 50 HZ Unit verall Dimensions Height Width Depth W O Drip Tray Depth W Drip Tray Shipping Weight approx 420 pounds 1 312028000 Table 1 Design Data cont d Refrigeration System Compressor Horsepower 2 H P Refrigerant Type And Charge See Unit Nameplate Ambient Operating Temperature 40 F to 100 F s uuu Eee Operating Voltage See Unit O
108. ry replenished as instructed PRODUCT FLAVOR CHANGE Perform syrup flavor change as instructed CHECKING CO SUPPLY CO carbon dioxide gas leaks in the entire CO and soft drink system If 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 CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation WARNING CO displaces oxygen Strict attention must be observed in the prevention of Make sure CO cylinder shutoff valve is fully opened and regulator assembly 1800 psi gage indicator is not in shaded change CO cylinder portion of dial If so CO 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 Figur
109. s Restricting air circulation through the Unit will decrease its cooling efficiency THE CON DENSER COIL MUST BE CLEANED PERIODICALLY AS INSTRUCTED IN THE SERVICE AND MAIN TENANCE 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 37 312028000 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
110. s 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 43 312028000 000820216 22 23 5 6 7 2 5 9 Ss q ag 25 20222207 Product Inlet Fitting Scraper Blade 2 Evaporator Coil Relief Valve Port O Ring Flatwasher 4 Hex Nut 4 Faceplate Relief Valve i 10 11 E 24 2 13
111. secondary regulator s IMPORTANT The carbonator tank secondary CO regulator must be adjusted 25 psi higher or more above the product blender tanks secondary 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 CO 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 CO 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 regulators and product sample valves 2 Check product blender tanks secondary 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 pr
112. sent 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 Open 24 inches min Back side 0 inches Sides 6 inches min Front 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 AND CITY PLAIN WATER SOURCES Route coiled up syrup and plain water lines out through the hole provided in the Unit base 312028000 9 INSTALLING PRIMARY CO REGULATOR ASSEMBLY ON CO CYLINDER see
113. spensing valve until product flows from valve then close valve Open No 1 system product sample valve until prod uct flows from valve then close valve 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 Disconnect soft drink tank containing syrup from No 1 syrup system Connect clean empty soft drink tank into No 1 syrup system 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 Place waste container under No 1 system product sample valve Slowly open valve and purge remaining product out of product blender tank Disconnect empty soft drink tank from No 1 syrup system and install tank containing syrup 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 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 51 312028000 38 After carbonator water pump cycles off inte
114. t 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 41 312028000 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
115. tank TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES Trouble ONE OR MORE CONTROL A PANEL SWITCHES NOT OPERATING ALL CONTROL PANEL A SWITCHES NOT OPERATING Probable Cause Flat cable not properly connected to control switch module or master circuit board Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Inoperable switch s on control panel switch module Master circuit board not operating properly Electric power disconnected from Unit SECURITY SWITCH has not been pressed to activate control panel switches SECURITY SWITCH inoperable control switches deactivated Flat cable not properly connected to control switch module or master circuit board 63 A Remedy Properly connect flat cable to control switch module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace control panel switch module Replace master circuit board Restore electric power to Unit Press and hold SECURITY SWITCH for 3 seconds to restore control panel switches to operation Replace control panel switch module Properly connect flat cable to control switch module or master circuit board 312028000 Trouble ALL CONTROL PANEL SWITCHES NOT OPERATING cont d CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED PARTIAL MESSAGE OR DULL
116. tch 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 COR RECTED DEFROST TIME INTO UNIT 17 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
117. tem 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 L4 and L 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 L and L 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 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 WARNING The Unit must be electrically grounded to avoid possible fatal electrical shock 2 Connect electrical power circuit from a 30 amp 60 Hz Un
118. ter 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 CO 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 317965000 Retainer 312196000 Spring 312419000 Ball 312415000 Washer 300 1 0 312418000 Quad Ring 317963000 Body 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 2 3 Service water pump water strainer screen befo
119. tors 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 be tween 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
120. uit board Properly connect flat cable to control switch module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace control panel switch module Repair wire 312028000 Trouble MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN DEFROST SWITCH IS PRESSED cont d DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING CANCEL DEFROST SWITCH TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR A D Probable Cause Master circuit board not operating properly Flat cable not properly connected to control switch module or master circuit board Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Inoperable CANCEL DEFROST switch on control panel switch module Master circuit board not operating properly CARBONATOR WATER PUMP No electrical power to Unit MOTOR WILL NOT OPERATE 312028000 B AUTO BLEND 1 or AUTO BLEND 2 switches have not been pressed H2O OUT fault message is on CO OUT fault message is on Loose or broken electrical wires Overheated water pump motor cut off by overload protector Binding water pump new or replacement pump only Inoperative water pump and or motor Inoperative carbonated water tank level control switches Binding damaged or dirty carbonated water tank balance mechanism Inope
121. 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 gas from freeze cylinder to atmosphere during filling with product and if gas pockets form in cylinder during op eration 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 s
122. xide gas leaks in the entire CO and soft drink system If a 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 CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation NOTE When indicator on primary cylinder regulator assembly 1800 psi gauge is in shaded change CO cylinder portion of the dial cylinder is almost empty and should be changed 1 Fully close clockwise CO cylinder valve 2 Slowly loosen CO regulator assembly coupling nut allowing CO pressure to escape then remove regula tor assembly from empty CO cylinder 3 Unfasten safety chain and remove empty CO cylinder 4 Position full CO cylinder and secure with safety chain WARNING To avoid personal injury and or property damage always secure CO cylinder in upright position with safety chain to prevent it from falling over Should valve become accidentally damaged or broken off CO cylinder can cause serious personal injury 5 Make sure gasket is in place inside CO regulator coupling nut then install regulator on CO cylinder 6 Open counterclockwise CO 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 CO connections for

Service Manual FCB Overcounter V3Plus with R404A

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