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Installation/Service Manual

1. YEL BLU 2 FLAVOR RIGHT 11 RIGHT 22 Bi Gut RIGHT me RIGHT 11 RIGHT 22 FT FT KLAUBER SCR LEFT 1 LEFT 42 kLAUBER UNITS E
2. Oo 01 22 23 5 6 7 d 25 3 SERA N P lt lt E NY 10 11 24 14 27 2 13 3 4 12 Product Inlet Fitting 10 Valve Lever 20 Beater Drive Motor Scraper Blade 2 11 Knob 21 Drive Shaft Assembly 12 Dispensing Valve 8 Evaporator Coi l 13 Beater 22 Sensor For 14 Allen Head Setscrew 2 15 Beater Shaft Coupling 177 4 16 Drive Pin 25 Shaft Release 4 17 Bearing Housing Locking Tab 4 26 Bearing acep ate 18 Bearing Retainer 27 Bearing Housing Relief Valve 19 Beater Motor Drive Shaft FIGURE 6 FREEZE CYLINDER CUTAWAY VIEW 1995 2014 Cornelius Inc 32 Publication Number 312026000 LOCK RING BEATER DRIVE MOTOR DRIVE SHAFT SEAL ASS Y BEATER DRIVE BEATER MOTOR SHAFT ALLEN HEAD H SET SCREW ALLEN HEAD IT FIN SET SCREW g f 2 1 FA D N EMI e Hie i COUPLING PLASTIC COUPLER O RING BEARING ALLEN HEAD SET SCREW 2 COUPLING DRIVE SHAFT DRIVE COUPLER COUPLER
3. TABLE 4 DIP SWITCH SETTINGS TABLE 5 MOTOR SELECT deren need P uerus TABLE 6 POINT OF SALE DISPLAY MESSAGES TABLE 7 TOTALS DISPLAYED CYCLES AND HOURS TOTALS MENU TABLE 8 DISPLAYED ERROR CONDITIONS Page 28 29 30 32 33 34 39 45 54 56 57 59 60 61 62 40 42 42 42 47 GENERAL INFORMATION 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 troubleshooting this equipment Warranty Registration Date to be filled out by customer Model Number Serial Number Install Date Local Authorized Service Center GENERAL DESCRIPTION This section gives the description theory of operation and design data for the FCB 3 H P Two Flavor Post Mix Dispenser with Hot Gas Defrost and V3 Features hereafter referred to as a Unit FIGURE 1 FCB DISPENSER UNIT DESCRIPTION The Two Flavor FCB Dispenser see Figure 1 consists basically of two freeze cylinders each containing an internal beater driven by an electric motor one refrigeration system with a 3 horsepower compressor two carbonated water tanks which feed both carbonator bl
4. mre oo d TABLE 5 MOTOR SELECT DIP SWITCH DIP SWITCH NO 1 NO 2 MESSAGE OFF OFF ENJOY A FROZEN BEVERAGE OFF NOT USED BLANK OFF HAVE DAY DISFRUTE UNA BEBIDA CONGELADA CARBONATADA For special messages contact you local sales representative TABLE 6 POINT OF SALE DISPLAY MESSAGES 1995 2014 Cornelius Inc 42 Publication Number 312026000 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 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 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 advance hours on display to desired hour Press DEFROST SELECT switch to lock in hour on display 3 After hour time of day has been locked in on m
5. 2 LIQUID CHECK DOUBLE PRIMARY REGULATOR ASS Y A VALVE 2 LIQUID SYRUP SOLD OUT VALVE FLOAT SWITCH 2 SYRUP SOLD OUT A gt SWITCH CO 5 PRESSURE 4727 SWITCH Y gue S 7 gt 29 9 2 Den pus AT ui CHECK A VALVE E CYLINDER E WATER PRESSURE CARBONATOR L SOFT DRINK WATER PUMP REGULATOR TANK 2 WATER ONEEK ALEA SECONDARY CO REGULATORS PRESSURE TO PRODUCT BLENDER SWITCH TANKS 60 PSI 2 PLAIN WATER SECONDARY REGULATOR SOURCE TO CARBONATOR TANK 100 PSI GAGE FIGURE 2 FLOW DIAGRAM Publication Number 312026000 5 1995 2014 Cornelius Inc 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 4 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
6. N 2 CAPILLARY lt ee IT LS ACCUMULATOR COMPRESSOR RECEIVER TANK REFRIGERATION COOLING COIL ASS Y HIGH PRESSURE CUTOUT SWITCH LOWER ELECTRICAL NOTE One refrigeration system is shown in this illustration A two flavor Unit has one refrigeration system CONTROL BOX FIGURE 16 REFRIGERATION FLOW DIAGRAM WATER COOLED REFRIGERATION SYSTEM Publication Number 312026000 61 1995 2014 Cornelius Inc 000920216 9
7. TS wo em 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 8 DISPLAYED ERROR CONDITIONS 6 Press and hold DEFROST SELECT switch Compressor cycles x 100 will appear on message display 7 Use CANCEL DEFROST ADVANCE switch to advance through remaining TOTALS DISPLAYED CYCLES AND HOURS TOTAL MENU see TABLE 7 Press DEFROST SELECT switch to obtain message display readings of the individual menu selections 8 Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS IMPORTANT Note 5 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 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 in
8. Mad ais abu 65 DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING CANCEL DEFROST SWITCH dns alkas dns de 66 TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATORS 66 CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE 66 CARBONATOR WATER PUMP WILL NOT SHUT OFF 66 ERRATIC CARBONATOR WATER PUMP CYCLING 66 TROUBLESHOOTING DISPENSED PRODUCT 67 BRIX WATER TO SYRUP RATIO TOO LOW 67 BRIX WATER TO SYRUP RATIO TOO HIGH 67 IMPROPER PRODUCT DISPENSED 67 PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE IN ONLY SMALL AMOUNTS OR ONLY LIQUID 67 FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING Ss died an a Padi A S Aa 67 FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY 67 CYLINDER 2 68 TROUBLESHOOTING REFRIGERATION SYSTEM 68 UNIT EQUIPPED WITH AIR COOLED REFRIGERATION SYSTEM ti 68 UNIT EQUIPPED WITH WATER COOLED REFRIGERATION SYSTEM 68 ACCESSORIES AND TOOLS shennan iens i dde 68 ACCESSORIES Tenue 68 GENERIC FLAVOR TABS 314v teh idet i end 68 SERVICE TOOLS 2 esrb Rb Rx Y manu an 68 TABLE CONTENTS cont d LIST OF FIGURES FIGURE 1 FCB
9. OFF 2 and SYRUP 2 fault messages will continue to be displayed 2 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 3 Open No 1 product blender tank product sample valve see Figure 2 and take sample approximately 6 ounces of product in a cup or glass NOTE Temperature compensated hand type refractometers P N 511004000 are available from The Cornelius Company 4 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 5 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 6 Press AUTO BLEND 1 switch to run new batch of product into product blender tank When product blender tank is full press FILL 1 switch to prevent more pr
10. 5 2 FLAVOR UNITS Fi a s 2 E 5 g 8 8 ELECTRONICS 5 5 START 2 amp 2 5 B 6 5 S i COOL ING 1 575771 aun A E RED 1 FAN RED ue Lo COMPRESSOR R 1 1 5 1 YEL BLK RIGHT 1 0520 OR ORN B BLK R 1 T 1 COMPRESSOR LEFT 1 1 BLK TI L1 M 1 PRESSURE 2 CUTOUT 2 2 L RED WH i 3564 RUN CAPAC Rev CONDENSER FAM WIRES REMOVED ONLY 2 FLAVOR SHOWN FIGURE 17 WIRING DIAGRAM 1995 2014 Cornelius Inc 62 Publication Number 312026000 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 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 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
11. 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 Press CANCEL DEFROST ADVANCE switch to advance and bring up COMPRESS on Message display Press DEFROST SELECT switch Compressor and condenser fan motor will start and operate while Switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up PUMP on message display Press DEFROST SELECT switch Carbonator water pump relay on master circuit board clicks when Switch is pressed ERROR RESET switch two times to exit from MENU SELECTIONS DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY see TABLE 3 and TABLE 7 1 TOTALS DISPLAYED CYCLES AND HOURS TOTALS may be displayed on message display as follows Refer to PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY and bring up the word CLOCK on message display Repeatedly press and release CANCEL DEFROST ADVANCE switch to advance through main menu until TOTALS menu appears on message display Press DEFROST
12. ais ko ias Saias ia ten 27 LOWER FRONT ACCESS PANEL 28 CONDENSER COIL ACCESS PANEL 28 EJB RICATION Gerson a r 28 CARBONATOR WATER PUMP MOTOR 28 SERVICING DISPENSING VALVES CAGED O RINGS AND FREEZE CYLINDERS DRIVE SHAFT SEAL ASSEMBLIES 28 CLEANING CONDENSER COIL 564325915 Mt 85 UNIT WITH AIR COOLED REFRIGERATION SYSTEM 35 TABLE CONTENTS cont d Page UNIT WITH WATER COOLED REFRIGERATION SYSTEM 36 ADJUSTMENTS EUR Late t 36 ADJUSTING PLAIN WATER PRESSURE REGULATOR 36 ADJUSTING CARBONATED WATER FLOW RATE 36 ADJUSTING CO2 REGULATORS 37 ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT nn nn nan cepe MP 38 PRODUCT CARBONATION ADJUSTMENT 38 ADJUSTING BEATER MOTOR CURRENT EITHER SIDE 39 ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS INTO UNIT 40 PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY 40 SETTING CLOCK TIME OF 40 PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT 41 PROGRAMMING SLEEP SLEEP TIME INTO UNIT 41 PROGRAMMING WAKE UP WAKE UP
13. DEFROST 1 or DEFROST 2 display messages will appear on message display if either freeze cylinder is in defrost mode DEFROST 1 or DEFROST 2 messages will remain on during defrost cycle and will disappear when cycle has ended POINT OF SALE Display Message Three POINT OF SALE display messages are available to choose from and may be programmed into Unit as instructed to appear on message display Common Outlet Temperatures Evaporator refrigeration coils inlet 1 and inlet 2 and common outlet temperatures may be displayed on control panel message display as instructed FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS The Unit is equipped with both manual and automatic hot gas defrost systems The automatic defrost system may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours between defrost time settings or the system may be completely turned off MANUAL DEFROST SYSTEM The Manual hot gas defrost system may be activated at any time by pressing DEFROST switch on front of the Unit Refrigeration compressor will operate for a short time then both freeze cylinders will go into defrost and defrost for approximately 60 seconds At end of manual defrost cycle Unit will return to normal operation Manual defrost may be cancelled at any time by pressing CANCEL DEFROST switch AUTOMATIC DEFROST SYSTEM The automatic hot gas defrost system may be programmed into the Un
14. 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 see Figure 4 are touch type switches and require only pressing to activate These switches are used to operate freeze cylinders beaters with no refrigeration during sanitizing AUTO 1 and AUTO 2 Control Switches AUTO 1 and AUTO 2 control switches located on control panel see Figure 4 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 see Figure 4 are touch type switches and require only pressing to activate These switches are used to stop freeze cylinders beaters and refrigeration system Publication Number 312026000 17 1995 2014 Cornelius Inc ERROR RESET Control Switch ERROR RESET control switch located on control panel see Figure 4 is a touch type switch and reguires only pressing to activate ERROR RESET switch is used to restore normal ope
15. see Figure 2 and 13 1 Press OFF 1 and OFF 2 switches to stop freeze cylinders beaters and refrigeration systems 1995 2014 Cornelius Inc 52 Publication Number 312026000 2 Disconnect electrical power from Unit 3 Close CO cylinder and water inlet supply line shutoff valve 4 Remove lower front access panel and left side panel as instructed for access to the water pump double liquid check valve assembly 5 Pull up on carbonator tank relief valve plastic cover to release pressure from tank 6 Disconnect carbonator tank water line from double liquid check valve assembly outlet 7 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 8 Disassemble each check valve as shown in Figure 11 9 Wipe each part with 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 10 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 valve female end with white tapered gasket inside is on inlet side of double liquid check valve assembly 11 Assemble check valves together DO NO OVERTIGHTEN 12 Make sure white tapered gasket is in place
16. 1 To disconnect soft drink tank from Unit syrup system 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 guick disconnect from soft drink tank 2 To connect soft drink tank into Unit syrup system A First connect guick disconnect to soft drink tank to pressurize tank B Second connect liguid guick disconnect to soft drink tank TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES Trouble ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING ALL CONTROL PANEL SWITCHES NOT OPERATING Publication Number 312026000 A 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
17. 10 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 REPLENISHING SUPPLY 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 1995 2014 Cornelius Inc 54 Publication Number 312026000 NOTE When indicator primary CO cylinder regulator assembly 1800 psi gage is shaded change cylinder portion of the dial cylinder is almost empty and should be changed 1 Fully close clockwise cylinder valve 2 Slowly loosen CO regulator assembly coupling nut allowing pressure to escape then remove regulator 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 posit
18. Pull up on the applicable product blender tank relief valve to release CO pressure from the tank 8 Disconnect carbonated water line from the outlet side of the applicable carbonated water flow regulator 9 Connect line long enough to reach to the outside of the Unit to the water flow regulator outlet then route the line to the outside of the Unit 10 Place end of the carbonated water line routed to the outside of the Unit in the container 11 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to activate the electrically operated carbonated water solenoid 12 When steady stream of water is flowing from the added length of line catch carbonated water in a container graduated in ounces for exactly 10 seconds Press applicable FILL 1 or FILL 2 switch to deactivate the carbonated water solenoid In 10 seconds 12 to 14 ounces of water should have been dispensed 13 If adjustment is necessary turn the carbonated water flow regulator adjusting screw to the left counterclockwise to reduce carbonated water flow rate or turn the screw to the right clockwise to increase the flow rate 1995 2014 Cornelius Inc 36 Publication Number 312026000 14 Repeat steps 11 through 13 until the desired carbonated water flow rate is achieved 15 Remove added length of line from the outlet side of the carbonated water flow regulator Connect the carbonated water line disconnected from the carbonated water flow regulator in ste
19. Tighten connections or replace wires Check for proper line voltage Check for restricted pump discharge Replace pump and or motor Replace level control switches Clean repair or replace balance mechanism Replace water pump and or motor 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 Publication Number 312026000 Trouble Probable Cause TROUBLESHOOTING DISPENSED PRODUCT WATER TO SYRUP RATIO TOO LOW WATER TO SYRUP RATIO TOO HIGH IMPROPER PRODUCT DISPENSED PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE IN ONLY SMALL AMOUNTS OR ONLY LIQUID FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY Publication Number 312026000 A Quick disconnect not secure on so t 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
20. a CD c C NS CONDENSER COIL ASS Y ACCUMULATOR COMPRESSOR FIGURE 15 REFRIGERATION FLOW DIAGRAM AIR COOLED REFRIGERATION SYSTEM 1995 2014 Cornelius Inc 60 Publication Number 312026000 HOT GAS DEFROST SOLENOID VALVE Des ASS Y 2 f L ELECTRONIC 4 EXPANSION VALVE 2 FREEZE CYLINDER 2 WATER FLOW RATE THROUGH COIL r VARIES DUE TO PRESSURE CHANGE ON HIGH SIDE OF COMPRESSOR WHICH INFLUENCES AND CLOSING OF VARIABLE WATER REGULATOR ADJUST VARIABLE WATER REGULATOR MAINTAIN 240 PSI REFRIGERATION HIGH SIDE PRESSURE L ie 2 a al Je KL COOLING WATER IN EVAPORATOR CITY PLAIN WATER COOLING WATER OUT TO DRAIN VARIABLE WATER REGULATOR ADJUSTMENT SCREW WO o aires e
21. an alarm will sound for a short duration then Unit will resume normal operation Publication Number 312026000 19 1995 2014 Cornelius Inc NOTE Automatic defrost sleep time and wake up time used combination together or separately FACEPLATE RELIEF VALVES The faceplate relief valves see Figure 4 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 operation PRODUCT SAMPLE VALVES The two product sample valves are located behind the lower front access panel see Figure 2 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 a 90 angle with line to close the valve PRODUCT SHUTOFF VALVES The two product shutoff valves located in lines leading from the product blender tanks to the freeze cylinders see Figure 2 are manually operated lever type ball valves and are used to prevent product from entering and filling freeze cylinders while adjusting BRIX of dispensed product Shutoff valves may also be used to shut off product to individual freeze cylinder for service and maintenance without disrupting operation of other freeze cylinder PRIMARY REGULATOR The primary CO
22. has occurred Program SLEEP SLEEP TIME into the Unit as instructed in SERVICE AND MAINTENANCE section PROGRAMMING WAKE UP WAKE UP TIME INTO the UNIT WAKE UP WAKE UP TIME May be programmed into the Unit to occur any time of the day to wake the Unit up return to normal operation after sleep time has occurred Program WAKE UP into the Unit as instructed in SERVICE AND MAINTENANCE section PROGRAMMING POINT OF SALE MESSAGE DISPLAY Three point of sale display messages are available to choose from and may be programmed into the Unit by placing No 1 and No 2 switches on the DIP SWITCH assembly on the master circuit board in appropriate positions Program point of sale display messages into the Unit as instructed in SERVICE AND MAINTENANCE section Publication Number 312026000 13 1995 2014 Cornelius Inc ADJUSTING VIS PRODUCT VISCOSITY DISPENSED PRODUCT Adjust 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 SERVICE AND MAINTENANCE 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
23. message display will go out indicating syrup float switch has been filled with syrup 37 Press AUTO BLEND 1 switch to fill No 1 product blender tank with product Carbonator water pump will start and begin pumping carbonated water into product blender tank along with syrup to make product in cylinder and lose carbonation CAUTION Do not relieve freeze cylinder pressure too fast or product will foam excessively 38 After carbonator water pump cycles off intermittently 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 system Product will be ready for dispensing in approximately 10 minutes 41 Install right hand side panel and front lower access panel by reversing removal procedure YEARLY OR AFTER WATER SYSTEM DISRUPTION WARNING The carbonator water pump double liquid check valve must be Inspected and serviced after any disruptions plumbing work earthquake etc to the water supply system and at least once a year under normal circumstances Foreign particles lodged in the double liquid check valve could cause gas to back flow into the water system and create a health hazard in the system SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE
24. 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 SERVICE AND MAINTENANCE section SECONDARY CO REGULATORS The secondary regulators located behind the lower front access panel see Figure 5 control CO2 pressure to the two carbonated water tanks and the two product blender tanks If necessary to adjust the secondary regulators adjust as instructed in SERVICE AND MAINTENANCE section CARBONATED WATER FLOW REGULATORS The adjustable carbonated water flow regulators see Figure 2 and Figure 5 located in their respective systems control carbonated water flow rate to the product blender tanks The water flow regulators are factory adjusted at 1 3 0 05 oz sec and should not normally require adjustment If adjustment is necessary adjust as instructed in SERVICE AND MAINTENANCE section SYRUP FLOW REGULATORS The syrup flow regulators see Figure 2 and 5 located in their respective systems are adjustable regulators that control syrup flow rate to the product blender tanks for desired BRIX of dispensed product Adjust syrup flow regulators for desired BRIX as instructed in SERVICE AND MAINTENANCE section DISPENSING VALVES Self closing dispensing valves see Figure 3 and 4 located on faceplates on front of Unit are operated one at a time or
25. regulators with 60 psi gages by turning their regulator adjusting screws to the right clockwise until their gages read 25 to 30 psig 3 Install the lower front stainless steel access panel by reversing the removal procedure Carbonated Water Tank Secondary Regulators see Figure 2 1 Remove the Unit lower front access panel as instructed for access to the carbonated water tanks secondary CO regulators IMPORTANT The carbonated water tanks secondary CO regulators 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 Carbonated water tanks secondary regulators not adjusted high enough will cause a decreased flow of carbonated water into the blender tanks which will increase the brix of the dispensed product 2 Adjust carbonated water tanks secondary regulators with 100 psi gages by turning regulators adjusting screws to the right clockwise until gages reads 50 to 60 psig 3 Install the lower front access panel by reversing the removal procedure Publication Number 312026000 37 1995 2014 Cornelius Inc ADJUSTING BRIX WATER TO SYRUP RATIO DISPENSED PRODUCT see Figures 2 and 5 1 Remove Unit front lower stainless steel access panel as instructed for
26. BOX 3 Install lower control box cover and secure with screws PREPARATION FOR OPERATION TURNING ON ELECTRICAL POWER TO UNIT Turn on electrical power to Unit Operational status of Unit is now being displayed as fault messages on control panel message display The following fault messages will be continuously displayed at 2 second intervals until necessary operation requirements are satisfied OFF 1 Beater Motor No 1 not operating OFF 2 Beater Motor No 2 not operating OUT No water supply to Unit CO OUT 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 UNIT 1 Open 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 IMPORTANT If bag in box syrup supply system will be connected to the Unit instead of soft drink tanks the primary CO regulator see figure 2 must be adjusted to no less than 80 PSI 2 For soft drink tanks installation see Figure 2 adjust primary CO regulator by turning regulator adjusting screw to the right clockwise until regulator pressure reads 80 to 100 psig OUT OF CO warning light on control panel message display should have gone out 1995 2014 Cornelius Inc 10 Publication Number 312026000 3 Pull up on product blender tanks relie
27. INCREMENTS 5 Connect electrical power to Unit and allow carbonated water tank to fill with water and until water pump cycles off 6 Repeat steps 2 through 5 preceding as many times as necessary until correct carbonated water volume adjustment is achieved 1995 2014 Cornelius Inc 58 Publication Number 312026000 RELIEF VALVE CARBONATED WATER TANK SWITCHES ACTUATOR BRACKET LEVEL CONTROL SWITCHES 2 2 P 7 ACTUATOR BRACKET ADJUSTMENT SCREW FIGURE 14 CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT Publication Number 312026000 59 1995 2014 Cornelius Inc ELECTRONIC O L EXPANSION VALVE 2 HOT GAS DEFROST _ SOLENOID VALVE 55 rr FREEZE CYLINDER 2 VEL med EVAPORATOR meet STRAINER DRYER A Xs 4 LES IL gt T
28. ITEM 6 PLASTIC HOUSING O RING SHAFT DRIVE SHAFT SEAL ASSEMBLY FIGURE 7 SERVICING BEATER MOTOR DRIVE SHAFT SEAL ASSEMBLY Publication Number 312026000 33 GAUGE DRIVE COUPLER 1995 2014 Cornelius Inc KEY ON END OF POST KEY ON END ON BLADE SCRAPER BLADES MUST BE MOUNTED TO THE BEATER BODY AS SHOWN USING THE PERFORATED EDGE AS THE LEADING EDGE LINE UP KEY ON END OF POSTS WITH KEY SLOT IN SCRAPER BLADES FIGURE 8 BEATERS AND SCRAPER BLADES INSTALLATION 1 Pull BEATER item 13 and SCRAPER BLADES item 2 from freeze cylinder 2 Using WRENCH item 5 reach into the freeze cylinder and turn the drive shaft seal assembly to the right clockwise to unlock its four locking tabs from the notches in the freeze cylinder retainer Pull the assembly out of the freeze cylinder retainer using the beater as a puller 3 Remove the coupling end fitting from the shaft by loosening the set screw the coupling then slide coupling off the shaft 4 Remove the lock ring bearing retainer from the end of the plastic housing 5 Using a block of wood tap the drive shaft and both bearings out of the plastic housing 6 Loosen bearings and remove shaft Remove two old inner drive shaft O Rings seals and two outer O Rings seals from the plastic housing Discard the old O Ring seals NOTE If old lubricant cannot be removed from the plastic
29. MESSAGE DISPLAY Press DEFROST SELECT switch to lock in on the selection This programs the proper refrigeration pulse rate into the Dispenser electronics 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 8 DISPLAYED ERROR CONDITIONS Publication Number 312026000 49 1995 2014 Cornelius Inc 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 TYPE CLEANERS Remove and wash drip tray in mild soap solution rinse with clean water then install drip tray on Unit SANITIZING SYRUP SYSTEMS NOTE The Unit should be sanitized every 120 days following Sanitizer Manufacturer s recommendation Use Chlor Tergent Oakite Products Inc or equivalent sanitizer The Unit should be sanitized every 120 days and before and after storage periods following parent company requirements and sanitizer manufacturer s recommendations One or both syrup systems may be sanitized at one time for routine 120 days sanitizing requirements The following sanitizing instructions use No 1 syrup System as an example No 2 syrup systems sanitizing instructions are identical to No 1 syrup system with exception of using applicable syste
30. Press CANCEL DEFROST ADVANCE switch to advance hours on display to desired hour Press DEFROST SELECT switch to lock in hour on display 4 After hour time of day has been locked in on message display minute numbers will be flashing on display Press CANCEL DEFROST ADVANCE switch to advance minute numbers to desired minutes time of day Press DEFROST SELECT switch to lock in minute time of day on display 5 Press DEFROST SELECT switch then repeat steps 2 3 and 4 to program in next defrost time setting MAKE SURE A MINIMUM OF TWO HOURS IS MAINTAINED BETWEEN DEFROST TIME SETTINGS IF A TIME SETTING OF LESS THAN TWO HOURS IS PROGRAMMED INTO THE UNIT A MOMENTARY ERROR MESSAGE WILL APPEAR ON THE MESSAGE DISPLAY WHEN OPERATOR TRIES TO EXIT DEFROST THE PROGRAM WILL NOT ALLOW THE OPERATOR TO EXIT THE DEFROST SETTING UNTIL THE LESS THEN TWO HOUR DEFROST TIME IS CORRECTED THE OPERATOR MUST PRESS CANCEL DEFROST ADVANCE SWITCH THEN REPEAT STEPS 2 3 and 4 TO PROGRAM CORRECTED DEFROST TIME INTO UNIT 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
31. Refrigerant Type and Charge See Unit Nameplate Ambient Operating Temp 40 F to 100 F Electrical Requirements Operating Voltage See Unit Nameplate Current Draw See Unit Nameplate REFRIGERATION SYSTEMS NOTE The FCB Dispenser depending upon the model number refrigeration system is either air cooled or water cooled AIR COOLED The air cooled FCB Dispenser refrigeration system is equipped with a condenser coil that is cooled by a condenser coil fan WATER COOLED The water cooled Two Flavor FCB Dispenser refrigeration system is equipped with a Refrigeration Cooling Coil Assembly that contains both refrigerant and plain water cooling coils Circulating cool plain water through the cooling coil cools the refrigerant also inside the coil During installation City cold plain water is connected to the FCB Dispenser Refrigeration Cooling Coil water inlet line labeled COOLING WATER IN The water drain line labeled COOLING WATER OUT must be routed to and be connected to a permanent drain 1995 2014 Cornelius Inc 2 Publication Number 312026000 THEORY OPERATION see Figure 2 IMPORTANT Before connecting electrical power to Unit refer to nameplate and note if Unit is to be operated with 50 or 60 Hz power source Note The following paragraph describes the theory of operation for the Two Flavor FCB Dispenser see Figure 2 A cylinder delivers ca
32. SELECT switch to lock TOTALS menu in place The word COMP HRS will appear on message display Press and hold DEFROST SELECT switch Compressor run hours will appear on message display Press CANCEL DEFROST ADVANCE switch to advance and bring up CYC on message display 1995 2014 Cornelius Inc 46 Publication Number 312026000 NOTE displaying SYR MIN 1 SYR MIN 2 message display will indicate time minutes syrup actually has been dispensed Refer to table and formula below to calculate how much syrup has been dispensed GALLONS x SYRUP MINUTES Using the table to the left choose the Note A numbers are based upon a ber that corresponds to your BRIX setting Multi 4 4 to 1 water to syrup ratio ply the A number by the syrup minutes reading to obtain the amount gallons of syrup used TABLE 7 TOTALS DISPLAYED CYCLES AND HOURS TOTALS MENU Publication Number 312026000 47 1995 2014 Cornelius Inc 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 Sensed on motor two F vean an een 9 OF 9 cmm
33. The gas check valves must be inspected serviced at least once year under normal conditions and after any servicing or disruption of the CO system ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR see Figures 5 and 7 IMPORTANT Note in 5 MOTOR SELECT the number of freeze cylinders beater drive motors Manufacturer s that are listed Your Unit was manufactured and equipped with freeze cylinders beater drive motors from one of these Manufacturer s The replacement freeze cylinder beater drive motor is also manufactured by one of these Manufacturer s listed WHEN REPLACING ONE OF THE BEATER MOTORS NOTE THE MANUFACTURER S NAME ON THE MOTOR THE BEATER MOTOR MANUFACTURER S NAME MUST BE PROGRAMMED INTO THE UNIT WHICH WILL MATCH THE MOTOR TO THE UNIT ELECTRONICS Proceed as follows to replace the freeze cylinder beater drive motor 1 Press OFF 1 and OFF 2 control switches to stop the refrigeration system and the beater drive motors 2 Disconnect electrical power to the Unit 3 Remove back and applicable side panels from the Unit 4 Tag the beater drive motor electrical wiring for identification then disconnect the wiring from the terminal block 5 Remove the bolt hex nuts and lockwashers securing the beater drive motor to the Unit frame 6 Very carefully remove the old beater drive motor from the Unit BE CAREFUL NOT TO LOSE THE LARGE RUBBER DRIVE
34. WARNING Disconnect electrical power to Unit to prevent personnel injury before attempting any internal maintenance Only qualified personnel should service internal components or electrical wiring PREPARING UNIT FOR SHIPPING STORING OR RELOCATING CAUTION Before shipping storing or relocating Unit syrup systems must be sanitized and all sanitizing solution must be purged from syrup systems All water must also be purged from plain and carbonated water systems A freezing ambient environment will cause residual sanitizing solution or water remaining inside Unit to freeze resulting in damage to internal components PERIODIC INSPECTION 1 Make sure CO cylinder valve is fully opened and primary 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 Circulating air required to cool the refrigeration systems condenser coil see Figure 15 is drawn in through louvers on front and exhausted out through louvers on sides and back of Unit Make sure louvers are not obstructed and refer to CLEANING CONDENSER COILS in this section REMOVAL OF DRIP TRAY AND BACK SIDES TOP LOWER FRONT ACCESS AND CONDENSER COIL ACCESS PANELS see Figure 4 DRIP TRAY Pull drip tray forward to disengage from drip tray supports BACK PANE
35. access to product blender tanks secondary regulators and product sample valves Check product blender tanks secondary regulators with 60 psi gages for proper pressure settings which is set at 25 to 30 psi for best textured dispensed product If adjustment is necessary adjust as instructed Remove both Unit side panels as instructed for access to product shutoff valves located close to product blender tanks Close product shutoff valve in line between applicable product blender tank and associated freeze cylinder BRIX adjustment will be performed on Press applicable FILL 1 or FILL 2 switch to prevent more product from filling product blender tank Open applicable product blender tank product sample valve and take sample approximately 6 ounces of product in cup NOTE Temperature compensated hand type refractometers P N 511004000 are available from the Cornelius Company T 13 14 Check product BRIX with a temperature compensated hand type refractometer BRIX should read 13 1 If BRIX is not within tolerance adjust applicable white syrup flow regulator as follows Turn syrup flow 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 applicable product sample valve Open valve to purge product out of product blender tank line and valve
36. enters the freeze cylinders and is frozen Transparent faceplate attached to the front of each freeze cylinder includes a self closing dispensing valve and a spring loaded relief valve that protects freeze cylinder from accidental over pressure The relief valve is also used to bleed CO gas pressure from the freeze cylinder to atmosphere when filling the cylinder with product Electronic sensing on each freeze cylinder motor provides a means of adjusting viscosity consistency of the dispensed product to suit customer preference 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 and defrost for approximately 60 seconds At the end of the manual defrost cycle the Unit will return to normal operation Manual defrost may be cancelled at any time by pressing the CANCEL DEFROST switch AUTOMATIC DEFROST SYSTEM The automatic hot gas defrost system may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours between
37. ete 14 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO THE MESSAGE DISPLAY 14 PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS 14 PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS ax ia a A a cauda 14 DISPLAYED ERROR CONDITIONS 15 INSTALLING CONTROL BOX COVER AND BACK SIDES LOWER ACCESS AND PANELS ON UNIT sd s cts cut a ay eds 15 OPERATORS INSTRUCTIONS 17 CONTROL PANEL SWITCHES AND DISPLAYED MESSAGES 17 CONTROL PANEL SWITCHES over tetris o ce 17 CONTROL PANEL DISPLAY MESSAGES 18 FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS 19 MANUAL DEFROST SYSTEM 19 AUTOMATIC DEFROST SYSTEM de te es 19 SLEEP SLEEP TIME a uc ta ates anton tee a a 19 WAKE UP WAKE UP aa a ii a mm 19 FACEPLATE RELIEF VALVES 20 PRODUCT SAMPLE VALVES sap kinase 20 PRODUCT SHUTOFF VALVES ie pan 20 PRIMARY CO2 REGULATOR ates pte ce ne se 20 SECONDARY COP REGULATORS 54 lun 20 CARBONATED WATER FLOW REGULATORS 20 SYRUP FLOW REGULATORS IM pus 20 DISPENSING VALVES pa
38. housing by washing use 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 HOUSING Wash the housing and the back of the freeze cylinder with warm water 8 Lubricate two new drive shaft O Ring seals with a generous amount of special light grade silicone grease then install O Rings inside the plastic housing 9 Inspect the drive shaft and both bearings Replace the drive shaft if worn and bearing s if found to be rough 1995 2014 Cornelius Inc 34 Publication Number 312026000 13 14 19 20 Reassemble the drive shaft seal assembly Using TOOL DRIVE COUPLER ADJUSTMENT GAUGE item 6 insert DRIVE end of adjustment gauge between drive pin and housing see Figure 7 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 Install coupling end fitting on end of the drive shaft Insert COUPLER end of the adjustment gauge between coupling end fitting and the plastic housing The adjustment gauge in place places the coupling end fitting 0 750 inch away from the plastic housing Make sure Allen Head set screw in the coupling end fitting is securely tightened and properly
39. in PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS in SERVICE AND MAINTENANCE section 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 SERVICE AND MAINTENANCE section for programming instructions 1995 2014 Cornelius Inc 14 Publication Number 312026000 DISPLAYED ERROR CONDITIONS Displayed error conditions associated errors and items affected by the errors are found in Table 8 DISPLAYED ERROR CONDITIONS INSTALLING CONTROL BOX COVER AND BACK SIDES LOWER ACCESS AND TOP PANELS ON UNIT 1 Install upper electrical control box cover and secure with four screws 2 Install back sides lower access and top panels on Unit by reversing removal procedures Publication Number 312026000 15 1995 2014 Cornelius Inc THIS PAGE LEFT BLANK INTENTIONALLY 1995 2014 Cornelius Inc 16 Publication Number 312026000 OPERATORS INSTRUCTIONS This section describes operating controls and indicators dispensed product conditions operating characteristics Unit operation replenishing syrup supply product flavor change checking CO supply operators daily cleaning of Unit and sanitizing requirements WARNING Disconnect electr
40. later than 15 daysfrom date of delivery and immediately reported to the delivering carrier Request a written inspectionreport from Claims Inspector to substantiate any necessary claim File claim with the delivering carrier not with Cornelius Inc 1 After Unit has been unpacked remove shipping tape and other packing material 2 Remove Unit sides top and back panels as instructed 3 LOOSE SHIPPED PARTS Make sure all items are present and in good condition 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 source 2 SPANNER WRENCH DISPENSING VALVE item 2 is used to remove shank nuts securing dispensing valves to faceplates 3 CLEANING BRUSH item 3 is used to clean faceplate relief valves passages Table 2 Loose Shipped Parts 1 178025100 Tapered Gasket White 322859000 Spanner Wrench Dispensing Valve 325216000 Cleaning Brush lt 311304000 Tapered Gasket Black Wrench Rear Seal Housing Tool Drive Coupler Adjustment Gauge Caster Kit 4 inch diameter Casters Note All parts for the Sound Baffle Drip Tray Assembly shipped with the Dispenser a separate box and must be installed on the Dispenser Refer to Installation Instructions provided with the Sound Baffle Drip Tray Assembly for installation procedure 4 TAPERED GA
41. operating properly B Remedy Properly connect flat cable to controls 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 TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATORS CARBONATOR WATER PUMP No electrical power to Unit MOTOR WILL NOT OPERATE CARBONATOR WATER PUMP WILL NOT SHUT OFF ERRATIC CARBONATOR WATER PUMP CYCLING 1995 2014 Cornelius Inc 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 Inoperative water pump and or motor Inoperative carbonated water tank level control switches Binding damaged or dirty carbonated water tank balance mechanism Inoperative water pump and or motor 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 66 A B 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
42. 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 1995 2014 Cornelius Inc 4 Publication Number 312026000 WATER PRESSURE REGULATOR IS FACTORY ADJUSTED TO 45 PSI AND SHOULD BE READJUSTED PRODUCT SAMPLE VALVE 2 SYRUP SOLD OUT SWITCHES ARE 71 FACTORY ADJUSTED AND SHOULD NOT BE READJUSTED HI 1 LINE LEGEND NN PLAIN WATER CARB WATER SYRUP CARBONATOR n J PRODUCT BLENDER A 2 5 PRODUCT SHUTOFF VALVE 2 o 2 CYLINDER 2 FREEZE CYLINDER OVERFLOW TUBE WATER VOLUME SAMPLE VALVE T a WATER n SOLENOID VALVE 2 Y 5 CARBONATED WATER 1 7 FLOW REGULATOR 2 C gt ES Ce Sor ENG syrup ELOW n 4 i V 2 REGULATOR 2
43. same way as clean gas This can also cause off taste problems Dispensing valve has ice particles in it Cylinder freeze up AUTO BLEND 1 or AUTO BLEND 2 switch not pressed Carbonator water pump not operating Lines restricted Dispensed product BRIX varying because Syrup and or water flow regulator sticking Primary CO regulator pressure insufficient 67 Remedy 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 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 Sanitize Unit as instructed a Clean regulator s b Primary CO regulator must be adjusted from 80 to 100 psi 1995 2014 Cornelius Inc Trouble FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY cont d CYLINDE
44. seated on the shaft flat surface Lubricate the two outer O Ring seals on the outside of the plastic housing with a generous amount of special light grade silicone grease Reinstall the drive shaft seal assembly in the freeze cylinder Push in and turn the drive shaft seal assembly to the left counterclockwise to lock its four locking tabs into four notches in the freeze cylinder retainer 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 as shown in Figure 6 Turn beater to the right clockwise to lock in place Lubricate O RING item 5 with water to facilitate faceplate installation Position O RING item 5 on FACEPLATE item 8 Install faceplate on Unit so dispensing valve spout faces down MAKE SURE FEMALE END OF THE BEATER IS PLACED OVER THE FACEPLATE STAINLESS STEEL STUD AND BUSHING BEFORE PUSHING THE FACEPLATE INTO POSITION ON ITS FOUR THREADED MOUNTING STUDS Tighten hex nuts until faceplate touches freeze cylinder all around flange CAUTION DO NOT OVERTIGHTEN HEX NUTS Turn dispensing valve spring housing to the left counterclockwise to put tension on torsion spring then tighten hold down plates to secure spring housing Test dispensing valve to make sure it closes by itself when lever is released If not readjust torsion spring tension Sanitize syrup system as instructed in CLEANING AND SAN
45. sia 20 DISPENSED PRODUCT CONDITIONS 20 OVERRUN AS APPLIED TO FROZEN CARBONATED BEVERAGES 20 OPERATING CHARACTERISTICS 21 OPERATING UNIT sodas bien Lee 22 REPLENISHING SYRUP SUPPLY Cad teda 22 PRODUCT FLAVOR CHANGE 22 CHECKING CO2 SUPPLY i 22 CLEANING AND SANITIZING 0 1 03 RO DO ERE S Po DONE 23 DAILY CLEANING Suo Lose Rot EOM oe 23 23 CLEANING CONDENSER 4 23 TABLE CONTENTS cont d Page LUBRICATION a Neo T a IT 23 ADJUSTMENTS Elo o Tien te 23 CARBONATED WATER FLOW RATE 23 CO2 REGULATORS fe di n 23 ADJUSTING BEATERS MOTORS CURRENTS 24 PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY 24 SETTING CLOCK TIME OF DAY 24 PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT 24 PROGRAMMING SLEEP SLEEP TIME INTO UNIT 24 PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT 24 PROGRAMMING POINT OF SALE MESSAGE DISPLAY 24 ADJUSTING VIS SET PRODUCT VISCOSITY OF
46. steel access panel as instructed for access to the carbonated water tanks secondary CO regulators with 100 psi gages 1995 2014 Cornelius Inc 38 Publication Number 312026000 HIDDEN SECURITY SWITCH MESSAGE DISPLAY AUTO BLEND 1 CANCEL AUTO DEFROST DEFROST BLEND 2 SELECT ADVANCE FIGURE 9 CONTROL PANEL 2 Observe pressure settings on the carbonated water tanks secondary CO regulators gages 3 To lower pressure loosen regulator adjusting screw lock nut Turn adjusting screw to the left counterclockwise until pressure gage reads 15 psi below desired reading then turn screw to the right clockwise until gage reads desired pressure DO NOT SET CO REGULATOR PRESSURE BELOW 25 PSI HIGHER THAN PRODUCT BLENDER TANKS CO REGULATORS ARE ADJUSTED TO SEE PRECEDING IMPORTANT NOTE Tighten adjusting screw lock nut after each adjustment 4 raise CO pressure turn regulator adjusting screw to the right clockwise until gage reads desired pressure DO 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 adjustment 5 Install Unit front lower access panel by reversing removal procedure 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 cu
47. 1 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 B Carefully install valve with caged O ring in dispensing valve body C Install spring fitting knob and lever parts torsion spring and spring housing assembly by reversing removal procedure Do not tighten down hold down plates securing spring housing at this time 10 Thoroughly clean RELIEF VALVE item 9 then screw relief valve into FACEPLATE item 8 11 Proceed to Servicing Beater Motor Drive Shaft Seal Assemblies Servicing Freeze Cylinders Drive Shaft Seal Assemblies see Figure 7 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 Publication Number 312026000 31 1995 2014 Cornelius Inc 000920216 ce 18 26 20
48. ATION 3 DEFROST SYSTEMS x nbi eed binis drei 3 MANUAL DEFROST SYSTEM 3 AUTOMATIC DEFROST SYSTEM 3 SLEEP SLEEP TIME scars cca cie arces ciet CS Te He e e y EXC Tice e 4 WAKE UP WAKE UP 4 INSTALLATION rcg amnia ca ciat ca 6 UNPACKING AND INSPECTION 6 IDENTIFICATION OF LOOSE SHIPPED PARTS 6 ELECTRICAL POWER REQUIREMENTS 7 SELECTING LOCATION 7 INSTALELING UNIT re tacta nt amid ao ote t 7 PLACING UNIT IN OPERATING LOCATION 7 INSTALLING SOUND BAFFLE DRIP TRAY ASS Y ON UNIT 8 INSTALLING PRIMARY CO2 REGULATOR ASSEMBLY ON CO2 EYLINDER M ETE I 8 CONNECTING SOFT DRINK TANKS 2 LINES TO PRIMARY CO2 REGULATOR ASSEMBLY 8 PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT DRINK TANKS 20 erra core acea rete a E e d 8 CONNECTING CITY PLAIN WATER SOURCE LINE S TO UNIT 9 CONNECTING ELECTRICAL POWER CIRCUIT TO UNIT 10 PREPARATION FOR 10 TURNING ON ELECTRICAL POWER T
49. DISPENSED PRODUC 24 VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT FREEZE CYLINDERS os rases ot tid di feq De ido mp ua 24 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 25 VOLTAGE DISPLAYED VOLTAGE READOUT 25 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE a r te a 25 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY ania a 25 PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS cu aed Fea n 25 PROGRAMMING PROPER REFRIGERANT INTO UNIT ELECTRONICS a a d etd ia Mou b dr UN he 25 DISPLAYED ERROR CONDITIONS 25 WATER PUMP DOUBLE LIQUID CHECK VALVE MAINTENANCE 26 CLEANING CO2 GAS CHECK VALVES 26 SERVICE AND MAINTENANCE 27 PREPARING UNIT FOR SHIPPING STORING OR RELOCATING 27 PERIODIC INSPECTION 5 27 REMOVAL DRIP TRAY AND SIDES LOWER FRONT ACCESS AND CONDENSER COIL ACCESS PANELS 27 PPT AV er te et 27 BACK PANEL RSR Ad ne 27 SIDE PANELS 27
50. DISPENSER FIGURE 2 FLOW FIGURE 3 SELF CLOSING DISPENSING VALVE FIGURE 4 OPERATING CONTROLS FIGURE 5 UNIT INTERNAL COMPONENTS FIGURE 6 FREEZE CYLINDER CUTAWAY VIEW FIGURE 7 SERVICING BEATER MOTOR DRIVE SHAFT SEAL ASSEMBLY FIGURE 8 BEATERS AND SCRAPER BLADES INSTALLATION FIGURE 9 CONTROL FIGURE 10 MASTER AND RELAY CIRCUIT BOARD FIGURE 11 LIQUID CHECK VALVE ASSEMBLY FIGURE 12 CO2 GAS CHECK VALVE FIGURE 13 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VABVE SEL A An A re ees Le E sU ais FIGURE 14 CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT iem Cade ii E pe ce ES FIGURE 15 REFRIGERATION FLOW DIAGRAM AIR COOLED REFRIGERATION SYSTEM FIGURE 16 REFRIGERATION FLOW DIAGRAM WATER COOLED REFRIGERATION SYSTEM FIGURE 17 WIRING DIAGRAM TABLE 1 DESIGN DATA TABLE 2 LOOSE SHIPPED PARTS TABLE 3 MAIN MENU SELECTIONS
51. Guli CORNELIUS INC One Cornelius Place 38 Anoka MN 55303 6234 Telephone 800 238 3600 Facsimile 612 422 3246 Installation Service Manual FCB 3 H P POST MIX DISPENSER TWO FLAVOR W HOT GAS DEFROST AND V3 FEATURES 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 ANSI ASME A112 1 2 1979 or an approved vacuum breaker or other such method as proved effective by test Water pipe connections and fixtures directly connected to a potable water supply shall be sized installed and maintained according to Federal State and Local laws Publication Number 312026000 Revision Date May 06 2014 Revision D THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment 1995 2014 CORNELIUS INC PRINTED IN U S A TABLE CONTENTS Page GENERAL INFORMATION 1 GENERAL DESCRIPTION 1 UNIT DESCRIPTION Rut oec Rendre mede eq Geer 1 REFRIGERATION SYSTEMS 2 AIR COOLED ae bit een e D Ca RUSSES 2 WATER COOLED 2 THEORY OF OPER
52. ITIZING Return Unit to operation CLEANING CONDENSER COIL UNIT WITH AIR COOLED REFRIGERATION SYSTEM see Figure 5 NOTE Circulating air required to cool the refrigeration system condenser coil is drawn in through louvers on front and exhausted out through louvers on sides and back of Unit Restricting air circulation through Unit will decrease its cooling efficiency Periodically clean condenser coil as follows 1 Press OFF 1 and OFF 2 switches on Unit control panel to stop refrigeration system and beaters motors Remove condenser coil access panel and condenser coil air filter s Clean condenser coil and condenser coil air filter s with vacuum cleaner low pressure compressed air or a soft brush Install condenser coil air filter s and condenser coil access panel by reversing removal procedure Press AUTO 1 and AUTO 2 switches on Unit control panel to start refrigeration system and beaters motors Publication Number 312026000 35 1995 2014 Cornelius Inc UNIT WITH WATER COOLED REFRIGERATION SYSTEM The high pressure cutout switch located inside the lower control box see Figure 16 will shut the Unit refrigeration system down when overheated high head pressure caused by lack of cooling water After problem has been corrected and the head pressure has decreased the reset button on the high pressure cutout switch must be pressed to restart the refrigeration system ADJUSTMENTS ADJUSTING PLAIN WA
53. L Remove two screws securing bottom of back panel then lift panel straight up to remove SIDE PANELS Remove screw securing bottom of side panel then lift panel straight up to remove TOP PANEL Remove two screws securing top panel then lift panel up off Unit Publication Number 312026000 27 1995 2014 Cornelius Inc LOWER FRONT ACCESS PANEL Remove two screws securing lower front panel then pull panel down to remove from Unit CONDENSER COIL ACCESS PANEL Pull out on top of condenser coil access panel then lift panel up and out to remove LUBRICATION CARBONATOR WATER PUMP MOTOR see Figure 13 The carbonator water pump motor bearings must be lubricated periodically Refer to oiling instructions on motor DO NOT OVER OIL SERVICING DISPENSING VALVES CAGED O RINGS AND FREEZE CYLINDERS DRIVE SHAFT SEAL ASSEMBLIES Servicing Dispensing Valves Caged O Rings see Figure 3 NOTE Dispensing valves caged O Rings should be serviced lubricated every six months and O Rings should be replaced once a year RETAINING SPRING HOUSING d SCREW 2 TORSION SPRING HOLD DOWN SPRING PLATE 2 DISPENSING O VALVE BODY CAGED O RING CO f FIGURE 3 SELF CLOSING DISPENSING VALVE 1995 2014 Cornelius Inc 28 Publication Number 312026000 AUTO BLEND 1 CANCEL AUTO DEFROST DEFROST BLEND 2 SELECT ADVANCE 2 CONTROL PANEL HIDDEN SECURITY 8 FAULT MESSAGE DI
54. MESSAGE DISPLAY and bring up the word CLOCK on display 1995 2014 Cornelius Inc 44 Publication Number 312026000 NO 1 AND NO 2 EVAPORATOR COILS REFRIGERATION COMMON OUTLET TEMPERATURES 2 EVAPORATOR REFRIGERATION COIL INLET TEMPERATURE 1 EVAPORATOR REFRIGERATION COIL INLET TEMPERATURE MOTOR CURRENT ADJUSTMENT O RELAY CIRCUIT BOARD NO 1 MASTER CIRCUIT BOARD 7 RELAY CIRCUIT BOARD NO 2 POINT OF SALE MESSAGE DISPLAY SELECT SEE TABLE 6 SEE NOTE BEATER MOTORS CURRENT READOUT SEE TABLE 4 MOTOR CURRENT SELF CALIBRATION SEE TABLE 4 USED DIP SWITCH ASS Y 1 2 3 4 5 6 7 8 9 APPLICABLE ELECTRIC OR GAS DEFROST SEE TABLE 4 SERVICE USE ONLY o Note Switch No 3 must be in OFF position for standard Units with pulse expansion valves 9 Switch No 3 must be in ON position for Units with mechanical expansion valves FIGURE 10 MASTER AND RELAY CIRCUIT BOARD 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 st
55. NES FOR CONNECTION TO SOFT DRINK TANKS see Figure 2 1 Route Unit syrup inlet lines labeled No 1 and No 2 out through hole provided in the Unit base to the soft drink tanks location 1995 2014 Cornelius Inc 8 Publication Number 312026000 2 Install liquid disconnects on ends of Unit syrup inlet lines DO CONNECT SYRUP LINES TANKS AT THIS TIME CONNECTING CITY PLAIN WATER SOURCE LINE S TO UNIT NOTE All of the Units require connection to a city plain water source line with a minimum water pressure of 12 psig to be connected to the Unit plain water inlet line which provides plain water to the Unit post mix system The Unit equipped with a water cooled refrigeration system also requires a city plain water source line be connected to the refrigeration cooling coil assembly plain water inlet line Proceed as follows to connect a city plain water source line to the Unit Connecting City Plain Water Source Line to Unit Post Mix System see Figure 2 NOTE Cornelius Inc recommends that a water shutoff valve and water filter be installed in the city plain water source line see applicable Figure NO TAG that provides plain water to the Dispenser post mix system Cornelius Water Filter P N 313860000 and Quick Disconnect Set P N 313867000 are recommended 1 Before connecting the city plain water source line to the Unit that provides plain water to the post mix system open shutoff valve in city plain water so
56. O UNIT 10 TURNING ON CO2 SUPPLY TO UNIT 10 TURNING ON CITY PLAIN WATER SOURCE LINE TO UNIT 11 CONNECTING SOFT DRINK TANKS TO UNIT SYRUP SYSTEMS 11 ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODBUGT Cat DOR IACTA a e aan 12 FILLING FREEZE CYLINDERS WITH PRODUCT 12 ADJUSTING WATER COOLED UNIT REFRIGERATION SYSTEM VARIABLE WATER REGULATOR 13 ADJUSTING BEATER MOTOR CURRENT EITHER SIDE 13 PROGRAMMING MAIN MENU SELECTIONS THE MESSAGE DISPLAY odds Dai casco ots ches 13 PROGRAMMING AUTOMATIC SETTINGS INTO THE UNIT 13 PROGRAMMING SLEEP SLEEP TIME INTO THE UNIT 13 PROGRAMMING WAKE UP WAKE UP TIME INTO THE UNIT 13 PROGRAMMING POINT OF SALE MESSAGE DISPLAY 13 TABLE CONTENTS cont d Page ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT NEA 14 VIS READ ACTUAL VISCOSITY READOUT PRODUCT FREEZE CYLINDERS sinc na aaa 14 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 14 VOLTAGE DISPLAYED VOLTAGE READOUT 14 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE INTO cote Sa
57. R FREEZE UP Probable Cause Remedy Cylinder freeze up causing ice Refer to CYLINDER formation in center of cylinder FREEZE UP and liguid 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 TROUBLESHOOTING REFRIGERATION SYSTEM UNIT EQUIPPED WITH AIR COOLED REFRIGERATION SYSTEM UNIT EQUIPPED WITH WATER COOLED REFRIGERATION SYSTEM 1995 2014 Cornelius Inc A Dispenser refrigeration system A Clean Unit condenser coil as overheating instructed see NOTE below NOTE The Dispenser condenser coil must be periodically cleaned to maintain proper cooling of the refrigeration system A Water supply to refrigeration A Restore water supply to cooling coil assembly refrigeration cooling coil disruppted assembly B Insufficient water supply to B Increase water supply to refrigeration cooling coil refrigeration cooling coil assembly disruppted assembly C Variable water regulator onthe Properly adjust variable water refrigeration cooling coil regulator as instructed in manual assembly not properly adjusted ACCESSORIES AND TOOLS ACCESSORIES 1155 Installation Kit 511005000 Cup Holder 511006000 Cup Holder 511035000 Changeover Kit 1040 Seal Kit Rear O Ring Housing and O
58. RN OR 142 BLU BLK YEL 1 11 YEL 1 it MASTER BOARD BOARD MASTER BOARD 5 BOND Rp 2 gc 4 D il 1 2 IDR Ne 112 ji 115 BLK YEL 194 154 167 167 LE pue 11 T woi ada Sac 11 EET AU SE 5 02 PSI SW RIGHT 11 5 RIGHT 22 i 3 nolo uer M REFG 5 fim 1 an a 5 8 REF 1 z REFG le So soL zz ilg 2 Su gt D gt 8 5 gt I T e 8 2 m T d 15 gt 5 6 SG E 5 TE gt 2 i RIGHT RIGHT IGHT 11 LE LEFT 2 LEFT 2 15000 EB TT amp mi RIGHT 22 RIGHT 22 COND zji 2555050 i DISPLAY 2 a a FAN POWER SUPPLY 5 MOTOR CODE 0O I I 2 WTR syrup WIR i E BOARD 2 WIR SYRUP SYRUP gt 0 JL DISPLAY 5 SOL 50 SOL TOUCH SWT S 3 6 SOL SOL SOL sol in TECEN T a EN 1 Taiga Na TOUCH SWT S 8 2 S GRAY GRAY d i m Ll d 56 YEL 1 YEL za BLU E COND WHT SUE pef amp 4 WHT i MOTOR GRAY 272 M i x i a i 5 1 5 1 DE y 5 y 2 8 FAN i In IE 5 5 5 a MOTOR RELAY RELAY des i D D x 2 L 9 BLK BLU BLK ELECTRONICS COND 1 1 COOLING amp v
59. Rings GENERIC FLAVOR TABS 1085 Cola 1086 Cherry 1087 Orange 1088 Grape 1089 Lemon Lime 1090 Strawberry 1091 Banana SERVICE TOOLS 281884000 3 gallon Sanitizing Tank 322859000 Spanner Wrench Dispensing Valve 511004000 Refractometer 0 30 Scale 2899 Wrench rear Seal Housing 3810 Gauge Shaft Housing Adjustment 68 Publication Number 312026000 Publication Number 312026000 69 1995 2014 Cornelius Inc CORNELIUS INC CORPORATE HEADQUARTERS One Cornelius Place Anoka Minnesota 55303 6234 612 421 6120 800 238 3600
60. SERVICE AND MAINTENANCE section DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be displayed on the message display as instructed in SERVICE AND MAINTENANCE section VOLTAGE DISPLAYED VOLTAGE READOUT Displayed voltage readout may be displayed on the message display as instructed in SERVICE AND MAINTENANCE section PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE INTO the UNIT DIAGNOSE DIAGNOSTIC MODE may be programmed into the Unit to check certain components for operation Program DIAGNOSE into Unit the and check components for proper operation as instructed in SERVICE AND MAINTENANCE section DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO the MESSAGE DISPLAY TOTALS DISPLAYED CYCLES AND HOURS TOTALS may be displayed on the message display as instructed in SERVICE AND MAINTENANCE section PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS IMPORTANT Note in TABLE 5 MOTOR SELECT the number of freeze cylinders beater drive motors Manufacturer s that are listed Your Unit was manufactured and equipped with freeze cylinders beater drive motors from one of these Manufacturer s The beater motors were programmed at the factory to match the Unit electronics THE BEATER MOTORS PROGRAMMING MUST BE RE CHECKED AT THE TIME OF UNIT INSTALLATION as instructed
61. SET switch two times to exit fom MENU SELECTIONS DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be displayed on message displays as follows 1 Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up SENSORS TEMPERATURES READOUT on message display 2 Press DEFROST SELECT switch to bring up evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit Left Reading Refrigeration Coils Inlet No 1 Middle Reading Refrigeration Coils Inlet No 2 Right Reading Common Outlet 3 Press ERROR RESET switch two times to exit from MENU SELECTIONS VOLTAGE DISPLAYED VOLTAGE READOUT Displayed voltage readout may be displayed on message display as follows 1 Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up VOLTAGE DISPLAYED VOLTAGE READOUT on message display 2 Press DEFROST SELECT switch to bring up voltage readout on message display 3 Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE INTO UNIT DIAGNOSE DIAGNOSTIC MODE may be programmed into the Unit to check certain components for operation Program DIAGNOSE into Unit and check components for proper operation as follows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO
62. SHAFT COUPLER 1995 2014 Cornelius Inc 56 Publication Number 312026000 WATER PRESSURE REGULATOR DOUBLE LIQUID CHECK VALVE ASS Y 2 WHITE TAPERED GASKET 2 gt WATER PUMP AND WATER PUMP MOTOR 2 SYRUP SOLD OUT FLOAT SWITCH 2 CARBONATED WATER FLOW REGULATOR 2 SYRUP FLOW REGULATOR 2 LIGUID CHECK VALVE 4 CARBONATED WATER SOLENOID VALVE 2 SYRUP SOLENOID VALVE 2 FIGURE 13 WATER STRAINER SCREEN AND DOUBLE LIGUID CHECK VALVE Publication Number 312026000 57 1995 2014 Cornelius Inc 7 Remove platic coupler from the old beater drive motor shaft and install on the new motor shaft SURE THE ALLEN HEAD SET SCREWS ARE SECURELY TIGHTENED AND PROPERLY SEATED ON THE SHAFT FLAT SURFACE 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 8 Remove the screw from the vent hole on top of the beater drive motor gear box BE CAREFUL NOT TO LAY THE MOTOR ON ITS SIDE WHICH WILL CAUSE OIL TO LEAK OUT OF THE GEAR BOX 9 Very carefully place the new beater drive motor into position in the Unit with the motor shaft engaged in the beater drive shaft large plastic coupler 10 Secure beater drive motor to the Unit frame with bolt hex nuts and lockwashers 11 Connect the beater drive motor electrical wiring to the terminal block 12 Install the sides and back
63. SKET BLACK item 4 is used to seal connection when connecting plain water source line to Unit water inlet line 5 WRENCH REAR SEAL HOUSING item 5 used to remove the drive shaft seal assembly from inside the freeze cylinder 6 TOOL DRIVE COUPLER ADJUSTMENT GAUGE item 6 is used for servicing the beater motor drive shaft seal assembly see Figure 7 1995 2014 Cornelius Inc 6 Publication Number 312026000 7 CASTER KIT item 7 to be installed on the Unit as instructed in Instructions provided in the Kit 8 All parts for the SOUND BAFFLE DRIP TRAY ASS Y item 8 are shipped with the Dispenser in a separate box and must be installed on the Dispenser during Dispenser installation ELECTRICAL POWER REQUIREMENTS IMPORTANT Before connecting electrical power to Unit refer to nameplate and Note if Unit is to be operated with 50 or 60 Hz power source A properly grounded 198 253 VAC 60Hz single phase electrical circuit with 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 the Unit ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES MAKE SURE UNIT IS PROPERLY GROUNDED SELECTING LOCATION CAUTION This Unit is intended for indoor installation only Do not install this Unit in an outdoor environment which would expose it to the outside elements IMPORTANT Unit operating ambient temperature MUST NOT E
64. SPLAY TOP PANEL UPPER CONTROL BOX TOP PANEL RETAINING SCREW 2 RELAY CIRCUIT MASTER BOARD NO 1 CIRCUIT BOARD RELAY CIRCUIT BOARD NO 2 CONTROL PANEL gt _ FACEPLATE RELIEF VALVE 2 LOWER FRONT ACCESS PANEL PANEL FACEPLATE 2 DISPENSING VALVE 2 L Zoe 771 PANEL 2 SOUND BAFFLE N VENTILATION LOUVERS SIDE PANEL NOTE The No 1 freeze cylinder is the left hand RETAINING SCREW cylinder facing the front of the Unit No 2 freeze cylinder is to the right of No 1 freeze cylinder FIGURE 4 OPERATING CONTROLS Publication Number 312026000 29 1995 2014 Cornelius Inc RELIEF VALVE 2 CARBONATED WATER FLOW REGULATOR 2 PRODUCT BLENDER TANK 2 UPPER CONTROL BOX COVER SYRUP FLOW REGULATOR 2 FAULT MESSAGE DISPLAY FREEZE CYLINDER BEATER DRIVE 2 4 MOTOR 2 SECONDARY REGULATOR 4 CARBONATED WATER TANK 2 RECEIVER TANK REFRIGERATION COMPRESSOR LOWER CONTROL BOX CONDENSER COIL ACCUMULATOR FIGURE 5 UNIT INTERNAL COMPONENTS 1995 2014 Cornelius Inc 30 Publication Number 312026000 1 Defrost freeze cylinders shut Unit down disconnect electrical power from Unit close product shutoff valves in lines leading from the product bl
65. TER PRESSURE REGULATOR see Figure 2 and 13 The carbonator water pump 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 5 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 1 Press applicable OFF 1 or OFF 2 switch to prevent more product from entering the applicable product blender tank 2 Disconnect Unit syrup inlet line from the applicable soft drink tank 3 Remove applicable side panel from the Unit as instructed for access to the applicable carbonated water flow regulator product shutoff valve and product sample valve 4 Close applicable product shutoff valve to prevent more product from entering the freeze cylinder 5 Place container under applicable product sample valve Open the valve and allow all product to be purged from the product blender tank then close the valve 6 Remove the lower front access panel as instructed for access to the secondary regulators 7 Note pressure setting on the applicable secondary CO regulator with 60 psi gage for the applicable product blender tank Turn regulator adjusting screw out counterclockwise until gage reads 0
66. TIME INTO UNIT 43 PROGRAMMING POINT OF SALE MESSAGE DISPLAY 43 ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED a ot a 43 VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT FREEZE CYLINDERS s ier rau iria oo este 44 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 44 VOLTAGE DISPLAYED VOLTAGE READOUT 44 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE NTO tee anne ramener 44 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY sauni ui es i 46 PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS ons Re ann a ea 48 PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS incepet ns a a L LABES 49 DISPLAYED ERROR CONDITIONS 49 CLEANING AND SANITIZING ees 50 DAILY CLEANING OF UNIT a 50 SANITIZING SYRUP SYSTEMS 50 YEARLY OR AFTER WATER SYSTEM DISRUPTION 52 SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK SINE o dan eed Neda 52 REPLENISHING SYRUP SUPPLY 53 REPLENISHING CO2 SUPPLY 54 SYR
67. UP FLAVOR CHANGE 55 CLEANING CO2 GAS CHECK VALVES 56 REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR 56 ADJUSTING CARBONATED WATER TANKS LIQUID LEVEL 58 TABLE CONTENTS cont d Page TROUBLESHOOTING s cesa TARSA 63 TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES 5 i a 63 ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING 63 ALL CONTROL PANEL SWITCHES NOT OPERATING 63 ALL CONTROL PANEL SWITCHES NOT OPERATING COND T 64 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 FAULT MESSAGE GOES ON DURING OPERATION S d denda 65 ERROR 1 OR ERROR 2 FAULT MESSAGE GOES ON DURING OPERATION re aaa an SR tS 65 FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT OPERATE ai ais a et iai 65 UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE 65 MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN DEFROST SWIKCH AS PRESSED
68. XCEED 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 Locate Unit so the following requirements are satisfied 1 Close to a plain water inlet supply line with a minimum pressure of 12 psig NOTE AIR COOLED FCB DISPENSER The air cooled FCB Dispenser refrigeration system is equipped with a condenser coil that is cooled by a condenser coil fan Circulating air required to cool the refrigeration system s condenser coil is drawn in through the grille on front and exhausted out through the sides and back of Unit Restricting air circulation through the Unit will decrease its cooling efficiency 2 When installing Unit do not allow obstruction to block grille on front which will block off air intake to inside of Unit If installation dictates only one side or back being unobstructed allow 18 inches clearance between Unit and obstruction If both sides or one side and back are unobstructed allow 12 inches clearance If both sides and back are unobstructed allow 6 inches clearance CAUTION Do not place or store anything on top of the Unit INSTALLING UNIT PLACING UNIT IN OPERATING LOCATION 1 Place Unit in operating location meeting requi
69. ace 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 gt 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 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 drink The degree of freezing is limited because finished drink is intended to be sipped through a straw This is not possible if product is too solid OPERATING CHARACTERISTICS The product viscosity product consistency can be varied by adjustment and secondary CO regulator setting from a high overrun light drink to a wet heavy drink The length of free
70. aks and tighten or repair if evident OUT fault message should have gone out but SYRUP 1 and SYRUP 2 fault messages will continue to be displayed City Plain Water Source Line Connected to Unit With Water Cooled Refrigeration System Open shutoff valve in City water line connected to the refrigeration cooling coil assembly Check for water leaks and tighten or repair if evident CONNECTING SOFT DRINK TANKS TO UNIT SYRUP SYSTEMS IMPORTANT Product shutoff valves located in lines leading from product blender tanks to freeze cylinders see Figure 2 and 5 must be closed at this time Closing valves prevents product from filling freeze cylinders while checking BRIX of product in product blender tanks 1 Close product shutoff valves located in lines leading from product blender tanks to freeze cylinders to prevent product from entering cylinders 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 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 Pressurize soft drink ta
71. ank B Second connect liquid quick disconnect to soft drink tank 8 Disconnect soft drink tank containing syrup from No 1 syrup system 9 Connect clean empty soft drink tank into No 1 syrup system 10 Place waste container under No 1 cylinder dispensing valve nozzle Open dispensing valve and dispense all product from cylinder As product level lowers in cylinder partially close valve to avoid spurting 11 Remove Unit front lower access panel as instructed for access to No 1 product blender tank product sample valve 12 Place waste container under No 1 product blender tank product sample valve Slowly open valve and purge remaining product out of tank then close valve 1995 2014 Cornelius Inc 50 Publication Number 312026000 13 14 Disconnect empty soft drink tank from No 1 syrup system 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 drink tank cover until pressure has been released from tank WARNING To avoid possible injury or property damage do not attempt to remove soft 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 i
72. art 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 display 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 display Press DEFROST SELECT switch No 2 defrost relay will click when switch is pressed Publication Number 312026000 45 1995 2014 Cornelius Inc 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Press CANCEL DEFROST ADVANCE switch to advance and bring up SYRUP 1 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
73. ault 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 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 OUT Fault Message OUT fault message will appear on message display when 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 OUT fault message SYRUP 1 or SYRUP 2 Fault Messages SYRUP 1 or SYRUP 2 fault messages will appear on message display if product tanks are not connected to Unit or product tanks are empty Syrup systems syrup float switches must be filled with syrup to extinguish SYRUP 1 or SYRUP 2 fault messages 1995 2014 Cornelius Inc 18 Publication Number 312026000 DEFROST 1 or DEFROST 2 Display Messages
74. ct 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 Publication Number 312026000 53 1995 2014 Cornelius Inc 317965000 Retainer 312196000 Spring 312419000 312415000 Washer 300 I D 312418000 Quad Ring 317963000 Body Install new ball seat each servicing FIGURE 11 LIQUID CHECK VALVE ASSEMBLY 3 To connect soft drink tank into Unit syrup system A First connect quick disconnect to soft drink tank to pressurize tank Second connect liquid quick disconnect to soft drink tank 4 Disconnect inlet 2 and outlet syrup lines from empty soft drink tank 5 Check soft drink tank quick disconnects for sticky or restricted operation Rinse disconnects in warm water 6 First pressurize full soft drink tank by connecting line to tank then connect Unit syrup inlet line to tank 7 Press applicable FILL 1 or FILL 2 switch to fill applicable No 1 or No 2 syrup system syrup float switch with syrup 8 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill applicable No 1 or No 2 system product blender tank with product 9 Press applicable AUTO 1 or AUTO 2 switch to start refrigeration system and beater in applicable No 1 or No 2 freeze cylinder
75. defrost settings At the start of each automatic defrost cycle refrigeration compressor will operate for 30 seconds to pump freon out of the freeze cylinders evaporator coils After freon has been pumped out of the freeze cylinders evaporator coils No 1 freeze cylinder only will go into defrost cycle and defrost for approximately 7 minutes then will return to normal operation This ends the automatic defrost cycle of No 1 freeze cylinder No 2 freeze cylinder will defrost 30 minutes after the start of No 1 freeze cylinder The next automatic defrost cycle will occur according to the time programmed into the Unit Automatic defrost may be cancelled at any time by pressing the CANCEL DEFROST switch Publication Number 312026000 3 1995 2014 Cornelius Inc SLEEP SLEEP TIME SLEEP SLEEP TIME may be programmed into Unit to allow Unit to go into sleep time Unit shut down freeze cylinders beaters and refrigeration systems not operating At start of sleep time refrigeration compressor will operate for 30 seconds to pump freon out of freeze cylinders evaporator coils then No 1 freeze cylinder will go into defrost and defrost for 60 seconds After No 1 freeze cylinder has defrosted No 2 freeze cylinder will go into defrost and defrost for 60 seconds At end of No 2 freeze cylinder defrost Unit will shut down and go into sleep time WAKE UP WAKE UP TIME WAKE UP WAKE UP TIME may be programmed into the Unit to allow Unit to
76. e 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 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 conditio
77. e as instructed CHECKING CO SUPPLY 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 1995 2014 Cornelius Inc 22 Publication Number 312026000 Make sure CO cylinder shutoff valve is fully opened regulator assembly 1800 psi gage indicator is not in shaded change 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 Remove and wash drip tray and cup rest with warm water and mild detergent rinse with clean water then install them on Unit SANITIZING The Unit should be sanitized as instructed every 120 days and before and after storage periods following parent company requirements and sanitizer manufacturers recommendations CLEANING CONDENSER COIL Circulating air reguired to cool the refrigeration system condenser coil see Figure 15 is drawn in through louvers
78. e sure OUT fault message is not displayed on message display This indicates no CO gas supply to Unit 3 Make sure SYRUP 1 or SYRUP 2 fault messages 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 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 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 necessary replenished as instructed PRODUCT FLAVOR CHANGE Perform syrup flavor chang
79. ed in SERVICE AND MAINTENANCE section VOLTAGE DISPLAYED VOLTAGE READOUT Displayed voltage readout may be displayed on message display as instructed in SERVICE AND MAINTENANCE 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 Unit and check components for proper operation as instructed in SERVICE AND MAINTENANCE 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 SERVICE AND MAINTENANCE section PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS Note in TABLE 5 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 SERVICE AND MAINTENANCE section PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS The Dispenser electronics must be programmed for the proper refrigeration pulse rate according to the type of refrige
80. ed into the Unit 1995 2014 Cornelius Inc 40 Publication Number 312026000 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 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 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
81. een filled with syrup 28 Press AUTO BLEND 1 switch to fill No 1 Product blender tank with product Carbonator water pump will start and begin pumping carbonated water into product blender tank along with syrup to make product 29 After carbonator water pump cycles off completely fill No 1 freeze cylinder with product by repeatedly pulling and releasing faceplate relief valve and until product comes out of relief valve port Open dispensing valve until product flows from valve then close valve Open No 1 system product sample valve until product flows from valve then close valve 30 Press WASH 1 switch to start No 1 freeze cylinder beater Allow beater to operate for five minutes then press OFF 1 switch to stop beater 31 Disconnect soft drink tank containing syrup from No 1 syrup system 32 Connect clean empty soft drink tank into No 1 syrup system 33 Hold appropriate container under dispensing valve and dispense until all Product has been dispensed from freeze cylinder As product level lowers in freeze cylinder partially close valve to avoid spurting 34 Place waste container under No 1 system product sample valve Slowly open valve and purge remaining product out of product blender tank 35 Disconnect empty soft drink tank from No 1 syrup system and install tank containing syrup 36 Press FILL 1 switch to fill No 1 syrup system syrup float switch with syrup 1 fault message
82. ender tanks a timer controlled automatic hot gas defrost system to defrost the freeze cylinders and interconnecting tubing components and fittings necessary to regulate transfer and dispense product The components are attached to a steel frame and are enclosed in a steel cabinet The cabinet panels are easily removed to facilitate installation and service and maintenance A transparent faceplate with an integral relief valve and a removable self closing dispensing valve is mounted on front of each freeze cylinder removable tray with cup rest is located directly below the dispensing valves Publication Number 312026000 1 1995 2014 Cornelius Inc CAUTION Before shipping storing or relocating Unit syrup systems must be sanitized and all sanitizing solution must be purged from syrup systems All water must also be purged from plain and carbonated water systems A freezing ambient environment will cause residual sanitizing solution or water remaining inside Unit to freeze resulting in damage to internal components Table 1 Design Data Unit Part Number Two Flavor 3 H P Air Cooled 4166200000 Two Flavor 3 H P Water Cooled 4166220000 Overall Dimensions Height 60 1 2 inches Width 19 1 4 inches Depth W O Drip Tray 32 1 2 inches Depth W Drip Tray 38 inches Shipping Weight approx 466 pounds Compressor Horsepower 3 Refrigeration System
83. ender 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 6 2 Remove HEX NUTS item 7 and FLATWASHERS item 6 securing FACEPLATE item 8 to freeze cylinder then remove faceplate from cylinder 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 3 as follows A Remove two screws and hold down plates securing spring housing to dispensing valve body then remove housing Remove torsion spring from dispensing valve Remove knob spring sleeve and lever from dispensing valve Remove spring fitting from dispensing valve Press valve with caged O ring down and out of dispensing valve body SEX BH 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 2 to clean faceplates relief valve passages 7 Submerge all parts in four percent solution of approved sanitizing agent for time recommended by sanitizer manufacturer 8 Remove parts from sanitizing solution and place on clean paper towels NOTE Use Dow Corning DC 11
84. essage 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 4 Press CANCEL DEFROST ADVANCE switch to bring up flashing hour number on display 5 Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING POINT OF SALE MESSAGE DISPLAY see Figure 10 and TABLE 6 Note Point of sale display messages may be turned off by placing No 1 DIP SWITCH on master circuit board in OFF position and 2 SWITCH in ON position see Figure 10 and 4 and 6 assembly in appropriate positions 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 10 and TABLE 4 and TABLE 6 on the DIP SWITCH ASSEMBLY in the appropriate positions ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT Adjusting VIS SET PRODUCT VISCOSITY determines what product consistency of the dispensed product will be present in each freeze cylinder Adjust VIS SET PRODUCT VISCOSITY of the dispensed product as follows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS INTO MESSAGE DISPLAY and bring up VIS SET on message display 2 Press DEFROST SELECT switch to bring up numbers on message display Note The direction of arrow
85. f valves to purge air from tanks 4 Remove Unit lower stainless steel access panel as instructed for access to carbonator secondary regulators see Figure 4 5 Check product blender tanks secondary CO regulators with 60 psi gages for pressure setting which should set at 25 to 30 psi for best textured product If further adjustment is necessary adjust as instructed IMPORTANT The carbonated water tanks secondary CO regulators must be adjusted 25 psi higher or more above 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 Carbonated water tanks secondary regulators not adjusted high enough will cause decreased flow of carbonated water into the product blender tanks which will increase brix of the dispensed product 6 Adjust carbonated water tanks secondary CO regulators with 100 psi gages by turning regulators adjusting screws to the right clockwise until gages reads 50 to 60 psi 7 Pull up on carbonated water tanks relief valves plastic covers to purge air from the tanks TURNING ON CITY PLAIN WATER SOURCE LINE TO UNIT City Plain Water Source Line Connected to Unit Post Mix System Water Cooled and Air Cooled Refrigeration Units Open shutoff valve in City plain water line connected to the Unit Post mix system Check for water le
86. ge display 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 istalled in the refrigeration system Note Dispenser serial plate for the type of refrigerant gas that has been installed then proceed as follows to program the Dispenser 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up REF TYPE REFRIGERANT TYPE on the message display Press DEFROST SELECT switch to lock in on the selection The sub menu of refrigerant types that may be brought up on the MESSAGE DISPLAY from REF TYPE REFRIGERANT TYPE are as follows A R404A2HP V3 Dispenser with 2 Copeland Compressor and R 404A Refrigerant B R404A3HP V3 Dispenser with Copeland Compressor and R 404A refrigerant C R502 V3 and V3 Dispensers using Bristol or Tecumseh Compressor and R502 refrigerant D R402B5OH V3 and V3 Dispensers using a Bristol Compressor and R 402B refrigerant Refer to Dispenser serial plate to identify the type of refrigerant gas installed in the refrigeration system Press CANCEL DEFROST ADVANCE switch as many times as necessary to bring up applicable refrigerant type from sub menu of REF TYPE REFRIGERANT on
87. hown in Figure 9 The following instructions outline adjustments and programming main menu selections components DIAGNOSE DIAGNOSTIC MODE and TOTALS DISPLAYED CYCLES AND HOURS TOTALS into the Unit NOTE Plain water and syrup supplies to Unit must be satisfied to turn off H20 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 3 may be brought up on the message display as follows 1 Press AUTO 1 WASH 1 and BLEND 1 control switches see Figure 9 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 To advance through the MENU SELECTIONS repeatedly press the CANCEL DEFROST ADVANCE switch Once you reach the desired selection press the DEFROST SELECT switch to lock in on the selection NOTE To exit MENU SELECTION and go back to MAIN MENU SELECTIONS press ERROR RESET RESET switch Press ERROR RESET RESET switch again to exit from MAIN MENU SELECTIONS SETTING CLOCK TIME OF DAY NOTE The CLOCK TIME OF DAY must be programmed into Unit before DEFROST AUTOMATIC SLEEP SLEEP TIME and WAKE UP WAKE UP TIME can be programm
88. iable water regulator must be adjusted to maintain 240 psi refrigeration high side pressure Adjust the variable water regulator see Figure 16 to maintain 240 psi refrigeration high side pressure as instructed in the SERVICE AND MAINTENANCE section ADJUSTING BEATER MOTOR CURRENT EITHER SIDE 1 Remove four screws securing the upper control box cover then remove cover for access to the master circuit board inside the control box 2 Adjust beaters motors currents as instructed in SERVICE AND MAINTENANCE section PROGRAMMING MAIN MENU SELECTIONS ONTO the MESSAGE DISPLAY The MAIN MENU SELECTIONS see Table 3 may be brought up on message display as instructed in SERVICE AND MAINTENANCE section Program CLOCK TIME OF DAY into Unit as instructed in SERVICE AND MAINTENANCE section PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO the 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 SERVICE AND MAINTENANCE section PROGRAMMING SLEEP SLEEP TIME INTO the UNIT SLEEP SLEEP TIME may be programmed into the Unit to occur any time of the day after the Unit automatic defrost cycle has occurred The Unit will shut down go into sleep time and will not wake up return to normal operation until programmed WAKE UP WAKE UP TIME
89. ical power to the Unit to prevent personnel injury before attempting any internal maintenance Only qualified personnel should service internal components or electrical wiring NOTE The No 1 freeze cylinder see Figure 4 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 SWITCHES AND DISPLAYED MESSAGES CONTROL PANEL SWITCHES The Unit is equipped with one control panel which is equipped with a message display See Figure 4 The control panel controls operation of the No 1 and the No 2 freeze cylinders FILL 1 and FILL 2 Control Switches FILL 1 and FILL 2 control switches located on control panel see Figure 4 are touch type switches require only pressing to activate FILL 1 and FILL 2 control switches are used when filling syrup systems sold out floats during syrup replenishing syrup flavor changeover or sanitizing syrup systems After syrup systems sold out floats have been filled FILL 1 and FILL 2 switches may be used to prevent more product entering product blender tanks during BRIX test AUTO BLEND 1 and AUTO BLEND 2 Control Switches AUTO BLEND 1 and AUTO BLEND 2 control switches located on control panel see Figure 4 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
90. inside female end of double liquid check valve assembly then install check valve assembly on elbow in water pump outlet port 13 Connect carbonator tank water line to double liquid check valve assembly outlet DO NOT OVERTIGHTEN 14 Open CO cylinder and water inlet supply lines shutoff valves Check for water leaks and tighten any loose connections 15 Install Unit back panel by reversing removal procedure 16 Connect electrical power to Unit 17 Press both AUTO BLEND 1 and AUTO BLEND 2 switches 18 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 Press applicable OFF 1 or OFF 2 switch to stop applicable freeze cylinder beater and refrigeration system 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 2 To disconnect soft drink tank from Unit syrup system A Disconne
91. ion 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 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 on as instructed in 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 CO quick disconnect to soft drink tank to press
92. it of 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 and defrost for approximately 7 minutes then will return to normal operation This ends automatic defrost cycle of No 1 freeze cylinder No 2 freeze cylinder will defrost 30 minutes after the start of No 1 freeze cylinder The next automatic defrost cycle will occur according to time programmed into the Unit SLEEP SLEEP TIME SLEEP SLEEP TIME may be programmed into Unit to allow Unit to go into sleep time Unit shut down freeze cylinders beaters and refrigeration systems not operating At start of sleep time refrigeration compressor will operate for 30 seconds to pump freon out of freeze cylinders evaporator coils Then No 1 freeze cylinder will go into defrost for and defrost 60 seconds After No 1 freeze cylinder has defrosted No 2 freeze cylinder will go into defrost and defrost for 60 seconds At end of No 2 freeze cylinder defrost Unit will shut down and go into sleep time WAKE UP WAKE UP TIME 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
93. l panel switch module Loose or broken wire Master circuit board not operating properly 65 Remedy Replace master circuit board Replace fault message display module Open cylinder shutoff valve or replenish supply as instructed Adjust primary regulator as instructed Replace 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 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 Repair wire Replace master circuit board 1995 2014 Cornelius Inc Trouble DEFROST CYCLE DOES CANCEL AFTER PRESSING CANCEL DEFROST SWITCH 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 CANCEL DEFROST switch on control panel switch module Master circuit board not
94. ld 22 MOTOR 9 9 MOTOR MTR PSI SW TT SYRUP TT BEATER BEATER BEATER BEATER 11 22 BLU FLOATS BLENDER MOTOR MOTOR MOTORS WITHOUT START RELAY SYRUP LEER MOTOR MOTOR MOTORS WITHOUT START RELAY YEL NC FLOATS RIGHT 811 RIGHT 22 li Nas 5 5 LEFT LEFT 2 11 dr ut dr E 2 2 2 2 15 E BRN 1 2 15 BRN 5 BRN 1 Nc clo 8 YEL Nc cl i BEATER BEATER start 5 MOTOR SOLD OUT 1 X START WIR PSI SWT SOLD OUT nm RELAY T RELAY P SWITCHES COR ur RELAY 1 1 SWITCHES 25 4 LEFT 1 YEL 4B s 71 RIGHT 11 VEL 2 3 2 i 5 s 5 8 8 10 5 res NC a 8 d war 1 xe 1 BLK E y 7 nai i BLK BLK Pp BLK Ant LEFT 2 BLK f T WHT RIGHT 22 BLK o N CARB CARB cM CARB PUMP 11 PUMP 22 vea PUMP 2 9 5 n z RED E LEFT LEFT z 5 RIGHT 11 RIGHT 22 5 1 2 5 LU BLU SOL SOL 9 oy FILTER HOT BRN FILTER ricis EN GAS FILTER 9 BRN MTR CURRENT AD b NT ADJ 5 WHT 88 b 5 xe Hg ma REFR INLET H BOARD 1105 WHT o RR mEn 10 WHT NC NC REFR INLET 137 m REFR INLET 2 137 o RR OUTLET 16 eRome 161 EE i GRN OR TRAN 142 YEL G
95. lows 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 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 Place waste container under 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 WARNING Flush residual sanitizing solution from syrup system as instructed Residual solution left in system could create a heath hazard Publication Number 312026000 51 1995 2014 Cornelius Inc 27 Press FILL 1 switch to fill No 1 syrup system syrup float switch with syrup SYRUP 1 fault message message display will go out indicating syrup float switch has b
96. m switches Proceed as follows 1 Press OFF 2 switch to stop beater motor and refrigeration in No 2 freeze cylinder which is not to be defrosted OFF 2 fault message will appear on message display 2 Press DEFROST switch to start defrost cycle on No 1 freeze cylinder DEFROST 1 message will appear on message display as long as defrost cycle is in progress 3 Immediately press AUTO 2 control switch to restart beater in No 2 freeze cylinder Refrigeration in No 2 cylinder will not be operating 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 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 Second disconnect quick disconnect from soft drink tank 7 To connect soft drink tank into Unit syrup system A First connect CO quick disconnect to soft drink tank to pressurize t
97. 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 1995 2014 Cornelius Inc Trouble ALL CONTROL PANEL SWITCHES NOT OPERATING cond t CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED PARTIAL MESSAGE OR DULL POORLY ILLUMINATED DISPLAY ONE OR MORE FAULT MESSAGES NOT OPERATING ALL FAULT MESSAGES NOT OPERATING 1995 2014 Cornelius Inc 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 cabl
98. n a more concentrated form because it will be diluted approximately four to one in product blender tank 16 17 18 20 21 22 23 24 25 26 Using clean empty soft drink tank prepare full tank of sanitizing solution using Chlor Tergent Oakite Product Inc or equivalent sanitizer Mix sanitizing solution by using 70 F to 100 F max plain water and 2 65 oz gallon sanitizer This mixture will provide 800 ppm of chlorine Sanitizing solution will be diluted to approximately 200 ppm inside product blender tank after carbonated water has been mixed with sanitizing solution Shake sanitizing solution tank to thoroughly mix solution then connect tank into No 1 syrup system Press FILL 1 switch to fill No 1 syrup system syrup float switch with sanitizing solution SYRUP 1 fault message on message display will go out indicating syrup float switch has been filled with sanitizing solution 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 repeatedly pulling and releasing relief valve knob on freeze cylinder faceplate and until sanitizing solution comes out of relief valve port Open dispensing valve until sanitizing solution f
99. n and repair or replace as necessary Publication Number 312026000 Trouble ALL FAULT MESSAGES NOT OPERATING cond t 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 Publication Number 312026000 Probable Cause Master circuit board not operating Fault message display module not operating properly supply turned off or exhausted Primary CO 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 contro
100. nks containing syrup then connect tanks to Unit syrup systems OFF 1 OFF 2 SYRUP 1 and SYRUP 2 fault messages will continue to be displayed Publication Number 312026000 11 1995 2014 Cornelius Inc ADJUSTING WATER TO SYRUP RATIO DISPENSED PRODUCT NOTE The Unit is equipped with one control panel see Figure 4 which controls operation of the two freeze cylinders The Unit control panel is equipped with a hidden SECURITY SWITCH located between FILL 1 and ERROR RESET control switches see Figure 4 Pressing in and holding the SECURITY SWITCH for 10 seconds deactivates the control switches preventing tampering with the Unit normal operation To reactivate the control switches press in and hold the SECURITY SWITCH for 10 seconds The following steps 1 through 9 are instructions for adjusting Brix Water to Syrup Ratio mixture of dispensed product on one of the two systems Note The adjustable carbonated water flow regulators see Figure 2 and 13 located in their respective systems control carbonated water flow rate to the product blender tanks The water flow regulators are factory adjusted at 1 3 0 05 oz sec and should not normally require adjustment If adjustment is necessary adjust as instructed 1 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
101. oduct from entering product blender tank OFF 1 OFF 2 and SYRUP 2 fault messages will continue to be displayed 7 Repeat steps 3 and 4 preceding to check product sample for BRIX 8 Repeat steps 5 through 7 preceding until proper BRIX adjustment is achieved 9 Repeat steps 1 through 8 preceding to adjust BRIX of dispensed product on No 2 system After completing BRIX adjustment on No 2 system only the OFF 1 and OFF 2 fault messages should continue to be displayed NOTE Syrup systems may be sanitized at this time as instructed FILLING FREEZE CYLINDERS WITH PRODUCT 1 Open product shutoff valves located in lines leading from product blender tanks to freeze cylinders 2 Press AUTO BLEND 1 and AUTO BLEND 2 switches to begin filling freeze cylinders Open freeze cylinders faceplates relief valves to bleed air from cylinders while filling with product then close valves Do not relieve freeze cylinder pressure too fast or product will foam excessively in cylinder and lose carbonation 1995 2014 Cornelius Inc 12 Publication Number 312026000 ADJUSTING WATER COOLED UNIT REFRIGERATION SYSTEM VARIABLE WATER REGULATOR IMPORTANT NOTICE Water Cooled Refrigeration System Dispenser Water flow rate through the refrigeration cooling coil varies due to pressure change on the high side of the refrigeration compressor which influences opening and closing of the variable water regula tor see Figure 16 The var
102. on front and exhausted out through louvers on sides and back of Unit Restricting air circulation through the Unit will decrease its cooling efficiency The condenser coil air filter and the condenser coil must be cleaned periodically as instructed in SERVICE AND MAINTENANCE section LUBRICATION The carbonator pump motor must be lubricated as instructed ADJUSTMENTS CARBONATED WATER FLOW RATE The black carbonated water flow regulators see applicable Figure 2 and 5 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 SERVICE AND MAINTENANCE section REGULATORS Primary CO Regulator The primary regulator see Figure 2 regulates 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 SERVICE AND MAINTENANCE section Secondary CO Regulators The secondary CO regulators see applicable Figure 2 and 5 regulate CO pressure to the carbonated water tanks and the product blender tanks If necessary to adjust secondary regulators adjust as instructed in SERVICE AND MAINTENANCE section Publication Number 312026000 23 1995 2014 Cornelius Inc ADJUSTING 5 MOTORS CURRENTS Beate
103. p 8 preceding to the regulator outlet 16 Turn the product blender tanks regulator with 60 psi gage adjusting screw clockwise until gage registers pressure noted in step 7 preceding 17 Pull relief valve on the applicable product blender tank to purge air from the tank then close the valve 18 Connect Unit syrup inlet line to the soft drink tank 19 Press the applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill the product blender tank with product 20 Open the product shutoff valve that was closed in step 4 preceding 21 Install the side panel and the lower front access panel by reversing removal procedure ADJUSTING 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 gage reads 5 psi lower than the new setting will be Turn the adjusting screw to the right clockwise until the gage registers new setting then tighten 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 regulator pressure reads 80 to 100 psig Product Blender Tanks Secondary Regulators see Figure 2 1 Remove the Unit lower front stainless steel access panel as instructed for access to the product blender tanks secondary CO regulators 2 Adjust the product blender tanks secondary CO
104. panels by reversing the removal procedures 13 Restore the Unit to operation 14 Refer to PROGRAMMING FREEZE CYLINDER BEATER MOTORS INTO UNIT ELECTRONICS in the SERVICE AND MAINTENANCE section to program the new replacement beater motor into the Unit to match the Unit electronics ADJUSTING CARBONATED WATER TANKS LIQUID LEVEL The carbonated water tank liquid level pump cut in and cutout was adjusted at the factory and should require no further adjustment However if incorrect setting is suspected check and make necessary adjustments as follows 1 Remove Unit back and side panels as instructed for access to the carbonated water tanks and the carbonated water volume sample valves see Figure 2 and 5 2 To check carbonator tank total fill allow carbonator water pump motor to operate and fill tank with carbonated water After pump cycles off disconnect electrical power from Unit 3 Using container graduated in ounces open applicable carbonated water tank carbonated water sample valve and completely drain carbonated water tank into the container Total carbonated water volume dispensed should be 40 to 58 ounces maximum 4 If total carbonated water dispensed is below 40 ounces loosen screw securing level control switches actuator bracket see Figure 14 and move actuator bracket up slightly If more than 58 ounces maximum of carbonated water was dispensed move actuator bracket down then tighten screw MAKE ADJUSTMENTS IN SMALL
105. r current readings were A155 145 and switch was then placed back in OFF position without readjusting to A150 B150 2 beater motor current has just been reset at A155 B145 Operating the FCB Dispenser at these current readings may have serious effects on its operation ANY TIME THE NO 4 BEATER MOTOR CURRENT READOUT SWITCH ON DIP SWITCH ASSEMBLY IS PLACED IN ON POSITION THE BEATER MOTOR CURRENT READINGS MUST BE READJUSTED TO A150B150 2 AS INSTRUCTED THEN SWITCH MUST BE PLACE BACK IN THE OFF POSITION Publication Number 312026000 39 1995 2014 Cornelius Inc ESTA ID w Im Im IN IO in joo lis Io In gt gt gt N I gt N NII In I TIN Jl O 0 Jl 1 DIAGNOSE DIAGNOSTIC MODE Programming Components Diagnose into See Table 7 and programming TOTALS TOTALS DISPLAYED CYCLES AND HOURS TOTALS into unit MOTORS BEATER MOTOR MANUFACTURER See Table 5 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 AUTOMATIC SLEEP SLEEP TIME and WAKE UP WAKE UP TIME will function TABLE 3 MAIN MENU SELECTIONS ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS INTO UNIT Note The Unit control panel switches are as s
106. rain and connect Seal connection with black TAPERED GASKET BLACK item 4 Publication Number 312026000 9 1995 2014 Cornelius Inc ELECTRICAL POWER CIRCUIT UNIT see Figure 17 is in OFF position WARNING Make sure disconnect switch not provided or equivalent HACR circuit breaker IMPORTANT Power circuit voltage across L4 and terminals on the contactor inside the lower control box with refrigeration compressor operating must be in the range of 198 253 VAC 60Hz 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 1 Remove lower control box located on lower right side facing front of Unit cover for access to contactor L4 and Lo terminals WARNING This Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator A green screw with lock washer is provided inside control box to connect power circuit ground wire electrically grounding the Unit 2 Connect electrical power from a 30 amp minimum rated disconnect switch not provided fused at 30 amps slow blow or through an equivalent HACR circuit breaker to L4 and L terminals on the contactor inside the control box MAKE SURE GROUND WIRE IS CONNECTED TO GREEN GROUND SCREW INSIDE CONTROL
107. rant 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 SERVICE AND MAINTENANCE section for programming instructions DISPLAYED ERROR CONDITIONS Displayed error conditions associated errors and items affected by the errors are found in TABLE 8 DISPLAYED ERROR CONDITIONS Publication Number 312026000 25 1995 2014 Cornelius Inc WATER DOUBLE LIQUID CHECK VALVE MAINTENANCE see Figures 2 and 13 WARNING The carbonator water pump double liquid check valve must be inspected and serviced after any disruptions plumbing work earthquake etc to the water supply system and at least once a year under normal circumstances Foreign particles lodged in the double liquid check valve could cause gas to back flow into the water system and create health hazard in the system Service water water pump double liquid check valve as instructed in SERVICE AND MAINTENANCE section CLEANING GAS CHECK VALVES see applicable Figure 2 and 12 The 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 SERVICE AND MAINTENANCE section 1995 2014 Cornelius Inc 26 Publication Number 312026000 SERVICE AND MAINTENANCE This section describes service and maintenance to be performed on the Unit
108. ration 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 control panel see Figure 4 Pressing in and holding SECURITY SWITCH for 3 seconds deactivates control switches preventing tampering with Unit normal operation To reactivate control switches press and hold SECURITY SWITCH for 3 seconds CONTROL PANEL DISPLAY MESSAGES see Figure 4 FILL 1 and FILL 2 Fault Messages FILL 1 and FILL 2 fault messages will appear on message display only when FILL 1 and FILL 2 control switches have been pressed and syrup systems sold out floats have been filled with product FILL 1 and FILL 2 fault messages will continue to be displayed until AUTO BLEND 1 or AUTO BLEND 2 control switches have been pressed to fill product blender tanks with product ERROR 1 and ERROR 2 Fault Messages ERROR 1 and ERROR 2 fault messages will appear on message display only if error within Unit has developed interrupting normal operation Error will have to be located and corrected then press ERROR RESET to restore normal operation ERROR 1 or ERROR 2 fault message will disappear from display OFF 1 and OFF 2 Fault Messages OFF 1 and OFF 2 f
109. rbon dioxide gas to an adjustable primary regulator assembly attached to the cylinder The primary regulator assembly in turn delivers gas to an adjustable secondary regulators inside the Unit and also to the soft drink tanks CO is delivered from the adjustable secondary regulators to the two carbonated water tanks and also to the 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 operated syrup solenoid valves and on to the product blender tanks At the same time plain water passes through the water pressure regulator and is pumped into the carbonated water tanks by the water pump and is carbonated by CO gas pressure also entering the tank Carbonated water is pushed by CO gas pressure from the carbonated water tanks through adjustable carbonated water flow regulators through electrically operated carbonated water solenoid valves and on to the product blender tanks Carbonated water and syrup enter the tanks properly proportioned blended for desired BRIX of dispensed product by adjustment of the syrup flow regulators From product blender tanks product is pushed by the CO gas into the freeze cylinders The beater in each freeze cylinder is driven by an electric motor Scraper blades attached to the beaters scrapes product from the cylinder walls as product
110. rements of SELECTING LOCATION IMPORTANT NOTICE The FCB Dispensers manufactured prior to the model 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 Publication Number 312026000 7 1995 2014 Cornelius Inc Note An alternate to sealing the Unit base to the floor would be to install the available 4 inch Caster Kit P N 309570000 2 After Unit has been placed in operating location make sure it is sitting in a level position 8 To comply with National Sanitation Foundation NSF requirements Unit installed with base contacting floor must have base sealed to floor with Dow Corning RTV 731 or equivalent INSTALLING SOUND BAFFLE DRIP TRAY ASS Y ON UNIT All parts for the SOUND BAFFLE DRIP TRAY ASS Y item 8 are shipped with the Dispenser in a separate box Refer to Installation Instructions provided with the Sound Baffle Drip Tray Assembly and install as instructed INSTALLING PRIMARY CO REGULATOR ASSEMBLY ON CO CYLINDER see Figure 2 WARNING To avoid personal injury and or property damage always secure CO cylinder in upright position with a safet
111. rrent 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 Place No 4 BEATER MOTOR CURRENT READOUT switch on DIP SWITCH assembly on master circuit board see Figure 10 in ON position Both freeze cylinders beater motors will start and operate and beaters motors current ratings will be displayed on message display 2 Display should be adjusted to read A150 B150 2 by adjusting MOTOR CURRENT ADJUSTMENTS located on No 1 and No 2 relay circuit boards see Figure 10 These figures will fluctuate slightly with variations in line voltage and motor loads 3 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 10 is in OFF position No 5 switch in OFF position allows the MOTOR CURRENT SELF CALIBRATION electronics to automatically self calibrate the beaters motors currents at completion of each defrost cycle CAUTION IF NO 4 BEATER MOTOR CURRENT READOUT SWITCH ON DIP SWITCH assembly is placed position and beater moto
112. rs motors currents must be adjusted as instructed in SERVICE AND MAINTENANCE section PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS see Table 3 may be brought up on message display as instructed in SERVICE AND MAINTENANCE 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 SERVICE AND MAINTENANCE 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 SERVICE AND MAINTENANCE section PROGRAMMING SLEEP SLEEP TIME INTO UNIT SLEEP SLEEP TIME may be programmed into Unit to occur any time of the day after the Unit automatic defrost cycle has occurred Unit will shut down go into sleep time and will not wake up return to normal operation until programmed WAKE UP WAKE UP TIME has occurred Program SLEEP SLEEP TIME into Unit as instructed in SERVICE AND MAINTENANCE section PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT WAKE UP WAKE UP TIME May be programmed into Unit to occur any time of
113. s 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 flashing on message display 4 Press CANCEL DEFROST ADVANCE switch to advance viscosity number to desired setting Press DEFROST SELECT switch to lock in viscosity setting The right side freeze cylinder viscosity number will now be flashing Publication Number 312026000 43 1995 2014 Cornelius Inc 5 Press CANCEL DEFROST ADVANCE switch to advance viscosity number to desired setting Press DEFROST SELECT switch to lock in viscosity setting 6 Press ERROR RESET switch two times to exit from MENU SELECTIONS VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT IN FREEZE CYLINDERS VIS READ ACTUAL VISCOSITY READOUT may be brought up on message display to actually read the viscosity product consistency of the product in the freeze cylinders while the Unit is in operation Bring VIS READ up on message display as follows 1 Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up VIS READ of product in freeze cylinders 2 Press DEFROST SELECT switch to bring up actual viscosity readout of product in each freeze cylinder 3 Press ERROR RE
114. 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 t is caused primarily by CO gas breakout and secondary by freezing 1995 2014 Cornelius Inc 20 Publication Number 312026000 Overrun is Variable percentage or degree of overrun depends a number of factors The specific syrup BRIX low dispensing volume carbonation level in liquid product and freezing all affect overrun After these factors have been considered desired viscosity product consistency adjustment may be made on the Unit The viscosity adjustment adjusts product texture from very wet to light Specific Product Ingredients Affect Overrun Each syrup has its own specific formulation of makeup Baume an important ingredient factor may fall within an wide range Fruit flavors contain acids that colas do not Colas also differ in ingredients from one brand to another Each product formulation has its own peculiarities regarding the way the product will absorb carbonation and the way it will release carbonation BRIX Affects Overrun Sugar in carbonated drinks is like anti freeze in water The higher the BRIX in a product the greater resistance the product has to freezing Conversely in products with lower BRIX freezing takes pl
115. the day to wake Unit up return to normal operation after sleep time has occurred Program WAKE into Unit as instructed in SERVICE AND MAINTENANCE 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 SERVICE AND MAINTENANCE 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 SERVICE AND MAINTENANCE 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 SERVICE AND MAINTENANCE section 1995 2014 Cornelius Inc 24 Publication Number 312026000 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be displayed on message display as instruct
116. then close valve 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 Repeat steps 6 and 7 preceding to check product sample for BRIX Repeat steps 7 through 10 preceding until proper BRIX adjustment is achieved Open product shutoff valve in line between product blender tank and freeze cylinder Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch Install Unit side panels and front lower access panel by reversing removal procedures PRODUCT CARBONATION ADJUSTMENT see Figures 2 and 5 Carbonation of dispensed product can also be varied to suit consumer preference by adjusting Unit carbonated water tanks secondary CO regulators as follows IMPORTANT The carbonated water tanks secondary CO regulators must be adjusted 25 psi higher or more above 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 Carbonated water tanks secondary regulators not adjusted high enough will cause decreased flow of carbonated water into the product blender tanks which will increase BRIX of the dispensed product 1 Remove Unit front lower stainless
117. to the Unit electronics 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up MOTORS on the message display Press DEFROST SELECT switch to lock in on the selection 1 MFG 1 represents No 1 freeze cylinder beater motor will appear on the message display 1995 2014 Cornelius Inc 48 Publication Number 312026000 Press DEFROST SELECT switch again A motor Manufacturer s name see TABLE 5 will appear on the message display and will be non blinking Press CANCEL DEFROST ADVANCE switch The motor Manufacturer s name will start blinking Press the CANCEL DEFROST ADVANCE switch again which will change to another blinking Manufacturer s name 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 After 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 Press DEFROST SELECT switch to return to MOT MFG1 Press CANCEL DEFROST ADVANCE switch to go from MOT MFG to represents 2 freeze cylinder beater motor which will appear on the messa
118. urce line for a period of time to flush out any metal shavings 2 Route Unit plain water inlet line out through hole in bottom of Unit base NOTE The carbonator plain water inlet adjustable water pressure regulator see Figure 2 is factory adjusted to 45 psi and should not be readjusted 3 Connect Unit plain water inlet line to the city plain water source line 12 psi minimum pressure Seal connection with TAPERED GASKET BLACK item 4 DO NOT OPEN THE CITY PLAIN WATER SOURCE LINE SHUTOFF VALVE AT THIS TIME Connecting City Plain Water Source Line to Unit With Water Cooled Refrigeration System See Figure 16 NOTE The water cooled Two Flavor FCB Post Mix Dispenser has one water cooled refrigeration system that requires connection of a City plain water source line to its refrigeration cooling coil plain water inlet line THE CITY PLAIN WATER SOURCE LINE MUST INCLUDE A WATER SHUTOFF VALVE Proceed as follows to connect the City plain water source line to the Dispenser refrigeration cooling coil plain water inlet line 1 Route the refrigeration cooling coil plain water inlet line labeled COOLING WATER IN and line labeled COOLING WATER OUT out through hole in bottom of the Unit base 2 Connect the refrigeration cooling coil plain water inlet line labeled COOLING WATER IN to the City plain water inlet line Seal connection with TAPERED GASKET BLACK item 4 3 Route the line labeled COOLING WATER OUT to a permanent d
119. urize tank B Second connect liquid quick disconnect to soft drink tank 4 First pressurize soft drink tank containing new flavor syrup by connecting line to tank then connect Unit syrup inlet line to tank 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 Publication Number 312026000 55 1995 2014 Cornelius Inc 8 After carbonator water pump cycles off intermittently pull and release applicable No 1 2 freeze cylinder faceplate relief valve This bleeds from freeze cylinder and allows product to enter and fill cylinder 9 f necessary adjust BRIX product viscosity product consistency and product carbonation of dispensed product as instructed QUAD RING 183294000 BALL 5 183290000 SPRING ja 183207000 Ba RETAINER 183298000 CD BODY E QUAD RING SEAL MUST BE REPLACED EACH TIME CHECK VALVE IS SERVICED FIGURE 12 GAS CHECK VALVE CLEANING GAS CHECK VALVES see Figure 2 and 12
120. 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 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 Publication Number 312026000 41 1995 2014 Cornelius Inc SWITCH NO FUNCTION POINT OF SALE MESSAGE SELECT See Table 6 POINT OF SALE MESSAGE SELECT See Table 6 4 BEATER MOTOR CURRENT READOUT ON Display current readout OFF No displayed current readout 5 MOTOR CURRENT SELF CALIBRATION ON Disabled OFF Operating LS DEFROST ON Hot gas OFF Electric Note Switch No 3 must be in OFF position for standard Units with pulse expansion valves Switch No 3 must be in ON position for older Units with mechanical expansion valves TABLE 4 DIP SWITCH SETTINGS meus wr Wie bor win a GE wiae rengo E Fasc gear boc wita JS bos usng a Fasco wasenge es
121. y chain to prevent it from falling over Should the valve become accidentally damaged or broken off COs 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 cap with chain attached from cylinder valve Open CO cylinder valve slightly counterclockwise to blow any dirt or dust from outlet fitting before installing primary CO regulator then close valve 2 Remove shipping plug from primary 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 REGULATOR ASSEMBLY see Figure 2 1 Connect soft drink tanks CO lines to primary regulator manifold assembly as shown in Figure 2 2 Install gas quick disconnects on ends of soft drink tanks lines DO NOT CONNECT LINES TANKS AT THIS TIME PREPARING UNIT SYRUP INLET LI
122. zing cycle and amount of CO present in product combine to create drink dispensed The dispensed product will have a normal variance due to the following conditions Publication Number 312026000 21 1995 2014 Cornelius Inc 1 If some time has elapsed since the last drink was drawn from a particular freeze cylinder and the compressor has not cycled on the drink dispensed will have a tendency to be wetter have slightly less overrun than normal for the setting and will not mound up as high See Drawing 1 NOTE A cylinder freeze up may be expected under casual draw conditions if an attempt is made to eliminate drink described above by adjusting viscosity 2 If product is drawn from freeze cylinder quite regularly its viscosity product consistency will be maintained at whatever viscosity adjustment was made within the normal variance of the compressor off and on cycle See Drawing 2 3 If product is drawn continuously from freeze cylinder and rate is approaching capacity of the dispensing unit overrun of drink will increase just prior to point capacity is exceeded and drink dispensed will turn slightly wetter see Drawing 3 OPERATING UNIT NOTE The No 1 freeze cylinder see Figure 4 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 on message display This indicates no water supply to Unit 2 Mak

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