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Service Manual FCB Solid-State Post

1. 000660926 4 FLAVOR UNITS NEL RIGHT 11 RIGHT 22 RIGHT 11 RIGHT 22 FT LEFT Ae 2 FLAVOR gt ZN FT FT LE B WTR PSI SWT RICHT Mit RIS w22 i YRUP LEFT 1 co 1 wit 22 BLU is BLENDER S i SE Di FLOATS BEATER BEATER 1 1 MOTOR MOTOR 1 1 p MOTOR MOTOR gt 4 gt
2. KELLY a am EVAPORATOR lt gt lt o STRAINER DRYER VALVE A LD s ga A O LI e CO gt a lt lt CONDENSER COIL COMPRESSOR ee RECEIVER TANK FIGURE 16 REFRIGERATION FLOW DIAGRAM ONE OF TWO REFRIGERATION SYSTEMS SHOWN 326093000 60 19
3. 25 LUBRICATION do set pa nenne bo si 25 ADJUSTMENTS eee ee ae e oxen 25 CARBONATED WATER FLOW RATE 25 326093000 i TABLE OF CONTENTS cont d Page BOREGULMHO Sean ee 26 BRIX WATER TO SYRUP OF DISPENSED PRODUCT 26 ADJUSTING BEATERS MOTORS CURRENTS 26 ADJUSTING CARBONATOR TANK LIQUID LEVEL 26 PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY 26 SETTING CLOCK TIME DAY 26 PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT 26 PROGRAMMING SLEEP SLEEP TIME INTO UNIT 26 PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT 27 PROGRAMMING POINT OF SALE MESSAGE DISPLAY 27 ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED AN 27 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 27 VOLTAGE DISPLAYED VOLTAGE 27 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE NIOUN Tee ee 27 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY un a o een 27 DISPLAYED ERROR CONDITIONS 27 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE MAINTENANCE Alka au
4. 17 DISPLAYED ERROR CONDITIONS 17 OPERATORS INSTRUCTIONS 19 CONTROL PANEL SWITCHES AND DISPLAYED MESSAGES 19 CONTROL PANEL SWITCHES ee 19 CONTROL PANEL DISPLAY MESSAGES 20 FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS 21 MANUAL DEFROST SYSTEM 21 AUTOMATIC DEFROST SYSTEM 21 SLEEP SLEEP TIME 2 1 21 WAKE UP WAKE UP 22 FACEPLATE RELIEF VALVES 22 PRODUCT SAMPLE VALVES N ae 22 PRODUCT SHUTOFF VALVES See 22 PRIMARY CO2 REGULATOR Senden eek 22 SECONDARY CO2 REGULATORS 0 el essen 22 CARBONATED WATER FLOW REGULATORS 22 SYRUP FLOW REGULATORS Se nennen een 22 DISPENSING VALVES la nen een 22 DISPENSED PRODUCT CONDITIONS 23 OPERATING CHARACTERISTICS aidai are 24 OPERATING UNIT Asse 24 REPLENISHING SYRUP SUPPLY 24 PRODUCT FLAVOR CHANGE 24 CHECKING CO2 SUPPLY aa on ae 25 CLEANING AND SANITIZING a ee 25 DAILY 25 25 CLEANING CONDENSER COIL
5. 1 lt 4LOCKING TABS 2 90 APART 4 2 SLOTS T 4 180 APART VIEW B FIGURE 7 SELF CLOSING DISPENSING FIGURE 8 SERVICING BEATER DRIVE VALVE SHAFT SEAL ASSEMBLY 5 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 CLEANING BRUSH item 5 Table 3 to clean faceplates relief valve passages 6 Submerge all parts in four percent solution of approved sanitizing agent for time recommended by sanitizer manufacturer 7 Remove parts from sanitizing solution and place on clean paper towels NOTE Use Dow Corning DC 111 P N 321471000 light grade silicone lubricant 8 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 Carefully install valve with caged O ring in dispensing valve body 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 D Turn spring housing to the left counterclockwise to put tension on torsion spring then tighten hold down plates to secure spring housing E Test disp
6. 28 CLEANING CO2 GAS CHECK VALVES 28 SERVICE AND MAINTENANCE 29 PREPARING UNIT FOR SHIPPING STORING OR RELOCATING 29 PERIODIC INSPECTION 5 sian ala ua e io ja ao 29 REMOVAL OF DRIP TRAY BACK PANEL SIDE PANELS TOP PANEL LOWER FRONT ACCESS PANEL AND CONDENSER COILS ACCESS PANEL 29 DEP TEAM ua eka saaa ans 29 BACKSPANE ies 29 SIDE PANELS ne ee tations Ais a iai asia 29 a eee 29 LOWER FRONT ACCESS PANEL 30 CONDENSER COILS ACCESS PANEL 30 LUBRICATION een een ban at tatiana Lens 30 CARBONATORS WATER PUMP MOTORS 30 DISPENSING VALVES CAGED O RINGS AND BEATERS DRIVE SHAFTS SEALS ASSEMBLIES 30 CLEANING CONDENSER Su aan 34 ADJUSTMENT S kt rer 34 ADJUSTING PLAIN WATER PRESSURE REGULATORS 34 ADJUSTING CARBONATED WATER FLOW RATE 34 ADJUSTING CO2 REGULATORS neh 35 ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCTA a aaa a ma a ar 36 PRODUCT CARBONATION ADJUSTMENT 37 ili 326093000 TABLE OF CONTENTS cont d Page ADJUSTING BEATER MOTOR C
7. SECURITY SWITCH has B Press and hold SECURITY not been pressed to activate SWITCH 3 seconds to restore control panel for switches control panel switches to operation ALL CONTROL PANEL SECURITY SWITCH C Replace control panel switch SWITCHES NOT OPERATING inoperable control switches module deactivated D Flat cable not properly D Properly connect flat cable to connected to control switch control switch module or master module or master circuit circuit board board 63 326093000 Trouble 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 326093000 Probable Cause Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Master circuit board not operating properly Not pressing and holding SECURITY SWITCH for 3 seconds to deactivate control switches SECURITY SWITCH inoperable Extremely low voltage Flat cable not properly connected to fault message module or master circuit board Flat cable connected between fault message module and master circuit board pinched and shorted out or broken wire in cable External sensing device failing to signal master circuit board which in turn signals fault message display External sensing devices cable connectors not sec
8. 2 Install DRAIN FITTING item 15 in drip tray and secure with LOCKWASHER INTERNAL TOOTH item 16 and HEX NUT 5 8 32 item 17 3 Push DRAIN HOSE item 19 over drip tray fitting and secure with DRAIN HOSE CLAMP item 18 NOTE Drip tray drain hose may be routed to a waste container but is not recommended due to sanita tion and cleaning problems Connection of drain hose to a permanent drain is most highly recom mended 4 Route drip tray drain hose to and connect to permanent drain 5 Place CUP REST item 12 in drip tray INSTALLING PRIMARY CO REGULATOR ASSEMBLY ON CO CYLINDER see Figure 2 in an upright position with safety chain to prevent it from falling over Should the shutoff valve become accidentally broken off cylinder can cause serious personal injury N WARNING To avoid personal injury and or property damage always secure cylinder 11 326093000 WARNING displaces oxygen Strict attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire and soft drink system If gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of gas will experience tremors which are followed rapidly by loss of consciousness and suffocation 1 Unscrew protector cap with chain attached from CO cylinder valve Open CO cylinders valve slightly
9. 3 After completion of adjusting beater motor currents to A150B150 2 make sure No 5 MOTOR CURRENT SELF CALIBRATION switch on DIP SWITCH assembly on motor 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 A CAUTION If 4 MOTOR CURRENT READOUT SWITCH ON DIP SWITCH assembly is place in ON position and beater motor current readings were A155B145 and switch was then placed back in OFF position without readjusting to A150B150 2 beater motor current has just been reset at A155B145 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 PLACED BACK IN OFF POSITION ADJUSTMENTS AND PROGRAMMING MAIN MENU SELECTIONS COMPONENTS DIAGNOSE DIAGNOSTIC MODE AND TOTALS DISPLAYED CYCLES AND HOURS INTO UNIT NOTE The Unit control panel switches are as shown in Figure 9 The following instructions outline adjustments and programming main menu selections components DIAG NOSE DIAGNOSTIC MODE and TOTALS DISPLAYED CYCLES AND HOURS
10. CO2 OUT FAULT1 MESSAGE GOES ON DURING OPERATION 65 H20 OUT FAULT MESSAGE GOES ON DURING OPERATION 65 SYRUP 1 OR SYRUP 2 FAULT MESSAGE GOES ON DURING OPERATION nn se Das Ta k a a 65 ERROR 1 OR ERROR 2 FAULT MESSAGE GOES ON DURING OPERATIONS See ker wre aren een 65 FREEZE CYLINDERS AUTOMATIC DEFROST SYSTEM DOES NOT OPERATE ee ee 65 UNIT DOES GO OFF AUTOMATIC DEFROST CYCLE 66 MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN DEFROST SWITCHIS PRESSED ne teka dp bon de a es 66 DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING CANCEL DEFROST SWITCH ze aina aaa Sa era 66 CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE 67 CARBONATOR WATER PUMP WILL NOT SHUT OFF 67 ERRATIC CARBONATOR WATER PUMP CYCLING 67 BRIX WATER TO SYRUP RATIO TOO LOW 67 BRIX WATER TO SYRUP RATIO TOO HIGH 68 IMPROPER PRODUCT DISPENSED 68 PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE IN ONLY SMALL AMOUNTS OR ONLY LIQUID pan ae 68 FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING 68 FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY 68 CYLINDER FREEZE In ee Ss seen 68 WARRANTY Een 70 LIST OF FIGURES FIGURE 1 FCB SOLID STATE POST MIX FOUR FLA
11. a YEL Inc Inc SOLD OUT WIR PSI SWT SwitcHes a z E parse SUSE En LET a1 YEL T ko RIGHT 11 YEL T NC e NC 8 8 ORN zu u B x BLK 51 3 a LEFT 42 BLK RIGHT 22 CARB N NOTOR NC LEFT A a Oz 5 RED n z LEFT a 5 RIGHT 11 RIGHT 22 Fi FILTER HOT FILTER FILTER GAS FILTER BLK YEL BLK YEL BLK YEL 1 2 211 111 4 1 8e YEL r 7 ka n YEL i REFR INET 1 g Si REFR INLET NE REFR INLET 2 n INLET gt A n A2 A REFR OUTLET 2 EL BLU n MASTER BOARD PSI SWT MASTER BOARD i BK _ 1 he n pei n BLK YEL Tr CEPT Se RIGHT 11 RIGHT 22 3 a 3 FR B A 1 lt REFG 2 REFG S Rerc ka 2 50 SOL 515 8 g 50 50 SER 5 m 0 2 2 12 6 RICHT 27 LEFT 2 LEFT 2 sis 0 RIGHT A RIGHT 22 RIGHT 22 a Al Ga Ge 2 g RUP ISyRUP wir 00502 2 2 wre syrun syaue wR 2 sy N AC DISPLAY 5 SOL SoL so gt TOUCH SWT S 3 5 SOL SoL so BOARD 7 T 7 T n St 8 7 T 5 TOUCH SWT S 8 8 tt E GRAY gt P
12. is a touch type switch and requires only pressing to activate ERROR RESET switch is used to restore normal operation after error within Unit in dicated 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 RE SET switch on control panel see Figure 5 Pressing in and holding SECURITY SWITCH for 3 seconds de activates control switches preventing tampering with Unit normal operation To reactivate control switches press in and hold SECURITY SWITCH for 3 seconds CONTROL PANEL DISPLAY MESSAGES see Figure 5 FILL 1 and FILL 2 Fault Messages FILL 1 and FILL 2 fault messages will appear on message display only when FILL 1 and FILL 2 control switches have been pressed and syrup systems syrup float switches have been filled with product FILL 1 and FILL 2 fault messages will continue to be displayed until AUTO BLEND 1 or AUTO BLEND 2 control switches have been pressed to fill product blender tanks with product ERROR 1 and ERROR 2 Fault Messages ERROR 1 and ERROR 2 fault messages will appear on message display only if error within Unit has devel oped interrupting normal operation Error will have to be located and corrected then press ERROR RESET to restore normal operation E
13. vent 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 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 NOTE Unit control panels are equipped with hidden SECURITY SWITCHES located between FILL 1 and ERROR RESET control switches see Figure 5 Pressing in and holding SECURITY SWITCHES for 3 seconds deactivates control switches on both control panels preventing tampering with Unit nor mal operation To reactivate control switches press in and hold SECURITY SWITCHES for 3 sec onds 2 Pressurize soft drink tanks containing syrup then connect tanks to Unit syrup systems OFF 1 OFF 2 SYRUP 1 and SYRUP 2 fault messages on both message displays will continue to be displayed ADJUSTING BRIX WATER TO SYRUP RAT
14. 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 the 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 defrost for one minute After No 1 freeze cylinder has defrosted No 2 freeze cylinder will go into defrost and defrost for one minute At end of No 2 freeze cylinder defrost unit will shut down and go into sleep time 21 326093000 WAKE UP WAKE UP TIME WAKE WAKE UP TIME may be programmed into the Unit to allow Unit to resume normal operation at desired time When programmed wake up time is reached an alarm will sound for a short duration then Unit will resume normal operation NOTE Automatic defrost sleep time and wake up time may be used in any combination together or separately FACEPLATE RELIEF VALVES The faceplate relief valves see Figure 5 located in each 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 see Figures 2 and 6 located behind front lower access panel are manually operated lever type ball val
15. counterclockwise to blow any dirt or dust from outlet fitting before installing primary CO regulator then close the valve 2 Remove shipping plug from primary CO regulator 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 CO CYLINDER VALVE AT THIS TIME CONNECTING SOFT DRINK TANKS CO LINES TO PRIMARY CO REGULATOR ASSEMBLY see Figure 2 NOTE syrup bag n box system may be connected to Unit in place of soft drink tanks shown 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 CO LINES TO TANKS AT THIS TIME PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT DRINK TANKS see Figure 2 NOTE The four Unit syrup inlet lines are labeled 1 2 11 and 22 Lines labeled 1 and 2 provide syrup to No 1 and No 2 left side cylinders facing front of unit freeze cylinders Lines labeled 11 and 22 pro vide syrup to two right side freeze cylinders 1 Route Unit syrup inlet lines labeled 1 2 11 and 22 out through hole provided in Unit base to soft drink tanks location 2 Install liquid disconnects on ends of Unit syrup inlet lines DO NOT CONNECT SYRUP LINES TO TANKS AT THIS TIME CONNECTING PLAIN WATER INLET SUPPLY LINE TO UNIT see Figure 2 NOTE I
16. 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 3 BEATERS AND SCRAPER BLADES INSTALLATION 326093000 8 000660926 1 Product Inlet Fitting 2 Scraper Blade 2 3 Evaporator Coil 4 Relief Valve Port 5 O Ring 6 Flatwasher 4 7 Hex Nut 4 8 Faceplate 9 Relief Valve 10 Valve Lever 11 Knob 12 Dispensing Valve 13 Beater 14 Drive Shaft Seal Assembly 15 Allen Head Setscrew 16 Beater Shaft Coupling 17 Drive Pin 18 Bearing Guide Pin 4 19 Power Coupler plastic 20 Beater Motor Drive Shaft 21 Beater Drive Motor Shaft Coupling 22 Beater Drive Motor 23 Unit Frame 24 Drive Shaft Assembly 25 Viscosity Sensor 26 Spinner 27 Spring 28 Shaft Release FIGURE 4 FREEZE CYLINDER CUTAWAY VIEW INSTALLING BEATERS 13 AND SCRAPER BLADES 2 see Figures 3 and 4 1 Remove four HEX NUTS and FLATWASHERS see Figure 4 that secure each faceplate to freeze cylin ders Pull faceplates off freeze cylinders 2 Position two SCRAPER BLADES item 2 on BEATER item 13 as shown in Figure 3 3 Slide beater assembly into one of the freeze cylinders so beater slotted hooks engage DRIVE PIN on DRIVE SHAFT as shown in Figure 4 4 Repeat procedure outlined in step 3 preceding to assemble and install beater assemblies in remaining freeze cylinder
17. CARBONATORS WATER PUMPS DOUBLE LIQUID CHECK 50 REPLENISHING SYRUP SUPPLY 51 REPLENISHING CO2 SUPPLY 53 SYRUP FLAVOR CHANGE ana tesa een 53 CLEANING CO2 GAS CHECK VALVES 54 REPLACING FREEZE CYLINDER BEATER DRIVE SHAFT BEARING 54 SHUTTING UNIT DOWN Ara cot S 54 REMOVING BEATER DRIVE MOTOR AND BEATER DRIVE SHAFT ASS Y Soe dt de sete 55 INSTALLING BEATER DRIVE SHAFT BEARING ASS Y 55 INSTALLING BEATER DRIVE SHAFT ASS Y AND BEATER DRIVE MOTOR IN ON 56 RESTORING UNIT OPERATION 57 REPLACING BEATER DRIVE SHAFT SEALASS Y 57 REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR 57 ADJUSTING CARBONATOR TANK LIQUID LEVEL 58 TROUBLESHOOTING En an 63 ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING 63 ALL CONTROL PANEL SWITCHES NOT OPERATING 63 CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED 64 326093000 iv TABLE OF CONTENTS cont d Page PARTIAL MESSAGE OR DULL POORLY ILLUMINATED DISPLAY 64 ONE OR MORE FAULT MESSAGES NOT OPERATING 64 ALL FAULT MESSAGES NOT OPERATING 64
18. MESSAGE DISPLAY and bring up CLOCK on display Press DEFROST SELECT switch to lock in on selection 2 Press CANCEL DEFROST ADVANCE switch to bring up flashing hour number on display 3 Press CANCEL DEFROST ADVANCE switch to advance hours on display to desired hour Press DE FROST SELECT switch to lock in hour on display 4 After hour time of day has been locked in on message display minute numbers will be flashing on display Press CANCEL DEFROST ADVANCE switch to advance minute numbers to desired minutes time of day Press DEFROST SELECT switch to lock in 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 TO MESSAGE DISPLAY and bring up DE FROST on message display Press DEFROST SELECT switch to lock in on selection 2 Press CANCEL DEFROST ADVANCE switch to bring up flashing hour number on display 3 Press CANCEL DEFROST ADVANCE switch to advance hours on display to desired hour Press FROST SELECT switch to lock in hour on display 4 After ho
19. SANITIZING SYRUP SYSTEMS NOTE The Unit should be sanitized every 90 days following Sanitizer Manufacturer s recommenda tion Use Chlor Tergent Oakite Products Inc or equivalent sanitizer The Unit should be sanitized every 90 days and before and after storage periods following parent company requirements and sanitizer manufacturer s recommendations One or all syrup systems may be sanitized at one time for routine 90 days sanitizing requirements The following sanitizing instructions use No 1 syrup system as an example Other syrup systems sanitizing instructions are identical to No 1 syrup system with exception of using applicable system switches Proceed as follows 1 Press OFF 2 switch to stop beater motor and refrigeration in No 2 freeze cylinder which is not to be de frosted OFF 2 fault message will appear on message display 2 Press DEFROST switch to start defrost cycle on No 1 freeze cylinder DEFROST 1 message will p pear 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 IMPORT
20. UNIT 12 CONNECTING ELECTRICAL POWER CIRCUIT TO UNIT 13 PREPARATION FOR OPERATION 13 50 OR 60HZ OPERATION AND BEATER MOTOR SELECT 13 TURNING ON ELECTRICAL POWER TO UNIT 14 TURNING ON CO2 SUPPLY TO UNIT 14 TURNING ON PLAIN WATER SUPPLY TO UNIT 14 CONNECTING SOFT DRINK TANKS TO UNIT SYRUP SYSTEM 14 ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT 15 FILLING FREEZE CYLINDERS WITH PRODUCT 16 ADJUSTING BEATER MOTOR CURRENT EITHER SIDE 16 326093000 TABLE OF CONTENTS cont d Page PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY 16 PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT 16 PROGRAMMING SLEEP SLEEP TIME INTO UNIT 16 PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT 17 PROGRAMMING POINT OF SALE MESSAGE DISPLAY 17 ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT AE AR A Feen 17 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 17 VOLTAGE DISPLAYED VOLTAGE 0 17 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE IN FOU NET res a a AA 17 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY entre a
21. 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 Carbonators tanks secondary CO regulators not adjusted high enough will cause decreased flow of carbonated water into blender tanks which will increase brix of dispensed product 6 Adjust carbonators secondary CO regulators with 100 5 gages by turning regulators adjusting screws to the right clockwise until gages reads 60 psi 7 Pull up on carbonators tanks relief valves plastic covers to purge air from tanks TURNING ON PLAIN WATER SUPPLY TO UNIT 1 Open plain water inlet supply line shutoff valve Check for water leaks and tighten or repair if evident OUT fault messages on both message displays should have gone out but OFF 1 OFF 2 SYRUP 1 and SYRUP 2 fault messages on both displays will continue to be displayed CONNECTING SOFT DRINK TANKS TO UNIT SYRUP SYSTEM IMPORTANT Product shutoff valves located in lines leading from product blender tanks to freeze cylinders see Figure 2 and 6 must be closed at this time Closing valves prevents product from filling freeze cylinders while checking BRIX of product in product blender tanks 326093000 14 1 Close product shutoff valves located in lines leading from product blender tanks to freeze cylinders to pre
22. n box syrup system if used and secondary regulators located behind Unit lower front access panel Adjust primary CO regulator by turning regulator adjusting screw to the right clockwise until regulator pressure reads 80 to 100 psi if regulator is providing CO pressure to soft drink tanks If regulator is controlling CO pressure to bag n box syrup sys tem adjust regulator to 80 psi maximum 35 326093000 Product Blender Tanks Secondary CO Regulators see Figures 2 and 6 1 Remove Unit lower front access panel as instructed for access to product blender tanks secondary regulators with 60 psi gages 2 Adjust product blender tank secondary CO regulators by turning regulator adjusting screws to the right clockwise until gages reads 30 psi 3 Install lower front access panel by reversing removal procedure Carbonators Secondary CO Regulators see Figures 2 and 6 1 Remove Unit lower front access panel as instructed for access to carbonators secondary CO regulators IMPORTANT Carbonators tanks secondary 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 wa ter and syrup Carbonators tanks secondary regulators not adjusted high enough will cause decreased flow of carbonated w
23. relief valve is also used to bleed CO gas pressure from freeze cylinder to atmosphere when fill ing cylinder with product Electronic sensing on each freeze cylinder beater motor provides a means of adjusting viscosity product consistency of 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 Unit to occur up to nine different times a day with a minimum of two hours between defrost time sittings or system may be completely turned off 326093000 4 MANUAL DEFROST SYSTEMS The Manual hot gas defrost system may be activated at any time by pressing DEFROST switch on front of Unit Refrigeration compressor will operate for a short time then both No 1 and No 11 or No 2 and No 22 de pending upon which DEFROST switch was pressed freeze cylinder only will go into defrost and defrost for one minute At the end of manual defrost cycle Unit will return to normal operation Manual defrost may be can celled at any time by pressing CANCEL DEFROST switch AUTOMATIC DEFROST SYSTEMS NOTE The following describes Automatic Hot gas Defrost system operation for No 1 and No 2 freeze cylinders Automatic defrost system operation for the No 11 and No 22 freeze cylinders is identical to the No 1 and No 2 freeze cylinders The Automatic hot gas defrost system may be programmed into Unit to oc
24. tem Product will be ready for dispensing in approximately 10 minutes Install right hand side panel and front lower access panel by reversing removal procedure Flat Washer Stainless Steel 3 312418 Ball Seat quad ring 312419 Ball 2 312196 Spring 317965 Retainer a 317963 Housing 1 312415 FIGURE 11 LIQUID CHECK VALVE ASSEMBLY YEARLY OR AFTER WATER SYSTEM DISRUPTION A WARNING The carbonators water pumps water strainer screens and double liguid check valves must be inspected and serviced after any disruptions plumbing work earthguake etc to the water supply system and at least once a year under normal circumstances Water pumps with no strainer screens or defective screens would allow foreign particles to foul the double liquid check valves CO gas could then back flow into water system and create health hazard in water system 49 326093000 SERVICING CARBONATORS WATER PUMPS WATER STRAINER SCREENS see Figure 12 1 Press OFF 1 and OFF 2 switches to stop freeze cylinders beaters and refrigeration systems Disconnect electrical power from Unit Close CO cylinder and water inlet supply line shutoff valve Remove Lower front access panel left side panel as instructed for access to the water pump water strainer screen Pull up on each carbonator tank relief valve plastic cover to release pressure from tanks Loosen screen retainer in water pump port then remove scr
25. 3000 54 4 5 Remove back and applicable side panels as instructed Close product shutoff valve leading from product blender tank to freeze cylinder beater drive shaft Drain product from freeze cylinder REMOVING BEATER DRIVE MOTOR AND BEATER DRIVE SHAFT ASS Y FROM UNIT 1 2 Remove access cover plate from back of beater drive motor for access to motor electrical terminals Tag motor electrical wiring for identification then disconnect wiring from motor terminals Remove bolts and lockwashers securing beater motor to Unit frame While supporting back of motor remove U bolt hanger and its two spacers from around motor Very carefully pull beater drive motor out of Unit BE CAREFUL NOT TO LOSE PLASTIC COUPLER LOCATED BETWEEN BEATER DRIVE MOTOR SHAFT COUPLING AND BEATER DRIVE SHAFT AS SEMBLY COUPLING NOTE Items in parentheses are in reference to Figure 4 6 Remove HEX NUTS item 7 and FLATWASHERS item 6 securing FACEPLATE item 8 to freeze cylin der then remove faceplate Remove beater shaft and scraper blades from inside freeze cylinder Pull beater drive shaft seal assembly from socket in back of freeze cylinder using Cornelius Puller P N 322063 000 Pull beater drive shaft assembly out back of freeze cylinder INSTALLING BEATER DRIVE SHAFT BEARING ASS Y see Figure 14 IMPORTANT Bearing retaining collar has a special cam action that locks it up tightly against bearing inner race when p
26. ALL INCREMENTS Connect electrical power to Unit and allow carbonator tank to fill with water and until water pump cycles off Repeat steps 2 through 5 preceding as many times as necessary until correct carbonated water volume adjustment is achieved To check differential using container graduated in ounces open carbonated water volume sample valve and dispense into container until carbonator water pump cycles on then immediately close sample valve Total volume dispensed differential should be 7 to 20 ounces Install back and right side panels by reversing removal procedure Press AUTO 1 and AUTO 2 switches to resume normal operation 6093000 58 RELIEF VALVE no CARBONATED k E SWITCHES ACTUATOR BRACKET LEVEL CONTROL Q SWITCHES 2 a b _ ACTUATOR ADJUSTMENT SCREW BES se FIGURE 15 CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT 59 326093000 ELECTRONIC O EXPANSION VALVE 2 HOT GAS DEFROST Oct SOLENOID VALVE lt lt ASS Y 2 e A L lt 2 FREEZE CYLINDER 2
27. ALLEN HEAD DRIVE SHAFT SETSCREW ALLEN TYPE PIN BEATER DRIVE SETSCREW MOTOR SHAFT BEATER SHAFT COUPLING DRIVE SHAFT SEAL ASS Y FIGURE 14 BEATER DRIVE MOTOR AND SHAFT SEAL ASS Y REPLACEMENT INSTALLING BEATER DRIVE SHAFT ASS Y AND BEATER DRIVE MOTOR IN UNIT NOTE Use Beater Drive Shaft Assembly Alignment Tool Kit P N 0726 when installing beater drive shaft assembly 1 11 Lubricate beater drive shaft bearing boot with DOW CORNING DC 111 P N 321471 000 light grade silicone lubricant Install beater drive shaft assembly in freeze cylinder Place plastic power coupler in beater drive motor shaft coupling TAPE POWER COUPLER TO MOTOR SHAFT COUPLING TO PREVENT COUPLER FROM FALLING OUT DURING INSTALLATION OF MO TOR IN UNIT Very carefully slide beater drive motor shaft through hole in Unit frame up to coupling on end of beater drive shaft assembly Engage plastic coupler on end of beater drive motor shaft in coupling on end of beater drive shaft as sembly Suspend motor in position with U bolt and its spacers DO NOT TIGHTEN U BOLT NUTS AT THIS TIME Secure beater drive motor to Unit frame with bolts and lockwashers Tighten U bolt nuts securely DO NOT OVER TIGHTEN NUTS Connect electrical wiring to beater drive motor terminals then install access cover plate on motor Refer to DISPENSING VALVES CAGED O RINGS AND BEATERS DRIVE SHAFTS SEALS AS SEMBLIES under LUBRICATION and pe
28. ANT 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 To disconnect soft drink tank from Unit syrup system c 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 d Second disconnect CO quick disconnect from soft drink tank To connect soft drink tank into Unit syrup system a First connect quick disconnect to soft drink tank to pressurize tank Second connect liquid quick disconnect to soft drink tank Disconnect soft drink tank containing syrup from No 1 syrup system Connect clean empty soft drink tank into No 1 syrup system S Place waste container under 1 cylinder dispensing valve nozzle Open dispensing valve dispense all product from cylinder As product level lowers in cylinder partially close valve to avoid spurting 9 Remove Unit front lower access panel as instructed for access to No 1 product blender tank product sam ple valve 10 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 11 Disconnect empty soft drink tank from No 1 syrup system 12 Refer to DISPENSING VALVE
29. CREW INSIDE CONTROL BOX 3 Install lower control box cover and secure with screws PREPARATION FOR OPERATION The Unit is equipped with two control panels with associated message displays see Figure 5 The left side control panel facing front of Unit controls the two left side freeze cylinders and right side control panel con trols the two right side freeze cylinders 50 OR 60HZ OPERATION AND BEATER MOTOR SELECT IMPORTANT Before connecting electrical power refer to Unit nameplate and note if Unit is to be operated with 50 or 60 Hz power and also note beaters drive motors manufacturer s name Set No 6 No 7 and No 8 switches on DIP switch assemblies on master circuit boards according to motor manufacturer and for 50 or 60 Hz operation 1 Remove four screws securing unit upper control box cover then remove cover for access to the master circuit board see Figure 10 2 After noting if unit is to be operated with 50 or 60HZ electrical power and beater motors manufacturer s name refer to Figure 10 and Table 5 to place dip switch assembly No 6 No 7 and No 8 switches in ap propriate positions 13 326093000 TURNING ON ELECTRICAL POWER Turn on electrical power to Unit Operational status of Unit is now being displayed as fault messages on both control panels message displays The following fault messages on message displays will be continuously dis played at 2 second intervals until necessary operation requi
30. CT 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 re turn to normal operation after sleep time has occured Program WAKE UP into Unit as follows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up WAKE UP on message display Press DEFROST SELECT switch to lock in on selection 2 Press CANCEL DEFROST ADVANCE switch to bring up flashing hour number on display 3 Press CANCEL DEFROST ADVANCE switch to advance hours on display to desired hour Press DE FROST SELECT switch to lock in hour on display 4 After hour time of day has been locked in on message display minute numbers will be flashing on display Press CANCEL DEFROST ADVANCE switch to advance minute numbers to desired minutes time of day Press DEFROST SELECT switch to lock in minutes time of day on display 5 Press ERROR RESET switch two times to exit from MENU SELECTIONS Table 6 POINT OF SALES DISPLAY MESSAGES DIP DIP DIP SWITCH SWITCH SWITCH NO 1 NO 2 NO 3 OFF ENJOY A FROZEN BEVERAGE OFF NOT USED BLANK N HAVE NICE DAY DISFRUTE BEBIDA CONGELADA CARBONATADA NOT USED BLANK N NOT USED BLANK O
31. Cie REMCOR CORNELIUS INC One Cornelius Place Anoka MN 55303 6234 Telephone 800 238 3600 Facsimile 612 422 3246 Service Manual FCB SOLID STATE POST MIX DISPENSER Four Flavor Hot gas Defrost With V3 Electronics IMPORTANT TO THE INSTALLER It is the responsibility of the Installer to ensure that the water supply to the dispensing equipment is provided with protection against backflow by an air gap as defined in ANSI ASME A112 1 2 1979 or an approved vacuum breaker or other such method as proved effective by test Water pipe connections and fixtures directly connected to a potable water supply shall be sized installed and maintained according to Federal State and Local Codes WMI QUI Part No 326093000 August 11 1988 Revised February 4 1992 THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment IMI CORNELIUS INC 1988 92 PRINTED IN U S A TABLE OF CONTENTS Page SAFETY INFORMATION 1 RECOGNIZE SAFETY INFORMATION 1 UNDERSTAND SIGNAL 1 FOLLOW SAFETY INSTRUCTIONS 1 CARBON DIOXIDE WARNING 1 SHIPPING STORING OR RELOCATING UNIT 1 GENERAL DESCRIPTION Gu
32. Circulating air required to cool the refrigeration systems condenser coils 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 BACK PANEL SIDE PANELS TOP PANEL LOWER FRONT ACCESS PANEL AND CONDENSER COILS ACCESS PANEL see Figure 3 DRIP TRAY Pull drip tray forward to disengage from drip tray supports BACK PANEL Remove one 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 29 326093000 LOWER FRONT ACCESS PANEL Remove two screws securing lower front panel then pull panel down to remove from Unit CONDENSER COILS ACCESS PANEL Pull out on top of condenser coils access panel then lift panel up and out to remove LUBRICATION CARBONATORS WATER PUMP MOTORS see Figure 12 Carbonators water pumps motor bearings must be lubricated periodically Refer to oiling instructions on motor DO NOT OVER OIL DISPENSING VALVES CAGED O RINGS AND BEATERS DRIVE SHAFTS SEALS ASSEMBLIES NOTE Defrost freeze cylinders shut Unit down close product shutoff valves in lines leading from product blender tanks to freeze cylinders then drain product from freeze cylinders Lubricate disp
33. DISPLAY and bring up the word CLOCK on message display 2 Repeatedly press and release CANCEL DEFROST ADVANCE switch to advance through main menu until TOTALS menu appears on message display Press DEFROST SELECT switch to lock TO TALS 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 COMP CYC on message dis play 5 Press and hold DEFROST SELECT switch Compressor cycles x 100 will appear on message display 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 mes sage display readings of the individual menu selections 7 Press ERROR RESET switch two times to exit from MENU SELECTIONS DISPLAYED ERROR CONDITIONS Displayed error conditions associated errors and items affected by the errors are found in TABLE 8 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 326093000 46
34. ELECTIONS 40 TABLE 4 DIP SWITCH FUNCTIONS 41 TABLE 5 BEATER MOTOR 41 TABLE 6 POINT OF SALES DISPLAY 55 42 TABLE 7 TOTALS DISPLAYED CYCLES AND HOURS TOTALS MENU 45 TABLE 8 DISPLAYED ERROR CONDITIONS 46 ACCESSORIES AND TOOLS 69 326093000 vi SAFETY INFORMATION Recognize Safety Information This is the safety alert symbol When you see this symbol on our machine or in this manual be alert to the potentially of personal injury Follow recommended precautions and safe operating practices Understand Signal Words A signal word DANGER WARNING OR CAUTION is used with the safety alert symbol DANGER identi fies the most serious hazards Safety signs with signal word DANGER or WARNING A WA R N N G are typically near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety mes A CAUTI O N sages in this manual Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs Keep safety signs in good condition Replace missing or damaged safety signs Learn how to operate the machine and how to use the controls properly Do not let anyone operate the machine without instr
35. ES CAGED O RINGS AND BEATER DRIVE SHAFTS SEALS ASSEMBLIES under LUBRICATION for instructions to replace beater drive shaft seal assembly 2 Sanitize syrup system as instructed in CLEANING AND SANITIZING REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR see Figure 6 and 14 NOTE Use Beater Drive Shaft Assembly Alignment Tool Kit P N 0726 when installing beater drive shaft assembly 1 Press OFF 1 and OFF 2 control switches to stop refrigeration system and beaters motors Disconnect electrical power from Unit at disconnect switch Remove back and applicable side panels as instructed Remove access cover plate from back of beater drive motor for access to electrical terminals Tag motor electrical wiring for identification then disconnect wiring from motor terminals Remove bolts and lockwashers securing beater motor to Unit frame While supporting back of motor remove U bolt hanger and its two spacers from around motor NO Very carefully pull old beater drive motor out of Unit BE CAREFUL NOT TO LOSE PLASTIC COUPLER LOCATED BETWEEN BEATER DRIVE MOTOR SHAFT COUPLING AND BEATER DRIVE SHAFT AS SEMBLY COUPLING 9 Note how far beater drive motor shaft protrudes inside coupling Using allen wrench loosen allen head setscrew in coupling then remove coupling from motor shaft 10 Install coupling on new beater drive motor shaft then tighten allen head setscrew securely MAKE SURE COUPLING IS INSTALLED ON
36. FF NOT USED BLANK OFF NOTE For special messages contact your local sales representative 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 No 2 and No 3 switches on master circuit board see Figure 10 and Tables 4 and 6 assembly in appropriate positions Three point of sale display messages are available to choose from and may be programmed by placing switch No 1 No 2 and No on DIP SWITCH assembly on master circuit board in appropriate positions See Figure 10 and Tables 4 and 6 and program desired point of sale display message which will be displayed on message display 326093000 42 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 ONTO MESSAGE DISPLAY and bring up VIS SET on message display 2 Press DEFROST SELECT switch to bring up numbers on message display NOTE The direction of arrows message display indicates which set of numbers be longs 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 d
37. IO OF DISPENSED PRODUCT The following steps are instructions for adjusting Brix Water to Syrup Ratio mixture of dispensed product on one of the four system NOTE The adjustable carbonated water flow regulators see Figures 2 and 6 located in their respec tive systems control carbonated water flow rate to the product blender tanks The water flow regula tors are factory adjusted at 1 5 6 05 oz sec and should not normally require adjustment If adjust ment is necessary adjust as instructed 1 Press FILL 1 switch to fill No 1 system float switch SYRUP 1 fault message will go out and FILL 1 fault message will come on OFF 1 OFF 2 and SYRUP 2 fault messages will continue to be dis played 2 Press AUTO BLEND 1 switch to fill No 1 system product blender tank 1 4 full of product FILL 1 fault message will go out when AUTO BLEND 1 switch is pressed When product blender tank is 1 4 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 Figures 2 and 6 and take sample approxi mately 6 ounces of product in cup NOTE Temperature compensated hand type refractometers P N 511004 000 are available from IMI Cornelius Inc 4 Check product BRIX with a temperature compensated hand type refractometer B
38. MI Cornelius Inc recommends that a water shutoff valve and water filter be installed in plain water inlet supply line see Figure 2 A Cornelius Water Filter P N 313860000 and Quick Disconnect Set P N 313867000 are recommended 1 If fitting connector is not available tap into plain water supply line with 3 8 flare Saddle Valve P N 315664000 or equivalent 2 Before connecting plain water inlet supply line to Unit open shutoff valve in water supply line for a period of time to flush out any metal shavings resulting from installing fitting or saddle valve 3 Route water inlet line out through hole in bottom of Unit base NOTE Carbonators plain water inlets adjustable water pressure regulators see Figure 10 are factory adjusted to 45 psi and should not be readjusted 4 Connect Unit water inlet line to plain water inlet supply line 12 psi minimum pressure Seal connection with TAPERED GASKET BLACK item 2 DO NOT OPEN WATER INLET SUPPLY LINE SHUTOFF VALVE AT THIS TIME 326093000 12 CONNECTING ELECTRICAL POWER CIRCUIT see Figure 17 A WARNING Make sure unit 50 minimum rated disconnect switch not provided eguivalent HACR circuit breaker is in OFF position Domestic Unit IMPORTANT Power circuit voltage across L and L terminals on contactor inside lower electrical control box with refrigeration compressor operating must be in operating range of between 219 and 242 VAC 60Hz single phas
39. MOTOR SHAFT SAME DISTANCE AS NOTED IN STEP 8 preceding A CAUTION New beater drive motor is provided with two gear box vent holes that are plugged with hex socket plugs to prevent oil from leaking out of gear box It must be determined which vent hole will be in up position when motor is in installed position Remove up position hex socket plug and install loose shipped vent plug 57 326093000 13 14 15 16 17 18 19 20 21 22 Determine which beater drive motor gear box vent hole will be in up position when motor is in installed position Remove hex socket plug from vent hole and install Ioose shipped vent plug DO NOT LAY MOTOR IN POSITION THAT WILL ALLOW OIL TO LEAK OUT OF GEAR BOX THROUGH VENT PLUG Place plastic power coupler in beater drive motor shaft coupling TAPE POWER COUPLER TO MOTOR SHAFT COUPLING TO PREVENT COUPLER FROM FALLING OUT DURING INSTALLATION OF MO TOR IN UNIT Very carefully slide beater drive motor shaft through hole in Unit frame up to coupling on end of beater drive shaft assembly Engage plastic coupler on end of beater drive motor shaft in coupling on end of beater drive shaft as sembly Suspend motor in position with U bolt and its spacers DO NOT TIGHTEN U BOLT NUTS AT THIS TIME Secure beater drive motor to Unit frame with bolts and lockwashers Tighten U bolt nuts securely DO NOT OVER TIGHTEN NUTS Connect electrical wiring to beater drive motor
40. N LOUVERS SIDE PANEL RETAINING SCREW FIGURE 5 OPERATING CONTROLS 31 326093000 RELIEF VALVE 4 UPPER ELECTRICAL CONTROL BOX COVER RETAINING SCREW 4 UPPER ELECTRICAL CONTROL BOX COVER FAULT MESSAGE DISPLAY MODULE 2 FREEZE CYLINDER 4 SECONDARY CO REGULATOR 6 RECIEVER TANK 326093000 PRODUCT SAMPLE PRODUCT SHUTOFF VALVE 4 SYRUP FLOW VALVE REGULATOR 4 PRODUCT BLENDER TANK 4 BEATER DRIVE MOTOR 4 ML at J N g by A el D Di ui PA so SL Ta je D CARBONATED WATER ul 5 a SOLENOID 4 5 LA CARBONATED WATER PA FLOW REGULATOR 4 REFRIGERATION COMPRESSOR 2 LOWER ELECTRICAL CONTROL BOX CONDENSER COIL 2 SYRUP FLOAT SWITCH 4 SYRUP SOLENOID 4 FIGURE 6 UNIT INTERNAL COMPONENTS 32 RETAINING RUNNING SPRING HOUSING SCREW 2 TORSION SPRIN STATIONARY HOLD DOWN O RING SPRING PITTING PLATE 2 DISPENSING LI VALVE BODY CD PLASTIC SLEEVE haa
41. O 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 1 Clean regulator 2 Primary regulator must be adjusted as instructed Refer to CYLINDER FREEZE UP NOTE Defrost freeze cylinder as instructed A Refer to BRIX Water to Syrup Ratio too low B Adjust dispensed product viscosity as instructed ACCESSORIES AND TOOLS ACCESSORIES 1155 511005 000 511006 000 511035 000 1040 Installation Kit Cup Holder Cup Holder CO Changeover Kit Seal Kit Rear O Ring Housing and O Rings GENERIC FLAVOR TABS 1085 Cola 1086 Cherry 1087 Orange 1088 Grape 1089 Lemon Lime 1090 Strawberry 1091 Banana SERVICE TOOLS 151689000 Spanner Wrench Flow Regulator 281884000 3gallon Sanitizing Tank 322859000 Spanner Wrench Dispensing Valve 511004000 Refractometer 030 Scale 322063000 Shaft Seal Assembly Puller 0726 Alignment Tool Kit Beater Drive Shaft Ass y 69 326093000 WARRANTY IMI Cornelius Inc warrants that all equipment and parts are free from defects in material and workmanship un der normal use and service For copy of the warranty applicable to your Cornelius Re
42. OWER SUPPLY YEL CPAN WHT 1 4 BLK i i MOTOR WHT 1 1 GRAY l i i 5 a gt Ty 095 20 0520 ip n i E 4 10 4 10 WHT BLK BLU BLK ELECTRONICS COOLING 1 1 FAN TI Le Ti T2 1 T2 L gt 1 WHT WHT amp That a La s ae 2 FLAVOR UNITS e gac z je zi ELECTRONICS ei 5 1425 5 kan CAPAC 1 NOTES ir 1 SWITCHES SHOWN IN STABLE STATE OF NO POWER NO PRESSURE LIQUIDS COMPRESSOR LEFT SPATI te ore ttn Sa NOt a a AN di 326084000 REV G FIGURE 17 WIRING DIARGRAM THIS PAGE LEFT BLANK INTENTIONALLY 326093000 62 TROUBLESHOOTING IMPORTANT Only qualified personnel should service internal components or electrical wiring the applicable product tank then relieve the system pressure before proceeding If repairs are to be made to the CO system stop dispensing shut off the CO supply then relieve the system pressure before proceeding If repairs are to be made to the refrigeration system make sure electrical power is disconnected from the unit WARNING If repairs are to be made to a product system remove quick disconnects from IMPORTANT The following and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or
43. P 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 326093000 26 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 occured Program WAKE UP into Unit as instructed in SERVICE AND MAINTENANCE 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 No 2 and No 3 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 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 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES Evaporator refrigeration coils inlet and common out
44. PORE 16 TUAS STREET SINGAPORE 2263 65 862 5542 FAX 65 862 5604 SPAIN POLIGONO INDUSTRAIL RIERA DEL FONOLLAR E 08830 SANT BOI DE LLOBREGAT BARCELONA SPAIN 34 3 640 2839 FAX 34 3 654 3379 USA ONE CORNELIUS PLACE ANOKA MINNESOTA 612 421 6120 FAX 612 422 3255 LD004 4 21 98 318832000 70 THIS PAGE LEFT BLANK INTENTIONALLY 71 326093000 IMI CORNELIUS INC CORPORATE HEADQUARTERS One Cornelius Place Anoka Minnesota 55303 6234 612 421 6120 800 238 3600
45. R TO SYRUP TOO LOW Quick disconnect not secure on soft drink tank Syrup flow regulator set too low Carbonated water flow regulator adjusted too high Syrup flow regulators stuck Restriction in syrup line Syrup Baume not in proper range 67 Connect electrical power to Unit Check power source Press AUTO BLEND 1 or AUTO BLEND 2 switch Restore water supply to Unit Replenish supply as instructed Tighten connections or replace wires Check for proper line voltage Check restricted pump discharge Remove water pump from motor Rotate pump coupling shaft 180 degrees then reinstall pump Replace pump and or motor Replace level control switches Clean repair or replace balance mechanism Replace water pump and or motor Clean repair or replace balance mechanism Increase water inlet supply line pressure Water inlet supply line must have large enough diameter Replace water filter Secure tank quick disconnect Adjust BRIX of dispensed product as instructed Carbonated water flow regulator must be adjusted for a flow rate of 1 5 as instructed Clean syrup flow regulators Sanitize Unit as instructed Change syrup supply as instructed 326093000 Trouble BRIX WATER TO SYRUP TOO HIGH IMPROPER PRODUCT DISPENSED PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE IN ONLY SMALL AMO
46. RIX should read 13 5 095 BRIX is not within tolerance adjust white syrup flow regulator for No 1 syrup system as fol lows A Loosen jamb nut on syrup flow regulator 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 C Tighten jamb nut on syrup flow regulator then lightly tap regulator to register adjustment 15 326093000 5 Place container under 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 then press FILL 1 switch to prevent more product from entering blender tank OFF 1 OFF 2 and 2 fault mes sages 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 No 2 system After complet ing BRIX on No 2 system only OFF 1 and OFF 2 fault messages should continue to be displayed 10 Repeat steps 1 through 9 preceding to adjust Brix Water to Syrup Ratio mixture of dispensed product on remaining syst
47. RROR 1 or ERROR 2 fault message will disappear from display OFF 1 and OFF 2 Fault Messages OFF 1 and OFF 2 fault messages will appear on message display when either freeze cylinder beater is not in operation 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 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 pres sure 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 OUT fault message will disappear from message display CO OUT Fault Message OUT fault message will appear on message display when CO supply to Unit has been turned off or if CO pressure drops below 50 psi A minimum CO pressure of 75 psi must be available to Unit to extinguish CO OUT fault message SYRUP 1 or SYRUP 2 Fault Messages SYRUP 1 or SYRUP 2 fault messages will appear on message display if 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 SYR
48. RS TOTAL into Unit 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 1 AND 2 EVAPORATOR COILS REFRIGERATION COMMON OUTLET TEMPERATURES NO 2 EVAPORATOR REFRIGERATION COIL INLET TEMPERATURE NO 1 EVAPORATOR REFRIGERATION COIL INLET TEMPERATURE MOTOR CURRENT ADJUSTMENT RELAY CIRCUIT BOARD NO 1 MASTER CIRCUIT BOARD RELAY CIRCUIT BOARD NO 2 DIP SWITCH ASS Y POINT OF SALE MESSAGE DISPLAY SELECT SEE Table 6 BEATER MOTORS CURRENT READOUT SEE Table 4 MOTOR CURRENT SELF CALIBRATION SEE Table 4 bearer MOTOR SELECT SEE Table 5 APPLICABLE ELECTRIC OR GAS DEFROST SEE Table 4 SERVICE USE ONLY FIGURE 10 MASTER AND RELAY CIRCUIT BOARDS 326093000 40 Table 4 DIP SWITCH FUNCTIONS SWITCH NO FUNCTIONS 1 POINT OF SALE MESSAGE SELECT 2 POINT OF SALE MESSAGE SELECT SEE TABLE 6 3 POINT OF SALE MESSAGE SELECT 4 BEATER MOTOR CURRENT READOUT ON DISPLAY CURRENT READOUT OFF NO DISPLAYED CURRENT READOUT 5 MOTOR CURRENT SELF CALIBRATION ON DISABLED OFF OPERATING 6 BEATER MOTOR SELECT 7 BEATER MOTOR SELECT SEE
49. RUP 1 OR SYRUP 2 FAULT MESSAGE GOES ON DURING OPERATION ERROR 1 OR ERROR 2 FAULT MESSAGE GOES ON DURING OPERATION FREEZE CYLINDERS AUTOMATIC DEFROST SYSTEM DOES NOT OPERATE Probable Cause Flat cable connected between fault message display module and master circuit board pinched and shorted out or broken wire in cable Master circuit board not operating Fault message display module not operating properly CO supply turned off or exhausted Primary regulator adjusted too low Inoperable 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 Automatic defrost system not programmed into Unit Loose or broken electrical wires Inoperable automatic defrost timer 65 Remedy Check cable for pinched or broken wire condition and repair or replace as necessary Replace master circuit board Replace fault message display module Open CO cylinder shutoff valve or replenish CO supply as instructed Adjust primary CO regulator as instructed Replace CO pressure switch Turn on water supply or check water supply line pressure Change water filter or clean water pump strainer screen as instructed Replace water pressure switch Replenish syrup sup
50. S CAGED O RINGS AND DRIVE SHAFTS SEALS ASSEMBLIES under LUBRICATION and perform procedure to lubricate dispensing valve caged O ring and drive shaft seal as sembly remove soft drink tank cover until CO pressure has been released from tank A WARNING To avoid possible personal injury or property damage do not attempt to 47 326093000 13 Pull up on empty soft drink tank cover relief valve to release CO pressure from tank prior to adding to soft drink tank A WARNING If powder type sanitizer is used it must be thoroughly dissolved with water NOTE Sanitizing solution is used in a more concentrated form because it will be diluted approximately four to one in product blender tank 14 15 16 20 21 22 23 24 Using clean empty soft drink tank prepare full tank of sanitizing solution using Chlor Tergent Oakite Prod ucts 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 of chlorine Sanitizing solution will be diluted to approximately 200 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
51. TABLE 5 8 BEATER MOTOR SELECT 9 DEFROST ON HOT GAS OFF ELECTRIC 10 SERVICE USE Table 5 BEATER MOTOR SELECT DIP DIP DIP SWITCH SWITCH SWITCH NO 6 NO 7 NO 8 MOTOR SELECTED 6oHZ VON WER 6 Repeat step 5 as many times as necessary to program desired number of defrost time settings into the Unit 7 Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING SLEEP SLEEP TIME INTO UNIT SLEEP SLEEP TIME may be programmed into Unit to occur any time of the day after Unit automatic defrost cycle has occurred Unit will shut down go into sleep time and will not wake up return to normal operation until programmed WAKE UP WAKE UP TIME has occurred Program SLEEP SLEEP TIME into Unit as follows 1 Refer to PROGRAMMING MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up SLEEP on message display Press DEFROST SELECT switch to lock in on selection 44 326093000 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 FROST SELECT switch to lock in hour on display 4 After hour time of day has been locked in on message display minute numbers will be flashing on display Press CANCEL DEFROST ADVANCE switch to advance minute numbers to desired minutes time of day Press DEFROST SELE
52. TED WATER u FLOW REGULATOR 4 SYRUP FLOAT CARBONATED WATER SWITCH 4 LIQUID CHECK SOLENOID 4 VALVE 4 Mon LIQUID CHECK SHUTOFF VALVE VALVE 4 PLAIN WATER SOURCE 1 PRIMARY CO DR REGULATOR FILTER LINE LEGEND co PLAIN WATER CARB WATER SYRUP PRODUCT GAS CHECK VALVES 5 CYLINDER FIGURE 2 FLOW DIAGRAM 326093000 6 INSTALLATION This section covers unpacking and inspection installing loose shipped parts selecting location installing Unit preparing for operation and operation UNPACKING AND INSPECTION 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 the time of delivery or not later than 15 days from date of delivery and immediately reported to the delivering carrier Request a written inspec tion report from Claims Inspector to substantiate any necessary claim File claim with the delivering carrier not with IMI 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 Remove shipping bolts that secure Unit to skid then remove skid 4 Unpack LOOSE SHIPPED PARTS Make sure all items are present and in good condition Table 2 Loose Shipped Parts P
53. TOTALS into Unit NOTE Plain water CO and syrup supplies to Unit must be satisfied to turn off OUT CO OUT SYRUP 1 and SYRUP 2 fault messages on message display before adjustments and programming procedures can be performed on the Unit PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS see Table 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 the MAIN MENU SELECTIONS as shown Table 3 To advance through the MENU SELECTIONS repeatedly press the CANCEL DEFROST AD VANCE switch Once you reach the desired selection press the DEFROST SELECT switch to lock in on the selection 326093000 38 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 CLOCK TIME OF DAY must be programmed into Unit before DEFROST AUTOMATIC SLEEP SLEEP TIME and WAKE UP WAKE UP TIME can programmed into the Unit Program CLOCK TIME OF DAY into Unit as follows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO
54. UNTS OR ONLY LIQUID FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY CYLINDER FREEZE UP 326093000 Probable Cause A Syrup flow regulators set too high B Syrup Baume not in proper range C Carbonated water flow regulator adjusted too low D Restricted water filter A Secondary regulators not properly adjusted B Dirty supply CO must be clean and free of water oil and dirt Water will not absorb dirty gas in same way as clean gas This can also cause off taste problems A Dispensing valve has ice particles in it B Cylinder freeze up AUTO BLEND 1 or AUTO BLEND 2 switch not pressed gt B Carbonator water pump not operating C Lines restricted A Dispensed product BRIX varying because 1 Syrup flow regulator sticking 2 Primary regulator pressure insufficient B Cylinder freeze up causing ice formation in center of cylinder and liquid product channels around ice formation A Dispensed product BRIX too low Viscosity of dispensed product not properly adjusted 68 Remedy Adjust BRIX OF dispensed product as instructed Change syrup supply as instructed Carbonated water flow regulator must be adjusted for a flow rate of 1 5 0 85 07 5 as instructed Replace water filter Adjust secondary regulators as instructed Replace C
55. UP 2 fault messages 326093000 20 DEFROST 1 or DEFROST 2 Display Messages DEFROST 1 or DEFROST 2 display messages will 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 Four 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 NOTE The Unit is equipped with both manual and automatic hot gas defrost systems The automatic defrost system may be programmed into Unit to occur up to nine different times a day with a minimum of two hours between defrost time sittings or 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 Unit Refrigeration compressor will operate for a short time then both No 1 and No 11 or No 2 and No 22 de pending upon which DEFROST switch was pressed freeze cylinder only will go into defrost for one minute At end of manual defrost cycle Unit will return to no
56. URRENT EITHER SIDE 37 ADJUSTMENTS AND PROGRAMMING MAIN MENU SELECTIONS COMPONENTS DIAGNOSE DIAGNOSTIC MODE AND TOTALS DISPLAYED CYCLES AND HOURS INTO UNIT 38 PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY 38 SETTING CLOCK TIME OF DAY 39 PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT 39 PROGRAMMING SLEEP SLEEP TIME INTO UNIT 41 PROGRAMMING WAKE UP WAKE UP TIME INTO 42 PROGRAMMING POINT OF SALE MESSAGE DISPLAY 42 ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED ae Melanie e AN Bee 44 VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT IN FREEZE CYLINDERS uns a dra eter 43 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 43 VOLTAGE DISPLAYED VOLTAGE 43 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE INTO NL donc 44 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY kote aa ate ene se si 46 DISPLAYED ERROR CONDITIONS Ma ee 46 CLEANING AND SANITIZING 2 een 46 YEARLY OR AFTER WATER SYSTEM DISRUPTION 49 SERVICING CARBONATORS WATER PUMPS WATER STRAINER SCREENS a cose 50 SERVICING
57. VOR DISPENSER 3 FIGURE 2 FLOW DIAGRAM Zee ate ok ken an espas in ana 6 FIGURE 3 BEATERS AND SCRAPER BLADES INSTALLATION 8 FIGURE 4 FREEZE CYLINDER CUTAWAY VIEW 9 FIGURE 5 OPERATING CONTROLS 31 FIGURE 6 UNIT INTERNAL COMPONENTS 32 FIGURE 7 SELF CLOSING DISPENSING VALVE 33 FIGURE 8 SERVICING BEATER DRIVE SHAFT SEAL ASSEMBLY 33 FIGURE 9 CONTROL PANEL nase Agate aa ae 38 FIGURE 10 MASTER AND RELAY CIRCUIT 40 FIGURE 11 LIQUID CHECK VALVE ASSEMBLY 49 FIGURE 12 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK js o ai 52 FIGURE 13 CO2 GAS CHECK VALVE 54 FIGURE 14 BEATER DRIVE MOTOR AND SHAFT SEAL ASS Y REPLACEMENT 56 V 326093000 TABLE OF CONTENTS cont d Page LIST OF FIGURES CONT D FIGURE 15 CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT ur Baer ak Dein 59 FIGURE 16 REFRIGERATION FLOW DIAGRAM ONE OF TWO REFRIGERATION SYSTEMS SHOWN 60 FIGURE 17 WIRING DIARGRAM 61 LIST OF TABLES TABLE A DESIGN ae da welder ala 4 TABLE 2 LOOSE SHIPPED PARTS 7 TABLE MAIN MENU S
58. ainer screen and double liguid check valve Service water strainer screen and double liguid check valve as instructed CLEANING CO GAS CHECK VALVES see Figures 2 and 13 The CO gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO system as instructed 326093000 28 SERVICE AND MAINTENANCE This section describes service and maintenance to be performed on the Unit attemping any internal maintenance Only qualified personnel should service the internal components or electrical wiring N WARNING Disconnect electrical power from the Unit to prevent personnel injury before PREPARING UNIT FOR SHIPPING STORING OR RELOCATING sanitized and all sanitizing solution must be purged from the syrup systems All water must N CAUTION Before shipping storing or relocating this Unit the syrup systems must be also be purged from the plain and carbonated water systems A freezing ambient environment will cause residual water in the Unit to freeze resulting in damage to internal components PERIODIC INSPECTION 1 Make sure CO cylinder valve is fully opened and primary CO cylinder regulator assembly 1800 5 indicator is 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
59. air or replace as necessary Replace control panel switch module Repair wire Replace master circuit board Properly connect flat cable to control panel 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 Trouble Probable Cause Remedy 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 B B AUTO BLEND 1 or AUTO BLEND 2 switch has not been pressed OUT fault message is on CO OUT fault message is on Loose or broken electrical wires Overheated water pump motor cut off by overload protector Binding water pump new or replacement pump only Inoperative water pump and or motor Inoperative carbonated water tank level control switches Binding damaged or dirty carbonated water tank balance mechanism Inoperative water pump and or motor Binding damaged or dirty carbonated water tank balance mechanism Insufficient water supply pressure H O OUT fault message goes on and off intermittently and water pump cycles on and off during carbonator tank fill cycle Water filter restricted TROUBLESHOOTING DISPENSED PRODUCT BRIX WATE
60. ally clean condenser coils as follows 1 Press OFF 1 and OFF 2 switches on Unit control panels to stop refrigeration systems and beater mo tors 2 Remove condenser coils access panel as instructed 3 Clean condenser coils with vacuum cleaner low pressure compressed air or a soft brush 4 Install condenser coils access panel by reversing removal procedure 5 Press AUTO 1 and AUTO 2 switches on Unit control panels to start refrigeration systems and beater motors ADJUSTMENTS ADJUSTING PLAIN WATER PRESSURE REGULATORS see Figure 2 Carbonators plain water inlet adjustable water pressure regulators are factory adjusted to 45 psi and should not be readjusted ADJUSTING CARBONATED WATER FLOW RATE The black carbonated water flow regulators see Figures 2 and 6 which control carbonated water flow rate into product blender tanks are factory adjusted for flow rate of 1 5 0285 ounces per second and normally do not require adjustment However if adjustment is necessary proceed as follows 326093000 34 13 14 15 16 17 18 19 20 21 Press applicable OFF 1 or OFF 2 switch to prevent more product from entering applicable product blender tank Disconnect Unit syrup inlet line from applicable soft drink tank Remove applicable side panel from Unit as instructed for access to applicable carbonated water flow regu lator product shutoff valve and product sample valve Close produ
61. ard must be available to the Unit ALL WIRING MUST CONFORM TO NATIONAL AND LO CAL CODES MAKE SURE UNIT IS PROPERLY GROUNDED EXPORT UNIT IMPORTANT Power circuit voltage across L and L terminals on contactor inside lower electrical control box with refrigeration compressor operating must be in operating range of between 219 and 242 VAC 50Hz single phase range for proper operation If voltage is below or above this range A means to provide voltage within operating range must be provided A properly grounded 219 to 242 VAC 50Hz single phase electrical circuit with 50 minimum rated disconnect switch not provided fused at 50 amps slow blow must be available to the Unit SELECTING LOCATION IMPORTANT Unit operating ambient temperature MUST NOT EXCEED 100 F Operating ambient excess of 100 F will automatically void 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 326093000 10 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 Circulating air required to cool the refrigeration system s condenser coils is drawn in through louvers on front and exhausted out through louvers on sides and back of Unit Restr
62. art No Name Numbers in parentheses are in reference to items in Figure 2 1 1 3 7 3 RE _2_ 6 ER ES EA IDENTIFICATION LOOSE SHIPPED PARTS 1 TAPERED GASKETS WHITE item 1 used to seal connections when connecting Unit product inlet lines to product tanks and connecting Unit CO inlet to CO source 7 326093000 2 TAPERED GASKETS BLACK item 2 used to seal connection when connecting Unit plain water inlet line to water source line 3 SPANNER WRENCH FLOW REGULATORS item 3 is used to adjust flow regulators inside Unit 4 SPANNER WRENCH DISPENSING VALVE item 4 is used to remove shank nuts securing dispensing valves to faceplates 5 CLEANING BRUSH item 5 is used to clean faceplates relief valves passages 6 INSTRUCTIONS SCRAPER BLADES item 6 pictorially shows how to install BEATERS item 7 and SCRAPER BLADES item 8 in freeze cylinders 7 DRIP TRAY SUPPORTS item 10 to be installed on front of unit and secured with THREAD CUTTING SCREWS item 9 8 CUP REST item 12 to be installed in DRIP TRAY item 13 then drip tray to be installed in FRAME DRIP TRAY item 11 Assembled drip tray then to be installed on drip tray supports on front of Unit 9 DRIP TRAY KIT item 14 to be installed on drip tray as instructed BEATER KEY ON END OF POST A KEY ON END OF POST KEY SLOT ON BLADE SCRAPER
63. ater into blender tanks which will increase brix of dispensed product 2 Adjust carbonators secondary CO regulators with 100 psi gages by turning regulators adjusting screws to the right clockwise until gages read 60 psi 3 Install lower front access panel by reversing removal procedure ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT see Figures 2 and 6 1 Remove Unit front lower access panel as instructed for access to product blender tanks secondary regulators and product sample valves 2 Check product blender tanks secondary regulators with 60 psi gages for proper pressure settings which are set at 30 psi for best textured dispensed product If adjustment is necessary adjust as instructed 3 Remove both Unit side panels as instructed for access to product shutoff valves located close to product blender tanks 4 Close product shutoff valve in line between applicable product blender tank and associated freeze cylinder BRIX adjustment will be performed on 5 Press applicable FILL 1 or FILL 2 switch to prevent more product from filling product blender tank 6 Open applicable product blender tank product sample valve and take sample approximately 6 ounces of product in cup NOTE Temperature compensated hand type refractometers P N 511004000 are available from the Cor nelius Company 7 Check product BRIX with a temperature compensated hand type refractometer BRIX shoul
64. by adjusting Unit carbonator secondary regulator as follows IMPORTANT Carbonator tank secondary CO regulator must be adjusted 25 psi higher or more above product blender tanks secondary regulators pressure settings Carbonated water and syrup pressures must be able to overcome and vent product blender tanks head pressures while tanks are filling with carbonated water and syrup Carbonator tank secondary CO regulator not adjusted high enough will cause decreased flow of carbonated water into blender tanks which will increase BRIX of dispensed product 1 Remove Unit front lower access panel as instructed for access to carbonator secondary CO regulator with 100 psi gage 2 Observe pressure setting on carbonator secondary CO regulator gage 3 To lower CO pressure loosen regulator adjusting screw lock nut Turn adjusting screw to the left counter clockwise until pressure gage reads 15 psi below desired reading then turn screw to the right clockwise until gage reads desired pressure DO NOT SET REGULATOR PRESSURE BELOW 25 PSI HIGH ER THAN PRODUCT BLENDER TANKS REGULATORS ARE ADJUSTED TO SEE PRECEDING IMPORTANT NOTE Tighten adjusting screw lock nut after each adjustment 4 To raise CO pressure turn regulator adjusting screw to the right clockwise until gage reads desired pres sure DO NOT SET PRESSURE HIGHER THAN 60 PSI Make sure primary regulator on cylin der is set at 80 to 100 psi Tigh
65. ch 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 dis play 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 dis play Press DEFROST SELECT switch No 2 refrigeration solenoid clicks when switch is pressed 326093000 44 22 Press CANCEL DEFROST ADVANCE switch to advance and bring up COMPRESS on Message dis play 23 Press DEFROST SELECT switch Compressor and condenser fan motor will start and operate while switch is pressed 24 Press CANCEL DEFROST ADVANCE switch to advance and bring up PUMP on message dis play 25 Press DEFROST SELECT switch Carbonator water pump relay on master circuit board clicks when switch is pressed 26 ERROR RESET switch two times to exit from MENU SELECTIONS Table 7 TOTALS DISPLAYED CYCLES AND HOURS TOTALS MENU TOTALS MENU COMMANDS COMP HRS COMP CYC DESTYGI DFSTYG2 BLDRCYGI BLDROYC2 50100071 50100072 BMTRHRS BMTRHRS2 PWR ON AUTOONT AUTO ON ERR HRS ERR HRS SLEEP HRS SYR MIN 1 se not SYR MIN see NOTE Displaying SYR MIN 1 or SYR MIN 2 on message display will indicate time in minutes syrup actually has been dis pensed refer to tab
66. condary regulators inside the Unit and also to the four soft drink tanks CO gas is delivered from adjustable secondary CO regula tors to two carbonators and also four product blender tanks inside the Unit gas pressure pushes syrup out of soft drink tanks through syrup sold out switches through electrically operated syrup solenoid valves through adjustable syrup flow regulators and on to product blender tanks At the same time plain water passes through water pressure regulators and is pumped into carbonators tanks by water pumps and is carbonated by gas pressure also entering the tanks Carbonated water is pushed by CO gas pressure from carbonators tanks through electrically operated carbonated water solenoid valves through adjustable carbonated water flow regulators and on to product blender tanks Carbonated water and syrup enter tanks properly proportioned blended for desired BRIX of dispensed product by adjustment of syrup flow regulators From product blender tanks product is pushed gas into the freeze cylinders The beater in each freeze cylinder is driven by electric motor Scraper blades attached to beaters scrapes product from cylinders walls as product enters freeze cylinders and is frozen Transparent faceplate attached to 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
67. ct shutoff valve to prevent more product from entering freeze cylinder Place container under applicable product sample valve Open valve and allow all product to be purged from product blender tank then close valve Remove lower front access panel as instructed for access to secondary CO regulators Note pressure setting on secondary CO regulator with 60 psi gage for applicable product blender tank Turn regulator adjusting screw to the left counterclockwise until regulator gage reads 0 5 Pull up on product blender bank relief valve to release CO pressure from tank then release valve Disconnect carbonated water line from outlet side of applicable carbonated water flow regulator Connect line long enough to reach to outside of Unit to water flow regulator outlet then route line to out side of Unit Place end of carbonated water line routed to outside of Unit in container Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to activate electrically operated carbon ated water solenoid When steady stream of water is flowing from added length of line catch carbonated water in container graduated in ounces for exactly 10 seconds Press applicable FILL 1 or FILL 2 switch to deactivate carbonated water solenoid In 10 seconds 14 to 16 ounces of water should have been dispensed If adjustment is necessary loosen jam nut on carbonated water flow regulator Turn regulator adjusting screw to the left co
68. cur 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 cylinders only will go into defrost cycle and defrost for approximately 7 minutes then will return to normal operation This ends automatic defrost cycle of No 1 freeze cylinder 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 Automatic defrost may be cancelled at any time by pressing CANCEL DEFROST switch SLEEP SLEEP TIME NOTE The following describes Sleep Time operation for half of the Unit No 1 No 2 freeze cylin ders Sleep Time operation for No 11 and No 22 freeze cylinders is identical to the No 1 and No 2 freeze cylinders 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 the 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 defrost for one minute then No 2 freeze cylinder will defrost for one minute After freeze cylinde
69. d particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of gas will experience tremors which are followed rapidly by loss of consciousness suffocation NOTE When indicator on primary CO cylinder regulator assembly 1800 psi gage is in shaded change CO cylinder portion of the dial cylinder is almost empty and should be changed 1 Fully close clockwise CO cylinder valve 2 Slowly loosen CO regulator assembly coupling nut allowing CO pressure to escape then remove regula tor assembly from empty cylinder 3 Unfasten safety chain and remove empty cylinder WARNING To avoid personal injury and or property damage always secure cylinder in an upright position with safety chain to prevent it from falling over Should the shutoff valve become accidentally broken off cylinder can cause serious personal injury 4 Position cylinder and secure with safety chain 5 Make sure gasket is in place inside CO regulator coupling nut then install regulator on CO cylinder 6 Open counterclockwise 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 all syrup flavors ca
70. d read 13 tr If BRIX is not within tolerance adjust applicable white syrup flow regulator as follows A Loosen jamb nut on applicable syrup flow regulator B Turn syrup flow regulator adjusting screw to the left counterclockwise no more than 1 8 tum 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 C Tighten jamb nut on syrup flow regulator then lightly tap regulator to register adjustment 326093000 36 8 Place container under applicable product sample valve Open valve to purge product out of product blender tank line and valve then close valve 9 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 10 Repeat steps 6 and 7 preceding to check product sample for BRIX 11 Repeat steps 7 through 10 preceding until proper BRIX adjustment is achieved 12 Open product shutoff valve in line between product blender tank and freeze cylinder 13 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch 14 Install Unit side panels and front lower access panel by reversing removal procedures PRODUCT CARBONATION ADJUSTMENT see Figures 2 and 6 Carbonation of dispensed product can also be varied to suit consumer preference
71. 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 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 43 326093000 Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up VOLTAGE DIS PLAYED VOLTAGE READOUT on message display Press DEFROST SELECT switch to bring up voltage readout on message display Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE INTO UNIT DIAGNOSE DIAGNOSTIC MODE may be programmed into the Unit to check certain components for opera tion Program DIAGNOSE into Unit and check components for proper operation as follows 1 10 11 12 13 14 15 16 17 18 19 20 21 Refer PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up the word CLOCK on display Press CANCEL DEFROST ADVANCE switch to bring up DIAGNOSE menu on message display Press DEFROST SELECT switch to lock in place The word MOTOR 1 will appear on message dis play Pres
72. e range Fruit flavors contain citric acids that colas do not Colas also differ in ingredients from one brand to another Each product formulation has its own peculiarities regarding the way the product will absorb carbonation and the way it will release carbonation BRIX Affects Overrun Sugar in carbonated drinks is like anti freeze in water The higher the BRIX in a product the greater resistance the product has to freezing Conversely in products with lower BRIX freezing takes place at higher tempera tures 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 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 then will drinks that contain 2 0 volumes of CO gas Freezing Affects Ove
73. e range for proper operation If voltage is below or above this range 1 5 KVA Step Up Step Down Transformer P N 325674000 is available to correct below or above voltage condition Use 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 Export Unit IMPORTANT Power circuit voltage across L and L terminals contactor inside lower electrical control box with refrigeration compressor operating must be in operating range of between 219 and 242 VAC 50Hz single phase range for proper operation If voltage is below or above this range A means to provide voltage within operating range must be provided 1 Remove lower electrical control box located on lower right side facing front of Unit cover for access to contactor L and L 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 electrical control box to connect power circuit ground wire electrically grounding the Unit 2 Connect electrical power from 50 amp minimum rated disconnect switch not provided fused at 50 amps slow blow or through an equivalent HACR circuit breaker to L and L terminals on contactor inside control box MAKE SURE GROUND WIRE IS CONNECTED TO GREEN GROUND S
74. een retainer and strainer screen from port Pull strainer screen from screen retainer Clean any sediment from screen retainer and water pump port gs 995 50 Inspect strainer screen for holes restrictions corrosion and other damage Discard damaged strainer screen 9 Check O ring on screen retainer Replace worn or damaged O ring P N 315349000 NOTE Strainer screen should always be used otherwise particles could foul double liquid check valve 10 Install good or new strainer screen P N 315348 000 in screen retainer then screw retainer into water pump port and tighten securely 11 Service other carbonator water pump water strainer screen by repeating steps 6 through 10 preceding 12 Proceed to SERVICING CARBONATORS WATER PUMPS DOUBLE LIQUID CHECK VALVES SERVICING CARBONATORS WATER PUMPS DOUBLE LIQUID CHECK VALVES see Figures 2 and 12 1 Service water pump water strainer screen before servicing water pump double liquid check valve 2 Disconnect carbonator tank water line from double liquid check valve assembly outlet 3 Remove double liquid check valve assembly from elbow in water pump outlet port Retain white tapered gasket inside inlet female end of double liquid check valve 4 Disassemble each check valve as shown in Figure 11 5 Wipe each part with clean lint free cloth Inspect each part especially ball for burrs nicks corrosion dete rioration and other damage Discard ball seat and any damaged or s
75. ems 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 On both control panels press AUTO BLEND 1 AUTO BLEND 2 switches to begin filling freeze cyl inders 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 cylin der and lose carbonation ADJUSTING BEATER MOTOR CURRENT EITHER SIDE 1 Remove four screws securing upper control box cover then remove cover for access to master circuit board inside control box 2 Adjust beaters motors currents as instructed in SERVICE AND MAINTENANCE PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS see Table 2 may be brought up on message display as instructed in SERVICE AND MAINTENANCE 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 PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT The automatic defrost system may be programmed into the Unit to occur up to nine different ti
76. ensing valve to make sure it closes by itself when lever is released If not readjust torsion spring tension 9 Thoroughly clean RELIEF VALVE item 9 then screw relief valve into FACEPLATE item 8 10 Service beater drive shaft seal assembly as follows NOTE Use Dow Corning DC 111 P N 321471000 light grade silicone lubricant A Pull BEATER item 13 and SCRAPER BLADES item 2 from freeze cylinder B Pull beater drive shaft seal assembly from freeze cylinder socket using seal puller Cornelius P N 322063 000 from front side Disassemble shaft seal assembly and discard O rings NOTE If old lubricant cannot be removed from plastic sleeve by washing use nylon pot and pan scrubber 3M Company Scotchbrite or equivalent to remove residue Do not scrape sleeve Replace any sleeve that has rough edges in O ring sealing areas 33 326093000 C Remove old lubricant from plastic sleeve and stainless steel seal retainer see Figure 8 with paper towels Do not scrape the sleeve Wash sleeve retainer and socket and back of freeze cylinder in warm water D Install No 1 stationary O ring in groove of plastic sleeve and No 2 stationary O ring in inner groove of stainless steel seal retainer Lubricate both O rings E Install new running O rings No 3 and No 4 in outer grooves of stainless steel seal retainer then lubricate O rings with generous amount of special light grade silicone grease F Slide stainless stee
77. ensing valves caged o rings see Figure 7 and beaters drive shafts seals assemblies see Figure 8 each time Unit is sanitized as follows NOTE Item numbers in reference to Figure 4 1 Remove HEX NUTS item 7 and FLATWASHERS item 6 securing FACEPLATE item 8 to freeze cylin der then remove faceplate from cylinder 2 Carefully remove large O RING item 5 from FACEPLATE item 8 3 Unscrew RELIEF VALVE item 9 from FACEPLATE item 8 4 Disassemble dispensing valve see Figure 7 as follows A Remove two screws and hold down plates securing spring housing to dispensing valve body then remove housing Remove torsion spring from dispensing valve Remove knob spring sleeve and lever assembly from dispensing valve Remove spring fitting from dispensing valve Press valve with caged O ring down and out of dispensing valve body pee TL Carefully remove caged O ring from valve 326093000 30 CANCEL DEFROST ADVANCE FAULT MESSAGE DISPLAY AUTO BLEND 2 CONTROL PANEL HIDDEN SECURITY SWITCH TOP PANEL TOP PANEL RETAINING SCREW 2 RELAY CIRCUIT BOARD NO 1 MASTER CIRCUIT BOARD RELAY CIRCUIT BOARD NO 2 CONTROL PANEL FACEPLATE RELIEF As ka D 44 N BACK PANEL 6 gt LOWER FRONT ACCESS PANEL CUP REST FACEPLATE 4 DRIP TRAY DISPENSING VALVE 4 SIDE PANEL 2 CONDENSER COIL ACCESS PANEL VENTILATIO
78. etailed information per taining to questions that arise during installation operation service or maintenance of this equip ment GENERAL DESCRIPTION This section gives the description theory of operation and design data for the FCB Solid State Post Mix Four Flavor Dispenser with Hot Gas Defrost hereafter referred to as a Unit UNIT DESCRIPTION The Unit see Figure 1 consists basically of four freeze cylinders each containing an internal beater driven by an electric motor two refrigeration systems one for each two freeze cylinders two carbonators one carbona tor feeding two carbonator blender tanks timer controlled automatic hot gas defrost system to defrost the freeze cylinders and interconnecting tubing components and fittings necessary to regulate transfer and dis pense 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 cylin der A removable drip tray with cup rest is located directly below the dispensing valves sanitized and all sanitizing solution must be purged from the syrup systems All water must also be purged from the plain and carbonated water systems A freezing ambient environment will cause residual water in the Unit to freeze resulti
79. 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 quick disconnect from soft drink tank 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 Trouble Probable Cause Remedy TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES ONE OR MORE CONTROL A Flat cable not properly A Properly connect flat cable to PANEL SWITCHES NOT connected to control switch control switch module or master OPERATING module or master circuit circuit board board B Flat cable connected between B Check cable for pinched or control switch module and broken wire condition and repair master circuit board pinched or replace as necessary and shorted out or broken wire in cable Inoperable switch s on control Replace control panel switch panel switch module module D Master circuit board not D Replace master circuit board operating properly ALL CONTROL PANEL A Electric power disconnected A electric power to Unit SWITCHES NOT OPERATING from Unit B
80. icting air circula tion through the Unit will decrease its cooling efficiency 2 installing Unit do not allow obstructions to block louvers on front which will block off air intake to in side of Unit If installation dictates only one side or back being unobstructed allow 18 inches clearance be tween 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 of clearance INSTALLING UNIT PLACING UNIT IN OPERATING LOCATION 1 Place Unit in location meeting requirements of SELECTING LOCATION 2 After Unit has been installed in operating position make sure front dispensing valve side is approximately 1 4 inch to 3 8 inch higher than the rear to eliminate gas pockets being trapped inside freeze cylinders 3 comply with NSF International NSF requirements Unit installed with base contacting floor must have base sealed to floor with Dow Corning RTV 731 or equivalent INSTALLING DRIP TRAY SUPPORTS DRIP TRAY AND CUP REST 1 Install DRIP TRAY SUPPORTS item 10 on panel above lower front access panel on front of Unit Secure supports to panel with THREAD CUTTING SCREWS item 9 2 Place DRIP TRAY item 13 in FRAME DRIP TRAY item 11 then slide frame up on drip tray supports on front of Unit INSTALLING DRIP TRAY DRAIN KIT ITEM 14 see Figure 5 1 Drill 5 8 inch diameter hole in lowest point center in bottom of drip tray
81. ill 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 8 If freeze cylinder is not full of product repeatedly pull and release faceplate relief valve to slowly bleed CO 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 51 326093000 CARBONATED WATER FLOW REGULATORS 4 SYRUP SOLENOID VALVE 4 326093000 DOUBLE LIQUID CHECK VALVE ASS Y SCREEN RETAINER gt O RING P N 315349000 SCREEN P N 315348000 lt 5 WATER PUMP MOTOR S CARBONATED WATER TANK RELIEF VALVE WATER e WATER PRESSURE REGULATOR lt I LIQUID CHECK VALVE 4 CARBONATED WATER SYRUP FLOAT SOLENOID VALVE 4 SWITCH 4 FIGURE 12 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE 52 WHITE TAPERED GASKET WATER PRESSURE SWITCH REPLENISHING SUPPLY WARNING displaces oxygen Strict attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire and soft drink system If a gas leak is suspecte
82. int capacity is exceeded and drink dispensed will turn slightly wetter OPERATING UNIT NOTE 1 freeze cylinder is cylinder on left hand side facing front of Unit 1 Make sure OUT fault message is not displayed on message display This indicates no water supply to Unit 2 Make sure OUT fault message is not displayed on message display This indicates no gas sup ply to Unit 3 Make sure SYRUP 1 or SYRUP 2 fault messages are not displayed on message display This indicates no syrup supply to Unit 4 Makes 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 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 To connect soft d
83. ispensed 3 Press CANCEL DEFROST ADVANCE switch The left side freeze cylinder viscosity number will be flashing on message display 4 Press CANCEL DEFROST ADVANCE switch to advance viscosity number to desired setting Press DEFROST SELECT switch to lock in viscosity setting The right side freeze cylinder viscosity number will now be flashing 5 Press CANCEL DEFROST ADVANCE switch to advance viscosity number to desired setting Press DEFROST SELECT switch to lock in viscosity setting 6 Press ERROR RESET switch two times to exit from MENU SELECTIONS VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT IN FREEZE CYLINDERS VIS READ ACTUAL VISCOSITY READOUT may be brought up on message display to actually read the viscosity product consistency of the product in the freeze cylinders while the Unit is in operation Bring VIS READ up on message display as follows 1 Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up VIS READ of product in freeze cylinders 2 Press DEFROST SELECT switch to bring up actual viscosity readout of product in each freeze cylinder 3 Press ERROR RESET switch two times to exit from MENU SELECTIONS DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be dis played on message
84. just secondary CO regulators adjust as instructed BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT BRIX is Water to Syrup Ratio mixture of dispensed product If necessary to adjust BRIX adjust as instructed ADJUSTING BEATERS MOTORS CURRENTS Beater motors currents must be adjusted as instructed in SERVICE AND MAINTENANCE ADJUSTING CARBONATOR TANK LIQUID LEVEL The carbonator tank liquid level pump cut in and cut out was adjusted at the factory and should require no further adjustment However if incorrect setting is suspected check and adjust as instructed PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS see Table 5 may be brought up on message display as instructed in SERVICE AND MAINTENANCE 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 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 PROGRAMMING SLEEP SLEEP TIME INTO UNIT SLEEP SLEE
85. king CO supply operators daily cleaning of Unit and sanitizing requirements A WARNING Disconnect electrical power to Unit to prevent personal injury before attempting any internal maintenance Only qualified personnel should service internal components or electrical wiring CONTROL PANEL SWITCHES AND DISPLAYED MESSAGES NOTE The Unit is equipped with two control panels each having its own message displays see Figure 6 The left side control panel facing front of Unit controls the two left side freeze cylinders and right side control panel controls the two right side freeze cylinders CONTROL PANEL SWITCHES FILL 1 and FILL 2 Control Switches FILL 1 FILL 2 control switches located on control panel see Figure 5 are touch type switches and require only pressing to activate FILL 1 and FILL 2 control switches are used when filling syrup systems syrup float switches during syrup replenishing syrup flavor changeover or sanitizing syrup systems After syrup systems syrup float switches 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 5 are touch type switches and require only pressing to activate These switches are used to fill prod
86. l seal retainer in plastic sleeve until running O ring No 3 is just covered by plas tic sleeve as shown in View B of Figure 8 G Carefully place shaft seal assembly over beater drive shaft and locate slots of seal retainer on drive shaft pin Then carefully and simultaneously push and turn plastic sleeve to locate locking tabs on sleeve in notches of freeze cylinder retainer When tabs are seated in notches press assembly firmly in place H Position SCRAPER BLADES item 2 on BEATER item as shown in Figure 4 Slide beater into freeze cylinder so slotted hooks engage DRIVE PIN item 17 on DRIVE SHAFT item 24 Turn beat er 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 Tighten hex nuts until faceplate touches freeze cylinder all around flange CAUTION DO NOT OVERTIGHTEN HEX NUTS 11 Open product shutoff valves leading from product blender tanks to freeze cylinders fill freeze cylinders with product then restore Unit to operation CLEANING CONDENSER COILS see Figure 6 NOTE Circulating air required to cool the refrigeration systems condenser coils is drawn in through louvers on front and exhausted out through louvers on sides and back of Unit Restricting air circula tion through Unit will decrease its cooling efficiency Periodic
87. le and formula below to calculate how much syrup has be dispensed ATS GALLONS A x SYRUP MINUTES Using the above table choose the A number that corresponds to your BRIX setting Multiply the A number by the syrup minutes reading to obtain the amount gallons of syrup used 45 326093000 Table 8 DISPLAYED ERROR CONDITIONS Items Affected By Error Message Beater Beater Displayed Motor 1 Motor 2 Motor 1 Low current lt 109 Sensed on motor one Motor 2 Low current lt 109 Sensed on motor two 4 OFF Motor 1 High current gt 255 Sensed on motor OFF one Motor 2 High current gt 255 Sensed on motor one i OFF OFF OFF FF Syrup 1 Syrup 2 OUT OUT SENSOR 1 SENSOR 2 SENSOR 3 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 ee Deere L Maximum Run Time on Compressor J OFF E peye Zor 955 1 E El EC DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY see Tables 3 and 7 TOTALS DISPLAYED CYCLES AND HOURS TOTALS may be displayed on message display as follows 1 Refer to PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE
88. let temperature readings in degrees Fahrenheit may be displayed on message display as instructed in SERVICE AND MAINTENANCE VOLTAGE DISPLAYED VOLTAGE READOUT Displayed voltage readout may be displayed on message display as instructed in SERVICE AND MAINTENANCE 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 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY TOTALS DISPLAYED CYCLES AND HOURS TOTALS may be displayed on message display as instructed in SERVICE AND MAINTENANCE DISPLAYED ERROR CONDITIONS Displayed error conditions associated errors and items affected by the errors are found in Table 8 DISPLAYED ERROR CONDITIONS 27 326093000 WATER STRAINER SCREEN AND DOUBLE LIQUID VALVE MAINTENANCE see Figures 2 and 12 must be inspected and serviced after any disruptions plumbing work earthquake etc to the water supply system and at least once a year under normal circumstances Water pump with no screen or defective screen in strainer would allow foreign particles to foul the double liquid check valve CO gas could then back flow into water system and create health hazard in system A WARNING The carbonator water pump water str
89. mally require adjustment If adjustment is necessary adjust as instructed SYRUP FLOW REGULATORS The syrup flow regulators See Figures 2 and 6 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 DISPENSING VALVES Self closing dispensing valves see Figure 5 and 7 located on faceplates on front of Unit are operated one at a time or all at once to deliver product to the customer 326093000 22 DISPENSED PRODUCT CONDITIONS OVERRUN AS APPLIED TO FROZEN CARBONATED BEVERAGES Overrun Defined Overrun is product expansion that takes place in the frozen carbonated drink It is caused primarily gas breakout and secondary by freezing Overrun is a Variable The percentage or degree of overrun depends on a number of factors The specific syrup BRIX low dispensing volume carbonation level in liquid product and freezing all affect overrun After these factors have been con sidered desired viscosity product consistency adjustment may be made on the Unit The viscosity adjustment adjusts product texture from very wet to light SE CE DRAWING 1 DRAWING 2 DRAWING 3 Specific Product Ingredients Affect Overrun Each syrup has its own specific formulation or makeup Baume an important ingredient factor may fall within an extremely wid
90. mcor Wilshire prod uct in your country please write fax or telephone the IMI Cornelius office nearest you Please provide the equipment model number serial number and the date of purchase IMI Cornelius Offices AUSTRALIA 210 RIVERWOOD NSW 2210 AUSTRALIA 61 2 533 3122 FAX 61 2 534 2166 AUSTRIA LANGEN FELDE 32 A 1222 VIENNA AUSTRIA 43 233 520 FAX 43 1 2335 2930 BELGIUM BOSKAPELLEI 122 B 2930 BRAASCHAAT BELGIUM 32 3 664 0552 FAX 32 3 665 2307 BRAZIL RUA ITAOCARA 97 TOMAS COELHO RIO DE JANEIRO BRAZIL 55 21 591 7150 FAX 55 21 593 1829 ENGLAND TYTHING ROAD ALCESTER WARWICKSHIRE B49 6 EU ENGLAND 44 789 763 101 FAX 44 789 763 644 FRANCE 71 ROUTE DE ST DENIS F 95170 DEUIL LA BARRE PARIS FRANCE 33 34 28 6200 FAX 33 1 34 28 6201 GERMANY CARL LEVERKUS STRASSE 15 D 4018 LANGENFELD GERMANY 49 2173 7930 FAX 49 2173 77 438 GREECE 488 MESSOGION AVENUE AGIA 153 42 ATHENS GREECE 30 1 600 1073 FAX 30 1 601 2491 HONG KONG 1104 TAIKOTSUI CENTRE 11 15 CHEUNG ST TAIKOKTSUE HONG KONG 852 789 9882 FAX 852 391 6222 ITALY VIA PELLIZZARI 11 1 20059 VIMARCATE ITALY 39 39 608 0817 FAX 39 39 608 0814 NEW ZEALAND 20 LANSFORD CRES BOX 19 044 AVONDALE AUCKLAND 7 NEW ZEALAND 64 9 8200 357 FAX 64 9 8200 361 SINGA
91. mes 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 PROGRAMMING SLEEP SLEEP TIME INTO UNIT SLEEP SLEEP TIME may be programmed into Unit to occur any time of the day after the Unit automatic defrost cycle has occurred Unit will shut down go into sleep time and will not wake up return to normal opera tion until programmed WAKE UP WAKE UP TIME has occurred Program SLEEP SLEEP TIME into Unit as instructed in SERVICE AND MAINTENANCE 326093000 16 PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT WAKE UP WAKE UP TIME be programmed into Unit to occur any time of the day to wake Unit up re turn to normal operation after sleep time has occured Program WAKE UP into Unit as instructed in SER VICE AND MAINTENANCE 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 No 2 and No 3 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 ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT Adjust VIS SET PRODUCT VISCOSITY determines what product consistency of the dispensed product will be present in each freeze cylinder Adju
92. n be changed at the same time Perform flavor change on one system as follows 1 Perform sanitizing procedure on syrup system syrup flavor change will be made as instructed in Service and Maintenance Section 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 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 2 First pressurize soft drink tank containing new flavor syrup by connecting CO line to tank then connect Unit syrup inlet line to tank 3 Press applicable FILL 1 or FILL 2 switch to fill applicable No 1 or No 2 syrup system syrup float switch with syrup 53 326093000 4 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill applicable No 1 2 system product blender tank with product 5 Press applicable AUTO 1 or AUTO 2 switch to star
93. ng in damage to internal components N CAUTION Before shipping storing or relocating this Unit the syrup systems must be FIGURE 1 FCB SOLID STATE POST MIX FOUR FLAVOR DISPENSER 3 326093000 Table 1 Design Data Model Numbers Domestic Unit Export Unit Overall Dimensions Height Width Depth Without Drip Tray Depth With Drip Tray Shipping Weight approx Compressor Horsepower each compressor efrigeration System Refrigerant Type Refrigerant Charge Ambient Operating Temperature 416100 416100 496100 60 1 2 inches 32 1 2 inches 37 1 4 inches 45 1 4 inches 800 pounds 2H P R 50 See Nameplate 40F to 100 lectrical Requirements Domestic Unit Operating Voltage 219 242VAC 60Hz Single Phase Current Draw 40 Amps Export Unit Operating Voltage 219 242VAC 50Hz Single Phase Current Draw 40 Amps THEORY OF OPERATION IMPORTANT Before connecting electrical power refer to Unit nameplate and note if Unit is to be operated with 50 or 60 Hz power source and also note beaters drive motors manufacturer s name No 6 No 7 and No 8 switches on DIP switch assemblies on master circuit boards must be set according to motors manufacturer and for 50 or 60 Hz operation cylinder delivers carbon dioxide CO gas to an adjustable primary CO regulator assembly attached to the cylinder Primary CO regulator assembly in turn delivers CO gas to adjustable se
94. out indicating syrup float switch has been filled with sanitizing solu tion Press AUTO BLEND 1 switch to fill No 1 product blender tank with sanitizing solution Carbonator water pump will start and begin pumping carbonated water into product blender tank which will dilute sanitizing solution also entering tank After carbonator water pump cycles off completely fill No 1 freeze cylinder with sanitizing solution by re peatedly pulling and releasing relief valve knob on freeze cylinder faceplate and until sanitizing solution comes out of relief valve port Open dispensing valve until sanitizing solution flows from valve then close valve Open product blender tank sample valve until sanitizing solution flows from valve then close valve Press WASH 1 switch to start No 1 freeze cylinder beater Allow sanitizing solution to remain in freeze cylinder for no less than ten or 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 way Place waste container under No 1 system product sample valve Slowly o
95. pen valve and purge remaining sanitizing solution out of product blender tank then close valve Disconnect empty sanitizing solution tank from No 1 syrup system Connect soft drink tank containing syrup into No 1 syrup system solution left in system could create a health hazard A WARNING Flush residual sanitizing solution from syrup system as instructed Residual 25 26 27 28 Press FILL 1 switch to No 1 syrup system syrup float switch with syrup SYRUP 1 fault message on message display will go out indicating syrup float switch has been filled with syrup Press AUTO BLEND 1 switch to fill No 1 product blender tank with product Carbonator water pump will start and begin pumping carbonated water into product blender tank along with syrup to make product After carbonator water pump cycles off completely fill No 1 freeze cylinder with product by repeatedly pull ing and releasing faceplate relief valve and until product comes out of relief valve port Open dispensing valve until product flows from valve then close valve Open No 1 system product sample valve until prod uct flows from valve then close valve Press WASH 1 switch to start No 1 freeze cylinder beater Allow beater to operate for approximately five minutes then press OFF 1 switch to stop beater 326093000 48 29 30 31 32 33 34 35 Disconnect soft drink tank containing syrup from No 1 syrup s
96. play 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 sys tem IMPORTANT The following CO and liquid disconnect 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 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 2 Disconnect inlet CO3 and outlet syrup lines from empty soft drink tank 3 Check soft drink tank quick disconnects for sticky or restricted operation Rinse disconnects in warm water 4 First pressurize full soft drink tank by connecting CO line to tank then connect Unit syrup inlet line to tank 5 Press applicable FILL 1 or FILL 2 switch to f
97. ply as instructed Locate and correct error then press ERROR RESET switch to restore normal operation Program automatic defrost system into Unit as instructed Repair electrical wires Replace master circuit board 326093000 Trouble UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN DEFROST SWITCH IS PRESSED DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING CANCEL DEFROST SWITCH 326093000 Probable Cause Automatic defrost timer stuck in automatic defrost cycle Flat cable not properly connected to control panel switch module or master circuit board Flat cable connected between control panel switch module and master circuit board pinched and shorted out or broken wire in cable Inoperable DEFROST switch on control panel switch module Loose or broken wire Master circuit board not operating properly Flat cable not properly connected to control panel switch module or master circuit board Flat cable connected between control panel switch module and master circuit board pinched and shorted out or broken wire in cable Inoperable CANCEL DEFROST switch on control panel switch module Master circuit board not operating properly 66 Remedy Replace master circuit board Properly connect flat cable to control panel switch module or master circuit board Check cable for pinched or broken wire condition and rep
98. rements are satisfied OFF 1 Beater Motor No 1 not operating OFF 2 Beater Motor No 2 not operating OUT No water supply to Unit OUT No 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 CO 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 n box syrup supply system will be connected to Unit instead of soft drink tanks primary regulator see Figure 2 must be adjusted no higher than 80 psi maximum 2 Adjust primary regulator see Figure 2 by turning regulator adjusting screw to the right clockwise until regulator pressure reads 80 to 100 psig OUT OF CO warning lights on both control panel message displays should have gone out 3 Pull up on product blender tanks relief valves to purge air from tanks 4 Remove Unit front lower access panel as instructed for access to carbonator secondary CO regulators see Figure 2 and 6 5 Check product blender tanks secondary CO regulators with 60 psi gages for pressure settings which should be set at 30 psi for best textured product If further adjustments are necessary adjust as instructed IMPORTANT Carbonators secondary CO regulators must be adjusted 25 psi higher or
99. rform procedure to lubricate beater drive shaft seal assembly Carefully place shaft seal assembly over beater drive shaft and locate slots of seal retainer on drive shaft pin Then carefully and simultaneously push and turn plastic sleeve in notches of freeze cylinder retainer When tabs are seated in notches press assembly firmly in place 326093000 56 12 Install beater shaft and scraper blades in freeze cylinder see Figure 3 13 Lubricate faceplate O ring with water to facilitate installation then install faceplate on Unit Secure face plate with hex nuts and lockwashers DO NOT OVERTIGHTEN HEX NUTS RESTORING UNIT OPERATION 1 Open product shutoff valve leading from product blender tank to freeze cylinder 2 Connect electrical power to Unit 3 Sanitize syrup system as instructed in CLEANING AND SANITIZING 4 Press AUTO BLEND 1 and AUTO BLEND 2 to begin filling freeze cylinder Open freeze cylinder face plate relief valve to bleed air from cylinder while filling with product then close valve Do not relieve freeze cylinder pressure too fast or product will foam excessively in cylinder and lose carbonation 5 Press AUTO 1 and AUTO 2 switches to start freeze cylinders beaters and refrigeration system 6 Check for leaks and repair if evident 7 Install back and side panels by reversing removal procedure REPLACING BEATER DRIVE SHAFT SEAL ASS Y see Figures 4 and 14 1 Refer to DISPENSING VALV
100. rink tank into Unit syrup system a First connect quick disconnect to soft drink tank to pressurize tank b Second connect liquid quick disconnect to soft drink tank Syrup supply should be checked daily and if necessary replenished as instructed PRODUCT FLAVOR CHANGE Perform syrup flavor change as instructed 326093000 24 CHECKING CO SUPPLY WARNING displaces oxygen Strict attention must be observed in the prevention of CO 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 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation Make sure cylinder shutoff valve is fully opened and regulator assembly 1800 5 gage indicator is not shaded change cylinder portion of dial If so 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 TYPE 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 e
101. rmal operation Manual defrost may be cancelled at any time by pressing CANCEL DEFROST switch AUTOMATIC DEFROST SYSTEM NOTE The following describes Automatic defrost system operation for No 1 and No 2 freeze cylinders Automatic defrost system operation for the No 11 and No 22 freeze cylinders is identical to the No 1 and No 2 freeze cylinders The automatic hot gas defrost system may be programmed into Unit to occur up to nine different times a day with a minimum of two hours between defrost time 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 cylinders only will go into defrost cycle 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 Automatic defrost may be cancelled at any time by pressing CANCEL DEFROST switch SLEEP SLEEP TIME NOTE The following describes Sleep Time operation for half of the Unit No 1 and No 2 freeze cylin ders Sleep Time operation for No 11 and No 22 freeze cylinders is identical to the No 1 and No 2 freeze cylinders
102. roperly installed Cam action type bearing retaining collar prevents bearing inner race from turning on beater drive shaft and prevents drive shaft from working in and out of freeze cylinder causing a knock when in operation 1 Loosen allen type setscrew securing bearing retaining collar on beater drive shaft Rotate collar slightly to the left counterclockwise to unlock cam action from bearing inner race then remove collar and bearing from shaft Remove boot from old and install on new bearing Install new bearing with boot in place on beater drive shaft Install bearing retaining collar as follows A a Slide bearing retaining collar up on beater drive shaft to bearing inner race B Rotate bearing retaining collar to the right clockwise so its cam action locks it securely against bear ing inner race When in locked position its allen type setscrew must align with flat on beater drive shaft C Tighten allen type setscrew to secure bearing retaining collar on beater drive shaft 55 326093000 FREEZE CYLINDER BEARING SOCKET BEATER BEATER DRIVE _ RETAINING DRIVE MOTOR MOTOR SHAFT COUPLING COLLAR BOOT BEARING 0 POWER COUPLER ASSEMBLY PLASTIC SEATER DRIVE SHAFT H C 5 d A E
103. rrun Freezing causes approximately 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 23 326093000 OPERATING CHARACTERISTICS The product viscosity product consistency can be varied by adjustment and secondary regulator setting from a high overrun light drink to a wet heavy drink The length of freezing cycle and amount of CO present in product combine to create drink dispensed The dispensed product will have a normal variance due to the fol lowing conditions 1 If some time has elapsed since last drink was drawn from particular freeze cylinder and compressor has not cycled on the drink dispensed will have a tendency to be wetter have slightly less overrun than normal for the setting and will not mound up as high See Drawing 1 NOTE A cylinder freeze up may be expected under casual draw conditions if an attempt is made to eliminate drink described above by adjusting viscosity 2 If product is drawn from freeze cylinder quite regularly its viscosity product consistency will be maintained at whatever viscosity adjustment was made within the normal variance of the compressor off and on cycle See Drawing 2 3 If product is drawn continuously from freeze cylinder and rate is approaching capacity of the dispensing Unit overrun of drink will increase just prior to po
104. rs have been de frosted Unit will go into sleep time WAKE UP WAKE UP TIME Wake up wake up time may be programmed into the unit to allow unit to resume normal operation at a de sired time When programmed wake up time is reached an alarm will sound for a short duration then unit will resume normal operation NOTE Automatic defrost sleep time and wake up time may be used in any combination together or separately 5 326093000 WATER PRESSURE REGULATORS ARE FACTORY SYRUP SOLDOUT SWITCHES ARE FACTORY ADJUSTED TO 45 PSI AND SHOULD NOT BE READJUSTED ADJUSTED AND SHOULD NOT BE READJUSTED PRODUCT SAMPLE VALVE 4 1 PRODUCT BLENDER N TANK 4 A PRODUCT SHUTOFF VALVE 4 SYRUP FLOW REGULATOR 4 SECONDARY REGULATORS TO PRODUCT BLENDER TANKS 60 PSI GAGES SECONDARY REGULATORS TO CARBONATOR TANKS 100 PSI GAGES FREEZE CYLINDER 4 PRESSURE i SWITCH FREEZE CYLINDERS OVERFLOW TUBE DOUBLE LIQUID CHECK VALVE 2 7 T Na CARBONATOR TANK 2 A x B 52958 WATER PUMP 2 WATER PRESSURE i REGULATOR 2 e ae ee CARBONATED SAMPLE VALVE 2 t SYRUP z 1 SOLENOID 4 WATER PRESSURE Li CARBONA
105. s 5 Lubricate each faceplate O RING see Figure 4 with Dow Corning DC 111 light grade silicone to facili tate installing faceplates on freeze cylinders Position each FACEPLATE on freeze cylinders so dispensing valves faucets face down Secure each faceplate to freeze cylinder with four HEX NUTS and FLAT WASH ERS removed in step 1 preceding Tighten HEX NUTS until faceplates touch all the way around on freeze cylinder flanges CAUTION DO OVERTIGHTEN HEX NUTS ELECTRICAL POWER REQUIREMENTS IMPORTANT Refer to Unit nameplate to determine if Unit is to be operated with 50HZ or 60 HZ power source Also note beaters motors manufacturer No 6 No 7 and No 8 switches on DIP switch assembly on master circuit board must be set according to motors manufacturers and for 50HZ or 60HZ operation DOMESTIC UNIT IMPORTANT Power circuit voltage across L and L terminals on contactor inside lower electrical control box with refrigeration compressor operating must be in operating range of between 219 and 242 VAC 60Hz single phase range for proper operation If voltage is below or above this range 1 5 KVA Step Up Step Down Transformer P N 325674000 is available to correct below or above voltage condition A properly grounded 219 to 242 VAC 60Hz single phase electrical circuit with 50 minimum rated dis connect switch not provided fused at 50 amps slow blow or a circuit connected through a equivalent HACR circuit bo
106. s DEFROST SELECT switch No 1 beater motor will start and operate while switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up the word MOTOR 2 on mes sage display Press DEFROST SELECT switch 2 beater motor will start and operate while switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up DEFROST 1 on message dis play Press DEFROST SELECT switch No 1 defrost relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up DEFROST 2 on message dis play Press DEFROST SELECT switch No 2 defrost relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up SYRUP 1 on message display Press DEFROST SELECT switch No 1 syrup solenoid relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up SYRUP 2 on message display Press DEFROST SELECT switch No 2 syrup solenoid relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up WATER 1 on message display Press DEFROST SELECT switch No 1 carbonated water solenoid relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up WATER 2 on message display Press DEFROST SELECT swit
107. s koun aks lk aaa 3 GENERAL DESCRIPTION aus aus inda ni uni aa 3 UNIT DESCRIPTION o Aa Gate ia 3 THEORY OF OPERATION eg lecker 4 DEFROST SYSTEMS xis ee ae 4 MANUAL DEFROST SYSTEMS 5 AUTOMATIC DEFROST SYSTEMS 5 SLEEP SLEEP TINE Zan sod 5 WAKE UP WAKE UP TIME 5 INSTALLATION a as ek 7 UNPACKING AND INSPECTION ai 7 IDENTIFICATION OF LOOSE SHIPPED PARTS 7 INSTALLING BEATERS AND SCRAPER BLADES 10 ELECTRICAL POWER REQUIREMENTS 10 DOMESTIC UNIT ee ee 10 EXPORT UNIT fat As ea 10 SELECTING LOCATION 2 10 INSTALLING UNIT ee e be 11 PLACING UNIT IN OPERATING LOCATION 11 INSTALLING DRIP TRAY SUPPORTS DRIP TRAY AND CUP REST 11 INSTALLING DRIP TRAY DRAIN 11 INSTALLING PRIMARY 2 REGULATOR ASSEMBLY ON CO2 CYLINDERS u i rn nn are 11 CONNECTING SOFT DRINK TANKS CO2 LINES PRIMARY CO2 REGULATOR ASSEMBLY 3 Ah none Saad 12 PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT DRINK TANKS at e Gn n of a ai 12 CONNECTING PLAIN WATER INLET SUPPLY LINE
108. st VIS SET PRODUCT VISCOSITY of the dispensed product as instructed in SERVICE AND MAINTENANCE DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be dis played on message display as instructed in SERVICE AND MAINTENANCE VOLTAGE DISPLAYED VOLTAGE READOUT Displayed voltage readout may be displayed on message display as instructed in SERVICE AND MAINTE NANCE PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE INTO UNIT DIAGNOSE DIAGNOSTIC MODE may be programmed into the Unit to check certain components for opera tion Program DIAGNOSE into Unit and check components for proper operation as instructed in SERVICE AND MAINTENANCE DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY TOTALS DISPLAYED CYCLES AND HOURS TOTALS may be displayed on message display as instructed in SERVICE AND MAINTENANCE DISPLAYED ERROR CONDITIONS Displayed error conditions associated errors and items affected by the errors are found in Table 8 DIS PLAYED ERROR CONDITIONS 17 326093000 THIS PAGE LEFT BLANK INTENTIONALLY 326093000 18 OPERATORS INSTRUCTIONS This section describes operating controls and indicators dispensed product conditions operating characteris tics Unit operation replenishing syrup supply product flavor change chec
109. t refrigeration system and beater in applicable No 1 or No 2 freeze cylinder CAUTION Do relieve freeze cylinder pressure too fast or product will foam excessively in freeze cylinder and lose carbonation 6 After carbonator water pump cycles off intermittently pull and release applicable 1 or No 2 freeze cyl inder faceplate relief valve This bleeds CO from freeze cylinder and allows product to enter and fill cylin der 7 If necessary adjust BRIX product viscosity product consistency and product carbonation of dispensed product as instructed QUAD RING 183294000 BALL pe 188288000 SPRING 183297000 RETAINER 183298000 gt BODY 183295100 QUAD RING SEAL MUST REPLACED EACH TIME CHECK VALVE IS SERVICED FIGURE 13 GAS CHECK VALVE CLEANING CO GAS CHECK VALVES see Figures 2 and 13 The CO gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO system ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED REPLACING FREEZE CYLINDER BEATER DRIVE SHAFT BEARING see Figures 4 8 and 14 SHUTTING UNIT DOWN 1 Press DEFROST switch to defrost product in freeze cylinders 2 After defrost cycle is completed press OFF 1 and OFF 2 control switches to stop refrigeration system and beaters motors 3 Disconnect electrical power to Unit 32609
110. ten 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 current adjustments or doing any preventa tive maintenance current readings check Any current adjustments or preventative maintenance current readings check on the beater motor current ei ther side must be performed with both freeze cylinders fully defrosted A partially defrosted freeze cylinder will cause false correct readings to be displayed on the message display Adjust beater motor current either side as follows 37 326093000 CANCEL DEFROST DEFROST BLEND 2 SELECT ADVANCE FAULT MESSAGE DISPLAY CONTROL PANEL HIDDEN SECURITY SWITCH FIGURE 9 CONTROL PANEL 1 Place No 4 BEATER MOTOR CURRENT READOUT switch on DIP SWITCH assembly on master cir cuit 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 lo cated on No 1 and No 2 relay circuit boards see Figure 10 These figures will fluctuate slightly with varia tions in line voltage and motor loads
111. terminals then install access cover plate on motor Install back and side panels Connect electrical power to Unit at disconnect switch Press AUTO BLEND 1 and AUTO BLEND 2 control switches then press AUTO 1 and AUTO 2 switches to start freeze cylinders beaters and refrigeration system ADJUSTING CARBONATOR TANK LIQUID LEVEL 1 9 10 32 The carbonator tank liquid level pump cut in and cut out was adjusted at the factory and should require no further adjustment However if incorrect setting is suspected check and make necessary adjustments as follows Remove Unit back and right side panels as instructed for access to carbonator and carbonated water vol ume sample valve see Figures 2 and 6 To check carbonator tank total fill allow carbonator water pump motor to operate and fill tank with carbo nated water After pump cycles off disconnect Unit electrical power at disconnect switch Using container graduated in ounces open carbonator carbonated water sample valve and completely drain carbonator tank into container Total carbonated water volume dispensed should be 40 to 58 ounces maximum If total carbonated water dispensed is below 40 ounces loosen screw securing level control switches ac tuator bracket see Figure 15 and move actuator bracket up slightly If more than 58 ounces maximum of carbonated water was dispensed move actuator bracket down then tighten screw MAKE ADJUST MENTS IN SM
112. uct blender tanks after syrup float switches have been filled using FILL 1 and FILL 2 switches AUTO BLEND 1 and AUTO BLEND 2 and AUTO 1 and AUTO 2 switches must be pressed to operate freeze cylinders beaters and re frigeration system during normal operation WASH 1 and WASH 2 Control Switches WASH 1 and WASH 2 control switches located on control panel see Figure 5 are touch type switches and require only pressing to activate These switches are used to operate freeze cylinders beaters with no refrig eration during sanitizing AUTO 1 and AUTO 2 Control Switches AUTO 1 and AUTO 2 control switches located on control panel see Figure 5 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 systems 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 5 are touch type switches and require only pressing to activate These switches are used to stop freeze cylinders beaters and refrigeration sys tems 19 326093000 ERROR RESET Control Switch ERROR RESET control switch located on control panel see Figure 5
113. uctions Keep your machine in proper working condition Unauthorized modifications to the machine may impair function and or safety and affect the machine life CO Carbon Dioxide Warning 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 Person nel exposed to high concentration of CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation Shipping Storing Or Relocating Unit CAUTION Before shipping storing or relocating this Unit the syrup systems must be sanitized and all sanitizing solution must be purged from the syrup systems All water must also be purged from the plain and carbonated water systems A freezing ambient temperature will cause residual water remaining inside the Unit to freeze resulting in damage to internal components of the Unit 1 326093000 THIS PAGE LEFT BLANK INTENTIONALLY 326093000 2 GENERAL DESCRIPTION This section gives the Unit description theory of operation and design data for Solid State Post Mix Dis penser the user of this manual This manual is a guide for installing operating and main taining this equipment Refer to the Table of Contents for page location for d
114. unterclockwise to reduce carbonated water flow rate or turn screw to the right clock wise to increase flow rate Tighten jam nut and tap on regulator to register adjustment Repeat steps 11 through 13 until desired carbonated water flow rate is achieved Remove added length of line from outlet side of carbonated water flow regulator Connect carbonated wa ter line disconnected from carbonated water flow regulator in step 8 preceding to regulator outlet Turn product blender tanks CO regulator with 60 psi gage adjusting screw in clockwise until gage regis ters pressure noted in step 7 preceding Pull relief valve on applicable product blender tank to purge air from tank then close valve Connect Unit syrup inlet line to soft drink tank Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill product blender tank with product Open product shutoff valve that was closed in step 4 preceding Install side panel and lower front access panel by reversing removal procedure ADJUSTING CO REGULATORS NOTE To readjust regulator to a lower setting loosen adjusting screw lock nut then turn screw to the left counterclockwise until pressure gage reads 5 psi lower than new setting will be Turn adjust ing screw to the right clockwise until gage registers new setting then tighten lock nut Primary CO Regulator see Figure 2 The primary CO regulator controls CO pressure to soft drink tanks also to bag
115. ur 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 MO MENTARY ERROR MESSAGE WILL APPEAR ON THE MESSAGE DISPLAY WHEN OPERATOR TRIES TO EXIT DEFROST THE PROGRAM WILL NOT ALLOW THE OPERATOR TO EXIT THE DE FROST SETTING UNTIL THE LESS THEN TWO HOUR DEFROST TIME IS CORRECTED THE OPER ATOR MUST PRESS CANCEL DEFROST ADVANCE SWITCH THEN REPEAT STEPS 2 3 and 4 TO PROGRAM CORRECTED DEFROST TIME INTO UNIT 39 326093000 Table 3 Main Menu Selections Message Display Menu Commands Example Readouts CLOCK TIME OF DAY see note below DEFROST AUTOMATIC SLEEP SLEEP TIME WAKE UP WAKE UP TIME VIS SET PRODUCT VISCOSITY SETTING VIS READ ACTUAL VISCOSITY READOUT SENSORS TEMPERATURES READOUT VOLTAGE DISPLAYED VOLTAGE READOUT DIAGNOSE DIAGNOSTIC MODE See Programming Components Diagnose into Unit TOTALS See Table 4 5 and Programming Totals DISPLAYED CYCLES AND HOU
116. urely 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 display module or master circuit board 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 display module or master circuit board Trouble ALL FAULT MESSAGES NOT OPERATING CONT D CO OUT FAULT1 MESSAGE GOES ON DURING OPERATION OUT FAULT MESSAGE GOES ON DURING OPERATION SY
117. uspicious parts and replace with new parts during reassemble 6 Reassemble liquid check valves as shown in Figure 11 ALWAYS INSTALL NEW BALL SEAT QUAD RING P N 312418 000 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 7 Assemble check valves together DO NOT OVERTIGHTEN 8 Make sure white tapered gasket is in place inside female end of double liquid check valve assembly then install check valve assembly on elbow in water pump outlet port 9 Connect carbonator tank water line to double liquid check valve assembly outlet DO NOT OVERTIGH TEN 10 Service other carbonator water pump double liquid check valve by repeating steps 2 through 9 preceding 326093000 50 11 Open CO cylinder and water inlet supply lines shutoff valves Check for water leaks and tighten any loose connections 12 Install Unit back panel by reversing removal procedure 13 Connect electrical power to Unit 14 Press both AUTO BLEND 1 and AUTO BLEND 2 switches 15 Press both AUTO 1 AUTO switches to start freeze cylinders beaters and refrigeration system REPLENISHING SYRUP SUPPLY NOTE Sugar free diet syrups cannot by 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 dis
118. very 90 days and before and after storage periods following parent company requirements and sanitizer manufacturers recommendations CLEANING CONDENSER COIL NOTE Circulating air required to cool the refrigeration systems condenser coils see Figure 5 is drawn in through louvers on front and exhausted out through louvers on sides and back of Unit Restricting air circulation through the Unit will decrease its cooling efficiency Condenser coils must be cleaned periodically as instructed LUBRICATION Carbonators water pump motors must be lubricated as instructed on motors ADJUSTMENTS CARBONATED WATER FLOW RATE The adjustable carbonated water flow regulators see Figures 2 and 6 located in their respective systems con trol carbonated water flow rate to the product blender tanks The water flow regulators are factory adjusted at 1 5 and should not normally require adjustment If adjustment is necessary adjust as instructed 25 326093000 CO REGULATORS Primary CO Regulator The primary CO regulator see Figure 2 controls CO pressure to soft drink tanks also to bag n box syrup system if used and secondary CO regulators located behind Unit lower front access panel If necessary to adjust primary CO regulator adjust as instructed Secondary CO Regulators The secondary regulators see Figures 2 and 6 regulate pressure to carbonators and product blender tanks If necessary to ad
119. ves used to check product BRIX Turn valve lever to line up with attached line to open valve and at 90 angle with line to close valve PRODUCT SHUTOFF VALVES The four product shutoff valves located in lines leading from product blender tanks to freeze cylinders see Fig ures 2 and 6 are manually operated lever type ball valves and are used to prevent product from entering and filling freeze cylinders while adjusting BRIX of dispensed product Shutoff valve may also be used to shut off product to individual freeze cylinder for service and maintenance without disrupting operation of other freeze cylinders PRIMARY CO REGULATOR The primary CO regulator see Figure 2 controls CO pressure to soft drink tanks also to bag n box syrup system if used and Unit secondary regulators located behind lower front access panel If necessary to ad just primary CO regulator adjust as instructed SECONDARY CO REGULATORS The secondary regulators located behind lower front access panel see Figures 2 and 6 control CO pres sure to carbonators and product blender tanks If necessary to adjust secondary CO regulators adjust as instructed CARBONATED WATER FLOW REGULATORS The adjustable carbonated water flow regulators see Figures 2 and 6 located in their respective systems con trol carbonated water flow rate to the product blender tanks The water flow regulators are factory adjusted at 1 5 0905 02 sec and should not nor
120. ystem Connect clean empty soft drink tank into No 1 syrup system Hold appropriate container under dispensing valve and dispense until all product has been dispensed from freeze cylinder As product level lowers in freeze cylinder partially close valve to avoid spurting Place waste container under No 1 system product sample valve Slowly open valve and purge remaining product out of product blender tank then close valve Disconnect empty soft drink tank from No 1 syrup system and install tank containing syrup Press FILL 1 switch to fill No 1 syrup system syrup float switch with syrup SYRUP 1 fault message on message display will go out indicating syrup float switch has been filled with syrup Press AUTO BLEND 1 switch to fill No 1 product blender tank with product Carbonator water pump will start and begin pumping carbonated water into product blender tank along with syrup to make product A Do not relieve freeze cylinder pressure too fast or product will foam excessively 36 37 38 39 in cylinder and lose carbonation After carbonator water pump cycles off intermittently pull and release No 1 freeze cylinder faceplate relief valve This bleeds CO from freeze cylinder and allows product to enter and fill cylinder Open No 2 product blender tank product shutoff valve Press both AUTO 1 and AUTO 2 switches to start both freeze cylinders beaters and refrigeration sys

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