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Service Manual FCB Pinnacle 2 and 4 Flavor

1. FIGURE 12 From the SET WAKE UP menu the system wake up times are set These are the times when the system will resume normal operation freeze cylinder refrigeration and beater motor operation after an inactive period sleep Each day of the week can have a separate wake up time or ALL DAYS of the week can be programmed to wake up at the same time Each cylinder will wake up in the mode that it was in when it went to sleep For instance if cylinder 1 was ON and cylinder 2 was in MOTOR before going to sleep the cylinders will wake up in those modes Wake up times can be setin 15 minute increments When NONE appears it means that no wake up time has been set for that day The preset time format used by the system will be used by the SET WAKE UP menu SET WAKE UP Menu Button Descriptions 1 BACK go back to the previous menu 2 DAY Vis Saras cycle through the list of days 3 NEXT cycle through the time fields 4 UP increase the selected field by 1 hour or 15 minute increment 5 DOWN decrease the selected field by 1 hour or 15 minute increment To set wake up times 1 Press lt DAY gt to select 1 of 8 options SUNDAY MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY ALL DAYS 2 Press lt NEXT gt to change the field from HOURS to MINUTES 3 Press lt UP gt and lt DOWN gt to change the setting in the field 4 Press lt BACK gt to save the changes 2003 IMI Cornelius Inc
2. Comelis FCB PINNACLE 2 and 4 Flavor Service Manual ADA EEEE gt FCB 2 Flavor FCB 4 Flavor am Release Date October 30 2003 Publication Number 560007298SER Revision Date NA Revision A CONTACT INFORMATION The products technical information and instructions contained in this manual are subject to change with out notice These instructions are not intended to cover all details or variations of the equipment nor to provide for every possible contingency in the installation operation or maintenance of this equipment This manual assumes that the person s working on the equipment have been trained and are skilled in working with electrical plumbing pneumatic and mechanical equipment Appropriate safety precautions should be followed and all local safety and construction requirements should be met To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact IMI Cornelius Inc Internet Corporate Headquarters i One Cornelius Place www cornelius com Anoka MN 55303 6234 E mail U S A tech service cornelius com In the U S A Outside the U S A phone 763 421 6120 phone 763 421 6120 800 238 3600 fax 800 535 4231 faye 763 422 3297 Trademarks and Copyrights Aurora Cornelius Decade Hydro Boost Olympus Sitco Spirit UF 1 Vanguard Venture and Vista are registered trademarks of IMI Cornelius Optifill trademar
3. If 5 volts is present continue If not remove the connector from J2 and measure the same pins on the Inverter board If 5 volts is present the cabling to the Hall board or the Hall board itself is bad Replace it If the 5 volts is not present the Inverter board is bad Replace it Connect black lead from the meter to the black wire connection at connector Rotate slowly and watch for the hall board to switch Move the red lead and repeat test FIGURE 51 2 Place Barrel 1 in the OFF mode Remove the product and face plate from barrel 1 Keep the beater bar Rotate slowly engaged with the drive magnet in the back of the freeze cylinder You will be slowly turning the beater bar by hand 3 I p FIGURE 52 3 Using a voltmeter in the DC mode place the black probe on pin 5 Black and the red probe on pin 2 White Slowly turn 5 to 10 degrees per second the beater bar in either direction Watch the voltmeter If the Hall sensor is operating properly the voltage will be changing between 0 volts and 5 volts If you are turning at a uniform speed the voltage on the voltmeter should toggle back and forth uniformly If the voltage is NOT changing replace the Hall Board If the voltage is changing very erratically replace the Hall Board 2003 IMI Cornelius Inc 45 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Voltage should switch from 5 V D C to 025 approx F
4. front of the cylinder Reinstall 4 washers and nuts finger rod on tight Then approximately 1 4 turn with a wrench shaft Y Make sure bushing on face plate beater bar shaft is in good condition 9 When all the hardware is securely in place turn the blendonator ON then turn the product cylinder supply valve ON bleed the cylinder and use the control panel to turn the cylinder ON There is a short delay before the beater bar starts rotating Publication Number 560007298SER 34 2008 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual DC CONTROL Drive Motor BOARD REPLACEMENT EMERSON CAUTION Use a grounding strap 1 Disconnect the power to the unit DC Control Drive Motor Board m ml Ea i EE E FIGURE 35 2 Open the merchandiser door then remove the top front panel and front hinged panel work on the unit Working on the unit before the 5 minutes have passed could result in electrical shock or death 3 Unscrew the 3 mounting screws on the Control Drive Motor board mounting bracket and slide the bracket up while tilting it out Do NOT detach the wires from the board yet 4 Secure the new board in place One at time remove the wires from the old board and connect them to the new board 5 Connect the power 6 Re attach the panels DANGER HIGH VOLTAGE after disconnecting power wait for approximately 5 minutes to MAIN AND PRODUCT DELIVERY
5. 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 763 421 6120 FAX 763 422 3255 2003 IMI Cornelius Inc 63 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual C Queis D Publication Number 560007298SER 64 2003 IMI Cornelius Inc IMI Cornelius Inc One Cornelius Place Anoka MN 55303 1592 U S A
6. BALDOR 1 Disconnect the power to the unit 2 Open the merchandiser door then remove top front panel and hinged panel DANGER HIGH VOLTAGE after disconnecting power wait for the D33 red light to go out indi A cating that it is safe to work on the unit Working on the unit when the red D33 light is lit could result in electrical shock or death 3 Unscrew the 4 screws holding the board cover Carefully reach behind the cover and disconnect the wires ribbon cable phone cable power cable Mounting standoff 4 2 gt A Display Board 4 Remove the board from the 4 standoffs Cover 5 Install the new board with the ribbon cable protruding through the top Ribbon cable FIGURE 42 6 Reconnect the wires while installing the cover 7 Connect the power and check to see that the control panel works properly Secure the circuit board door and follow a normal startup procedure 8 Re attach the panels 2003 IMI Cornelius Inc 39 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cines MERCHANDISER LIGHT BALLAST REPLACEMENT Disconnect the power to the unit 2 Lift the merchandiser and slide it left or right to lock it in place 3 Remove the ballast cover 2 screws 4 Remove the ballast 2 screws 5 One ballast at a time remove the wires from the old one then insert the wires to the same connector on the new ballast 6 Install the new ballast and bal
7. a A B on each a side FIGURE 48 SYRUP WATER VALVE REPLACEMENT 1 Disconnect the power to the unit If applicable remove the drip tray drip tray mounting panel 2 screws and splash panel 2 screws 2 Turn off water and syrup sources then turn off the cylinder product supply valve Bleed pressure from the feed lines at the rear disconnects 3 Slide out the product tray by removing the 2 screws on each side and pulling the tray out 4 Disconnect wires to flow control Disconnect fitting at back of flow control pump fitting Remove hold down clamp 1 screw Slide flow control assembly up while pulling inlet line out of the front 5 Reverse the procedure to install new flow control assembly Be sure and check for leaks after pressurizing the system 6 Re connect the power and go through normal start up procedure 7 BRIX the cylinder with the new flow control Publication Number 560007298SER 42 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual CO REGULATOR REPLACEMENT 1 6 Disconnect the power to the unit If applicable remove the drip tray drip tray mounting panel 2 screws and splash panel 2 screws Remove the side panel 3 screw by the faulty regulator Turn off CO source then turn off the cylinder product supply valve Relieve pressure from blendonator by opening the face plate relief valve Disconnect 3 quick disconnect fittings to CO regulator using a span
8. ship under normal use and service For a copy of the warranty applicable to your Cornelius product in your country please write fax or telephone the IMI Cornelius office nearest you Please provide the equipment model number and the date of purchase Australia P O 210 Riverwood NSW 2210 Australia 61 2 533 3122 FAX 61 2 534 2166 Austria Am Langen Felde 32 A 1222 Vienna Austria 43 1 233 520 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 1 34 28 6200 FAX 33 1 34 28 6201 Germany Carl Leverkus Strasse 15 D 4018 Langenfeld West Germany 49 2173 7930 FAX 49 2173 77 438 Greece 488 Messogion Avenue Agia Paraskevi 153 42 Athens Greece 30 1 600 1073 FAX 30 1 601 2491 Hong Kong 1104 Taikotsui Centre 11 15 Kok 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 P O Box 19 044 Avondale Auckland 7 New Zealand 64 9 8200 357 FAX 64 9 8200 361 Singapore 16 Tuas Street Singapore 2263 65 862 5542 FAX 65
9. 2 and 4 Flavor Service Manual SAFETY SAFETY INSTRUCTIONS Read and Follow all Safety Instructions Read and follow all safety instructions in this manual and on the machine decals labels and laminated cards Read and understand all applicable OSHA Occupation Safety and Health Administration safety regula tions before operating the machine Recognize Safety Alerts This is the safety alert symbol When you see it in this manual or on the machine be alert to the potential of personal injury or damage to the machine Different Types of Alerts There are 3 types of safety alerts A DANGER Indicates an immediate hazardous situation which if not avoided WILL result in seri Ous injury death or equipment damage WARNING Indicates a potentially hazardous situation which if not avoided COULD result in serious injury death or equipment damage CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury or equipment damage SAFETY TIPS e Carefully read all safety messages in this manual and safety signs on the machine e Keep safety signs in good condition and replace missing or damaged safety signs e Learn how to operate the machine and how to use the controls properly e Do not let anyone operate the machine without proper training This appliance is not intended for use by very young children or infirm persons without supervision Young children shou
10. BOARD REPLACEMENT EMERSON 1 Disconnect the power to the unit 2 Open the merchandiser door then remove top front panel Product Delivery DC Control Drive Product Delivery and front hinged panel Boards Motor Boards Boards A work on the unit Working on the unit before the 5 minutes have passed could result in electrical shock or death DANGER HIGH VOLTAGE after discon necting power wait approximately 5 minuets to 3 Remove all wires from board being replaced 4 Disconnect the 4 mounting standoffs and remove the board 5 Secure the new board in place and reconnect the wiring Main Boards FIGURE 36 2003 IMI Cornelius Inc 35 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual C Ginelius D 6 If the Main Board was replaced program the previous setting for time defrost sleep walk up and viscosity 7 Re attach the panels CHIP CHANGE PROCEDURE The purpose of this notice is to describe the proper method for changing a chip on the master board of a Cornelius machine should it become necessary NOTE Static electricity can destroy sensitive electronic circuits Always wear static straps or keep yourself grounded to the machine while working in the electronic boards Tools needed e 32 pin dip extractor chip puller 790327 Wrist ground strap 790326 Unplug machine Remove top panel on floor models Open door to access the control box on the OC2 machine Remove l
11. Button 5 FIGURE 7 Pressing a button performs the action labeled just above the button For example from the BARREL STATUS menu pressing button 1 labeled MENU displays a menu with more options pressing button 5 labeled ERR displays error messages from the control system 2003 IMI Cornelius Inc 11 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cines Control Panel Menu Descriptions The following section describes the information displayed on each Control Panel menu and the actions that are taken from each menu Menu 1 BARREL STATUS BARREL 3 i N Cylinder acies ju Status 10 38AM Button Labels MENU FIGURE 8 The BARREL STATUS menu is the main menu of the Control Panel This menu displays the system clock and to the right of the words BARREL STATUS the present status of each cylinder Listed below are the status messages that may be displayed for each cylinder BARREL STATUS Menu Button Descriptions 1 MENU bring up the CHOOSE MODE menu menu 2 2 gt ON L sk ows turn all freeze cylinders ON beater bar TURNING and refrigeration ACTIVE 3 OFF turn all freeze cylinders OFF beater bar OFF and refrigeration INACTIVE 5 ERR Pressing ERR displays the ERROR menu which lists all system errors NOTE If there are no errors the ERR message is not displayed for button 5 BARREL STATUS Menu Non Error Messages ON 224 oe irk ye are beater bar is
12. Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual Menu 15 OPTION SELECT STATUS CELSIUS FAHREN Option FA HR same Option anae UP DOWN Status FIGURE 23 The OPTION SELECT STATUS menu allows system options to be selected and customized These options will be displayed on the OPTIONS menu OPTION SELECT STATUS Menu Button Descriptions 1 BACK go back to the previous menu 2 OPTION 1 select this option the button label changes depending on the option being dis played 3 OPTION 2 select this option the button label changes depending on the option being dis played 4 UP scrolls list up 5 DOWN scrolls list down To display select and change system options 1 Press lt UP gt or lt DOWN gt to select the desired option 2 Press the lt OPTION 1 gt button to change that option 3 Press the lt OPTION 2 gt button to change that option 4 Press lt UP gt or lt DOWN gt to display the next option The options that can be displayed and changed are described below Option Name Button 1 Button 2 Description DAYLT SAVINGS disable enable Daylight Savings Time CELCIUS FAHREN FAHR CELS select temperature for display DATE FORMAT EURO selects date format U S mm dd yy or European dd mm yy TIME FORMAT 12HR 24HR selects 12 hour AM PM or 24 hour time format SECURITY disable enable security lockout of system parameters LANGUAGE ENGL OTHER select language as availabl
13. TURNING and refrigeration to this freeze cylinder is ACTIVE OFF oreore ad sa beater bar is NOT TURNING and refrigeration to this freeze cylinder is INAC TIVE MOTOR beater bar is TURNING and refrigeration to this freeze cylinder is INACTIVE DFRST freeze cylinder is presently in DEFROST mode From the BARREL STATUS menu pressing lt MENU gt displays the CHOOSE MODE menu menu 2 NOTE See the Control Panel Error Descriptions for a description of the system errors Publication Number 560007298SER 12 2003 IMI Cornelius Inc Pinnacle 2 and 4 Flavor Service Manual Menu 2 CHOOSE MODE mend pP Menu Scroll List Item AULA US S gt 0ON OFF MOTOR not all items on Balti MODE S E CONO the list are dis SET WAKE UP played at once Button Labels VOLT y Use UP and DOWN buttons to scroll the list up and down FIGURE 9 System menus are chosen from the CHOOSE MODE menu The VOLT menu is accessed from this menu The menu list is scrolled up and down pressing UP and DOWN buttons The menu item that has the pointer in front of it is activated when lt GO gt is pressed CHOOSE MODE Menu Button Descriptions 1 BACK go back to the BARREL STATUS menu menu 1 go to the menu that is selected by the pointer go to the VOLT menu menu 19 scroll up the menu list scroll down the menu list CHOOSE MODE Menu Scroll List Item ON OFF MOTOR SET CLOCK SET WAKE UP SET SL
14. has run COMP n xxxxx CYC number of run cycles compressor n has performed AGITAT n xxxxx HR number of hours agitator motor n has run BRL ON n xxxxx HRnumber of hours cylinder n has been in ON mode MOTOR n xxxxx HR number of hours cylinder motor n has run SYRUP n xxxxx MIN number of minutes syrup flow n has been called for ERROR n xxxxx HR number of hours cylinder n has had any errors SYR SO Hn xxxxx HRnumber of hours cylinder n is out of syrup DEFRST Zn xxxxx HRnumber of hours cylinder n has been in auto defrost BLENDR n xxxxx HRnumber of blender cycles on cylinder n z resetting these totals to zero is allowed 2003 IMI Cornelius Inc 21 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual C Ginelius D Menu 12 DIAGNOSTICS Selection Pointer Item or Subsystem FIGURE 20 The DIAGNOSTICS menu allows the selection of manual or automatic display of system information The manual mode allows the operator to select which output is activated The automatic mode cycles through all of the outputs 1 after the other The automatic mode begins at the selection pointer and stops at the end of the list or when the AUTO is pressed again The automatic mode cycles through each output for 2 seconds ON and 3 seconds OFF The output list scrolls down as the automatic mode progresses All system functions and control
15. inlet line from pail of sanitizing solution 2003 IMI Cornelius Inc 7 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cre D 10 Flush the system by completing the following steps A CAUTION Flush the system thoroughly residual sanitizing solution left in the system could cre ate a health hazard e Use a clean 5 gallon pail bag in box system filled with plain water e Turn barrel 1 blendonator ON from BLENDONATOR menu to fill blendonator e Fill barrel 1 with plain water by repeatedly pulling and releasing the faceplate relief valve until solution comes out e Open the dispensing valve until water flows from the valve then close the valve e Open blendonator tank sample valve see Figure 4 until water flows from the valve then close the valve e Place barrel 1 in MOTOR mode from ON OFF MOTOR menu to start barrel 1 beater Allow beater to operate for 2 minutes then place barrel 1 in OFF mode from ON OFF MOTOR menu to stop the beater 11 Repeat procedure for side 2 3 and 4 Stainless Steel Double Check Valve Inspection 8 Cleaning CAUTION The product pump double liquid check valve must be inspected after any disrup tions to the water supply system plumbing work earth quakes etc It should also be inspected at least once a year under normal conditions If particles lodge in the check valve CO gas could back flow into the water system and create a health h
16. list will reflect this when updated NOTE The Syrup Sold Out condition is not effected by the RESET button ERROR Menu Button Descriptions 1 MENU go back to the previous menu He SON asa go to SYRUP SOLD OUT menu 3 OFF begin MANUAL ERROR RESET 4 UP scrolls list up 5 DOWN scrolls list down ERROR 43 22 02 09 52AM LOG IB REFRIG 1 CLEARED 154M BALK NEXT Corea D FIGURE 29 The error history log records errors to diagnose potential issues The error log will retain information on the 50 most recent sets of events All errors dated will have occurred during testing and set up This is a default that is used before the time clock is programmed The error log history is only accessible from the BARREL STATUS menu To enter the error history you must press the 2 far right buttons on the display panel This will bring up the error history log menu and the most recent event will be displayed PREV moves you backwards in the list of events and NEXT moves you forwards in the list of events The error history can be accessed while the security lock out is activated To return to the main menu press BACK 1 BACK go back to the BARREL STATUS menu 4 NEXT display the next later error log entry 5 PREV display previous earlier error log entry Publication Number 560007298SER 30 O 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual Contro
17. magnet is very strong and heavy Be careful not to pinch hands and fingers between the magnet and a steel object WARNING Strong Magnetic Field Person wearing pacemaker implanted cardioverter defibrillator or other implanted medical device may be effected by the magnetic field and must keep the magnet at 6 or more inches from the device The magnetic field can affect operation of these devices which may cause bodily injury or death If disruption of device occurs or operation is adversely effected immediately move the victim far away from magnet and seek medical assistance 10 TI 12 Disconnect product supply line Disconnect wire harness Remove foam insulation Remove screw in center of stator assembly Unbend the index tabs and remove end cap Remove the stator assembly from the cylinder 4 nuts Reclaim refrigerant Remove 4 bolts and pry off stator plate Remove front splash panel and drip tray mounting panel Underside of Remove 2 nuts on bottom of foam pack front and rear Foam pack mounting bars Slot in Frame Back of Unit Face plate screws 2 FIGURE 72 13 Remove refrigeration line insulation from back of foam pack and remove thermistors sensors from refrigeration lines Unsweat fittings from the back of the foam pack Lift the foam pack out the front of the unit 14 Reverse the procedure to install new foam pack Replace the dryer Evacuate and recharge the system Publication Numbe
18. tight only 14 Re connect the power and go through the normal start up procedure CONDENSER FAN MOTOR REPLACEMENT INTEGRAL ONLY Disconnect the power to the unit Remove top cover 1 screw Unplug motor wiring harness Hemove 4 screws securing fan shroud to frame Lift fan motor and shroud out Hemove 4 screws securing fan motor to shroud Heverse the procedure to install new motor oo gt eo qw ct Scr ws FIGURE 69 CONDENSER FiLTER REPLACEMENT INTEGRAL ONLY Disconnect power Remove top back panels 4 screws Slide filters out of tracks right and left side Clean or replace Re install A AN FIGURE 70 2003 IMI Cornelius Inc 51 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cines FOAM PACK REPLACEMENT ml 2 3 e 6 Disconnect the power to the unit Remove back middle panel 4 screws and side panels 3 screw each Turn OFF the blendonator valve Drain the cylinder of the faulty foam pack by opening the dispensing valve When only CO comes out turn the cylinder product supply valve off Relieve CO pressure by opening the faceplate pressure relief valve Remove the cylinder face plate 4 nuts Remove beater bar and scrapper blades Use the magnet puller tool p n 560003662 that comes with the unit to remove the magnet NOTE Sufficient force must be used to break the magnet lose from the end of the cylinder A A CAUTION The
19. 15 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cre D Menu 6 SET SLEEP TIME 07 00PM Sleep Day ALL DAYS WECXSTT Lp FIGURE 13 From the SET SLEEP TIME menu the system sleep times are set These are the times when the system will discontinue normal operation cylinder refrigeration and beater motor operation Each day of the week can have a separate sleep time or all days of the week can be programmed to sleep at the same time An item on the OPTIONS menu menu 15 will allow the Ice Bank to be maintained during sleep or allow the Ice Bank to discontinue normal operation Sleep times can be set in 15 minute increments When NONE appears it means that no sleep time has been set for that day The preset time format used by the system will be used by the SET SLEEP TIME menu SET SLEEP TIME Menu Button Descriptions 1 BACK go back to the previous menu 2 DAY cycle through the list of days 3 NEXT cycle through the time fields 4 UP increase the selected field by 1 hour or 15 minute increment 5 DOWN decrease the selected field by 1 hour or 15 minute increment To set sleep times 1 Press lt DAY gt to select 1 of 8 options SUNDAY MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY ALL DAYS 2 Press lt NEXT gt to change the field from HOURS to MINUTES 3 Press lt UP gt and lt DOWN gt to change the setting in the field 4 Press lt
20. 2 Publication Number 560007298SER 48 2003 IMI Cornelius Inc eines D Pinnacle 2 and 4 Flavor Service Manual DC STATOR ASSEMBLY REPLACEMENT 1 2 3 gt oon 7 Disconnect the power to the unit Remove back panel 4 screws and side panels 3 screws each Turn off the blendonator valve Drain the cylinder of the faulty motor by opening the dispensing valve When only CO comes out turn the cylinder product supply valve off Relieve CO pressure by opening the faceplate pressure relief valve Remove the cylinder face plate 4 nuts Remove beater bar and scraper blades Use the magnet puller tool p n 560003662 that comes with the unit to remove the magnet NOTE Sufficient force must be used to break the magnet lose from the end of the cylinder A verter defibrillator or other implanted medical device may be effected by the magnetic field and must keep the magnet at 6 or more inches from the device The magnetic field can affect operation of these devices which may cause bodily injury or death If disruption of device occurs or operation is adversely effected immediately move the victim far away from mag net and seek medical assistance Wire b harnesses CAUTION The magnet is very strong and heavy Be careful not to pinch hands and fingers between the magnet and a steel object WARNING Strong Magnetic Field Stator Assembly Person wearing pacemaker implanted cardio
21. 3 in 34 in 34 in 41 in with drip 41 in with drip 42 in with drip 42 in with drip tray tray tray tray Shipping 429 lbs approx 732 lbs approx 525 lbs approx 858 lbs approx weight Line Voltage The recommended line voltages for the Pinnacle unit are as follows The unit has a low voltage cut out at 180 VAC and a high voltage cut out at 260 VAC 180 to 190 VAC 191 to 208 VAC 209 to 240 VAC 241 to 253 VAC 254 to 272 VAC Above 272 VAC Accessories Included Madre puller esp sara Ao aa 560003662 John Guest fitting t00l ooooooooooooooo 560003481 Publication Number 560007298SER 4 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual SERVICE CAUTION Only trained and certified electrical plumbing and refrigeration technicians should service this unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES PREVENTIVE MAINTENANCE Preventive Maintenance Summary Preventive Maintenance Summary Clean air filter on air cooled units Clean condenser Change or rotate scraper blades Double Liquid Check Valve Check for leaks Clean BIB connectors Check clock setting Cleaning Air Filter Integral Only 1 The air filter should be cleaned every month Remove the filter by sliding it straight up Wash with mild soap solution rinse with clean water and shake out excess water or blow with low pressure compressed air if availa
22. BACK gt to save the changes Publication Number 560007298SER 16 2003 IMI Cornelius Inc eines D Pinnacle 2 and 4 Flavor Service Manual Menu 7 SELECT DEFROST TIME amp SET DEFROST TIME Defrost Time Select Number defrost cycle Defrost Time Defrost Day Defrost Time Number Defrost Time Defrost Day FIGURE 15 From the 2 SELECT DEFROST TIME menu the system automatic defrost cycles are set These menus program the automatic hot gas defrost cycle for each freeze cylinder The first menu sets the defrost day s and the second menu sets the defrost time s When ALL DAYS is selected the defrost time entered into a specific defrost number will be scheduled for every day of the week When NONE appears it means 1 of the following e no defrost time has been set for that defrost number e all of the times for that defrost number are not the same NOTE All days can NOT be used to verify defrost times only to set them SELECT DEFROST TIME Menu Button Descriptions 1 BACK go back to the previous menu 2 DAY cycle through the list of days 3 GO go to the second defrost menu SET DEFROST TIME 4 UP increase the defrost number for this day 1 9 5 DOWN decrease the defrost number for this day 1 9 SET DEFROST TIME Menu Button Descriptions 1 BACK go back to the previous menu 2 DEF cycle through the list of 9 defrost ti
23. Disconnect product supply line Disconnect wire harness Remove foam insulation Remove screw in center of stator assembly Unbend the index tabs and remove end aia eap tabs FIGURE 63 Remove stator assembly from cylinder 4 nuts Apply silicon grease Dow Corning NC111 around the inside of the new stator and on the outside of the cylinder Be sure to put a new gasket in the cylinder inlet tube Silicon grease inside of stator Silicon grease outside of cylinder FIGURE 65 10 Slide new stator on end of cylinder Torque nuts to 15 18 foot pounds Replace end cap and bend index O tabs down Replace center screw Replace foam insulation Reconnect wire harness Reconnect product supply line 2003 IMI Cornelius Inc 49 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cines 11 Replace magnet into opening of cylinder Use magnet removal tool to slowly and carefully push magnet to back of cylinder NOTE As magnet approaches end of cylinder the magnet force increases and care must be taken to not let the magnet slam into the end of the cylinder 12 Reinstall the beater bar and scrapper blades Be sure the bushing is on the front of the beater bar shaft Make sure that the beater bar is engaged with the magnet 13 Reinstall the faceplate by pressing until it contacts the front of the cylinder and then install the washers and nuts finger tight only 14 Re connect the power a
24. EEP zo SET DEFROSTS VISCOSITY SET VISC DISPLAY go to change BARREL STATUS menu go to SET CLOCK menu go to SET WAKE UP menu go to SET SLEEP TIME menu go to SET DEFROST menu go to VISC SET Menu menu go to VISC DISPLAY menu EVAPORATOR TEMPSgo to EVAPORATOR TEMPERATURE menu TOTALS DIAGNOSTICS BARREL DATA BLENDONATOR OPTIONS go to TOTALS menu go to DIAGNOSTICS menu go to BARREL DATA menu go to BLENDONATOR menu go to OPTIONS menu go to BRIX menu MANUAL DEFROSTgo to MANUAL DEFROST menu From the CHOOSE MODE menu pressing BACK will display the BARREL STATUS menu and press ing GO will display the scroll list item with the pointer in front of it 2003 IMI Cornelius Inc 13 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Menu 3 CHANGE BARREL STATUS ON OFF MOTOR Menu NS TS E TEN Item CHAINES mI GERE STATUS See lee B BACK ON DOES MOTOR DOWN FIGURE 10 Cylinder Status Messages The CHANGE BARREL STATUS menu allows the operator to select the operational mode for each of the cylinders on a cylinder by cylinder basis The present status of each cylinder is also displayed see menu 1 for a list of messages CHOOSE MODE Menu Button Descriptions 1 BACK go back to the previous menu 2 ON turn the selected cylinder ON beater bar TURNING and refrigeration ACTIVE 3 OFF turn the selec
25. IGURE 53 FIGURE 54 4 Repeat step 4 above between Pins 3 amp 5 as well as Pins 4 amp 5 If any of these three combinations show erratic voltage changing replace the Hall board 5 To test the Hall Board on Barrel 2 do steps 1 through 5 on connector J3 of the inverter board Hall Board Replacement Procedure 1 Disconnect the power to the unit Remove back middle panel 4 screws 2 Disconnect wire harness Remove foam insulation Remove 2 screws and bracket Remove Hall Effect sensor 3 Reverse the procedure to replace the Hall Effect sensor Wire harness Hall Effect sensor Bracket FIGURE 55 Publication Number 560007298SER 46 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual DC STATOR TEST EMERSON 1 Remove the stator connection from the inverter board Test stator and connecting wiring at the inverter board 2 Check the resistance of all 3 yellow red and blue of the terminals The correct reading should be approximately 37 ohms FIGURE 57 Bees Ms Publication Number 560007298SER 2003 IMI Cornelius Inc Pinnacle 2 and 4 Flavor Service Manual Cines DC STATOR TEST BALDOR 1 Remove the stator connection from the inverter board Test stator and connecting wiring at the inverter board 2 Check the resistance of all three of the terminals FIGURE 60 The correct reading should be approximately 80ohms FIGURE 61 FIGURE 6
26. TED Errors It is also possible to generate these errors if low voltage commu nication wires or phone cables are in the vicinity of the Inductor on the Main Board That would be the black capacitors on the Invertor Board and the wire wrapped coil on the Main Board LOW or HIGH VOLTAGE Error This message means that the incoming voltage is out of specification 180V to 260V for the unit LOW VOLTAGE Error If the voltage at the junction box is good high voltage may not be getting up to the main board Check this voltage at J10 on the main board lf the voltage is good at the board and the low voltage error remains main board is bad Display voltage to be 5 VAC from measured J10 Voltage DRIVE Error The motor has been commanded to rotate but will not rotate OVER TORQUE Error This error occurs when the motor load is greatly increased and causes the barrel viscosity to be more than 250 and the motor is still turning It can also occur when the inverter board has a problem lf the viscosity is less than 25 with the motor running the high viscosity reading could have been because of a mechanical load REFRIG Error Means that a specific evaporator has NOT been satisfied within a set time limit The entire refrigeration system will be disabled The REFRIG error time limits are e Freeze Barrel 46 minutes Ice Bath 120 minutes for 60Hz or 240 minutes for 50Hz SYRUP Error Syrup supply empty CO2 Error Carbon dioxide supply empty H20 Error
27. Viscosity Selection Pointer p gt 1 2 BARREL H2 9 Viscosity i pE ya ds Settings Cylinder vidL Numbers 9 48PM BSRSDUM DISSE GO U P DOWN FIGURE 16 The desired viscosity thickness of the product in each cylinder is set from this menu The viscosity set point can be set between 1 and 9 A viscosity setting of 1 produces a very thin watery product and a set ting of 9 produces a very thick icy product VISC SET TIME Menu Button Descriptions 1 BACK go back to the previous menu 2 ALL sets the viscosity of all cylinders to the setting of the currently selected cylinder HO GO PA toggle between cylinder selection and viscosity setting 4 UP increase the selected field by 1 hour or 15 minute increment 5 DOWN decrease the selected field by 1 hour or 15 minute increment To change the viscosity setting for a cylinder 1 Press UP or lt DOWN gt to select the cylinder to be adjusted The pointer will be in front of the cur rently selected cylinder 2 Press lt GO gt to move the selection pointer to the viscosity setting for that cylinder 3 Press UP or lt DOWN gt to increase or decrease the viscosity setting 4 Press lt GO gt to move selection pointer back to the cylinder selection 5 Repeat steps 1 4 for remaining cylinders Publication Number 560007298SER 18 O 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual M
28. Water supply empty SENSOR Error Means that a thermal sensor thermistor is not functioning properly During a refrigeration cycle if a barrel sensor s reading is at 97 F or at 30 F for more than 600 seconds the control system will display a SENSOR ERROR for that evaporator During a refrigeration cycle if a ice bank sensor s reading is at 49 F or at 30 F for more than 2400 seconds the control system will dis play a SENSOR ERROR for the Ice Bank NOTE The 5600075xx Series controls will have an upper limit of 150xF for barrel sensors 2003 IMI Cornelius Inc 31 Publication Number 560007298SER YAS86cZ0009S JequNN uoneorqng Z OU sni 9uJ02 INI E00Z System Response Display Output play Error BDC ES MN play Outp Priority Response 4 ectronics E ycle e 8 E 8 Power Real Time Cloc C ycle e O 8 OCK OCK ERROR Power ERROR Hot Gas Valve d e 6 O 6 HO AS EX HO AS EX a A BEEN OFF L LL L 9 ast Known V HIGH VO State of System ow Voltage ast Known VO OW VOLTA State of System ylinder Drive ON ast Known DRIV DRIVE EX State of System bod mn bad 9 ON ast Known ORQU ORQUE X 9 ON ast Known HEFR BRL REFRIG X ce ban Vianua 9 9 ON ast Known REFR B REFRIG Y Auto ylinder Viotor 8 ast Known YRUP YRUP X Viotor 8 ast Known 8 02 OU Viotor 8 ast Known H20 H20 OU 9 9 ast Known NSOF BR YSOR EN ee bo State of System J O ast Known NSOR 3 SENSOR FY 9 State of System The c
29. arbonated product e The components are enclosed in a steel frame The frame is then covered with panels e The panels enclosing the components and frame are easily removable to facilitate installation service and maintenance e Each barrel has a transparent faceplate with an integral relief valve and a removable self closing dis pensing valve mounted on the front of each faceplate e A removable drip tray with cup rest is located directly below the dispensing valves e Lighted merchandising compliments each unit e 20r 4 blendonators using a refrigerated ice coil and water bath to cool the product before carbonating 1 self contained refrigeration system for the 2 flavor and 2 for the 4 flavor e A programmable system to defrost the freeze cylinders and components that dispense the product e Control Panel with 5 buttons that control operational and diagnostic functions and settings Lighted Display Double Refrigeration System Steel Frame Dispensing Valves amp Face Plates Control Panel Foam Pack amp Motor FIGURE 1 FIGURE 2 2003 IMI Cornelius Inc 3 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cre D SPECIFICATIONS Dimensions Overcounter Overcounter Integral Remote 2 Integral Remote 4 Flavor w Cornelius Flavor w Cornelius Cart Cart 43 75 in 74 75 in 74 75 in Overcounter Overcounter Integral Remote 2 Integral Remote 4 Flavor Flavor 28 in 14 5 in 28 in 3
30. ation Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Figure 86 demonstrates lampholder with lock properly engaged lamp omitted for clarity WARNING For proper and effective lamp func tion locks must be completely engaged FIGURE 86 Publication Number 560007298SER 58 2003 IMI Cornelius Inc Pinnacle 2 and 4 Flavor Service Manual TROUBLESHOOTING e f foul smell or bad taste check water filter e f water out message check water filter TROUBLESHOOTING THE SYSTEM Unit will not run Sleep display on cyl inder status menu Barrel status OFF 1 and 2 Low High voltage ERROR Como ERROR Torque ERROR A Unit not plugged in B Circuit breaker C No power at L1 or L2 on contac tor D Low voltage at T1 or T2 A Sleep time set B Clock incorrectly set C No wake time set A Notactivated B Error has shut off motors A Plugin unit B Heset replace circuit breaker C Check voltage at outlet Check wiring to contactor D Replace the contactor A Check programming B Check programming C Check programming A Turn to ON or MOTOR B Correct error amp turn to ON or MOTOR mode C Unit in Diagnostics C Exit diagnostics amp turn to ON or MOTOR mode D Defective touch switch A Line Voltage out of SPEC specis A 198 253 VAC for 60 Hz and 196 265 VAC for 50 Hz B Error range 180 260 A Display board is not c
31. ay the IN represents the inlet temperature and the OUT represents the outlet temperature The temperature scale used F or C is based on your input in the OPTIONS menu menu 15 The maximum temperatures are 97 F for the barrels BRL 1 or 2 and 48 F for the ice bank IB 1 The minimum temperatures for both the barrel and ice bank is 30 F EVAPORATOR TEMPERATURES Menu Button Descriptions 1 BACK go back to the previous menu Publication Number 560007298SER 20 2003 IMI Cornelius Inc eines D Pinnacle 2 and 4 Flavor Service Manual Menu 11 TOTALS Selection TOTALS POWER ON 123456 HR Pointer gt SLEEP 241211 HR Totals see Item or COMP Fl 206699 HR chart below Subsystem J1 amp 3RAm COMP P 215900 CYC BACK UP DOWN FIGURE 19 The TOTALS menu displays operational totals for the system The totals tracked by the computer are listed below Those totals marked with an can be reset to zero The RESET button will only appear when the reset option is enabled The reset option is enabled disabled from the OPTIONS menu menu 15 TOTALS Menu Button Descriptions 1 BACK go back to the previous menu 4 UP scroll totals list up 5 DOWN scroll totals list down TOTALS Menu Messages POWER ON xxxxx HRnumber of hours the system has been powered ON SLEEP anaana xxxxx HRnumber of hours system has been in SLEEP mode COMP n xxxxx HR number of hours compressor n
32. azard Press both lt OFF gt switches to stop cylinders beaters and refrigeration system Disconnect electrical power to the unit Shut OFF COs syrup and water supplies to the unit Disassemble valve Check seat and O rings Replace if necessary Reassemble valve Check for leaks Check BRIX Should be done whenever flavors are changed or any service is preformed 1 2 3 4 5 6 7 Publication Number 560007298SER 8 2003 IMI Cornelius Inc eines D Pinnacle 2 and 4 Flavor Service Manual ADJUSTMENTS Water Syrup amp CO Regulator Settings Regulator Settings CO Blendonator 22 28 psi Water source at unit minimum 25 psi flowing Syrup source at unit PINNACLE CoNTROL SYSTEM Control System Overview The Pinnacle uses a control system that monitors the major systems and components of the machine Temperatures and pressures are monitored and pumps valves and the refrigeration system are man aged by the control system to provide a consistently high quality product with optimal efficiency The control system is pre programmed at the factory to perform the tasks necessary to keep the Pinnacle operating correctly In addition to controlling the Pinnacle the control system keeps track of the diagnos tic information used when adjusting and or repairing the machine The control system needs to be accessed in the following situations e Installing the Pinnacle e Checking perf
33. ble 2 Vacuum the condenser coil or blow it out with low pressure compressed air before reinstalling the air filter 3 Reinstall the air filter Sanitizing The syrup systems should be sanitized every 6 months per the following procedure using a non scented liquid household bleach containing a 5 25 sodium hypochlorite concentration 1 For both sides of the 4 flavor cylinder press lt OFF gt from the BARREL STATUS menu on the Control Panels to stop beater and refrigeration on all cylinders 2 Take the following actions from the Control Panel e From the BARREL STATUS menu press lt MENU gt e From the CHOOSE MODE menu select MANUAL DEFROST gt and press GO e Select barrel and press lt DFRST gt 2003 IMI Cornelius Inc 5 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual CCincdius gt 3 Close barrel 1 freeze cylinder shutoff valve see below Freeze NWE Cylinder Shutoff Valve Le FIGURE 3 4 Turn blendonator 1 OFF from the BLENDONATOR menu to prevent more product from entering the blendonator 5 Place container under barrel 1 dispensing valve Open the valve and dispense all product from the freeze cylinder and the blendonator As product level lowers in the freeze cylinder partially close the valve to avoid spurting 6 Disconnect bag in box from barrel 1 7 Wash the system by completing the following steps e Use a clean 5 gallon pail bag in box system fil
34. ceed teen SEL i S Bd xp menu 8 VIS DISPLAY ova sr is e S r Es menu 9 EVAPORATOR TEMPERATURES lesse menu 10 TOTAUS nm menu 11 DIAGNOSTICS vs vaca vec mu gh Eee dedo pis S AE VE ROT OR CO ES menu 12 BARREL DATA c pariat er a Hoe bord esce ged dee ares menu 13 BLENDONATOPBN su i siai in eode ct cii qe gredi a a menu 14 OPTIONS H menu 15 n EET E EE menu 16 MANUAL DEFROST 2 0 00 e eee ee ee ees menu 17 SY AUP PRIME 000 siria are Dr eee aed Sea ae menu 18 oM menu 19 ERROR ara Ks Lera ir cubos e an bar Es se Uie menu 20 The Control Panel display has 2 main areas The first area presents information about the status and set tings of the machine It also displays menus of actions that are taken to change the functioning of the machine Control Panel Display BARREL Control Panel STATUS Display Area 10 394M MENU Control Panel Action Buttons FIGURE 6 Publication Number 560007298SER 10 2003 IMI Cornelius Inc eines D Pinnacle 2 and 4 Flavor Service Manual Control Panel Buttons The second display area is the button area There are 5 buttons that are pressed to activate various func tions of the control system Each button has a label directly above it that describes what happens if that button is pressed Menu Title BARREL L Message STATUS O Display System Area Time Button Labels Button 1 Button 2 Button 3 Button 4
35. ctivation of 2 minute manual defrost mode for a selected cylin der This defrost cycle can begin with the cylinder in any mode ON OFF Motor and will return the cylin der to that same mode Manual defrost can be activated on only 1 cylinder associated with a compressor at a time The description of the button 2 will change based on the status of the selected cylinder When not in defrost button 2 will read DFRST When in defrost button 2 will read CANCL Pressing DFRST will begin a manual defrost on the selected cylinder and pressing CANCL will end the manual defrost on the selected cylinder MANUAL DEFRST Menu Button Descriptions 1 BACK go back to the previous menu 2 DRFST begin manual defrost on selected cylinder defrost will last approx 2 minutes 4 UP move selection pointer up 5 DOWN move selection pointer down 2003 IMI Cornelius Inc 27 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cines Menu 18 SYRUP PRIME Selection SY RUP HA OFF Pointer PRIME Z7 SYRUP Syrup Prime Status ais 12 43PM Number LOL BACK PRIME UP DOWN FIGURE 26 The SYRUP PRIME menu allows manual priming of the syrup system of any or all cylinders Priming consists of opening the syrup valve and turning ON the blendonator pump on a specific cylinder for 5 seconds To prime a cylinder move the selection pointer by pressing UP or lt DOWNs gt the list to the desired c
36. de panel closest to the faulty blendonator tank 3 screws 3 Turn off the cylinder product supply valve 4 Slide out the product tray by removing the 2 screws on the front top side 5 Turn CO off at the source Relieve pressure from blendonator by opening faceplate pressure relief valve 6 Disconnect all quick disconnects Lift blendonator up note the location of the blendonator tank inputs Blendonator b NOTE The waterbath cover and agitator motor bracket tank E May need to be removed to get the blendanator tank out FIGURE 50 7 Reverse the procedure to install new blendonator Be sure and check for leaks after pressurizing the system 8 Bleed air from blendonator using pressure relief valve 9 Run through the normal start up procedure Publication Number 560007298SER 44 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual HALL EFFECT SENSOR DIAGNOSIS REPLACEMENT BALDOR Hall Board Diagnostic Procedure DANGER HIGH VOLTAGE this testing is done with the Pinnacle power ON Care must be A taken to avoid high voltage areas of the inverter board This procedure will test the Hall Board on Barrel 1 1 Locate Connector J2 on the Inverter Board e Pin 1 Red 5 volts e Pin 2 White Hall 1 e Pin 3 Brown Hall 2 e Pin 4 Green Hall 3 e Pin 5 Black Ground Using a voltmeter in the DC mode measure 5 volts between Pin 1 and Pin 5 Red and Black
37. donator pump has stopped turning remove the sample from the Blendonator through the BRIX Sample Valve for refractometer testing If the BRIX reading is within spec the BRIX adjustment for this barrel is complete If the BRIX reading is NOT within spec adjust the syrup Flow Control to bring the product within spec clockwise to increase BRIX counter clockwise to decrease BRIX Adjust Flow Control in no more than 1 2 turn increments Repeat step 8 above 3 times drain the Blendonator and dispose of this product Repeat steps 8 and 9 above and measure the sample with the refractometer Repeat steps 11 13 until the product BRIX is within spec Repeat steps 8 14 until Blendonator 2 product BRIX is within spec Scroll to the BLENDONATOR menu and turn both Blendonators ON BRIX Menu Button Descriptions 1 BACK go back to the previous menu TAS sd turn ON syrup and water solenoids and blendonator pump for selected cylinder for 3 seconds 3 CANCL turn OFF syrup and water solenoids and blendonator pump for selected cylin der ta UP is oben des move selection pointer up 5 DOWN move selection pointer down Publication Number 560007298SER 26 2003 IMI Cornelius Inc eines D Pinnacle 2 and 4 Flavor Service Manual Menu 17 MANUAL DEFRST Cylinder A Defrost Number DEFRST Y DFRST Status Selection Pointer 1243PM BACK DFRST UP DOWN FIGURE 25 The MANUAL DEFRST menu allows the a
38. e VALVE LOCK OUT DISAB ENAB Not Used RESET TOTALS DISAB ENAB disable enable resetting of totals in the TOTALS menu ICE BANK SLEEP SYRUP SOURCE Security Lockout Function The security function is enabled in the OPTION SELECT STATUS menu When the security lockout is enabled lockout will engage 15 minutes after last button press Once lockout is engaged the display goes to BARREL STATUS menu and the MENU button 1 is disabled Security is disengaged by pressing button 1 far left and 5 far right at the same time Ice Bank remains OFF ON while system is sleeping turns beeping of key inputs OFF ON TANKS What is source of syrup TANKS will enable Syrup Prime on syrup sold out 2003 IMI Cornelius Inc 25 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cre D Menu 16 BRIX Cylinder NN NENE Number BRIX 1 OFF in SELECT gt 2 BRIX o Selection Pointer 9 40AM BACK COT CANCE UP DOWN FIGURE 24 The BRIX menu allows the activation of syrup and water solenoids and blendonator pump motor for a selected cylinder DL Oh O D 10 11 12 13 14 15 16 Press MENU Scroll up to BLENDONATOR Turn Blendonators 1 and 2 OFF Drain each Blendonator through the BRIX Sample Valve Press BACK Scroll down to BRIX Press GO Once the BRIX SELECT menu is selected press GO to partially fill Blendonator 1 with a BRIX sample After the sample is complete Blen
39. ee RN e CUR ZEE d ai a 9 Water Syrup amp CO2 Regulator Settings 0 0 ce eee 9 Pinnacle Control System e racerene eee ee yrs 9 Control System OVeEIVIEW 2262 0 dg mae qubd EL do Sao ds 9 Control Panel Menu Descriptions LL ika 12 Control Panel Error Descriptions 0 0 0 0 ccc ees 31 COMPONENT SEVICE uua sapi coed one asd eet eee UE TU HP E ae eee as 33 Magnet Assembly Replacement LL is 33 DC Control Drive Motor Board Replacement Emerson LLL 35 Main and Product Delivery Board Replacement Emerson 35 Chip Change Procedure 0 ccc rrr 36 Display Board Replacement Emerson is 37 DC Inverter Board Replacement Baldor o oooooooooo 39 Main and Product Delivery Board Replacement Baldor 38 Display Board Replacement Baldor Lis 39 Merchandiser Light Ballast Replacement is 40 Transformer Replacement 453 e T sa a 4490 400 E ue OX 40 Contactor Replacement 2 0 0 00 cc arn 40 Start Components Replacement ana aaae ee eee 41 Pump Motor Replacement ias 41 Agitator Motor Replacement Emerson is 42 Agitator Motor Replacement Baldor 0 0 0 0 cee 42 Syrup Water Valve Replacement 00 000 ccc eee eee 42 2003 IMI Cornelius Inc Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cre D CO2 Regulator Replace
40. enu 9 VISC DISPLAY Actual Cylinder Viscosity CTUAL 1 021 l l ARREL o0 049 Actual Viscosity ES E Reading O BAM cc C Cylinder Numbers FIGURE 17 This menu displays the actual viscosity value for each cylinder The smaller the number the lower the vis cosity thinner product VISC DISPLAY Menu Button Descriptions 1 BACK go back to the previous menu The table below identifies the maximum and minimum viscosity values for specific viscosity settings For example with a viscosity setting of 2 the system calls for refrigeration when the viscosity drops below 43 Refrigeration continues until the viscosity reaches 60 when leveling begins NOTE There is a 2 minute timer to prevent the compressor from short cycling This timer is can celed out by a Blendonator actuation Viscosity Setting Maximum Viscosity Minimum Viscosity Value Value 1 50 36 2 60 43 3 70 58 4 80 68 5 90 78 6 100 86 7 110 96 8 120 106 9 130 116 2003 IMI Cornelius Inc 19 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cines Menu 10 EVAPORATOR TEMPERATURES Cylinders EYAP BRL IN 78 OUT 78 pon Fahrenheit TEMPS BRL 2 IN 78 OUT 78 Temperatures or Celsius F IB i IN 48 OUT 48 9 40AM Ice Bank BACK FIGURE 18 The input and output temperatures of each system evaporator both product freeze cylinders and ice bank are displayed In the displ
41. er Be sure and check for leaks after pressurizing the system MERCHANDISER LAMP REMOVAL AND INSTALLATION Removal 1 SHUT OFF POWER TO UNIT Remove lens and lens support 2 Press lamp locks to unlock lamp pins FIGURE 80 2003 IMI Cornelius Inc 55 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual 3 Disengage lamp pins by pulling lamp ina direction forward away from reflector surface and remove lamp NOTE Pulling down on lamp to disengage pins may result in damage to lampholders and spring clips Figure 82 demonstrates lampholder with lock com pletely disengaged lamp omitted for clarity NOTE Locks must be completely disengaged before removing lamp or damage to the lamp or the lock may result Publication Number 560007298SER Ds FIGURE 82 2003 IMI Cornelius Inc CCGinclius gt Pinnacle 2 and 4 Flavor Service Manual Installation 1 Slide lamp into spring clips at bottom of reflector 2 Engage lamp pins by pushing lamp in a direction toward the reflector surface making certain pins are fully engaged in lampholder see Figure 84 NOTE Pushing up on lamp to engage pins may result in damage to lampholders Ww Pins MUST be Fully Enga m FIGURE 84 3 Press the lamp into the lampholder firmly to engage locks Reinstall lens and lens support Restore power to unit FIGURE 85 2003 IMI Cornelius Inc 57 Public
42. er to give proper mixture e Put the sanitizing connector in the bucket of sanitizing solution NOTE This mixture will provide 800 ppm of chlorine Sanitizing solution will be diluted to approx imately 200 ppm inside the blendonator tank after carbonated water has been mixed with the san itizing solution NOTE If powder sanitizer is used be sure it is thoroughly dissolved and mixed with the correct amount of water e Turn barrel 1 blendonator ON from BLENDONATOR menu to fill blendonator e Fill barrel 1 with sanitizing solution by repeatedly pulling and releasing the faceplate relief valve until solution comes out e Open the dispensing valve until solution flows from the valve then close the valve e Open blendonator sample valve see Figure 4 until solution flows from the valve then close the valve e Place barrel 1 in MOTOR mode from ON OFF MOTOR menu to start barrel 1 beater Allow beater to operate for at least 10 minutes but not more than 15 minutes Then place barrel 1 in OFF mode from ON OFF MOTOR menu to stop the beater e Turn barrel 1 blendonator OFF from BLENDONATOR menu to prevent more sanitizing solution from entering the blender tank e Place container under barrel 1 dispensing valve Open the valve and dispense all sanitizing solu tion from the cylinder As sanitizing solution level lowers in the cylinder partially close the valve to avoid spurting e Disconnect sanitizing solution syrup
43. g net lose from the end of the cylinder CAUTION The magnet is very strong heavy and fragile Be careful not to pinch hands and fingers between the magnet and a steel object Make sure no foreign objects are attached to the magnet WARNING Strong Magnetic Field A Person wearing pacemaker implanted cardio verter defibrillator or other implanted medical device may be affected by the magnetic field and must keep the magnet at 6 or more inches from the device The magnetic field can affect operation of these devices which may cause bodily injury or death If disruption of device occurs or operation is adversely effected immediately move the victim far away from mag net and seek medical assistance 2003 IMI Cornelius Inc 33 Relieve CO pressure Remove nuts x4 FIGURE 30 Tool hooks into magnet FIGURE 31 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual 7 Install the magnet in the reverse order to removing it Use the magnet puller tool to install the magnet being careful to insert the magnet slowly and not let it slam into the end of the cylinder Magnet removal tool DO NOT let magnet slam into end of cylinder 8 Inspect parts to see if they should be replaced including Align notched the beater bars face plate O ring and beater bar hole in bushing beater bar with NOTE Install faceplate by pressing until it contacts the notched
44. hange these valves 2 Reclaim refrigerant Disconnect pulse valve wires Remove coil 1 screw 3 Unsweat and remove valve FIGURE 76 4 Install new valve by reversing the procedure Be sure to place a heat sink on the valve body when sweating the new valve to avoid damage to the valve components 5 Replace the dryer Evacuate and recharge the system WATER PRESSURE REGULATOR SWITCH REPLACEMENT 1 Disconnect the power to the unit Remove back lower and middle panel 4 screws each 2 Turn off water at source Bleed pressure from water feed line at the rear disconnect A S A AN Fo E O 1m m Syrup 2 Syrup 3 Water 3 amp 4 CO2 Water1 amp 2 FIGURE 77 3 Disconnect wires on pressure switch Disconnect 2 quick Water disconnect fittings using a spanner tool pressure regulator Water filter cap gt FIGURE 78 4 Remove and replace the regulator and or switch 5 Reassemble in the reverse order Be sure and check for leaks after pressurizing the system 6 Check regulator pressure setting Publication Number 560007298SER 54 2003 IMI Cornelius Inc CCGinclius gt Pinnacle 2 and 4 Flavor Service Manual WATER STRAINER CLEANING Disconnect the power to the unit Remove rear middle panel 4 screws Turn off water source then bleed pressure from water feed line at the rear disconnect Unscrew cap and remove Strainer ONS Clean Strainer and reassemble in the reverse ord
45. id to control box on Place the chip puller and new chip on the machine chip still in the container Attach ground strap to the bare metal control box Carefully remove the new chip from shipping container Save shipping container to pack old chip in Place chip puller on chip and gently squeeze until tool grips the chip Pull the chip puller straight up with a gentle end to end rocking motion to remove the chip Place old chip in the original container 9 Pull the chip puller straight up with a gentle end to end rock ing motion to remove the chip Place old chip in the original con E tainer M CONDO OF WN 10 Carefully place new chip in the socket and make sure all pins are started in their holes Press firmly straight down on the chip until it is fully engaged in the socket Note Proper placement of the chip can be confirmed by aligning the small indent on one end of the chip with the indent on the outline that is drawn on the board 11 Remove ground strap 12 Replace control box lid 13 Replace top machine panel or close access door 14 Plug in machine 15 Defrost both barrels 16 Check Viscosity read If both sides read 0 go to 17 17 If either side reads other than O beater motor currents needs to be reset 18 Turn machine on auto and check for normal operation 19 Secure machine Publication Number 560007298SER 36 O 2003 IMI Cornelius Inc eines D Pinnacle 2 and 4 Flavor Se
46. index tabs and remove end cap Stator Assembly index tabs TT c E Nuts 4 Product supply line 5 iar Wire harnesses gt i k W FIGURE 66 8 Remove stator assembly from cylinder 4 nuts 9 Apply silicon grease around the inside of the new stator and on the outside of the cylinder Be sure to put a new gasket in the cylinder inlet tube Stator screw P Stator mounting plate Publication Number 560007298SER 50 2003 IMI Cornelius Inc eines D Pinnacle 2 and 4 Flavor Service Manual Silicon grease outside of cylinder Silicon 1 grease inside of 7 stator FIGURE 67 FIGURE 68 10 Slide new stator on end of cylinder Torque nuts to 15 18 foot pounds Replace end cap and bend index tabs down Replace center screw Replace foam insulation Reconnect wire harness Reconnect product supply line 11 Replace magnet into opening of cylinder Use magnet removal tool to slowly and carefully push magnet to back of cylinder NOTE As magnet approaches end of cylinder the magnet force increases and care must be taken to not let the magnet slam into the end of the cylinder 12 Reinstall the beater bar and scrapper blades Be sure the bushing is on the front of the beater bar shaft Make sure that the beater bar is engaged with the magnet 13 Reinstall the faceplate by pressing until it contacts the front of the cylinder and then install the washers and nuts finger
47. indings Check resistance of compressor windings Troubleshoot replace if neces sary Repair leak and weigh in new charge Clean or repair Repair or replace Replace Repair or replace Repair or replace Clean filter Clean condenser Repair replace if necessary Ensure proper spacing around unit 2008 IMI Cornelius Inc Fan Motor Pulse Valve Hot Gas Valve Sensors 2003 IMI Cornelius Inc A Bad connection B Bad motor C Cracked or bent fan blade A Miswired B Defective coil C Defective valve D Defective product delivery board A Miswired B Defective coil C Defective product delivery board A Bad connection B Bad sensor C Sensor out of position D Defective product delivery board 261 Pinnacle 2 and 4 Flavor Service Manual A Check connect B Replace motor C Replace fan blade A Correct wiring B Replace coil C Replace valve D Replace board A Correct wiring B Replace coil C Replace A Repair and weigh in new charge A Correct wiring B Replace sensor C Reposition sensor and clip D Replace Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual C Queis D Publication Number 560007298SER 62 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual WARRANTY IMI Cornelius Inc warrants that all equipment and parts are free from defects in material and workman
48. isplays information about major system components for each cylinder BARAL DATA Menu Button Descriptions 1 BACK go back to the previous menu 4 UP scroll list up 5 DOWN scroll list down BARREL DATA menu information BARREL status of cylinder n ON OFF MOTOR DEFROST ERROR EVAPSIN evaporator temperature IN EVAPS OUT evaporator temperature OUT VISC SET viscosity set value AC ise a actual viscosity value BLENDONATOR blendonator mode ON OFF 2003 IMI Cornelius Inc 23 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual C Ginelius D Menu 14 BLENDONATOR Blendonator Status Cylinder D CAN ar 1 OFF H Number ONATOR gt 0 DIESE ai ST 8 Lun S 1 57PM SET BACK ON OFF UP DOWN FIGURE 22 The BLENDONATOR menu allows the selection of automatic blendonator tank filling With automatic mode ON the blendonator tank will fill when the float drops Scroll the selection pointer to the desired cylinder number and press ON or lt OFF gt to turn the auto matic filling ON or OFF BLENDONATOR Menu Button Descriptions 1 BACK go back to the previous menu 2 ON turns blendonator automatic fill mode ON HO OOPP sy ales turns blendonator automatic fill mode OFF 4 UP move selection pointer up 5 DOWN move selection pointer down Publication Number 560007298SER 24 O 2003 IMI Cornelius
49. k is pending This document contains proprietary information and it may not be reproduced in any way without permis sion from Cornelius Printed in U S A Copyright 2003 All Rights Reserved IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual TABLE OF CONTENTS A O 1 Salely INSIMICUONS ux 2 SR As da 1 Read and Follow all Safety Instructions clle 1 Recognize Safety Alerts o oo ooooooocooonor eee eens 1 Different Types of AlertS ti A A Aa US 1 A S s ao ea os 1 Qualified Service Personnel rica i os r r e ERR b SER S rs UR ea 1 CO2 Carbon Dioxide Warning aaa 1 Shipping And Storage L auks a pe tweed keeps ue db a ibus se e E 2 Magner VV atrii ud desde Sate bs rp ied ee che Ab bs e oe nd A duh haw dc 2 System OVEIVICW 2 2444 05555 L a r nde ed eee de eas 3 PROGUCTOVEIVIEWS n so edem doe T a be a ob s See eS 3 SPECICATION 54654 S o Lis k bi ida mnm 4 DIMENSIONS sae anite TT TTT 4 LING Voltage 550 ui SA Cees ika a See BERR ae og de een ee i 4 Accessories Included s Se ea A E GAR A Ron E RR OE cR 4 DOV ICS Nr eT 5 Preventive Maintenance leer 5 Preventive Maintenance Summary Laikas 5 Cleaning Air Filter Integral Only is 5 SAMA sce TC ore Sh were Da tl Ae ee eke 5 Stainless Steel Double Check Valve Inspection Cleaning 8 CHECK BRIX oraes a sto a epi ily G9 dk Sod he e en ne iia 8 AGJUSIMESNS ec xong wan oh e
50. l Panel Error Descriptions The following section describes the error messages displayed on the Control Panel the error priority and the appropriate actions to be taken Errors are displayed on the following menus e Main menu BARREL STATUS menu 1 e ON OFF MOTOR menu CHANGE BARREL STATUS menu 3 e BARREL DATA menu menu 13 e SET DEFROST menu menu 17 e ERROR menu menu 20 Errors are displayed in the above menus differently The response to error conditions are listed below COMO Error There is no communication between the J1 connector on the display board and the J17 connector on the main board ELECTRONICS Error Means 1 of 2 things e Communication has been not established or broken between the main board and 1 or more of the product delivery boards for ten consecutive communication cycles e Failure of the real time clock chip The new controls will display a CLOCK ERROR message HOT GAS Error X Indicates that the barrel outlet sensor for barrel X exceeded 120 F for 2 minutes Remove power to unit to reset this error Before placing barrel back into service verify that the hot gas valve serving that barrel is cooling properly and that hot gas valve serving that barrel is not stuck open HIGH VOLTAGE GENERATED Errors It is possible to generate Electronic or Como errors by routing phone lines or low voltage communication lines in the vicinity of high voltage components on the Inverter Board LOW VOLTAGE GENERA
51. last cover 2 screws each Flip the merchandiser back down and go through a normal start up procedure TRANSFORMER HEPLACEMENT 1 Disconnect the power to the unit 2 Remove right side panel 3 screws 3 Remove all 4 wires from the transformer note the connection locations 4 Remove the 2 nuts from the screws and remove the transformer 5 Attach the new transformer with the 2 nuts NOTE The Coil on the Pinnacle Contactor has 24 VAC 7 Contactor cover removed Transformers 2 FIGURE 44 6 Re attach the wires to the tabs on the transformer NOTE Make sure the wires are replaced in the same location noted in step 3 CONTACTOR REPLACEMENT Disconnect the power to the unit 2 Remove side panel 3 Remove contactor starter cover 1 screw Disconnect contactor 2 nuts Do NOT detach the wires from the contactor yet 4 One ata time remove the wires from the old contactor and connect them to the new contactor 5 Secure the new contactor in place install the cover and re attach the side panel Publication Number 560007298SER 40 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual START COMPONENTS REPLACEMENT 1 Disconnect the power to the unit 2 Remove side panel 3 Unfasten the strap 1 screw Start relay 4 Replace all start and run components note connection locations Run 4 Reassemble re connect power and go through a normal Capacitor TU Ld star
52. ld be supervised to ensure that they do not play with the appliance e Keep your machine in proper working condition and do not allow unauthorized modifications to the machine QUALIFIED SERVICE PERSONNEL CAUTION Only trained and certified electrical plumbing and refrigeration technicians should service this unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES CO CARBON DIOXIDE WARNING WARNING CO Displaces Oxygen Strict Attention must be observed in the prevention of CO gas leaks in the entire CO and soft drink system If a CO gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of CO gas will experience tremors which are followed rapidly by loss of consciousness 2003 IMI Cornelius Inc 1 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cre D SHIPPING AND STORAGE CAUTION Before shipping storing or relocating the Unit syrup systems must be sanitized and all sanitizing solution must be purged from the syrup systems All liquids after sanitizing must be purged from the unit A freezing ambient environment will cause residual sanitizing solution or water remaining inside the Unit to freeze resulting in damage to the internal components MAGNET WARNING CAUTION After removing the very strong magnet from the freeze c
53. led with a solution of household liquid detergent and warm water Mix approximately 1 ounce of household liquid detergent per gallon of warm water e Connect the sanitizing fitting p n cc 28688 to the bag in box connector Put the connector in the bucket of wash water e Turn barrel 1 blendonator ON from BLENDONATOR menu to fill blendonator e Fill barrel 1 with washing solution by repeatedly pulling and releasing the faceplate relief valve until solution comes out e Open the dispensing valve until solution flows from the valve then close the valve e Open blendonator sample valve see Figure 4 until solution flows from the valve then close the valve Blendonator Sample Valve e Place barrel 1 in MOTOR mode from ON OFF MOTOR menu to start barrel 1 beater Allow beater to operate for 5 minutes then place barrel 1 in OFF mode from ON OFF MOTOR menu to stop the beater 8 Flush the wash water from the system by completing the following steps e Turn barrel 1 blendonator OFF from BLENDONATOR menu to prevent more wash water from entering the blendonator Publication Number 560007298SER 6 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual e Place container under barrel 1 dispensing valve Open the dispense valve and dispense all wash water from the freeze cylinder and the blendonator As the wash water level lowers in the freeze cyl inder partially close the valve to avoid spu
54. ment o o o ooococococoo eee 43 Blendonator Float Switch Replacement 0 00000 cee eee eee 43 Blendonator Tank Replacement 0 000 eee eee 44 Hall Effect Sensor Diagnosis Replacement Baldor 45 Hall Board Diagnostic Procedure Ls 45 Hall Board Replacement Procedure LL is 46 DC Slater rests EMESSO se docu dra oi Ed n le ratas Sta DE Edda ais aos 47 DOC Stator Test BaldOfsssd os x ia E Re aed a Cod Bol a ACC o A 48 DC Stator Assembly Replacement 0 0 cee ee ees 49 DC Stator Assembly Replacement Baldor o oooooooooo 50 Condenser Fan Motor Replacement Integral Only 51 Condenser Filter Replacement Integral Only o o oooooooo 51 Foam Pack Replacement ias 52 Compressor Replacement LL aaa eee ees 53 Hot Gas Valve Rebuilding LL is 53 Pulse Valve Replacement Lis 54 Water Pressure Regulator Switch Replacement ooo ooooooooo 54 Water Strainer Cleaning ias 55 Merchandiser Lamp Removal and Installation les 55 REMOVA m 4554 M alos ae ace nts aia ee pio atte ve ee nes js dad eae 55 INSTallation bic dad is id add os ad 57 Hcr A AI E oe A 59 Troubleshooting the System 1 0 0 0 eens 59 Troubleshooting Product Not Cold 0 ais 60 Wallan P 63 Publication Number 560007298SER i 2003 IMI Cornelius Inc Ginelius gt Pinnacle
55. mes per day 3 NEXT cycle through time fields 4 UP increase item by 1 unit hour or 15 minute segment 5 DOWN decrease item by 1 unit hour or 15 minute segment Defrost times can be set in 15 minute increments When NONE appears it means that no sleep time has been set for that day The preset time format used by the system will be used by the SET DEFROST TIME menu 2003 IMI Cornelius Inc 17 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cre D Each freeze cylinder defrost cycle will terminate either when the suction temperature reaches 42 F to 50 F or it will time out after 8 minutes There may be 9 defrost times scheduled for each of the 7 days of the week Cylinder 1 will begin defrosting at the set defrost time Cylinder 2 will begin defrosting 15 min utes after cylinder 1 began defrosting To set defrost times 1 Press lt DAY gt to select 1 of 8 options SUNDAY MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY ALL DAYS 2 Press lt GO gt to advance to the SET DEFROST TIME menu Press lt NEXT gt to change the field from HOURS to MINUTES Press lt UP gt and lt DOWN gt to change the setting in the fields Press lt BACK gt to save the changes If desired repeat steps 2 5 to set more defrost times for the selected day If desired repeat steps 1 6 to select different days and times ND OF o Menu 8 VISC SET Set Cylinder
56. nd go through the normal start up procedure DC STATOR ASSEMBLY REPLACEMENT BALDOR 1 Disconnect the power to the unit Remove back panel 4 screws and side panels 3 screws each 2 Turn off the blendonator valve 3 Drain the cylinder of the faulty motor by opening the dispensing valve When only CO comes out turn the cylinder product supply valve off Relieve CO pressure by opening the faceplate pressure relief valve 4 Remove the cylinder face plate 4 nuts Remove beater bar and scraper blades Use the magnet puller tool p n 560003662 that comes with the unit to remove the magnet NOTE Sufficient force must be used to break the magnet lose from the end of the cylinder oon CAUTION The magnet is very strong and heavy Be careful not to pinch hands and fingers between the magnet and a steel object WARNING Strong Magnetic Field A Person wearing pacemaker implanted cardioverter defibrillator or other implanted medical device may be effected by the magnetic field and must keep the magnet at 6 or more inches from the device The magnetic field can affect operation of these devices which may cause bodily injury or death If disruption of device occurs or operation is adversely effected immediately move the victim far away from magnet and seek medical assistance 7 Disconnect product supply line Disconnect wire harness Remove foam insulation Remove screw in center of stator assembly Unbend the
57. ner tool Remove 2 nuts from mounting bracket Disconnect pressure switch wires Remove regulator assembly and replace regulator Reverse the procedure to install regulator assembly Be sure to check for leaks after pressurizing the system Reset regulator pressure to desired setting BLENDONATOR FLOAT SWITCH REPLACEMENT 1 Use the control panel to turn the blendonator OFF Remove the drip tray drip tray mounting panel 2 screws and splash panel 2 screws Turn off the cylinder product supply valve Slide the product tray out by removing the 2 screws on the top and front side Turn CO off at the source Relieve pressure from Wire blendonator by opening face plate relief valve connector L Disconnect guick disconnect from float assembly Unplug wires Unscrew float assembly Remove pins from wire connector Connector 7 pin removal Unscrew float from assembly Quick disconnect Float assembly FIGURE 49 Reverse the procedure to install new float switch Be sure and check for leaks after pressurizing the system Bleed air from blendonator using pressure relief valve Go through the normal start up procedure 2003 IMI Cornelius Inc 43 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cre D BLENDONATOR TANK REPLACEMENT Use the control panel to turn the blendonator OFF 2 Remove the drip tray drip tray mounting panel 2 screws splash panel 2 screws and si
58. ommunicat ing with the main board D Replace 1 Check line voltage 2 Check T1 T2 with Compressor running B Correct line voltage A Check connections at J6 and J17 See display board test in the Ser vice manual A Freeze up B Magnet and stator not aligned rectly C Magnet binding C A Defective pulse valve B Stator or magnet not installed cor Inspect and correct problem Electronic ERROR A Clock chip or bad line frequency A Replace the clock chip B Faulty communication B Check phone connections Drive ERROR Frozen Oylinder 2003 IMI Cornelius Inc A Motor not turning when itis com A manded to Freeze up 1 Check Brix 2 Check sold out 3 Check for leaking pulse valve 4 Defective binding magnet 5 Broken beater bar B Badinverter board Emerson A Low Brix B Pulse valve leaking C Broken beater bar D Broken drive coupler E No defrost F Are defrosts programmed all days 59 B Test and replace as necessary A Correct cause and reset Brix B Replace pulse valve C Replace beater bar D Replace the drive coupler E Program defrosts in unit F Reprogram to all days Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Detective Stator A Open or shorted A See stator test Defective Hall Board A Open or shorted A See Hall board test Baldor Stator or Misalignment No Po
59. ompressor associated with this refrigeration system where the error occurs will be commanded OFF not no longer needed The compressor associated with this freeze cylinder ice bank will stop providing cooling to this specific evaporator 1 The motor condition means the motor will continue operating if it was in operation prior to the error If the motor was OFF it will remain OFF 2 The Beeper will give a 5 beep sequence for each new error that occurs after a beeping sequence is completed 3 The Cylinder Status Light of the affected cylinder will flash green at a 1 Hz rate 50 DC on all errors 4 The Blender will NOT respond to float activations wen OFF and will respond when ON only is previously enabled ENUEN 99I119S JOAR 4 y pue z ejoeuulg Pinnacle 2 and 4 Flavor Service Manual COMPONENT SERVICE The following are procedures for servicing the major components of the Pinnacle MAGNET ASSEMBLY REPLACEMENT 1 Defrost the cylinder 2 Turn the blendonator OFF 3 Drain the cylinder by opening the dispensing valve When only CO comes out turn the cylinder product supply valve off Relieve CO pressure by opening the faceplate pressure relief valve 4 Remove the cylinder face plate 4 nuts and washers 5 Remove beater bar and scraper blades 6 Use the magnet puller tool p n 560003662 that comes with the unit to remove the magnet NOTE Sufficient force must be used to break the ma
60. on the unit Working on the unit when the red D33 light is lit could result in electrical shock or death 3 Unscrew the 4 mounting screws on the DC inverter board mounting bracket and slide the bracket up while tilting it out Do NOT detach the wires from the board yet 4 Secure the new board in place One at time remove the wires from the old board and connect them to the new board 5 Connect the power and check that the D33 light comes on 6 Re attach the panels MAIN AND PRODUCT DELIVERY BOARD REPLACEMENT BALDOR 1 Disconnect the power to the unit Product Delivery Inverter Boards Product Delivery Boards Emerson Boards 2 Open the merchandiser door then remove top front panel and front hinged panel A indicating that it is safe to work on the unit Work ing on the unit when the red D33 light is lit could result in electrical shock or death DANGER HIGH VOLTAGE after discon necting power wait for the D33 red light to go out E 3 Remove all wires from board being replaced 4 Disconnect the 4 mounting standoffs and remove the board 5 Secure the new board in place and reconnect the wiring Main Boards FIGURE 40 6 Ifthe Main Board was replaced program the previous setting for time defrost sleep walk up and viscosity 7 Re attach the panels Publication Number 560007298SER 38 2003 IMI Cornelius Inc CCGinclius gt Pinnacle 2 and 4 Flavor Service Manual DISPLAY BOARD REPLACEMENT
61. ormance e Servicing repairing the machine e Checking for error messages The control system is accessed with the control panel located behind the lighted merchandiser There are 2 levels of access to the control panel 1 used by the operator for normal operations and 1 used by qual ified service technicians for installation and service functions The service functions can be secured locked out so that the operator will not have access to them See the Security Lockout Function section under menu 15 for more information Control Panel Display gt FIGURE 5 The control panel has a variety of displays of called menus The first menu menu 1 that is displayed is the BARREL STATUS menu From each menu there is a button to return to the previous menu and another button to advance to the next menu The menus currently programmed into the computer are the following BARREL STATUS menu 1 CHOOSE MODE suut ficat rodeados Di hae ad menu 2 2003 IMI Cornelius Inc 9 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual CCincdius gt CHANGE BARREL STATUS ON OFF motor menu 3 SET CLOCK caet dos qaae A REN Eod E RICE US DOR wares RO dna bs menu 4 SEL WAKE DP i sacs sca dene Ron a ees eee e oco menu 5 SET SEBBEPTIME v i ua ax hx resina Fac VRAT ETE ES menu 6 SET DEFROST select time aka kas menu 7 SET DEFROST set tlm sia is ii i a c ch menu 7A MISC El spc sasadas es
62. r 560007298SER 52 2003 IMI Cornelius Inc Cinel D Pinnacle 2 and 4 Flavor Service Manual COMPRESSOR REPLACEMENT 1 2 Disconnect all wires to compressor Remove 4 mounting Disconnect the power to the unit Remove bottom rear cover 4 screws and side panels 3 screws each nuts d ia FIGURE 73 Reclaim refrigerant Remove insulation from around fittings Unsweat suction line first Cut the discharge line on top of the compressor be careful so the line can be spliced back together Remove the compressor and unsweat the discharge line Reverse the procedure to install new compressor Replace the dryer Evacuate and recharge the system HoT Gas VALVE REBUILDING 1 Disconnect the power to the unit Remove side panels 3 screws each Coil Ea 4 Reclaim refrigerant screw T PE Rebuild the hot gas valve per the manufacturer s instructions Hot Replace the dryer Evacuate and recharge the system iiid valves body Hot gas valve body FIGURE 75 2003 IMI Cornelius Inc 53 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cre D PULSE VALVE REPLACEMENT 1 Disconnect the power to the unit Remove side panels 3 screws each and rear panels if necessary CAUTION There are 6 pulse valves one for A each cylinder and one for each water bath The pulse valve for the water bath and the pulse valves for the cylinders are NOT the same DO NOT interc
63. rting e Use aclean syrup tank syrup tank system or a clean 5 gallon pail bag in box system filled with plain water e Connect the sanitizing fitting to the bag in box connector Put the connector in the bucket of plain water e Turn barrel 1 blendonator ON from BLENDONATOR menu to fill blendonator e Fill barrel 1 with plain water by repeatedly pulling and releasing the faceplate relief valve until solution comes out e Open the dispensing valve until water flows from the valve then close the valve e Open blendonator sample valve see Figure 4 until water flows from the valve then close the valve e Place barrel 1 in MOTOR mode from ON OFF MOTOR menu to start barrel 1 beater Allow beater to operate for 2 minutes then place barrel 1 in OFF mode from ON OFF MOTOR menu to stop the beater 9 Sanitize the system by completing the following steps e Turn barrel 1 blendonator OFF from BLENDONATOR menu to prevent more plain water from entering the blendonator e Place container under barrel 1 dispensing valve Open the dispense valve and dispense all plain water from the freeze cylinder and the blendonator As the plain water level lowers in the freeze cylin der partially close the valve to avoid spurting e Use aclean 5 gallon pail bag in box system to prepare sanitizing solution Mix approximately 1 ounce of household bleach per gallon of warm water When the blendonator runs it mixes with pota ble wat
64. rvice Manual DisPLAY BoARD REPLACEMENT EMERSON 1 Disconnect the power to the unit 2 Open the merchandiser door then remove top front panel and hinged panel DANGER HIGH VOLTAGE after disconnecting power wait approximately 5 minuets to work A on the unit Working on the unit before the 5 minutes have passed could result in electrical shock or death 3 Unscrew the 4 screws holding the board cover Carefully reach behind the cover and disconnect the wires ribbon cable phone cable power cable Mounting standoff 4 m d F Display 4 Remove the board from the 4 standoffs 5 Install the new board with the ribbon cable protruding through the top Ribbon cable FIGURE 38 6 Reconnect the wires while installing the cover 7 Connect the power and check to see that the control panel works properly Secure the circuit board door and follow a normal startup procedure 8 Re attach the panels 2003 IMI Cornelius Inc 37 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual C Queis D DC INVERTER BOARD REPLACEMENT BALDOR CAUTION Use a grounding strap 1 Disconnect the power to the unit DC Inverter board Baldor D33 light Baldor FIGURE 39 2 Open the merchandiser door then remove the top front panel and front hinged panel DANGER HIGH VOLTAGE after disconnecting power wait for the D33 red light to go out indi A cating that it is safe to work
65. s are disabled terminated during the diagnostic mode The diagnostic display order is organized on a cylinder by cylinder basis All outputs associated with a specific cylinder displayed as a group When that cylinder is done the next cylinder group will begin After the cylinders the ice banks information is displayed on an ice bank by ice bank basis DIAGNOSTICS Menu Button Descriptions 1 BACK go back to the previous menu 2 AUTO toggle begin end of automatic mode 3 EXEC activate the output at the selection pointer H 4 UP scroll list up 5 DOWN scroll list down DIAGNOSTICS Menu Messages AUDIBLE ALARM activate audible alarm on display board Cylinder Group X BRL PULSE VLV Xactivate cylinder pulse valve H20 SOLENOID X activate water solenoid DEFROST VLV X activate cylinder defrost valve DISP VALVE LO X activate dispense valve lockout CARB MTR PUMP Xactivate carbonator pump motor SYR SOLENOID Xactivate syrup solenoid BEATER MOTOR Xmake beater motor turn BRL STAT LITE X activate cylinder status light red amp green AUDIBLE ALARM activate audible alarm on main logic board Publication Number 560007298SER 22 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual Menu 13 BARREL DATA BARREL BARREL 1 OFF Information Items LAM EVAPS IN 23 OUT 26 VISC SET 1 ACT 034 12 43PM BLENDONATOR ON BACK UP DOWN FIGURE 21 The BARREL DATA menu d
66. ted cylinder OFF beater bar OFF and refrigeration INACTIVE 4 MOTOR turn the selected cylinder MOTOR beater bar TURNING and refrigeration INACTIVE 5 DOWN scroll down the menu list Menu 4 SET CLOCK System sino CLOCK 4 20 PM BA CK NEAT UP l DOWN FIGURE 11 From the SET CLOCK menu the system computer time and date are entered or changed The time is display in 12 or 24 hour format The time display format is selected in the OPTIONS menu menu 15 SET 04 19PM 01723798 System Date The date is displayed in either a US format mm dd yy or a European format dd mm yy The date dis play format is selected in the OPTIONS menu menu 15 To set the time and or date press lt NEXT gt to select 1 of 6 fields HOURS MINUTES AM PM if used DAY MONTH YEAR Press UP and lt DOWN gt to change the field Then press BACK to save the changes The clock can be set to automatically adjust for Daylight Savings time using the OPTIONS menu menu 15 SET CLOCK Menu Button Descriptions 1 BACK go back to the previous menu 3 NEXT select the next field 4 UP increase the selected field by 1 hour day etc 5 DOWN decrease the selected field by 1 Publication Number 560007298SER 14 2003 IMI Cornelius Inc Cenes D Pinnacle 2 and 4 Flavor Service Manual Menu 5 SET WAKE UP NONE Wake Up Wake Up Day Time SUNDAY MEXT U P
67. tup procedure Start AN capacitor n E To EN DELE FIGURE 45 Pump Motor REPLACEMENT 1 Disconnect the power to the unit Remove splash panel 2 screws drip tray and drip tray panel 2 screws 2 Turn off COs water and syrup sources Bleed pressure from the feed lines at the rear disconnects CO Regulators x4 FIGURE 46 Loosen 2 bolts holding Tray from sliding out during ship 1 in each corner Slide tray out Disconnect Guest fitting from pump Disconnect electrical leads Remove 2 screws holding motor on angled brackets Replace the bad pump in the reverse order of steps 3 through 6 Re connect the CO water and syrup Turn the bottom blendonator brix valve to blendonator position OO EN OF MI ae Re connect the power and go through the normal start up procedure 2003 IMI Cornelius Inc 41 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual Cre D AGITATOR MOTOR REPLACEMENT EMERSON 1 Disconnect the power to the unit Remove the side panel 3 screw 2 Unplug motor Remove 4 screws Remove ground wire green yellow wire from motor Lift motor 3 Reverse the procedure to install new motor 2 screws on each siae Ground screw FIGURE 47 AGITATOR MOTOR REPLACEMENT BALDOR 1 Disconnect the power to the unit Remove the side panel three screw 2 Unplug motor Remove 4 screws Lift motor 3 Reverse the procedure to install new motor 2 screws L k
68. wer to Stator Bad Magnet Compressor not Run ning Compressor Running but not Cooling Restricted Air Flow Publication Number 560007298SER Loose mounting nuts Missing or extra gasket Debris causing interference Hall board not mounted correctly Blown inverter fuse One side of inverter is defective Incorrect wiring Poor connections Defective beater bar coupler Worn magnet bushing Cracked damaged magnet hous ing Cylinder shaft not aligned Cylinder not in ON mode No voltage to compressor Bad start components Thermal overload protector open Open or shorted compressor windings Bad control board Low refrigerant Restricted condenser filter Condenser fan motor blade defective Any pulse valve stuck open or closed Hot gas valve leaking or open Defective compressor Dirty filter Dirty condenser Damaged fins Not enough clearance around unit 60 Tighten nuts Add or remove gasket Remove debris and tighten Assemble correctly Replace fuse after LED D33 light has gone out Swap side 1 amp 2 controls see if motor will run Check wiring with Pinnacle sche matic Check all connections Replace the defective part Replace bushing assembly check cylinder shaft Replace magnet Replace foam pack Turn cylinder to ON Check power at contactor L1 L2 T1 T2 Check components and wiring Check resistance of compressor w
69. ylin der Press lt PRIME gt to prime the selected cylinder All cylinders can be primed at once by pressing lt ALL gt The messages displayed are OFF ss rico si system has syrup SY AUP saciar syrup is sold out empty SYRUP PRIME Menu Button Descriptions 1 BACK go back to the previous menu 2 PRIME prime selected cylinder 3 ALL prime ALL cylinders at once 4 UP move selection pointer up 5 DOWN move selection pointer down Publication Number 560007298SER 28 2003 IMI Cornelius Inc eines D Pinnacle 2 and 4 Flavor Service Manual Menu 19 VOLT VOLT MENU VOLTAGE 234 V Voltage 11 05AM BH mM mM M FIGURE 27 The VOLT menu displays line voltage at the contactor The voltage will be displayed in Volts RMS VOLT Menu Button Descriptions 1 BACK go back to the previous menu 2003 IMI Cornelius Inc 29 Publication Number 560007298SER Pinnacle 2 and 4 Flavor Service Manual C Ginelius D Menu 20 ERROR FIGURE 28 The ERROR menu displays a list of errors that are presently on the system All system errors will be dis played on this list in the priority order The error list will scroll if necessary The display of the error list will be updated every 3 seconds The RESET function will silence the beeper if sounding and reset the errors that are capable of MAN UAL ERROR RESET As automatically correctable errors are satisfied the error
70. ylinder be careful to avoid crushing fingers between the magnet and any ferrous metal Keep the magnet free from metallic debris and wipe clean prior to reinstallation WARNING Strong Magnetic Field Person wearing pacemaker implanted cardioverter defibrillator or other implanted medical device may be affected by the magnetic field and must keep the magnet at 6 or more inches from the device The magnetic field can affect operation of these devices which may cause bodily injury or death If disruption of device occurs or operation is adversely effected immediately move the victim far away from magnet and seek medical assistance Publication Number 560007298SER 2 2003 IMI Cornelius Inc eines D Pinnacle 2 and 4 Flavor Service Manual SYSTEM OVERVIEW PRODUCT OVERVIEW The 2 and 4 Flavor Pinnacle see pictures below consists of the following e 2 or 4 freeze cylinders each containing an internal beater bar driven by DC electric motors utilizing external stator coils and internal rotor magnets These motors contain no seals there by eliminating leak age and minimizing preventive maintenance e A DC motor using magnetics to drive the beater bars in each cylinder e 1 refrigeration systems per 2 barrels 1 blendonator assembly per barrel a programmable defrost sys tem to defrost the freeze cylinders and interconnecting tubing components and fittings necessary to reg ulate transfer and dispense a quality frozen c

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