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Service Manual FCB Overcounter Post-Mix Dispenser

1. 138 X 141 139 J An 148 137 91 138 S497 143 139 138 91 111 23 lt 24 183 8 28 43 136 135 Se _ a dp yal I m D CJ Ag 4 E O A A Jum 127 91 71 d 126 Cl 155 136 T 148 80 91488 lt 45 129 x 130 155 FIGURE 19 CON T PLUMBING DIAGRAM 73 324229000 OVERCOUNTER FCB EVAPORATOR UNIT 416116 xxx Overcounter FCB 115V 60HZ 496116 Overcounter FCB 230V 50HZ 819941 Thread Rolling Screw SL Hex Washer Hd No 8 32 by 3 8 in Long 324125 068 Panel Top 324126 068 Panel Back 324127 068 Panel Side Right Hand 324128 068 Panel Side Left Hand 5 325767 Cover Control Box 324136 xxx Board Master 5 324137 Board Motor No 1 324138 Board Motor No 2 Support Board not shown Cable Ribbon not shown Cable Ribbon not shown 325981 069 Holder Flavor Tab 21 319739 Transformer 230 24 22 310198 133 Flow Regulator Syrup see FIGURE 19 23 324244 Fitting Tee Barbed for 312 1 0
2. ms KLAUBER MOTORS W O START RELAY 2 MOTOR BEATER MOTOR MOT 1 2 l D D D oO D H BEATER BEATER E x x 1 MOTOR MOTOR BRN mM BRN m START START 4 81120 2 1 2 Ke RELAY RELAY len S aD Eq T 5 FLO Sea 1 1 51 2 a WATER PSI 1 NC YEL YEL d 0 SWITCH BLK J d 2 NC BLK z lt BLK 9 5 E ORN GRAY a YEL ul a NC NC d HEATER HEATER Ji FAN 1 2 lt WHT gt TO BOARD 1 4123654024 D I 5 wad n Ge LI 187 BLK_ BOARD 1 142 7 n l l 2 1 2 MASTER BOARD Gei D SE Et g 82 CO PSI SWITCH D 174 L RED i 137 P a aa akin z 8112 42 a 11 e bo E nero LEGEND 85 a 2 5 8 5 deny FIELD WIRING E EI UNIT WIRING LIU L IE 5 2 2 E 3 5 WTR a SYRP SYRP WTR x TOUCH SWITCHES c SIS UV UR CH 5 GRAY J GRAY 24 VOLT CONTROL LINES BLUE TO REMOTE VEL RED BLK WHT RE
3. SYRUP FLOW REGULATOR 2 FLOW REGULATOR 2 CARBONATED WATER SOLENOID VALVE 2 SYRUP SOLENOID VALVE 2 PRIMARY CO REGULATOR ASS Y SYRUP SOLD OUT FLOAT SWITCH 2 SYRUP SOLD OUT SWITCH 1 1 G 2m FREEZE CYLINDER OVERFLOW TUBE LIQUID CHECK VALVE 2 WATER CH REGULATOR PLAIN WATER SOURCE EAE CYLINDER maoo wnan CHECK VALVE 3 lt SOFT DRINK TANK 2 SHUTOFF gt VALVE A 1 lt gt WATER PRESSURE SWITCH CARBONATOR WATER PUMP PRESSURE SWITCH Sisi zl SECONDARY CO REGULATOR SECONDARY REGULATORS TO CARBONATOR TANK 100 PSI GAGE TO PRODUCT BLENDER TANKS 60 PSI GAGE FIGURE 2 FLOW DIAGRAM 324229000 THIS PAGE LEFT BLANK INTENTIONALLY 324229000 6 INSTALLATION This section covers unpacking and inspection selecting location installing the FCB Overcounter Dispenser pre parin
4. INSTALLATION sice iguania REENERT d 3 3 3 3 3 4 7 UNPACKING AND INSPECTION 7 IDENTIFICATION OF LOOSE SHIPPED PARTS 7 SELECTING LOCATION 8 FCB OVERCOUNTER DISPENSER 8 60 AZ UNIT Pena Arcot uyum gd 8 ca fe Lo Ceo 8 REMOTE REFRIGERATION 55 9 INSTALLING FCB OVERCOUNTER DISPENSER 9 INSTALLING BEATERS ITEM 7 AND SCRAPER BLADES ITEM8 9 PLACING UNIT IN OPERATING LOCATION 9 INSTALLING DRIP TRAY SUPPORTS AND DRIP TRAY 9 INSTALLING DRIP TRAY DRAIN KIT bt AE EE ad Se 10 PREPARING UNIT SYRUP INLET LINES FOR CONNECTION SOFT DRINK TANKS Seege Na Na Na a e 10 CONNECTING 24 VAC ELECTRICAL CIRCUIT FROM REMOTE REFRIGERATION ASS Y TO FCB OVERCOUNTER DISPENSER 10 CONNECTING REMOTE REFRIGERATION ASS Y REFRIGERATION LINES TO FCB OVERCOUNTER DISPENSER 10 INSTALLING PRIMARY CO2 REGULATOR ASS Y ON CO2 CYLINDER 11 CONNECTING CO2 INLET LINE ITEM 12 TO FCB OVERCOUNTER DISPENSER Sod est ee as 11 CONNECTING PLAIN WATER INLET LINE ITEM 13 TO FCB OVERCOUNTER DISPENSER
5. BARA JOO awda INN 1euseMqe 4 Bulg O BARA POH epeig 1648 06 Bunya et DN OTH XD b OH FIGURE 3 FREEZE CYLINDER CUTAWAY VIEW 12 324229000 KEY ON END OF POST KEY ON END KEY SLOT ON BLADE SCRAPER BLADES MUST BE MOUNTED TO THE BEATER BODY AS SHOWN USING THE PERFO RATED EDGE AS THE LEADING EDGE LINE UP KEY ON END OF POSTS WITH KEY SLOT IN SCRAPER BLADES FIGURE 4 BEATERS AND SCRAPER BLADES INSTALLATION CONNECTING 208 230 VAC POWER CIRCUIT TO FCB OVERCOUNTER DISPENSER see Figure 17 1 Route 208 230 VAC applicable 50 or 60 Hz Single Phase electrical power circuit meeting requirements of SELECTING LOCATION through Unit base to electrical box inside the Unit 2 Remove cover from electrical box 3 Connect 208 230 VAC power circuit to electrical wires inside the electrical box then install cover on box DO NOT TURN ON ELECTRICAL POWER TO UNIT AT THIS TIME PREPARATION FOR OPERATION 50 OR 60 HZ OPERATION IMPORTANT Before connecting electrical power to Unit refer to Unit nameplate and note if Unit is to be operated with 50 or 60 Hz electrical power 1 Remove four screws securing Unit upper control box cover for access to the master circuit board see Figure 6 13 324229000 TURNING ON ELECTRICAL POWER REMOTE REFRIGERATION ASS Y AND FCB OVERCOUNTER DISPENSER 1 Turn o
6. 1 4 4174478 Tube 265 1 0 by 3 in Long Tube 265 1 0 by 92 Long 6 77460 Fitting Swivel Elbow 5 8 18 176272 396 174061 196 325558 Tube Ass y 250 1 0 176205 Nipple for 375 1 0 Tube 770104 Nipple for 265 1 0 and 250 1 0 Tube Tube Ass y 375 1 0 Tube Ass y 265 1 0 1 2 311242 Swivel Nut 5 8 18 3 176204 Ferrule for 610 O D Tube 176000 Ferrule for 520 O D Tube 176001 Ferrule for 395 O D Tube 4 174292 Tube 375 I D by 96 in Long 174478 Tube 265 I D by 96 in Long 174103 001 Tube 250 1 0 by 40 in Long 324169 Tube Ass y Carb Water 174103 001 Tube 250 I D by 15 in Long 174103 Tube 250 I D by 15 in Long 174103 Tube 250 I D by 4 in Long 174103 Tube 250 I D by 6 Long 176001 Ferrule 40 Jaw for 395 O D Tube 770104 Nipple for 250 1 0 Tube 325012 Shut off Valve 176017 Swivel Nut 7 16 20 7 770602 Fitting Cross 1 4 Barb 324229000 84 FIGURE 27 TUBING ASSEMBLY CON T Description 5 Tube Ass y Product sumed 2 174103 250 I D by 1 3 4 in Long 2 27 el 174103 250 LD by 2 1 2 in Long o 174103 250 LD by 18 1 2 in Long 174103 250 1 0 by 54 in Long 2 SO 2 Ca Bug 6 2 2 37 E Ge NM X 770601 Fitting Tee 1 4 Barb 3 4 O 5 pS 2 ss SE 324142 Tube Carb Water and Syrup 2 Regulato
7. BA Na Pa a qaa 66 UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE 66 MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN DEFROST SWITCH IS PRESSED 66 DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING CANCEL DEFROST SWITCH EE 66 TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR 67 CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE 67 CARBONATOR WATER PUMP WILL NOT SHUT OFF 67 ERRATIC CARBONATOR WATER PUMP CYCLING 67 TROUBLESHOOTING DISPENSED PRODUCT 68 BRIX WATER TO SYRUP RATIO TOO LOW 68 BRIX WATER TO SYRUP RATIO TOO HIGH 68 IMPROPER PRODUCT DISPENSED 68 PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE IN ONLY SMALL AMOUNTS OR ONLY LIQUID 55 antra racer emen 68 FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING t aaa aa aaa 68 FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY 69 CYLINDER FREEZE UP pP RO 69 TROUBLESHOOTING REMOTE REFRIGERATION ASSEMBLY 69 OVERCOUNTER FCB EVAPORATOR 74 uLGG TM 86 324229000 TABLE OF CONTENTS cont d Page LIST OF FIGURES FIGURE 1 FCB OVERCOUNTER POST MIX DISPENSER EVAPORATOR UNIT
8. DRIVEMOTOR DRIVE RETAINING Press OFF 1 and OFF 2 control switches to stop refrigeration system and beaters motors Disconnect electrical power from Unit Remove back and side panels as instructed Tag beater drive motor electrical wiring for identification then disconnect wiring from motor terminal block on Unit frame Remove hex nuts and lockwashers securing beater motor drive to Unit frame Very carefully remove old beater drive motor from Unit BE CAREFUL NOT TO LOSE PLASTIC COUPLER LOCATED BETWEEN BEATER DRIVE MOTOR SHAFT COUPLING AND BEATER DRIVE SHAFT ASSEMBLY COUPLING Note how far beater drive motor shaft protrudes inside coupling Using Allen wrench loosen Allen head setscrew in coupling then remove coupling from motor shaft FREEZE CYLINDER SOCKET BEARING MOTOR SHAFT COLLAR COUPLING 9 POWER COUPLER ASSEMBLY PLASTIC BEATER DRIVE SHAFT 1 Y O Q 9 O zx X C J ALLEN HEAD DRIVE SHAFT J SETSCREW ALLEN TYPE PIN SETSCREW BEATER DRIVE MOTOR SHAFT BEATER SHAFT r COUPLING PD BEATER DRIVE SHAFT SEAL ASS Y FIGURE 14 BEATER DRIVE MOTOR AND SHAFT SEAL ASS Y REPLACEMENT Install
9. 11 CONNECTING 208 230 VAC POWER CIRCUIT TO FCB OVERCOUNTER 5 5 de er 13 PREPARATION FOR OPERATION 13 50 OR 60 HZ OPERATION 13 TURNING ON ELECTRICAL POWER TO REMOTE REFRIGERATION ASS Y AND FCB OVERCOUNTER DISPENSER 14 ADJUSTING PRIMARY AND SECONDARY CO2 REGULATORS 14 STARTING FCB AND ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUGT zie Ee px 15 ADJUSTING BEATER MOTOR CURRENT EITHER SIDE 16 324229000 TABLE OF CONTENTS cont d Page ADJUSTMENTS AND PROGRAMMING MAIN MENU SELECTIONS COMPONENTS DIAGNOSE DIAGNOSTIC MODE AND TOTALS DISPLAYED CYCLES AND HOURS TOTALS INTO UNIT 17 PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY 17 SETTING CLOCK TIME OF 17 PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT 18 PROGRAMMING SLEEP SLEEP TIME INTO UNIT 19 PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT 19 PROGRAMMING POINT OF SALE DISPLAY MESSAGE 19 ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT ss iati 20 VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT FREEZE GYLINDERS si tcl Date Cite keen ati A 20 DISPLAYED EVA
10. and outlet syrup lines from empty soft drink tank 3 Check soft drink tank quick disconnects for sticky or restricted operation Rinse disconnects in warm water 4 First pressurize full soft drink tank by connecting CO line to tank then connect Unit syrup inlet line to tank 5 Press applicable FILL 1 or FILL 2 switch to fill applicable No 1 or No 2 syrup system syrup float switch with syrup 6 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill applicable No 1 or No 2 system product blender tank with product 324229000 52 7 Press applicable AUTO 1 or AUTO 2 switch to start refrigeration system and beater in applicable No 1 or No 2 freeze cylinder 8 If freeze cylinder is not full of product repeatedly pull and release faceplate relief valve to slowly bleed from freeze cylinder and allow product to fill cylinder Do not relieve freeze cylinder pressure too fast or product will foam excessively in cylinder and lose carbonation SYRUP FLAVOR CHANGE One or both syrup flavors can be changed at the same time Perform flavor change on one system as follows 1 Perform sanitizing procedure on syrup system syrup flavor change will be made on as instructed in SERVICE AND MAINTENANCE IMPORTANT The following and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows To d
11. DRAWING 1 DRAWING 2 DRAWING 3 SECONDARY REGULATORS The three secondary regulators located behind lower front access panel see Figures 2 and 8 control pressure to carbonator and product blender tanks CARBONATED WATER FLOW REGULATORS The adjustable carbonated water flow regulators see Figures 2 and 8 located in their respective systems con trol carbonated water flow rate to the product blender tanks The water flow regulators are factory adjusted at 1 5 0 05 oz sec and should not normally require adjustment 31 324229000 SYRUP FLOW REGULATORS The syrup flow regulators see Figures 2 and 8 located in their respective systems are adjustable regulators that control syrup flow rate to the product blender tanks for desired BRIX of dispensed product DISPENSING VALVES Self closing dispensing valves see Figures 7 and 9 located on faceplates on front of Unit are operated one ata time or simultaneously to deliver product to the customer DISPENSED PRODUCT CONDITIONS OVERRUN AS APPLIED TO FROZEN CARBONATED BEVERAGES Overrun Defined Overrun is product expansion that takes place in the frozen carbonated drink It is caused primarily by COs gas breakout and secondary by freezing OVERRUN IS A VARIABLE The percentage or degree of overrun depends on a number of factors The specific syrup BRIX low dispensing volume carbonation level in liquid product and freezing all affect overrun
12. 1 FIGURE 2 FLOW DIAGRAM iU cos este 5 FIGURE 3 FREEZE CYLINDER CUTAWAY 12 FIGURE 4 BEATERS AND SCRAPER BLADES INSTALLATION 13 FIGURE 5 CONTROL PANEL copus 17 FIGURE 6 MASTER AND RELAY CIRCUIT BOAPDS 22 FIGURE 7 OPERATING CONTROLS 41 FIGURE 8 UNIT INTERNAL COMPONENTS 42 FIGURE 9 SELF CLOSING DISPENSING VALVE 43 FIGURE 10 SERVICING BEATER DRIVE SHAFT SEAL ASSEMBLY 44 FIGURE 11 LIQUID CHECK VALVE ASSEMBLY 51 FIGURE 12 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK eeben 55 FIGURE 13 CO2 GAS CHECK VALVE 56 FIGURE 14 BEATER DRIVE MOTOR AND SHAFT SEAL ASS Y REPLACEMENT tach as dahlias de 58 FIGURE 15 LIQUID LEVEL CONTROL SWITCH ADJUSTMENT center use attack taker 60 FIGURE 16 REFRIGERATION FLOW 61 FIGURE 17 WIRING DIAGRAM FCB OVERCOUNTER DISPENSER 62 FIGURE 18 OVERCOUNTER FCB EVAPORATOR UNIT 72 FIGURE 19 FLOW REGULATOR ASSEMBLY 76 FIGURE 20 CARBONATOR TANK AND LINKAGE ASSEMBLY 77 FIGURE 21 DRIVE SHAFT ASSEMBLY 78 FIGURE 22 CO2 REGU
13. PARTIAL MESSAGE OR DULL POORLY ILLUMINATED DISPLAY ONE OR MORE FAULT MESSAGES NOT OPERATING 324229000 Probable Cause Flat cable not properly connected to control switch module or master circuit board Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Master circuit board not operating properly Not pressing and holding SECURITY SWITCH for 3 seconds to deactivate control switches SECURITY SWITCH inoperable Extremely low voltage Flat cable not properly connected to fault message module or master circuit board Flat cable connected between fault message module and master circuit board pinched and shorted out or broken wire in cable External sensing device failing to signal master circuit board which in turn signals fault message display External sensing devices cable connectors not securely connected to master circuit board connectors Disconnected or broken wire between master circuit board connector and external sensing device Master circuit board not operating properly Fault message display module not operating properly 64 Remedy Properly connect flat cable to control switch module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace master circuit board Press and hold SECURITY SWITCH for 3 seconds to deactiv
14. Properly connect flat cable to control switch module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace control panel switch module Repair wire Replace master circuit board Properly connect flat cable to control switch module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace control panel switch Replace master circuit board Trouble TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR Probable Cause CARBONATOR WATER PUMP A No electrical power to Unit MOTOR WILL NOT OPERATE CARBONATOR WATER PUMP WILL NOT SHUT OFF ERRATIC CARBONATOR WATER PUMP CYCLING B AUTO BLEND 1 or AUTO BLEND 2 switches have not been pressed H2O OUT fault message is on CO OUT fault message is on Loosen or broken electrical wires Overheated water pump motor cut off by overload protector Binding water pump new or replacement pump only Inoperative water pump and or motor Inoperative carbonated water tank level control switches Binding damaged or dirty carbonated water tank balance mechanism Inoperative water pump and or motor Binding damaged or dirty carbonated water tank balance mechanism Insufficient water supply pressure OUT fault message goes on and off intermittently and water pump cycles on and off du
15. 28 After carbonator water pump cycles off completely fill No 1 freeze cylinder with sanitizing solution by repeatedly pulling and releasing relief valve knob on freeze cylinder faceplate and until sanitizing solution comes out of relief valve port Open dispensing valve until sanitizing solution flows from valve then close valve Open product blender tank sample valve until sanitizing solution flows from valve then close valve Press WASH 1 switch to start No 1 freeze cylinder beater Allow sanitizing solution to remain in freeze cylinder for no less than 10 and no more than 15 minutes max contact time When sanitizing solution contact time has elapsed press OFF 1 switch to stop No 1 freeze cylinder beater Hold appropriate container under dispensing valve and dispense until soft drink tank containing sanitizing solution is empty and all sanitizing solution has been dispensed from freeze cylinder As sanitizing solution level lowers in freeze cylinder partially close valve to avoid spurting Dispose of sanitizing solution in a safe way Place waste container under No 1 system product sample valve Slowly open valve and purge remaining sanitizing solution out of product blender tank then close valve Disconnect empty sanitizing solution tank from No 1 syrup system then release pressure from tank by pulling up on cover relief valve Pull freeze cylinder faceplate relief valve to release all pressure from
16. B 404 V34 Dispenser with H P Copeland Compressor and R 404A refrigerant C R502 V3 and V3 Dispensers using Bristol or Tecumseh Compressor and R502 refrigerant D R402B5OH V3 and V3 Dispensers using a Bristol Compressor and R 402B refrigerant Refer to Dispenser serial plate to identify the type of refrigerant gas installed in the refrigeration system Press CANCEL DEFROST ADVANCE switch as many times as necessary to bring up applicable refriger ant type from sub menu of REF TYPE REFRIGERANT TYPE on MESSAGE DISPLAY Press DEFROST SELECT switch to lock in on the selection This programs the proper refrigerant pulse rate into the Dispenser electronics Press ERROR RESET switch two times to exit from MAIN MENU SELECTIONS DISPLAYED ERROR CONDITIONS Displayed error conditions associated errors and items affected by the errors are found in Table 9 DISPLAYED ERROR CONDITIONS INSTALLING CONTROL BOX COVER AND BACK SIDES AND TOP PANELS ON UNIT 1 2 Install upper electrical control box cover and secure with four screws Install back sides and top panels on Unit by reversing removal procedure 324229000 26 Table 9 DISPLAYED ERROR CONDITIONS ITEMS AFFECTED BY ERROR MESSAGE BEATER BEATER DISPLAY ERROR MOTOR 1 MOTOR 2 Motor 1 Low Current lt 109 OFF OFF Sensed on motor one Motor 2 Low Current lt 109 OFF OFF Sensed on motor two Motor 1 High current gt
17. Remove both Unit side panels as instructed for access to product shutoff valves located close to product blender tanks Close product shutoff valve in line between applicable product blender tank and associated freeze cylinder BRIX adjustment will be performed on Press applicable FILL 1 or FILL 2 switch to prevent more product from filling product blender tank Open applicable product blender tank product sample valve and take sample approximately 6 ounces of product in cup NOTE Temperature compensated hand type refractometers P N 511004 000 are available from the IMI Cornelius Inc 7 10 11 12 13 14 Check product BRIX with a temperature compensated hand type refractometer BRIX should read 14 3 If BRIX is not within tolerance adjust applicable white syrup flow regulator as follows A Loosen jamb nut on applicable syrup flow regulator B Turn syrup flow regulator adjusting screw to the left counterclockwise no more than 1 8 turn at a time to reduce syrup flow rate or turn screw to the right clockwise no more than 1 8 turn to increase flow rate C Tighten jamb nut on syrup flow regulator then lightly tap regulator to register adjustment Place container under applicable product sample valve Open valve to purge product out of product blender tank line and valve then close valve Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill product blender tank 1 4 full of new batc
18. Tube see Plumbing Diagram 24 311908 Clamp for 437 O D Tube see Plumbing Diagram 25 325742 Solenoid Valve Carb Water 26 310757 Flow Regulator Water see FIGURE 19 see Plumbing Diagram see Plumbing Diagram 324133 069 Support Drip Tray 33 Body Beater O Ring 859 1 0 by 139 C S 320814 O Ring 734 I D by 139 C S 325701 Extension Foam Pack 41 325282 Self Drilling Screw Hex Washer HD No 8 18 by 1 2 in Long 324229000 42 324123 Support Carbonator and Blender 43 300393 Tee see Flow Diagram 44 326136 Tank and Linkage Ass y see FIGURE 20 45 174058 Tube 156 1 0 11 in Long see Plumbing Diagram Support Carbonator Tee 1 8 Barb see Plumbing Diagram 324121 Foam Pack Ass y 326014 Drive Shaft Ass y see FIGURE 21 324132 Mount Motor 115V 60HZ 0598 Mount Motor 230V 50HZ 51 324120 Motor 115V 60HZ 2108 Motor 230V 50HZ 320899 Cap Screw Hex HD 5 16 18 by 3 4 in Long 186144 Cap Screw Hex HD 5 16 18 by 1 2 1 1 4 in Long 320737 Washer 343 1 0 320604 Twin Nut 5 16 18 186146 Hex Nut 5 16 18 Stainless Steel 320940 Self Drilling Screw Hex Washer HD No 10 by 5 8 in Long 343304 Lock Washer No 10 59 325937 Coupling Shaft 60 174058 Tube 156 I D by 1 in Long see Plumbing Diagram 320734 Machine Screw Phil Pan HD No 6 32 by 3 8 in Long 174058 Tube 156 1 0 by 3 in Long see Plumbing Diagram
19. Water flow regulator stuck Syrup Baume not in proper range Restricted water filter Secondary regulators not properly adjusted Dirty supply must be clean and free of water oil and dirt Water will not absorb dirty CO gas in same way as clean gas This can also cause off taste problems Dispensing valve has ice particles in it Oylinder freeze up AUTO BLEND 1 or AUTO BLEND 2 switch not pressed Carbonator water pump not operating Lines restricted 68 Remedy Secure tank quick disconnect Adjust BRIX of dispensed product as instructed Water flow regulator must be set at 1 5 0 05 oz sec Clean syrup flow regulators Sanitize Unit as instructed Change syrup supply as instructed Adjust BRIX of dispensed product as instructed Water flow regulator must be set for 1 5 50 05 oz sec Clean regulator Change syrup supply as instructed Replace water filter Adjust secondary CO regulators as instructed Replace CO supply as instructed Open and close dispensing valve repeatedly Defrost freeze cylinder as instructed If necessary check and adjust BRIX as instructed Adjust viscosity of dispensed product as instructed Refer to CYLINDER FREEZE UP Press AUTO BLEND 1 or AUTO BLEND 2 switch Check carbonator and restore to operation Sanitize Unit as instructed Trouble FROZEN PRODUCT Probable Cause Remedy Dispensed produ
20. slo NL LA gt JI I gt N LA O1 N m 1 1 Z 5 Z 5 7 5 5 3 0 VOLTAGE DISPLAYED VOLTAGE READOUT V R M 5 2 DIAGNOSE DIAGNOSTIC MODE e Programming Components Diagnose into See Table 7 and programming TOTALS TOTALS DISPLAYED CYCLES AND HOURS TOTALS into unit MOTORS BEATER MOTOR MANUFACTURER See Table 6 See PROGRAMMING PROPER REF TYPE REFRIGERANT TYPE REFRIGERANT TYPE INTO UNIT ELECTRONICS NOTE the CLOCK TIME OF DAY must be programmed into the Unit before DEFROST AUTOMATIC SLEEP SLEEP TIME and WAKE UP WAKE UP TIME will function PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT The automatic defrost system may be programmed into the Unit to occur up to nine different times during a day with a minimum of two hours between defrost time settings Program automatic defrost time settings into the Unit as follows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up DE FROST on message display Press DEFROST SELECT switch to lock in on selection Press CANCEL DEFROST ADVANCE switch to bring up flashing hour number on display Press CANCEL DEFROST ADVANCE switch to advance hours on display to desired hour Press DE FROST SELECT switch to lock in hour on display After hour time of day has been locked in on message display minute numbers will be flashin
21. 1 79 2 2 r r n A z 2 Includes 24 30 gt 26 183294 Quad Ring 145 1 0 By 070 C S 27 188296 Bal 2 2 S 33 Fitting 1 16 NPT By 5 32 Barb 324229000 FIGURE 23 PUMP AND MOTOR ASS Y 324157 Pump and Motor Ass y 115V 60HZ 187502 Fitting Elbow 3 8 MPT by 7 16 20 199020 Pump and Motor Ass y 230V 50HZ 311765 001 Dual Check Valve Ass y see FIGURE 24 300626 Motor 230V 60HZ 312996 Pump Water 90 G P H 6 178025 100 Tapered Gasket White 187483 Clamp Pump to Motor 324229000 80 FIGURE 24 DOUBLE CHECK VALVE ASSEMBLY 311765 001 Double Check Valve Ass y 311764 001 Single Check Valve Ass y includes 2 7 317965 312186 312419 312415 Washer 300 I D 6 312418 Quad Ring 329 1 0 317963 81 324229000 FIGURE 25 FACEPLATE ASSEMBLY 326106 Door Freeze Cylinder Ass y 325954 Relief Valve Ass y 320678 O Ring 4 60 I D by 210 C S 6 325918 Door Freeze Cylinder s est 324229000 82 10 x 9 PN 9 13 AN dd FIGURE 26 DISPENSING VALVE ASSEMBLY 1 321653 O Ring 862 by 103 5 317784 Thread cutting Screw Phil Truss HD 1555 Knob Stainless Steel No 8 32 by 3 8 in 3 321651 Lever Valve 9 1576 Body and Shank 5 O Ring Caged 562 I D by 210 C S Valve 83 324229000 FIGURE 27 TUBING ASSEMBLY
22. After these factors have been con sidered desired viscosity product consistency adjustment may be made on the Unit The viscosity adjustment adjusts product texture from very wet to light Specific Product Ingredients Affect Overrun Each syrup has its own specific formulation of makeup Baume an important ingredient factor may fall within an extremely wide range Fruit flavors contain citric acids that colas do not Colas also differ in ingredients from one brand to another Each product formulation has its own peculiarities regarding the way the product will ab sorb carbonation and the way it will release carbonation BRIX Affects Overrun Sugar in carbonated drinks is like anti freeze in water The higher the BRIX in a product the greater resistance the product has to freezing Conversely in products with lower BRIX freezing takes place at higher tempera tures than for high BRIX products Thus BRIX affects overrun because the amount of sugar in a drink has a direct bearing on the products freezing characteristics Low Dispensing Volume Affects Overrun When Unit sits idle for a period of time and no drinks are dispensed CO gas in the system takes a set When first few drinks are drawn off after an idle period CO gas has less tendency to break out as drink is dispensed The result is these casual drinks have less overrun than drinks dispensed during peak use periods Carbonation Level in Liquid Product Affects
23. MENU SYR MIN 2 see note SYRUP MINUTES SIDE 2 NOTE Displaying SYR MIN 1 or SYR MIN 2 on message display will indicate time in minutes syrup actually has been dispensed Refer to table and formula next page to calculate how much syrup has been dispensed 18 19 20 21 22 Press Press Press Press Press play 324229000 GALLONS A x SYRUP MINUTES Note A numbers are based upon a 4 4 to 1 water to syrup ratio Using the table to the left choose the A number that corresponds to your BRIX setting Multiply the A number by the syrup minutes reading to obtain the amount gallons of syrup used CANCEL DEFROST ADVANCE switch to advance and bring up RF SOL 1 on message display DEFROST SELECT switch Refrigeration relay clicks when switch is pressed CANCEL DEFROST ADVANCE switch to advance and bring up RF SOL 2 on message display DEFROST SELECT switch No 2 refrigeration solenoid clicks when switch is pressed CANCEL DEFROST ADVANCE switch to advance and bring up COMPRESS on Message dis 24 23 Press DEFROST SELECT switch Compressor and condenser fan motor will start and operate while switch is pressed 24 Press CANCEL DEFROST ADVANCE switch to advance and bring up H20 PUMP on message display 25 Press DEFROST SELECT switch Carbonator water pump relay on master circuit boa
24. 2 Disconnect carbonator tank water line from double liquid check valve assembly outlet 3 Remove double liquid check valve assembly from elbow in water pump outlet port Retain white tapered gasket inside inlet female end of double liquid check valve 4 Disassemble each check valve as shown in Figure 11 5 Wipe each part with clean lint free cloth Inspect each part especially ball for burrs nicks corrosion deterioration and other damage Discard ball seat and any damaged or suspicious parts and replace with new parts during reassemble 6 Reassemble liquid check valves as shown in Figure 11 ALWAYS INSTALL NEW BALL SEAT QUAD RING P N 312418 000 51 324229000 NOTE Make sure when assembling check valves together check valve female end with white tapered gasket inside is on inlet side of double liquid check valve assembly 7 Assemble check valves together DO NO OVERTIGHTEN 8 Make sure white tapered gasket is in place inside female end of double liquid check valve assembly then install check valve assembly on elbow in water pump outlet port 9 Connect carbonator tank water line to double liquid check valve assembly outlet DO NOT OVERTIGHTEN 10 Open CO cylinder and water inlet supply lines shutoff valves Check for water leaks and tighten any loose connections 11 Install Unit back panel by reversing removal procedure 12 Connect electrical power to Unit 13 Press both AUTO BLEND 1 and AUTO BLEND 2
25. CANCEL DEFROST ADVANCE switch to advance minute numbers to desired minutes time of day Press DEFROST SELECT switch to lock in minutes time of day on display 5 Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING POINT OF SALE DISPLAY MESSAGE see Figure 6 and Table 7 Note Point of sales display messages may be turned off by placing No 1 DIP SWITCH on master circuit board in OFF position and No 2 DIP SWITCH in position see Figure 6 and Table 5 and Table 7 19 324229000 Three point of sales display messages are available and the desired one may be programmed in to appear on the message display by placing No 1 and No 2 switches see Figure 6 Table 5 and Table 7 on the DIP SWITCH ASSEMBLY in the appropriate positions ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT Adjusting VIS SET PRODUCT VISCOSITY determines what product consistency of the dispensed product will be present in each freeze cylinder Adjust VIS SET PRODUCT VISCOSITY of the dispensed product as fol lows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up VIS SET on message display 2 Press DEFROST SELECT switch to bring up numbers on message display NOTE The direction of arrows lt gt on message display indicates which set of numbers belongs to which freeze cylinder A No 4 setting indicates the thinnest product consis
26. CO see Figure 2 regulator regulates CO pressure to soft drink tanks also to bag in box syrup system if used and secondary CO regulators located inside Unit If necessary to adjust primary CO regulator adjust as instructed in INSTALLATION SECTION Secondary CO Regulators The three secondary CO regulators see Figures 2 and 8 regulate CO pressure to carbonator and product blender tanks If necessary to adjust secondary CO regulators adjust as instructed in INSTALLATION SEC TION BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT BRIX is Water to Syrup Ratio mixture of dispensed product If necessary to adjust BRIX adjust as instructed in INSTALLATION SECTION VIS SET PRODUCT VISCOSITY SETTING VIS SET PRODUCT VISCOSITY SETTING adjustment determines the product consistency of the dispensed product Adjust product viscosity as instructed in INSTALLATION SECTION PRODUCT CARBONATION Carbonation of dispensed product can also be varied to the customers preference If necessary to readjust product carbonation adjust as instructed in SERVICE AND MAINTENANCE SECTION ADJUSTING BEATER MOTOR CURRENT EITHER SIDE Beater motors currents readouts displayed on message display must be adjusted to read 150 2 as instructed in INSTALLATION SECTION PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS see Table 4 may be brought up on message display as instructed in INSTAL LATI
27. Carbonator plain water inlet adjustable water pressure regulator is factory adjusted to 45 psi and should not be readjusted 324229000 44 ADJUSTING CARBONATED WATER FLOW RATE The black carbonated water flow regulators see Figures 2 and 12 which control carbonated water flow rate into product blender tanks are factory adjusted for flow rate of 1 5 0 05 ounces per second and normally do not require adjustment However if adjustment is necessary proceed as follows 1 10 11 12 13 14 15 16 17 18 19 20 21 Press applicable OFF 1 or OFF 2 switch to prevent more product from entering applicable product blender tank Disconnect Unit syrup inlet line from applicable soft drink tank Remove applicable side panel from Unit as instructed for access to applicable carbonated water flow regulator product shutoff valve and product sample valve Close applicable product shutoff valve to prevent more product from entering freeze cylinder Place container under applicable product sample valve Open valve and allow all product to be purged from product blender tank then close valve Remove lower front access panel as instructed for access to secondary regulators Note pressure setting on secondary CO regulator with 60 psi gage for product blender tanks Turn regulator adjusting screw out counterclockwise until gage reads 0 Pull up on applicable product blender tank relief valve to
28. Overrun The higher the specific carbonation level in a given product the greater the potential for carbonation breakout in frozen carbonated form of that drink For example drinks with 3 0 volume of carbonation will have more gas breakout in frozen carbonated form and more overrun than will drinks that contain 2 0 volumes of CO gas 324229000 32 Freezing Affects Overrun Freezing causes approximately a 10 percent expansion in dispensed frozen carbonated drink The degree of freezing is limited because finished drink is intended to be sipped through a straw This is not possible if product is too solid OPERATING CHARACTERISTICS The product viscosity product consistency can be varied by adjustment and secondary CO regulator setting from a high overrun light drink to a wet heavy drink The length of freezing cycle and amount of CO present in product combine to create drink dispensed The dispensed product will have a normal variance due to the fol lowing conditions 1 If some time has elapsed since last drink was drawn from particular freeze cylinder and compressor has not cycled on the drink dispensed will have a tendency to be wetter have slightly less overrun than normal for the setting and will not mound up as high See Drawing 1 NOTE A cylinder freeze up may be expected under casual draw conditions if an attempt is made to eliminate drink described above by adjusting viscosity 2 If product is drawn from
29. Strict attention must be observed in the prevention of carbon dioxide gas leaks in the entire and soft drink system If a gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation 1 Unscrew protector cap with chain attached from CO cylinder valve Before installing primary CO regulator on cylinder open CO cylinder valve slightly counterclockwise to blow away any dirt or dust from regu lator outlet fitting then close valve 2 Remove shipping plug from primary CO regulator assembly coupling nut and make sure gasket is in place inside nut Install regulator assembly on CO cylinder so gages can be easily read then tighten coupling nut DO NOT OPEN CO CYLINDER VALVE AT THIS TIME CONNECTING CO INLET LINE ITEM 12 TO FCB OVERCOUNTER DISPENSER 1 Route COs INLET LINE item 12 up through hole in bottom of Unit base to secondary CO regulator assem bly 2 Connect inlet line to elbow in secondary regulator assembly inlet Seal connector with TAPERED GASKET WHITE item 1 3 Connect other end of inlet line to manifold on primary regulator assembly installed on cylinder Seal connection with TAPERED GASKET WHITE item 1 CONNECTING PLAIN WA
30. and may be programmed into Unit by placing No 1 and No 2 switches on DIP SWITCH assembly on master circuit board in appropriate positions Program point of sale display messages into Unit as instructed in INSTALLATION section ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT Adjusting VIS SET PRODUCT VISCOSITY determines what product consistency of the dispensed product will be present in each freeze cylinder Adjust VIS SET PRODUCT VISCOSITY of the dispensed product as instructed in INSTALLATION section VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT IN FREEZE CYLINDERS VIS READ actual viscosity readout may be brought up on the message display to actually read the viscosity product consistency of product in the freeze cylinders while the Unit is in operation as instructed in INSTALLA TION section DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be dis played on message display as instructed in INSTALLATION section 324229000 36 VOLTAGE DISPLAYED VOLTAGE READOUT Displayed voltage readout may be displayed on message display as instructed in INSTALLATION section PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE INTO UNIT DIAGNOSE DIAGNOSTIC MODE may be programmed into the Unit to check certain components for opera tion Progra
31. cylinder Remove knurled nuts securing faceplate assembly to freeze cylinder Hold waste container below freeze cylinder then pull faceplate off freeze cylinder and allow remaining sanitizing solution to drain from cylinder Being careful not to touch inside surface surface that goes inside freeze cylinder of faceplate assembly install faceplate on freeze cylinder and secure with knurled nuts Connect soft drink tank containing syrup into No 1 syrup system WARNING Flush residual sanitizing solution from syrup system as instructed Residual 29 30 31 32 33 34 35 36 37 solution left in system could create a heath hazard Press FILL 1 switch to fill No 1 syrup system syrup float switch with syrup SYRUP 1 fault message on message display will go out indicating syrup float switch has been filled with syrup Press AUTO BLEND 1 switch to fill No 1 Product blender tank with product Carbonator water pump will start and begin pumping carbonated water into product blender tank along with syrup to make product After carbonator water pump cycles off completely fill No 1 freeze cylinder with product by repeatedly pulling and releasing faceplate relief valve until product comes out of relief valve port Open dispensing valve until product flows from valve then close valve Open No 1 system product sample valve until product flows from valve then close valve Press WASH 1 switch to start No 1 fre
32. drink tank 2 connect soft drink tank into Unit syrup system A First connect CO quick disconnect to soft drink tank to pressurize tank B Second connect liquid quick disconnect to soft drink tank TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES Trouble Probable Cause Remedy ONE OR MORE CONTROL A Flat cable not properly A Properly connect flat cable to PANEL SWITCHES NOT connected to control switch control switch module or master OPERATING module or master circuit circuit board board B Flat cable connected between B Check cable for pinched or control switch module and broken wire condition and repair master circuit board pinched or replace as necessary and shorted out or broken wire in cable C Inoperable switch s on control Replace control panel switch panel switch module module D Master circuit board not D Replace master circuit board operating properly ALL CONTROL PANEL A Electric power disconnected A Restore electrical power to Unit SWITCHES NOT OPERATING from Unit B SECURITY SWITCH has B Press and hold SECURITY been pressed to activate SWITCH for 3 seconds to control panel switches restore control panel switches to operation C SECURITY SWITCH C Replace control panel switch inoperable control switches module deactivated 63 324229000 Trouble ALL CONTROL PANEL SWITCHES NOT OPERATING CONT D CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED
33. faceplate relief valve This bleeds from freeze cylinder and allows product to enter and fill cylinder 7 f necessary adjust BRIX product viscosity product consistency and product carbonation of dispensed product as instructed REPLENISHING SUPPLY WARNING CO displaces oxygen Strict attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire CO and soft drink system If a gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation 53 324229000 NOTE When indicator on primary cylinder regulator assembly 1800 psi gage is in shaded change CO cylinder portion of the dial cylinder is almost empty and should be changed 1 Fully close clockwise cylinder valve 2 Slowly loosen COs regulator assembly coupling nut allowing CO pressure to escape then remove regulator assembly from empty cylinder 3 Unfasten safety chain and remove empty CO cylinder 4 Position full cylinder and secure with safety chain WARNING To avoid personal injury and or property damage always secure CO cylinder in upright position with safety chain to prevent it from falling over Should valve become accidentally damaged or broke
34. health hazard in water system 1 Press OFF 1 and OFF 2 switches to stop freeze cylinders beaters and refrigeration systems 2 Disconnect electrical power from Unit 3 Close cylinder and water inlet supply line shutoff valve 4 Remove lower front access panel and left side panel as instructed for access to the water pump water strainer screen 5 Pull up on carbonator tank relief valve plastic cover to release CO pressure from tank 6 Pull strainer screen from screen retainer Clean any sediment from screen retainer and water pump port 7 Inspect strainer screen for holes restrictions corrosion and other damage Discard damaged strainer Screen 324229000 50 2 3 312419 4 312415 Washer 300 1 0 5 312418 Quad Ring Install new ball seat each servicing FIGURE 11 LIQUID CHECK VALVE ASSEMBLY 8 Check O ring on screen retainer Replace worn or damaged O ring P N 315349 000 NOTE Strainer screen should always be used otherwise particles could foul double liquid check valve 9 Install good or new strainer screen P N 315348 000 in screen retainer then screw retainer into water pump port and tighten securely 10 Proceed to SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE see Figures 2 and 12 1 Service water pump water strainer screen before servicing water pump double liquid check valve
35. in ON position Both freeze cylinders beater motors will start and operate and beat ers motors current ratings will be displayed on message display 2 Display should be adjusted to read A150 B15022 by adjusting MOTOR CURRENT ADJUSTMENTS located on No 1 and 2 relay circuit boards see FIGURE 6 These figures will fluctuate slightly with variations in line voltage and motor loads 3 After completion of adjusting beater motor current A150 B150 2 make sure No 5 MOTOR CURRENT SELF CALIBRATION switch on DIP SWITCH assembly on master circuit board see FIGURE 6 is in OFF position No 5 switch in OFF position allows the MOTOR CURRENT SELF CALIBRATION elec tronics to automatically self calibrate the beater motors currents at completion of each defrost cycle CAUTION IF NO 4 BEATER MOTOR CURRENT READOUT SWITCH ON DIP SWITCH assembly is placed in position and beater motor current readings were A155 145 2 and switch was then placed back in OFF position without readjusting to A150 B150 2 beater motor current has just been reset at A155 B145 Operating the FCB Dispenser at these current readings may have serious effects on its operation 324229000 16 ANY TIME THE 4 BEATER MOTOR CURRENT READOUT SWITCH ON DIP SWITCH ASSEMBLY IS PLACED IN ON POSITION THE BEATER MOTOR CURRENT READINGS MUST BE READJUSTED TO A150 B150 2 AS INSTRUCTED THEN SWITCH MUST BE PLACED BACK IN THE OFF POSITION
36. release CO pressure from tank Disconnect carbonated water line from outlet side of applicable carbonated water flow regulator Connect line long enough to reach to outside of Unit to water flow regulator outlet then route line to outside of Unit Place end of carbonated water line routed to outside of Unit in container Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to activate electrically operated carbonated water solenoid When steady stream of water is flowing from added length of line catch carbonated water in container graduated in ounces for exactly 10 seconds Press applicable FILL 1 or FILL 2 switch to deactivate carbonated water solenoid In 10 seconds 14 to 16 ounces of water should have been dispensed If adjustment is necessary loosen jam nut on carbonated water flow regulator Turn regulator adjusting screw to the left counterclockwise to reduce carbonated water flow rate or turn screw to the right clockwise to increase flow rate Tighten jam nut and tap on regulator to register adjustment Repeat steps 11 through 13 until desired carbonated water flow rate is achieved Remove added length of line from outlet side of carbonated water flow regulator Connect carbonated water line disconnected from carbonated water flow regulator in step 8 preceding to regulator outlet Turn product blender tanks regulator with 60 psi gage adjusting screw in clockwise until gage registers pressure no
37. switches 14 Press both AUTO 1 and AUTO 2 switches to start freeze cylinders beaters and refrigeration system REPLENISHING SYRUP SUPPLY NOTE Sugar free diet syrup cannot be used with this Unit Although syrup replenishing can be done anytime syrup supply must be replenished when either SYRUP 1 or SYRUP 2 fault messages are displayed on message display indicating either No 1 or No 2 syrup system soft drink tank is empty NOTE The following instructions are applicable only when replenishing syrup supply Refer to SYRUP FLAVOR CHANGE when changing syrup flavors 1 Press applicable OFF 1 or OFF 2 switch to stop applicable freeze cylinder beater and refrigeration system IMPORTANT The following and liquid disconnect and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows To disconnect soft drink tank from Unit syrup system A Disconnect liquid disconnect from soft drink tank NOTE Disconnecting liquid quick disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment B Second disconnect CO quick disconnect from soft drink tank To connect soft drink tank into Unit syrup system C First connect quick disconnect to soft drink tank to pressurize tank D Second connect liquid quick disconnect to soft drink tank 2 Disconnect inlet
38. will resume normal operation NOTE Automatic defrost sleep time and wake up time may be used in any combination together or separately FACEPLATE RELIEF VALVES The faceplate relief valves see Figure 7 located in each faceplate are spring loaded valves that protect freeze cylinders from accidental over pressure The relief valve is also used to manually bleed CO gas from freeze cylinder to atmosphere during filing with product and if gas pockets form in cylinder during operation PRODUCT SAMPLE VALVES The two product sample valves see Figures 2 and 8 located behind front lower access panel are manually operated lever type ball valves used to check product BRIX Turn valve lever to line up with attached line to open valve and at 90 angle with line to close valve PRODUCT SHUTOFF VALVES The two product shutoff valves located in lines leading from product blender tanks to freeze cylinders see Fig ures 2 and 8 are manually operated lever type ball valves and are used to prevent product from entering and filling freeze cylinders while adjusting BRIX of dispensed product Shutoff valve may also be used to shut off product to individual freeze cylinder for service and maintenance without disrupting operation of other freeze cylinder PRIMARY REGULATOR The primary CO regulator see Figure 2 controls pressure to soft drink tanks and Unit secondary CO2 regulators located behind lower front access panel gt
39. 00 4 B CD Y 7 Pdl we 2 FIGURE 19 FLOW REGULATOR ASSEMBLY 310198 133 Flow Regulator Ass y Syrup 310757 Flow Regulator Ass y Water 310477 Lock Nut 7 16 5 moss Sew 1 324229000 eC Pat 7 Piston used on Syrup Flow Regula tor Piston used on Water Flow Reg ulator 310482 313657 Quad Ring 03 612 1 0 by 03 103 C S 180025 310632 Adjusting Screw 10 11 2 1 318936 033 318936 039 Body Syrup Regulator Body Water Regulator 76 326136 Carbonator Tank and Linkage Assy 315961 Machine Screw SL RD HD No 4 40 by 1 1 8 in Long 77 HD Sems No 8 32 by 3 8 in Long 326135 Tank Carbonator 318362 Relief Valve 324229000 2 a FIGURE 21 DRIVE SHAFT ASSEMBLY 3 pi 3260144088 Drive Shaft Ass y 2 325291 Boot Rubber 3 326013 Shaft Ass y 324229000 78 FIGURE 22 CO REGULATOR ASSEMBLY 326097 CO Regulator Ass y and Bracket Secondary 2 Flavor 1 183287 Gage 60 PSI 183286 Gage 100 PSI 2 183449 CO Regulator Ass y 60 PSI Orange Includes 3 18 183412 CO Regulator 100 PSI Gold Includes 3 18 3 183040 Machine Screw Phil Fill Hd No 10 32 By 7 8 In Long 183233 059 Cover Kit Includes Nonremovable Adjusting Screw 315424 Adjusting Spring 60 PSI 183020 Adjusting Spring 100 PSI 7 Diaphram Ass y 12 183008 O Ring 489 I D By 070 C S
40. 255 OFF OFF Sensed on motor one Motor 2 High current gt 255 OFF OFF Sensed on motor two wo men II Lal The refrigeration system and carbonator shall continue to operate for 1 5 minutes after a water pressure loss has been detected If water pressure loss continues beyond 1 5 minutes the refrigeration system and carbonator will stop 27 324229000 OPERATORS INSTRUCTIONS This section covers the FCB Overcounter Dispenser operating controls and indicators dispensed product condi tions operating characteristics operation and maintenance NOTE No 1 freeze cylinder is left hand cylinder facing front of the Unit CONTROL PANEL SWITCHES AND DISPLAYED MESSAGES CONTROL PANEL SWITCHES Fill 1 and Fill 2 Control Switches WARNING Disconnect electrical power to the FCB Overcounter Dispenser to prevent personal injury before attempting any internal maintenance on the Unit Only qualified personnel should service internal components or electrical wiring FILL 1 and 2 control switches located on control panel see Figure 7 are touch type switches and re quire only pressing to activate FILL 1 and FILL 2 control switches are used when filling syrup systems sold out floats during syrup replenishing syrup flavor changeover or sanitizing syrup systems After syrup systems sold out floats have been filled FILL 1 and FILL 2 switches may be used to prevent more product from en tering product ble
41. 272 396 Tube Ass y see Flow Diagram see FIGURE 27 129 311304 s Gasket Black see Flow Dia gram 130 174061 196 Tube Ass y see Flow Diagram see FIGURE 27 135 324169 Tube Ass y see Gier see FIGURE 27 309854 Clamp 409 O D Tube see Plumbing Diagram 178025 200 Tapered Gasket Red see Plumbing Diagram 325576 Syphon Tube see Plumbing Diagram 1578 Tube Ass y see Plumbing Diagram see FIGURE 27 183008 O Ring 489 1 0 by 070 C S 324142 Tube Ass y see Plumbing Diagram see FIGURE 27 326098 Tube Connector see Plumbing Dia gram 324141 Tube Connector see Plumbing Dia gram 325558 Tube Ass y see Plumbing Diagram see FIGURE 27 186150 Machine Screw Phil Pan Hd No 8 32 By 3 8 In Long 326002 Drain Kit Drip Tray not shown 312251 Thread Rolling Screw Phil Pan HD No 10 24 by 3 8 in Long 343313 Washer R I D by 030 C S 324234 Guard Splash 3231 Strain Relief 176193 Ba 7 16 20 see Plumbing Dia gram 325069 Machine Screw SL Hex HD No 10 24 by 1 2 in Long 325145 Washer No 10 325644 Lug Ground 188346 Washer 192 1 0 160 1019 Wire Harness Not Shown Zinc plated steel unless indicated otherwise Sold in bulk quantity 324229000 CAUTION ITEMS 6 AND 7 ARE A MATCHED SET DO NOT REPLACE SEPARATELY FOR SYRUP FLOW REGULATOR USE SLEEVE AND PISTON ASS Y P N 315553000 FOR WATER FLOW REGULATOR USE SLEEVE AND PISTON ASS Y P N 3134370
42. 325725 Bracket Regulators 189429 Hex Nut 1 4 20 186770 Machine Screw Phil RD HD No 10 24 by 5 8 in Long 326097 Regulator Ass y see FIGURE 22 324124 Bracket Float 320776 Strap Tube 325726 Access Panel 150918 Machine Screw SL Truss HD Stain less Steel No 8 32 by 3 8 in Long 320754 Drain Tube Stainless Steel 324157 Pump and Motor Ass y 115V 60HZ see FIGURE 23 2114 Pump and Motor Ass y 230V 50HZ see FIGURE 23 Electrical Box Door Ass y see FIGURE 25 320553 001 Hex Nut 7 16 14 320916 Washer 450 1 0 324171 Relay Start 115V 50HZ 326071 Solenoid Valve 324122068 80 324199 115 50 2 322967 Washer 6 OVERCOUNTER FCB EVAPORATOR UNIT No 6 32 by 1 in Long m 25 Leg not shown Pressure Switch CO 91 Tapered Gasket White Support P C Board Nut No 8 32 Cover Electrical Pressure Regulator Water Tube Ass y see Plumbing Diagram 770716 020 Fitting 7 16 Female by 5 8 18 see Plumbing Diagram 325777 Pressure Switch Water 8 32 by 1 2 in Long 112 326130 Tube Ass y 114 Bracket Tank Bracket ft No 10 24 by 3 4 in Long 117 Switch Float Ass y see FIGURE 27 119 Wire Harness Carb not shown 125 311751 Machine Screw SL Hex HD No 4 40 by 1 4 in Long 75 126 326111 Sold Out Switch Ass y see Flow Dia gram 127 2815 Tube Ass y see Flow Diagram see FIGURE 27 128 176
43. 5 ADJUSTING CO2 REGULATORS opu De ets 45 ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT 2225 siway tol tute SA ua tet bre dki 46 PRODUCT CARBONATION ADJUSTMENT 46 CLEANING AND SANITIZING 47 DAILY CLEANING OF UNIT 47 SANITIZING SYRUP SYSTEMS 47 YEARLY OR AFTER WATER SYSTEM DISRUPTION 50 SERVICING CARBONATOR WATER PUMP WATER STRAINER SCREEN 50 SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VAPVE cheers at M UPS 51 REPLENISHING SYRUP SUPPLY 52 SYRUP FLAVOR CHANGE 315 6 9 303 ese 53 REPLENISHING SUPPLY 53 CLEANING CO2 GAS CHECK VALVES 54 REPLACING FREEZE CYLINDER BEATER DRIVE SHAFT BEAR 54 SHUTTING UNIT DOWN 22 54 REMOVING BEATER DRIVE MOTOR AND BEATER DRIVE SHAFT ASS Y FROM UNIT nc och ane ale muere o 54 INSTALLING BEATER DRIVE SHAFT BEARING ASSY 56 INSTALLING BEATER DRIVE SHAFT ASS Y AND BEATER DRIVE MOTORON UNIT ac unuqa 57 RESTORING UNIT OPERATION 57 REPLACING BEATER DRI
44. 7930 FAX 49 2173 77 438 GREECE 488 MESSOGION AVENUE AGIA PARASKEVI e 153 42 ATHENS GREECE 30 1 600 1073 FAX 30 1 601 2491 HONG KONG e 1104 TAIKOTSUI CENTRE 11 15 KOK CHEUNG ST TAIKOKTSUE HONG KONG e 852 789 9882 FAX 852 391 6222 ITALY VIA PELLIZZARI 11 1 20059 e 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 e 16 TUAS STREET SINGAPORE 2263 e 65 862 5542 FAX 65 862 5604 SPAIN POLIGONO INDUSTRAIL RIERA DEL FONOLLAR E 08830 SANT BOI DE LLOBREGAT BARCELONA SPAIN e 34 3 640 2839 FAX 34 3 654 3379 USA ONE CORNELIUS PLACE ANOKA MINNESOTA e 612 421 6120 FAX 612 422 3255 LD004 4 21 98 324229000 86 THIS PAGE LEFT BLANK INTENTIONALLY 87 324229000 IMI CORNELIUS INC EECHER CORPORATE HEADQUARTERS One Cornelius Place Anoka Minnesota 55303 6234 612 421 6120 800 238 3600
45. 8 to 242 VAC 50Hz single phase electrical circuit with a 30 amp minimum rated discon nect switch not provided used at 20 amps slow blow must be available to the Unit 3 The Unit must be placed in a location which will allow shortest possible refrigeration lines route from Unit to Remote Refrigeration Assembly 324229000 8 IMPORTANT Unit operating ambient temperature MUST NOT EXCEED 100 F Several means are available to achieve proper ambient temperature and air circulation through the Unit which are wall air intake grilles and ceiling exhaust fans air conditioning etc Consult local codes Circulating air required to cool the beater drive motors enters through louvers on back of Unit Restricting air from entering the Unit will decrease cooling of the beater motors 4 When placing Unit in operating location do not allow wall or obstruction to block louvers on back of Unit A minimum of 6 inches clearance must be allowed between back of Unit and wall or obstruction and a Mini mum of 12 inches must be provided above the Unit for service and maintenance REMOTE REFRIGERATION ASS Y The Remote Refrigeration Assembly must be located in a location which will allow shortest possible refrigeration lines route from Refrigeration Assembly to the FCB Overcounter Post Mix Dispenser Refer to Installation Instruc tions provided with the Remote Refrigeration Assembly INSTALLING FCB OVERCOUNTER DISPENSER Very carefully tilt Unit up a
46. CT See TABLE 7 BEATER MOTOR CURRENT READOUT ON Display current readout OFF No displayed current readout MOTOR CURRENT SELF CALIBRATION ON Disabled OFF Operating e nouso OOOO DEFROST ON Hot gas OFF Electric SERVICE USE Note Switch No 3 must be in OFF position for standard Units with pulse expansion valves Switch No 3 must be in ON position for older Units with mechanical expansion valves Table 6 BEATER MOTOR SELECT DISPLAYED MODEL MOTOR DESCRIPTION KLBER_60 Klauber Over under gear box with a GE wide range voltage motor FASV3 60 Fasco VW Over under gear box with a Fasco wide range voltage motor FASCWR 60 Fasco VW Standard gear box using a Fasco wide range voltage motor VW GE 60 Fasco VW Standard gear box with a GE 219 242 volt motor EMRSN 60 Emerson Over under gear box with an Emerson wide range motor e m m m m FASV3 50 Fasco VW Over under gear box with a Fasco wide range voltage motor KLBER_50 Klauber Over under gear box with a GE wide range voltage motor Standard gear box using a Fasco wide range voltage motor FASCWR 50 Fasco VW VW GE 50 Fasco VW EMRSN 50 Emerson Standard gear box with a GE 219 242 volt motor Over under gear box with an Emerson wide range motor Table 7 POINT OF SALE DISPLAY MESSAGES special messages contact you local sales representative 23 324229000 Table 8 TOTALS DISPLAYED CYCLES AND HOURS TOTALS
47. DUCT 35 VIS SET PRODUCT VISCOSITY SETTING 35 PRODUCT CARBONATION 35 ADJUSTING BEATER MOTOR CURRENT EITHER SIDE 35 PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY 35 SETTING CLOCK TIME OF DAY 36 PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT 36 PROGRAMMING SLEEP SLEEP TIME INTO UNIT 36 PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT 36 PROGRAMMING POINT OF SALE MESSAGE DISPLAY 36 ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT a A 36 VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT FREEZE CYLINDERS entree ae ita eee ee 36 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 36 VOLTAGE DISPLAYED VOLTAGE READOUT 37 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE l RKROSS MEE 37 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY 37 PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT baies et Senders A eT ats 37 DISPLAYED ERROR CONDITIONS 37 PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELEGTRONIGS ere Di UE e EE er anne 37 WATER ST
48. EL DEFROST ADVANCE switch to bring up DIAGNOSE menu on message display Press DEFROST SELECT switch to lock in place The word MOTOR 1 will appear on message display Press DEFROST SELECT switch No 1 beater motor will start and operate while switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up the word MOTOR 2 on message display Press DEFROST SELECT switch No 2 beater motor will start and operate while switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up DEFROST 1 on message dis play Press DEFROST SELECT switch No 1 defrost relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up DEFROST 2 on message dis play Press DEFROST SELECT switch No 2 defrost relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up SYRUP 1 on message display Press DEFROST SELECT switch No 1 syrup solenoid relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up SYRUP 2 on message display Press DEFROST SELECT switch No 2 syrup solenoid relay will click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up WATER 1 message display Press DEFROST SELECT switch No 1 carbonated water solenoid relay w
49. HIDDEN SECURITY SWITCH MESSAGE DISPLAY CANCEL AUTO DEFROST DEFROST BLEND 2 SELECT ADVANCE FIGURE 5 CONTROL PANEL ADJUSTMENTS AND PROGRAMMING MAIN MENU SELECTIONS COMPONENTS DIAGNOSE DIAGNOSTIC MODE AND TOTALS DISPLAYED CYCLES AND HOURS TOTALS INTO UNIT NOTE The Unit control panel switches are as shown in FIGURE 5 The following instructions outline the adjustments programming and programming components diagnose into the Unit NOTE Plain water CO and syrup supplies to Unit must be satisfied to turn off OUT OUT SYRUP 1 and SYRUP 2 fault messages on message display before adjustments and programming procedures can be performed on the Unit PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS see Table 4 may be brought up on the message display as follows 1 Press AUTO 1 WASH 1 and BLEND 1 control switches see FIGURE 5 at the same time and hold them pressed for a minimum of 1 2 second to bring up MAIN MENU SELECTIONS on message display The word CLOCK will appear on display You are now in the MAIN MENU SELECTIONS shown in Table 4 To advance through the MENU SELECTIONS repeatedly press the CANCEL DEFROST ADVANCE switch Once you reach the desired selection press the DEFROST SELECT switch to lock in on the selection NOTE to exit MENU SELECTION and go back to MAIN MENU SELECTIONS press ERROR
50. IMI CORNELIUS INC One Cornelius Place 8 Anoka MN 55303 6234 Telephone 800 238 3600 Facsimile 612 422 3246 FCB OVERCOUNTER POST MIX DISPENSER WITH V3 ELECTRONICS Service Manual IMPORTANT TO THE INSTALLER It is the responsibility of the Installer to ensure that the water supply to the dispensing equipment is provided with protection against backflow by an air gap as defined in ANSI ASME A112 1 2 1979 or an approved vacuum breaker or other such method as proved effective by test Water pipe connections and fixtures directly connected to a potable water supply shall be sized installed and maintained according to Federal State and Local laws Part No 324229 000 January 9 1990 Revised March 3 1995 Control Code A THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment IMI CORNELIUS INC 1990 95 PRINTED IN U S A TABLE OF CONTENTS GENERAL DESCRIPTION 1 UNIT SYSTEM THEORY OF OPERATION DEFROST SYSTEMS aiat eh beech eras MANUAL DEFROST SYSTEM AUTOMATIC DEFROST SYSTEM SSLEEP SLEEP TIME ne ceed ue ad AS ee S WAKE UP WAKE UP TIME
51. L RED 12 2 RED besos L1 GND WHT BLK T Ll RED 55 BLK PE 524166000 324229000 62 TROUBLESHOOTING IMPORTANT Only qualified personnel should service internal components or electrical wiring the applicable product tank then relieve the system pressure before proceeding If repairs are to be made to the system stop dispensing shut off the supply then relieve the system pressure before proceeding If repairs are to be made to the refrigeration system make sure electrical power is disconnected from the unit WARNING If repairs are to be made to a product system remove quick disconnects from IMPORTANT The following and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows 1 To disconnect soft drink tank from Unit syrup system A Disconnect liquid disconnect from soft drink tank NOTE Disconnecting liquid quick discon nect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regu lator which may alter regulator adjustment B Second disconnect quick disconnect from soft
52. LATOR ASSEMBLY 79 FIGURE 23 PUMP AND MOTOR ASS Y 80 FIGURE 24 DOUBLE CHECK VALVE 81 FIGURE 25 FACEPLATE ASSEMBLY 82 FIGURE 26 DISPENSING VALVE ASSEMBLY 83 FIGURE 27 TUBING ASSEMBLY 84 LIST OF TABLES TABLE DESIGNIDATA Osee eel osse tele 2 TABLE 2 ACCESSORIES AND TOOLS 2 TABLE 3 LOOSE SHIPPED PARTS 7 TABLE 4 MAIN MENU SELECTIONS 18 TABLE 5 DIP SWITCH FUNCTIONS 23 TABLE 6 BEATER MOTOR 23 TABLE 7 POINT OF SALE DISPLAY MESSAGES 23 TABLE 8 TOTALS DISPLAYED CYCLES AND HOURS TOTALS MENU 24 TABLE 9 DISPLAYED ERROR CONDITIONS 27 324229000 vi GENERAL DESCRIPTION This section gives the description theory of operation and design data for the Two Flavor FCB Frozen Carbonated Beverage Overcounter Post Mix Dispenser with Electric Defrost hereafter referred to as a Unit IMPORTANT To the user of this manual This manual is a guide for installing operating and main taining this equipment Refer to the Table of Contents for page location for detailed
53. NS DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be dis played on message displays as follows 1 Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up SENSORS TEM PERATURES READOUT on message display 324229000 20 2 3 Press DEFROST SELECT switch to bring up evaporator refrigeration coils inlet and common outlet tem perature readings in degrees Fahrenheit Press ERROR RESET switch two times to exit from MENU SELECTIONS VOLTAGE DISPLAYED VOLTAGE READOUT Displayed voltage readout may be displayed on message display as follows 1 2 3 Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up VOLTAGE DIS PLAYED VOLTAGE READOUT on message display Press DEFROST SELECT switch to bring up voltage readout on message display Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE INTO UNIT DIAGNOSE DIAGNOSTIC MODE may be programmed into the Unit to check certain components for opera tion Program DIAGNOSE into Unit and check components for proper operation as follows 1 10 11 12 13 14 15 16 17 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up the word CLOCK on display Press CANC
54. ON CARBONATOR WATER PUMP MOTOR Carbonator water pump motor bearings must be lubricated periodically Refer to oiling instructions on motor DO NOT OVER OIL DISPENSING VALVES CAGED O RINGS AND BEATER DRIVE SHAFT SEALS ASSEMBLIES NOTE Defrost freeze cylinders shut Unit down close product shutoff valves in lines leading from product blender tanks to freeze cylinders then drain product from freeze cylinders Lubricate dispensing valves caged o rings see Figure 9 and beaters drive shafts seals assemblies see Figure 10 each time Unit is sanitized as follows NOTE Item numbers in parentheses in following steps 1 through 3 are in reference to Figure 3 1 Remove HEX NUTS item 7 and FLATWASHERS item 6 securing FACEPLATE item 8 to freeze cylinder then remove faceplate from cylinder 2 Carefully remove large O RING item 5 from FACEPLATE item 8 3 Unscrew RELIEF VALVE item 9 from FACEPLATE item 8 4 Disassemble dispensing valve see Figure 9 as follows A Remove two screws and hold down plates securing spring housing to dispensing valve body then remove housing Remove torsion spring from dispensing valve Carefully remove caged O ring from valve Remove knob spring sleeve and lever from dispensing valve Remove spring fitting from dispensing valve Press valve with caged O ring down and out of dispensing valve body G mg Carefully remove caged O ring from valve 5 Wash all parts in wa
55. ON section 35 324229000 SETTING CLOCK TIME OF DAY NOTE CLOCK TIME OF DAY must be programmed into Unit before DEFROST AUTOMATIC SLEEP SLEEP TIME and WAKE UP WAKE UP TIME can be programmed into the Unit Program CLOCK TIME OF DAY into Unit as instructed in INSTALLATION section PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT The automatic defrost system may be programmed into the Unit to occur up to nine different times during a day with a minimum of two hours between defrost time settings Program automatic defrost time settings into the Unit as instructed in INSTALLATION section PROGRAMMING SLEEP SLEEP TIME INTO UNIT SLEEP SLEEP TIME may be programmed into Unit to occur any time of the day after the Unit automatic defrost cycle has occurred Unit will shut down go into sleep time and will not wake up return to normal opera tion until programmed WAKE UP WAKE UP TIME has occurred Program SLEEP SLEEP TIME into Unit as instructed in INSTALLATION section PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT WAKE UP WAKE UP TIME May be programmed into Unit to occur any time of the day to wake Unit up re turn to normal operation after sleep time has occurred Program WAKE into Unit as instructed INSTALLATION section PROGRAMMING POINT OF SALE MESSAGE DISPLAY Three point of sale display messages are available to choose from
56. P SLEEP TIME SLEEP SLEEP TIME may be programmed into Unit to allow Unit to go into sleep time Unit shut down freeze cylinders beaters and refrigeration systems not operating At start of sleep time refrigeration compressor will operate for 30 seconds to pump freon out of freeze cylinders evaporator coils then both freeze cylinders will simultaneously go into defrost and defrost for approximately 15 minutes At end of defrost cycle Unit will go into sleep time 3 324229000 WAKE UP WAKE UP TIME WAKE UP WAKE UP TIME may be programmed into the Unit to allow Unit to resume normal operation at a desired time When programmed wake up time is reached an alarm will sound for a short duration then Unit will resume normal operation NOTE Automatic defrost sleep time and wake up time may be used in any combination together or separately 324229000 4 WATER PRESSURE REGULATOR IS FACTORY ADJUSTED TO 45 PSI AND SHOULD NOT BE READJUSTED SYRUP SOLD OUT SWITCHES ARE FACTORY ADJUSTED AND SHOULD NOT BE READJUSTED i J S 1 PRODUCT BLENDER TANK 2 E TANK PRODUCT SHUTOFF VALVE 2 FREEZE CYLINDER 2 CARBONATED WATER VOLUME SAMPLE CARBONATED WATER 1 LINE LEGEND PLAIN WATER CARB WATER E SYRUP P PRODUCT PRODUCT SAMPLE VALVE 2
57. PORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 20 VOLTAGE DISPLAYED VOLTAGE 21 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE NTO UNIT MES EE 21 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY 25 PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ne TEE 25 PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS Ee EE dures 26 DISPLAYED ERROR CONDITIONS 26 INSTALLING CONTROL BOX COVER AND BACK SIDES AND TOP PANELS ON UNIT aie rana ga Eo dal up maaa masis 26 OPERATORS INSTRUCTIONS 28 CONTROL PANEL SWITCHES AND DISPLAYED MESSAGES 28 CONTROL PANEL SWITCHES 28 CONTROL PANEL DISPLAY MESSAGES 29 FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS 30 MANUAL DEFROST SYSTEM 30 AUTOMATIC DEFROST SYSTEM 30 SLEEP SLEEP TIME OPERATION 30 WAKE UP WAKE UP TIME 81 FACEPLATE RELIEF VALVES 31 PRODUCT SAMPLE VALVES hte aches 31 PRODUCT SHUTOFF VALVES Ces tam ftia A su
58. RAINER SCREEN AND DOUBLE LIQUID CHECK VALVE 5 o a arah a aa a Ee a ee e Mx OR Meal eei xs 37 CLEANING CO2 GAS CHECK VALVES 38 iii 324229000 TABLE OF CONTENTS cont d Page SERVICE AND MAINTENANCE 39 PREPARING FCB OVERCOUNTER DISPENSER FOR SHIPPING STORING OR RELOCATING 39 PERIODIC INSPECTION 39 REMOVAL OF DRIP TRAY BACK PANEL SIDE PANELS TOP PANEL AND LOWER FRONT ACCESS PANEL AND CONDENSER COIL BC CESS PANEL ce sn aa an Sa wate tetas clade 39 DRIP TRAY a an 39 BACK PANEL Occ edita uyaq 39 SIDE PANELS Launa i e Ea E 39 TOP PAN EE C6 od Late laces A 39 LOWER FRONT ACCESS PANEL 40 LUBRICATION CENE CREER ORAE NOCHE 40 CARBONATOR WATER PUMP MOTOR 40 DISPENSING VALVES CAGED O RINGS AND BEATER DRIVE SHAFT SEALS ASSEMBLIES 40 CLEANING REMOTE REFRIGERATION ASS Y CONDENSER COIL 44 ADJUSTMENTS coast e reat thre 44 ADJUSTING PLAIN WATER PRESSURE REGULATOR 44 ADJUSTING CARBONATED WATER FLOW RATE 4
59. RATION Sa o Open product shutoff valve leading from product blender tank to freeze cylinder Connect electrical power to Unit Sanitize syrup system as instructed in CLEANING AND SANITIZING Press AUTO BLEND 1 and AUTO BLEND 2 to begin filling freeze cylinder Open freeze cylinder faceplate relief valve to bleed air from cylinder while filling with product then close valve Do not relieve freeze cylinder pressure too fast or product will foam excessively in cylinder and lose carbonation Press AUTO 1 and AUTO 2 switches to start freeze cylinder and refrigeration system Check for leaks and repair if evident Install back and side panels by reversing removal procedure Install coupling on new beater drive motor shaft then tighten Allen head setscrew securely MAKE SURE COUPLING IS INSTALLED ON MOTOR SHAFT SAME DISTANCE AS NOTED IN STEP 7 preceding REPLACING BEATER DRIVE SHAFT SEAL ASS Y see Figures 3 and 14 NOTE Use Beater Drive Shaft Assembly Alignment Tool Kit P N 0726 when installing beater drive shaft assembly 57 324229000 1 2 Refer to DISPENSING VALVES CAGED O RINGS AND BEATER DRIVE SHAFTS SEALS ASSEMBLIES under LUBRICATION for instructions to replace beater drive shaft seal assembly Sanitize syrup system as instructed in CLEANING AND SANITIZING REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR see Figures 8 and 14 1 2 3 4 8 10 11
60. RESET RE SET switch Press ERROR RESET RESET switch again to exit from MAIN MENU SELECTIONS SETTING CLOCK TIME OF DAY NOTE The CLOCK TIME OF DAY must be programmed into Unit before DEFROST AUTOMATIC SLEEP SLEEP TIME and WAKE UP WAKE UP TIME can be programmed into the Unit Program CLOCK TIME OF DAY into Unit as follows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up CLOCK on display Press DEFROST SELECT switch to lock in on selection 2 Press CANCEL DEFROST ADVANCE switch to bring up flashing hour number on display 17 324229000 Press CANCEL DEFROST ADVANCE switch to advance hours on display to desired hour Press DE FROST SELECT switch to lock in hour on display After hour time of day has been locked in on message display minute numbers will be flashing on display Press CANCEL DEFROST ADVANCE switch to advance minute numbers to desired minutes time of day Press DEFROST SELECT switch to lock in minute time of day on display Press ERROR RESET switch two times to exit from MENU SELECTION Press CANCEL DEFROST ADVANCE switch to bring up flashing hour number on display Table 4 Main Menu Selections MESSAGE DISPLAY MENU SELECTIONS EXAMPLE READOUTS CLOCK TIME OF DAY see note below I IO jI IO o o In IO gt gt
61. TER INLET LINE ITEM 13 TO FCB OVERCOUNTER DISPENSER see Figure 2 1 Route PLAIN WATER INLET LINE item 13 up through hole in bottom of Unit base to water pressure switch connected to water pressure regulator 2 Connect plain water inlet line to water pressure switch plain water inlet Seal connection with TAPERED GASKET BLACK item 2 NOTE IMI Cornelius Inc recommends that a water shutoff valve and water filter be installed in plain wa ter Inlet supply line see Figure 2 A Cornelius Water Filter P N 313860 000 and Quick Disconnect Set P N 313867 000 are recommended 3 Before connecting plain water inlet supply line to Unit open shutoff valve in water supply line for a period of time to flush out any metal shavings 4 Connect plain water inlet supply line to Unit plain water inlet line 11 324229000 YORE u pasn euo uey 1eujo sasayjueied 3108 HEYS Buuds Jeuuida JOSUSS MEODSIA jquuessy yeys saug MUN SANG 9 yeys SANG 01888 5 aag 1010 181898 nsed sajdnog t Buueeg EI LE Ge Ee Ge L 702 61 BL SANG LE Buwdno2 yeus 181888 9 Mejsjes PeaH GL eas yeys anug vt CL anea Bulsuedsig cb Lt JA07 SABA OL
62. UNTER DISPENSER Locate the FCB Overcounter Post Mix Dispenser so the following requirements are satisfied 1 Close to a filtered plain water inlet supply line with a minimum pressure of 12 psig 60 HZ UNIT IMPORTANT Power circuit voltage across black and white electrical wires inside electrical control box inside Unit must be in operating range of between 208 and 230 VAC 60Hz single phase for proper operation If voltage is below or above this range a 75 KVA Step Up Step Down Transformer P N 326138000 is available to correct below or above voltage condition 2 Close to a properly grounded 208 230 VAC 60Hz single phase electrical circuit with a 30 amp minimum rated disconnect switch not provided fused at 20 amps slow blow or power circuit wired through an equivalent HACR circuit breaker must be available to the Unit Use No 10 AWG copper wire or larger de pending upon line length in suitable conduit or BX sheath POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES MAKE SURE UNIT IS PROPERLY GROUNDED 50 HZ UNIT IMPORTANT Power circuit voltage across the black and white electrical wires inside electrical control box inside Unit must be in operating range of between 208 and 242 VAC 50Hz single phase range for proper operation If voltage is below of above this range a means to provide voltage within operating range must be provided A properly grounded 20
63. VE SHAFT SEAL 55 57 REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR 58 ADJUSTING CARBONATOR TANK LIQUID LEVEL 59 324229000 iv TABLE OF CONTENTS cont d Page TROUBLESHOOTING Tua anis KS EA aya uapa 63 TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT WEE 63 ONE OR MORE CONTROL PANEL SWITCHES NOT OPERATING 63 ALL CONTROL PANEL SWITCHES NOT OPERATING 63 CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED 64 PARTIAL MESSAGE OR DULL POORLY ILLUMINATED DISPLAY 64 ONE OR MORE FAULT MESSAGES NOT OPERATING 64 ALL FAULT MESSAGES NOT OPERATING 65 CO2 OUT FAULT MESSAGE GOES ON DURING OPERATION 65 2 OUT FAULT MESSAGE GOES ON DURING OPERATION 65 SYRUP 1 OR SYRUP 2 FAULT MESSAGE GOES ON DURING OPERATION Aerer iba 65 MOTOR 1 OR MOTOR 2 FAULT MESSAGE GOES DURING OPERATION En a CEU Ora 65 EVAPORATOR COIL SENSOR 1 OR 2 INLET OR COMMON OUTLET SENSOR 3 FAULT MESSAGE GOES ON DURING OPERATION 65 HEATER RL1 OR HEATER RL2 FAULT MESSAGE GOES ON DURING OPERATION d educ a m aS Seal Sean ard ea acy ca 65 REFRIG FAULT MESSAGE GOES ON DURING OPERATION 65 UNPLUG FAULT MESSAGE GOES ON DURING OPERATION 65 FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT OPERATE
64. able SENSOR or reconnect electrical wires to SENSOR Replace relay circuit board Refrigeration system problem Call Serviceman Disconnect electrical power from Unit then call Serviceman 324229000 Trouble FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT OPERATE UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN DEFROST SWITCH IS PRESSED DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING CANCEL DEFROST SWITCH 324229000 Probable Cause Loosen or broken electrical wires Inoperable automatic defrost timer Automatic defrost timer stuck in automatic defrost cycle Flat cable not properly connected to control switch module or master circuit board Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Inoperable DEFROST switch on control panel switch module Loose or broken wire Master circuit board not operating properly Flat cable not properly connected to control switch module or master circuit board Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Inoperable CANCEL DEFROST switch on control panel switch module Master circuit board not operating properly 66 Remedy Repair electrical wires Replace master circuit board Replace master circuit board
65. ank from Unit syrup system A Disconnect liquid soft drink tank NOTE Disconnecting liquid quick disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustments B Second disconnect CO quick disconnect from soft drink tank 2 To connect soft drink tank into Unit syrup system 33 324229000 A First connect quick disconnect to soft drink tank to pressurize tank B Second connect liquid quick disconnect to soft drink tank Syrup supply should be checked daily and if necessary replenished as instructed in SERVICE AND MAINTE NANCE SECTION SYRUP FLAVOR CHANGE Perform syrup flavor change as instructed in SERVICE AND MAINTENANCE SECTION CHECKING SUPPLY WARNING displaces oxygen Strict attention must be observed in the prevention of carbon dioxide gas leaks the entire and soft drink system If a gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of gas will experience tremors which are followed rapidly by loss of consciousness and suffocation Make sure CO cylinder shutoff valve is fully opened and regulator assembly 1800 psi gage indicator is not in shaded changed CO cylinder portion of dial If so CO cylinder is almost empty and must be replaced as instructed
66. ank into Unit syrup system C First connect quick disconnect to soft drink tank to pressurize tank D Second connect liquid quick disconnect to soft drink tank 3 Pressurize soft drink tanks containing syrup then connect tanks into Unit syrup systems OFF 1 OFF 2 SYRUP 1 and SYRUP 2 fault messages will continue to be displayed 4 The following steps a through are instructions for adjusting Brix Water to Syrup Ratio mixture of dis pensed product on one system NOTE Unit control panel is equipped with a hidden SECURITY SWITCH located between FILL 1 and ERROR RESET control switches see Figure 5 Pressing in and holding SECURITY SWITCH for 3 seconds deactivates control switches preventing tampering with Unit normal operation To reactivate control switches press in and hold SECURITY SWITCH for 3 seconds A Press FILL 1 switch to fill No 1 syrup system sold out float SYRUP 1 fault message will go out and FILL 1 fault message will come on OFF 1 and FILL 1 fault messages will continue to be dis played B Press AUTO BLEND 1 switch to fill No 1 product blender tank with product FILL 1 fault message will go out when AUTO BLEND 1 switch is pressed When product blender tank s full press FILL 1 switch to prevent more product from entering tank OFF 1 and OFF 2 and SYRUP 2 fault mes sages will continue to be displayed C Open 1 product blender tank pr
67. ate control switches Replace control panel switch module Upgrade voltage Properly connect flat cable to fault message module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace or repair external sensing device Make sure external sensing devices cable connectors are securely connected to master circuit board connectors Connect or repair wire between master circuit board connector and external sensing device Replace master circuit board Replace fault message display module Trouble ALL FAULT MESSAGES NOT OPERATING CO2 OUT FAULT MESSAGE GOES ON DURING OPERATION OUT FAULT MESSAGE GOES ON DURING OPERATION SYRUP 1 OR SYRUP 2 FAULT MESSAGE GOES ON DURING OPERATION MOTOR 1 OR MOTOR 2 FAULT MESSAGE GOES ON DURING OPERATION EVAPORATOR COIL SENSOR 1 OR 2 INLET OR COMMON OUTLET SENSOR 3 FAULT MESSAGE GOES ON DURING OPERATION HEATER RL1 OR HEATER RL2 FAULT MESSAGE GOES ON DURING OPERATION REFRIG FAULT MESSAGE GOES ON DURING OPERATION UNPLUG FAULT MESSAGE GOES ON DURING OPERATION Probable Cause No electrical power to Unit Flat cable not properly connected to fault message module or master circuit board Flat cable connected between fault message module and master circuit board pinched and shorted out or broken wire in cable Master circuit boa
68. bricate caged O ring Carefully install caged O ring on valve from straight end opposite tapered end Lubricate grooves in which O ring rides to fill in all void areas around O ring B Carefully install valve with caged O ring in dispensing valve body C Install spring fitting knob and lever parts torsion spring and spring housing assembly by reversing removal procedure Do not tighten down hold down plates securing spring housing at this time D Turn spring housing to the left counterclockwise to put tension on torsion spring then tighten hold down plates to secure spring housing E Test dispensing valve to make sure it closes by itself when lever is released If not readjust torsion spring tension 9 Thoroughly clean RELIEF VALVE item 9 then screw relief valve into FACEPLATE item 8 as shown in FIGURE 3 10 Service beater drive shaft seal assembly as follows NOTE Use Dow Corning DC 111 P N 321471 000 light grade silicone lubricant A BEATER item 13 and SCRAPER BLADES item 2 as shown in Figure from freeze cylinder B Pull beater drive shaft seal assembly from freeze cylinder socket using seal puller Cornelius P N 322063 000 from front side Disassemble shaft seal assembly and discard O rings NOTE If old lubricant cannot be removed from plastic sleeve by washing use nylon pot and pan scrubber 3M Company Scotchbrite or equivalent to remove residue Do not scrape sleeve Replace any s
69. coupling on new beater drive motor shaft then tighten Allen head setscrew securely MAKE SURE COUPLING IS INSTALLED ON MOTOR SHAFT SAME DISTANCE AS NOTED IN STEP 7 PRECEDING Place plastic power coupler in beater drive motor shaft coupling TAPE POWER COUPLER TO MOTOR SHAFT COUPLING TO PREVENT COUPLER FROM FALLING OUT DURING INSTALLATION OF MOTOR IN UNIT Very carefully slide beater drive motor shaft through hole in Unit frame up to coupling on end of beater drive shaft assembly Engage plastic coupler on end of beater drive motor shaft in coupling on end of beater drive shaft assembly 324229000 58 12 Secure beater drive motor to Unit frame with hex nuts and lockwashers 13 Connect beater drive motor electrical wiring to motor terminal block on Unit frame CAUTION The new beater drive motor is provided with a gear box vent that is plugged with a hex socket plug to prevent oil from leaking out of the gear box After beater drive motor has been installed remove hex socket plug and install vent plug loose shipped with beater drive motor 14 Remove hex socket plug from vent hole in beater drive motor and install loose shipped vent plug 15 Install back and side panels 16 Connect electrical power to Unit 17 Press AUTO BLEND 1 and AUTO BLEND 2 control switches then press AUTO 1 and AUTO 2 switches to start freeze cylinders beaters and refrigeration system ADJUSTING CARBONATOR TANK LIQUID LEVEL The carbonato
70. ct BRIX 5 CONSISTENCY VARIES EXCESSIVELY CYLINDER FREEZE UP varying because Syrup and Or water flow regulator sticking Dispensed product BRIX varying because Primary CO2 regulator pressure insufficient Cylinder freeze up causing ice formation in center of cylinder and liquid product channels around ice formation NOTE Defrost affected cylinder as instructed Clean regulator s Primary CO regulator must be adjusted from 80 to 100 psi Refer to CYLINDER FREEZE UP Refer to BRIX Water to Syrup Dispensed product too low Viscosity of dispensed product Ratio too low Adjust dispensed product viscosity as instructed Trouble not properly adjusted Probable Cause Remedy TROUBLESHOOTING REMOTE REFRIGERATION ASSEMBLY NOTE Refer to manual provided with the Remote Refrigeration Assembly for troubleshooting refrigeration assembly 69 324229000 THIS PAGE LEFT BLANK INTENTIONALLY 324229000 70 FCB OVERCOUNTER POST MIX DISPENSER WITH V3 ELECTRONICS MODEL NO 416116 xxx 496116 xxx ILLUSTRATED PARTS BREAKDOWN 71 324229000 FIGURE 18 OVERCOUNTER FCB EVAPORATOR UNIT 324229000 72
71. de beater into freeze cylinder so slotted hooks engage DRIVE PIN item 17 on DRIVE SHAFT item 24 Turn beater to the right clockwise to lock in place STATIONARY RUNNING O RING O RINGS STATIONARY O RING ur STAINLESS STEEL PLASTIC SLEEVE SEAL RETAINER VIEW A 1 4 4LOCKING TABS 2 90 APART 4 251075 180 APART 2 VIEW B FIGURE 10 SERVICING BEATER DRIVE SHAFT SEAL ASSEMBLY l Lubricate O RING item 5 with water to facilitate faceplate installation Position O RING item 5 on FACEPLATE item 8 Install faceplate on Unit so dispensing valve spout faces down MAKE SURE FEMALE END OF THE BEATER IS PLACED OVER THE FACEPLATE STAINLESS STEEL STUD AND BUSHING BEFORE PUSHING THE FACEPLATE INTO POSITION ON IT S FOUR THREADED MOUNTING STUDS Tighten hex nuts until faceplate touches freeze cylinder all around flange CAUTION DO NOT OVERTIGHTEN HEX NUTS 11 Open product shutoff valves leading from product blender tanks to freeze cylinders Fill freeze cylinders with product then restore Unit to operation CLEANING REMOTE REFRIGERATION ASS Y CONDENSER COIL The Remote Refrigeration Assembly connected to the FCB Overcounter Dispenser is equipped with a condenser coil that must be cleaned every 30 days Refer to manual provided with the Remote Refrigeration Assembly for condenser coil cleaning instructions ADJUSTMENTS ADJUSTING PLAIN WATER PRESSURE REGULATOR see Figures 2 and 12
72. ders beaters and refrigeration system 324229000 28 ERROR RESET Control Switch ERROR RESET control switch located on control panel see Figure 7 is a touch type switch and requires only pressing to activate ERROR RESET switch is used to restore normal operation after error within Unit has been corrected SECURITY SWITCH The Unit is equipped with a hidden SECURITY SWITCH located between FILL 1 switch and ERROR RE SET switch on control panel see Figure 7 Pressing in and holding SECURITY SWITCH for 3 seconds deactivates control switches preventing tampering with Unit normal operation To reactivate control switches press in and hold SECURITY SWITCH for 3 seconds CONTROL PANEL DISPLAY MESSAGES see Figure 7 FILL 1 and FILL 2 Fault Messages FILL 1 and FILL 2 fault messages will appear on message display only when FILL 1 and FILL 2 control switches have been pressed and syrup systems sold out floats have been filled with product FILL 1 and FILL 2 fault messages will continue to be displayed until AUTO BLEND 1 or AUTO BLEND 2 control switches have been pressed to fill product blender tanks with product ERROR Fault Messages An error fault message will appear on message display only if error within Unit has developed interrupting nor mal operation Error will have to be located and corrected then p
73. e 324229000 54 LIQUID CHECK VALVE 2 CARBONATED WATER SOLENOID RELIEF VALVE VALVE RELIEF VALVE CARBONATED WATER FLOW REGULATOR 2 S WATER PRESSURE REGULATOR PRODUCT BLENDER TANK 2 WATER PRESSURE SWITCH CARBONATOR TANK WATER PUMP MOTOR DOUBLE LIQUID CHECK WATER anaa ul Water pressure regulator is factory adjusted to 45 and should not be readjusted L FIGURE 12 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE 55 324229000 QUAD RING 183294 000 s BALL 183296 000 A SPRING 83297 000 RETAINER 183298 000 BODY 183295 100 Quad ring seal must be replaced each time check valve is serviced FIGURE 13 GAS CHECK VALVE 2 Remove hex nuts and lockwashers securing beater drive motor to Unit frame 3 Very carefully remove beater drive motor from Unit BE CAREFUL NOT TO LOSE PLASTIC COUPLER LOCATED BETWEEN BEATER DRIVE MOTOR SHAFT COUPLING AND BEATER DRIVE SHAFT ASSEMBLY COUPLING NOTE Items in parentheses are in reference to Figure 3 4 Remove HEX NUTS item 7 and FLATWASHERS item 6 securing FACEPLATE item 8 to freeze cylinder then remove faceplate 5 Remove beater shaft and scraper blades from inside freeze cylinder 6 Pull beater drive shaft seal assembly from socket in back of freeze cylinder using Cornelius Puller P N 322063 000 7 Pull beater drive s
74. ency of dispensed product to suit customer preference DEFROST SYSTEMS The Unit is equipped with both manual and automatic electric defrost systems The automatic defrost system ay be programmed into the Unit to occur up to nine different times during a day with a minimum of two hours be tween defrost time settings or the system may be completely turned off MANUAL DEFROST SYSTEM The Manual electric defrost system may be activated at any time by pressing DEFROST switch on front of the Unit Refrigeration compressor will operate for a short time then both freeze cylinders will go into defrost and defrost for approximately 15 minutes At end of manual defrost cycle Unit will return to normal operation Manu al defrost may be cancelled at any time by pressing CANCEL DEFROST switch AUTOMATIC DEFROST SYSTEM The automatic electric defrost system may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours between defrost settings At start of each automatic defrost cycle refrigeration compressor will operate for a short time No 1 freeze cylinder only will go into defrost cycle and defrost for approximately 15 minutes then will return to normal operation This ends automatic defrost cycle of No 1 freeze cylinder No 2 freeze cylinder will defrost 30 minutes after the start of No 1 freeze cylinder The next automatic defrost cycle will occur according to time programmed into the Unit SLEE
75. ent company requirements and sanitizer manufacturer s recommendations One or both syrup systems may be sanitized at one time for routine 90 days sanitizing requirements The following sanitizing instructions use No 1 syrup System as an example No 2 syrup systems sanitizing instructions are identical to No 1 syrup system with exception of using applicable system switches Proceed as follows 1 Press OFF 2 switch to stop beater motor and refrigeration in No 2 freeze cylinder which is not to be defrosted OFF 2 fault message will appear on message display 2 Press DEFROST switch to start defrost cycle on No 1 freeze cylinder DEFROST 1 message will appear on message display as long as defrost cycle is in progress 3 Immediately press AUTO 2 control switch to restart beater in No 2 freeze cylinder Refrigeration in No 2 cylinder will not be operating 4 Remove right hand side panel as instructed for access to No 2 product blender tank product shutoff valve 5 Close No 2 product blender tank product shutoff valve to prevent product bleeding back into No 1 product blender tank during sanitizing procedure IMPORTANT The following CO and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows 47 324229000 To disconnect soft drink tank from Unit syrup system A Disconnect liquid soft drink tank NOTE Di
76. er pump cycles on then immediately close sample valve Total volume dispensed differential should be 7 to 20 ounces 8 Install back and side panels by reversing removal procedure 9 Press AUTO 1 and AUTO 2 switches to resume normal operation 59 324229000 RELIEF VALVE CARBONATED WATER ol SWITCHES ACTUATOR BRACKET LEVEL CONTROL SWITCHES 2 2 aa Q y O ACTUATOR BRACKET ADJUSTMENT SCREW FIGURE 15 CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT 324229000 60 PROCESS LINE 2 Ir L t FREEZE T a e waM REMOTE REFRIGERATION ASS Y P N 416117000 ELECTRONIC EXPANSION VALVE 2 lt INLET SENSOR 0 7 cs E Eee INLET SENSOR SENSOR NIE 2 FIGURE 16 REFRIGERATION FLOW DIAGRAM 61 324229000
77. et Line Plain Water Inlet Line oa Drain Fitting 7 18 Lockwasher Internal Tooth Hex Nut 5 8 32 EN 2 ES ES EX EX ES ES 10 E 13 Ea ES 16 KA 18 EE 20 IDENTIFICATION OF LOOSE SHIPPED PARTS 1 TAPERED GASKETS WHITE item 1 are used to seal connections when connecting syrup and CO to Unit 2 TAPERED GASKET BLACK item 2 used to connect plain water source to Unit 7 324229000 10 11 DRIP TRAY SUPPORTS item 6 to be installed on front of Unit and secured with THREAD CUTTING SCREWS item 5 DRIP TRAY item 4 to be installed on drip tray supports then CUP REST item 3 to be installed in drip tray SPANNER WRENCH FLOW REGULATORS item 9 is used to adjust flow regulators inside the Unit SPANNER WRENCH DISPENSING VALVE item 10 is used to remove shank nuts securing dispensing valves to faceplates CLEANING BRUSH item 11 is used to clean faceplates relief valves passages CO INLET LINE item 12 to be connected to secondary CO regulator assembly inside the Unit and con nection sealed with TAPERED GASKET WHITE item 1 PLAIN WATER INLET LINE item 13 to be connected to water pressure switch water inlet inside Unit and connection sealed with TAPERED GASKET BLACK item 2 LEVELING LEGS item 14 to be installed on bottom of Unit KIT DRIP TRAY DRAIN item 15 to be installed on drip tray as instructed SELECTING LOCATION FCB OVERCO
78. eze cylinder beater Allow beater to operate for five minutes then press OFF 1 switch to stop beater Disconnect soft drink tank containing syrup from No 1 syrup system Connect clean empty soft drink tank into No 1 syrup system Hold appropriate container under dispensing valve and dispense until all product has been dispensed from freeze cylinder As product level lowers in freeze cylinder partially close valve to avoid spurting Place waste container under No 1 system product sample valve Slowly open valve and purge remaining product out of product blender tank Disconnect empty soft drink tank from No 1 syrup system then release CO pressure from tank by pulling up on cover relief valve 49 324229000 38 Pull both freeze cylinder faceplate relief valves to release all pressure from cylinders 39 Remove knurled nuts securing faceplate assembly to freeze cylinder 40 Hold waste container below freeze cylinder then pull faceplate off freeze cylinder and allow remaining product to drain from cylinder 41 Being careful not to touch inside surface surface hat goes inside freeze cylinder of faceplate assembly install faceplate on freeze cylinder and secure with knurled nuts 42 Connect soft drink tank containing syrup into No 1 syrup system 43 Press FILL 1 switch to fill No 1 syrup system syrup float switch with syrup SYRUP 1 fault message on message display will go out indicating syrup float switch ha
79. filled with syrup to extinguish SYRUP 1 or SYRUP 2 fault messages DEFROST 1 or DEFROST 2 Display Messages DEFROST 1 or DEFROST 2 display messages will appear on message display if either freeze cylinder is in defrost mode DEFROST 1 or DEFROST 2 messages will remain on during defrost cycle and will disappear when cycle has ended POINT OF SALE Display Message Three POINT OF SALE display messages are available to choose from and may be programmed into Unit to appear on message display as instructed in INSTALLATION Common Outlet Temperatures Evaporator refrigeration coils inlet 1 and inlet 2 and common outlet temperatures may be displayed on control panel message display as instructed in INSTALLATION SECTION FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS The Unit is equipped with both manual and automatic electric defrost systems The automatic defrost system may be programmed into the Unit to occur up to nine times a day or system may be completely turned off MANUAL DEFROST SYSTEM The Manual electric defrost system may be activated at any time by pressing DEFROST switch on front of Unit Refrigeration compressor will operate for a short time then both freeze cylinders will go into defrost and defrost for approximately 15 minutes At end of manual defrost cycle Unit will return to normal operation Manu al defrost may be cancelled at any time by pres
80. freeze cylinder quite regularly its viscosity product consistency will be maintained at whatever viscosity adjustment was made within the normal variance of the compressor off and on cycle See Drawing 2 3 If product is drawn continuously from freeze cylinder and rate is approaching capacity of the dispensing unit overrun of drink will increase just prior to point capacity is exceeded and drink dispensed will turn slightly wetter OPERATING UNIT NOTE No 1 freeze cylinder is cylinder on left hand side facing front of Unit 1 Make sure H20 OUT fault message is not displayed on message display This indicates no water supply to Unit 2 Make sure COs OUT fault message is not displayed on message display This indicates no CO gas sup ply to Unit 3 Make sure SYRUP 1 or SYRUP 2 fault messages are not displayed on message display This indicates no syrup supply to Unit 4 Make sure AUTO BLEND 1 AUTO BLEND 2 AUTO 1 and AUTO 2 control switches are pressed for normal operation 5 Place cup under dispensing valve then dispense until cup is full of product 6 Make sure viscosity product consistency is as desired If not adjust as instructed REPLENISHING SYRUP SUPPLY IMPORTANT The following and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows 1 To disconnect soft drink t
81. g for operation and operation UNPACKING AND INSPECTION NOTE The FCB Overcounter Dispenser was thoroughly inspected before leaving the factory and the car rier has accepted and signed for it Any damage or irregularities should be noted at time of delivery or not later than 15 days from date of delivery and immediately reported to the delivering carrier Request a written inspection report from Claims Inspector to substantiate any necessary claim File claim with the delivering carrier not with IMI Cornelius Inc 1 Unpack FCB Overcounter Dispenser and remove all shipping tape and packing materials 2 Unpack LOOSE SHIPPED parts Make sure all items are present and in good condition Table 3 Loose Shipped Parts 1 178025100 311304000 317660000 317659029 319941000 325723000 Drip Tray Support 2353 Beater item 13 325457000 Scraper Blade item 2 151689000 322859000 325216000 174061196 176272396 324252000 Leveling Leg 326002000 Kit Drip Tray Drain includes items 16 20 170413000 151281000 170423000 19 140133000 Drain Hose Clamp 20 113500039 Drain Hose 1 2 in 1 0 by 60 in long NOTE Numbers in parentheses are in reference to items in Figure 3 Tapered Gasket White Tapered Gasket Black N 3 4 5 Cup Rest Drip Tray Thread Cutting Screw Hex Hd No 8 32 by 3 8 in long 7 Spanner Wrench Flow Regulator 10 1 2 3 14 5 Spanner Wrench Dispensing Valve Cleaning Brush Inl
82. g on display Press CANCEL DEFROST ADVANCE switch to advance minute numbers to desired minutes time of day Press DEFROST SELECT switch to lock in minute time of day on display 324229000 18 5 Press DEFROST SELECT switch then repeat steps 2 3 and 4 to program in next defrost time setting MAKE SURE A MINIMUM OF TWO HOURS IS MAINTAINED BETWEEN DEFROST TIME SETTINGS IF TIME SETTING OF LESS THAN TWO HOURS IS PROGRAMMED INTO THE UNIT A MOMENTARY ERROR MESSAGE WILL APPEAR ON THE MESSAGE DISPLAY WHEN OPERATOR TRIES TO EXIT DEFROST THE PROGRAM WILL NOT ALLOW THE OPERATOR TO EXIT THE DEFROST SETTING UNTIL THE LESS THEN TWO HOUR DEFROST TIME IS CORRECTED THE OPERATOR MUST PRESS CANCEL DEFROST ADVANCE SWITCH THEN REPEAT STEPS 2 3 and 4 TO PROGRAM COR RECTED DEFROST TIME INTO UNIT 6 Repeat step 5 as many times as necessary to program desired number of defrost time settings into the Unit 7 Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING SLEEP SLEEP TIME INTO UNIT SLEEP SLEEP TIME may be programmed into Unit to occur any time of the day after Unit automatic defrost cycle has occurred Unit will shut down go into sleep time and will not wake up return to normal operation until programmed WAKE UP WAKE UP TIME has occurred Program SLEEP SLEEP TIME into Unit as follows 1 Refer to PROGRAMMING MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up SLEEP o
83. h of product When product blender tank is 1 4 full of product press applicable FILL 1 or FILL 2 switch to prevent more product from entering product blender tank Repeat steps 6 and 7 preceding to check product sample for BRIX Repeat steps 7 through 10 preceding until proper BRIX adjustment is achieved Open product shutoff valve in line between product blender tank and freeze cylinder Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch Install Unit side panels and front lower access panel by reversing removal procedures PRODUCT CARBONATION ADJUSTMENT see Figures 2 and 8 Carbonation of dispensed product can also be varied to suit consumer preference by adjusting Unit carbonator secondary regulator as follows 324229000 46 IMPORTANT Carbonator tank secondary regulator must be adjusted 25 psi higher or more above product blender tanks secondary regulators pressure settings Carbonated water and syrup pressures must be able to overcome and vent product blender tanks head pressures while tanks are filling with carbonated water and syrup Carbonator tank secondary regulator not adjusted high enough will cause decreased flow of carbonated water into blender tanks which will increase BRIX of dispensed product 1 Remove Unit front lower access panel as instructed for access to carbonator secondary CO regulator with 100 psi gage 2 Observe pressure setting on carbonator secondary CO regu
84. haft assembly out back of freeze cylinder INSTALLING BEATER DRIVE SHAFT BEARING ASS Y see Figure 14 IMPORTANT Bearing retaining collar has a special cam action that locks it up tightly against bearing inner race when properly installed Cam action type bearing retaining collar prevents bearing inner race from turning on beater drive shaft and prevents drive shaft from working in and out of freeze cylinder causing a knock when in operation 1 Loosen Allen type setscrew securing bearing retaining collar on beater drive shaft Rotate collar slightly to the left counterclockwise to unlock cam action from bearing inner race then remove collar and bearing from shaft 2 Remove boot from old bearing and install on new bearing 3 Install new bearing with boot in place on beater drive shaft 4 Install bearing retaining collar as follows A Slide bearing retaining collar up on beater drive shaft to bearing inner race B Rotate bearing retaining collar to the right clockwise so its cam action locks it securely against bearing inner race When in locked position its Allen type setscrew must align with flat on beater drive shaft 324229000 56 C Tighten Allen type setscrew to secure bearing retaining collar on beater drive shaft INSTALLING BEATER DRIVE SHAFT ASS Y AND BEATER DRIVE MOTOR ON UNIT NOTE Use Beater Drive Shaft Assembly Alignment Tool Kit P N 0726 when installing beater drive shaft assembly 1 10 Lubrica
85. ill click when switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up WATER 2 on message display Press DEFROST SELECT switch No 2 carbonated water solenoid relay will click when switch is pressed 21 324229000 SERVICE USE ONLY APPLICABLE ELECTRIC OR GAS DEFROST SEE TABLE 5 10 9 8 7 USED DIP SWITCH MOTOR CURRENT SELF CALIBRATION SEE TABLE 5 ASS Y 4 BEATER MOTORS CURRENT READOUT SEE TABLE 5 3 SEE NOTE 2 POINT OF SALE MESSAGE DISPLAY SELECT SEE TABLE 7 MOTOR CURRENT ADJUSTMENT Jr RELAY CIRCUIT BOARD NO 2 2 4 MASTER CIRCUIT BOARD RELAY CIRCUIT 2 BOARD NO 1 NO 2 EVAPORATOR REFRIGERATION COIL INLET TEMPERATURE NO 1 EVAPORATOR REFRIGERATION COIL INLET TEMPERATURE NO 1 AND NO 2 EVAPORATOR COILS REFRIGERATION COMMON OUTLET TEMPERATURES Note Switch No 3 must be in ON position for standard Units with pulse expansion valves Switch No 3 must be in OFF position for Units with mechanical expansion valves FIGURE 6 MASTER AND RELAY CIRCUIT BOARDS 324229000 22 Table 5 DIP SWITCH FUNCTIONS SWITCH NO FUNCTION POINT OF SALE MESSAGE SELECT See TABLE 7 POINT OF SALE MESSAGE SELE
86. in SERVICE AND MAINTENANCE SECTION CLEANING AND SANITIZING DAILY CLEANING Daily or more often if necessary wash all external surfaces of Unit rinse with clean water then wipe dry with clean soft cloth DO NOT USE ABRASIVE TYPE CLEANERS Remove and wash drip tray and cup rest with warm water and mild detergent rinse with clean water then install them on Unit SANITIZING The Unit should be sanitized as instructed in SERVICE AND MAINTENANCE SECTION every 90 days and before and after storage periods following parent company requirements and sanitizer manufacturers recom mendations REMOTE REFRIGERATION ASS Y MAINTENANCE The Remote Refrigeration Assembly connected to the FCB Overcounter Dispenser is equipped with a condens er coil that must be cleaned every 30 days Refer to manual provided with the Remote Refrigeration Assembly for condenser coil cleaning instructions LUBRICATION CARBONATOR WATER PUMP MOTOR Carbonator water pump must be periodically lubricated as instructed in SERVICE AND MAINTENANCE SECTION 324229000 34 ADJUSTMENTS CARBONATED WATER FLOW RATE The black carbonated water flow regulators see Figures 2 and 8 which control carbonated water flow rate into product blender tanks are factory adjusted and normally do not require further adjustment If adjustment should become necessary adjust as instructed in SERVICE AND MAINTENANCE SECTION REGULATORS Primary CO Regulator The primary
87. inder beater motor new Unit installation or the new installed replacement motor After applicable beater motor Manufacturer s name has been selected press DEFROST SELECT switch which will match the beater motor to the Unit electronics The motor Manufacturer s name will no longer be blinking Press DEFROST SELECT switch to return to MOT_MFG1 Press CANCEL DEFROST ADVANCE switch to go from MOT_MFG1 to MOT_MFG2 represents No 2 freeze cylinder beater motor which will appear on the message display Repeat steps 2 through 6 to program in the correct beater motor Manufacturer s name for No 2 freeze cylin der PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS The Dispenser electronics must be programmed for the proper refrigeration pulse rate according to the type of refrigerant gas that has been installed in the refrigeration system Note Dispenser serial plate for the type of re frigerant gas that has been installed then proceed as follows to program the Dispenser 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up REF TYPE REFRIGERANT TYPE on the message display Press DEFROST SELECT switch to lock in on the selection The sub menu of refrigerant types that may be brought up on the MESSAGE DISPLAY from REF TYPE REFRIGERANT TYPE are as follows A R404A2HP V3 Dispenser with 2 H P Copeland Compressor and R 404A Refrigerant
88. information per taining to questions that arise during installation operation service or maintenance of this equipment UNIT DESCRIPTION The Unit see Figure 1 consists basically of two freeze cylinders each containing an internal beater driven by an electric motor one carbonator which feeds both carbonator blender tanks an electronically controlled automatic electric defrost system to defrost the freeze cylinders and interconnecting tubing components and fittings nec essary to regulate transfer and dispense product The components are attached to a steel frame and are en closed in a steel cabinet The cabinet panels are easily removed to facilitate installation and service and maintenance A transparent faceplate with an integral relief valve and a removable self closing dispensing valve is mounted on front of each freeze cylinder A removable drip tray with a cup rest is located directly below the dispensing valves IMPORTANT The Two Flavor FCB Post Mix Dispenser Evaporator Unit must be used in con junction with the Remote Refrigeration Assembly P N 416117XXX 60 HZ or 496117XXX 50 HZ The FCB Overcounter Dispenser freeze cylinders evaporator coils are connected by refrigeration lines to and are refrigerated by the Remote Refrigeration Assembly sanitized and all sanitizing solution must be purged from the syrup systems All water must also be purged from the plain and carbonated water systems A freezing ambient environment
89. is 1 4 to 3 8 inch higher than the back to eliminate gas pockets being trapped inside the freeze cylinder INSTALLING DRIP TRAY SUPPORTS AND DRIP TRAY see Figure 7 1 Install DRIP TRAY SUPPORTS item 6 on front of Unit and secure with THREAD CUTTING SCREWS item 5 2 Install DRIP TRAY item 4 on drip tray supports 9 324229000 INSTALLING DRIP TRAY DRAIN KIT item 15 Drill 5 8 inch diameter hole in bottom center of drip tray Install DRAIN FITTING item 16 in drip tray and secure with LOCKWASHER INTERNAL TOOTH item 17 and HEX NUT 5 8 32 item 18 Push DRAIN HOSE item 20 over drip tray fitting and secure with DRAIN HOSE CLAMP item 19 Unscrew protector cap with chain attached from CO cylinder valve Before installing primary regulator on cylinder open CO cylinder valve slightly counterclockwise to blow away any dirt or dust from regu lator outlet fitting then close valve Remove shipping plug from primary CO regulator assembly coupling nut and make sure gasket is in place inside nut Install regulator assembly CO cylinder so gages can be easily read then tighten coupling nut DO NOT OPEN CO CYLINDER VALVE AT THIS TIME NOTE Drip tray drain hose may be routed to a waste container but is not recommended due to sanita tion and cleaning problems Connection of drain hose to a permanent drain is most highly recom mended 6 7 Route drip tray drain hose to and connect to permane
90. isconnect soft drink tank from Unit syrup system A Disconnect liquid disconnect from soft drink tank NOTE Disconnecting liquid disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment 1 Perform sanitizing procedure on syrup system syrup flavor change will be made on as instructed in SERVICE AND MAINTENANCE A Second disconnect CO quick disconnect from soft drink tank To connect soft drink tank into Unit syrup system B First connect CO quick disconnect to soft drink tank to pressurize tank C Second connect liquid quick disconnect to soft drink tank 2 First pressurize soft drink tank containing new flavor syrup by connecting CO line to tank then connect Unit syrup inlet line to tank 3 Press applicable FILL 1 or FILL 2 switch to fill applicable No 1 or No 2 syrup system syrup float switch with syrup 4 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill applicable No 1 or No 2 system product blender tank with product 5 Press applicable AUTO 1 or AUTO 2 switch to start refrigeration system and beater in applicable No 1 or No 2 freeze cylinder CAUTION Do not relieve freeze cylinder pressure too fast or product will foam excessively in freeze cylinder and lose carbonation 6 After carbonator water pump cycles off intermittently pull and release applicable No 1 or No 2 freeze cylinder
91. just BRIX of dispensed product on No 2 system After com pleting BRIX on No 2 system OFF 1 and OFF 2 fault messages should continue to be displayed NOTE Syrup systems may be sanitized at this time as instructed in SECTION IV SERVICE AND MAINTE NANCE K Open product shutoff valves located in lines leading from product blender tanks to freeze cylinders L Press AUTO BLEND 1 and AUTO BLEND 2 switches to begin filling freeze cylinders Open freeze cylinders faceplates relief valves to bleed air from cylinders while filling with product then close valves Do not relieve freeze cylinder pressure too fast or product will foam excessively in cylinder and lose car bonation ADJUSTING BEATER MOTOR CURRENT EITHER SIDE Adjusting beater motor current either side procedure is very important and must be performed as instructed Be sure you fully understand the instructions before performing the current adjustments or doing any preventative maintenance current readings check Any current adjustments or preventative maintenance current readings check on the beater motor cur rent either side must be performed with both freeze cylinders fully defrosted A partially defrosted freeze cylinder will cause false current readings to be displayed on the message display Adjust beater motor current either side as follows 1 Place No 4 BEATER MOTOR CURRENT READOUT switch on DIP SWITCH assembly on master circuit board see FIGURE 6
92. k 13 Pull up on empty soft drink tank cover relief valve to release CO pressure from tank WARNING If powder type sanitizer is used it must be thoroughly dissolved with water prior to adding to soft drink tank NOTE Sanitizing solution is used in a more concentrated form because it will be diluted approximately four to one in product blender tank 14 Using clean empty soft drink tank prepare full tank of sanitizing solution using Chlor Tergent Oakite Product Inc or equivalent sanitizer Mix sanitizing solution by using 70 F to 100 F max plain water and 2 65 oz gallon sanitizer This mixture will provide 800 ppm of chlorine Sanitizing solution will be diluted to approximately 200 ppm inside product blender tank after carbonated water has been mixed with sanitizing solution 15 Shake sanitizing solution tank to thoroughly mix solution then connect tank into No 1 syrup system 16 Press FILL 1 switch to fill No 1 syrup system syrup float switch with sanitizing solution SYRUP 1 fault message on message display will go out indicating syrup float switch has been filled with sanitizing solution 17 Press AUTO BLEND 1 switch to fill No 1 product blender tank with sanitizing solution Carbonator water pump will start and begin pumping carbonated water into product blender tank which will dilute sanitizing solution also entering tank 324229000 48 20 21 22 23 24 25 26 27
93. lator gage 3 To lower CO pressure loosen regulator adjusting screw lock nut Turn adjusting screw to the left counterclockwise until pressure gage reads 15 psi below desired reading then turn screw to the right clockwise until gage reads desired pressure DO NOT SET CO REGULATOR PRESSURE BELOW 25 PSI HIGHER THAN PRODUCT BLENDER TANKS CO REGULATORS ARE ADJUSTED TO SEE PRECEDING IMPORTANT NOTE Tighten adjusting screw lock nut after each adjustment 4 raise CO pressure turn regulator adjusting screw to the right clockwise until gage reads desired pressure DO NOT SET PRESSURE HIGHER THAN 60 PSI Make sure primary CO regulator on cylinder is set at 80 to 100 psi Tighten adjusting screw lock nut after each adjustment 5 Install Unit front lower access panel by reversing removal procedure CLEANING AND SANITIZING DAILY CLEANING OF UNIT Daily or more often if necessary wash all external surfaces of Unit with a mild soap solution Rinse with clean water then wipe dry with a clean soft cloth DO NOT USE ABRASIVE TYPE CLEANERS Remove and wash drip tray in mild soap solution rinse with clean water then install drip tray on Unit SANITIZING SYRUP SYSTEMS NOTE The Unit should be sanitized every 90 days following Sanitizer Manufacturer s recommendation Use Chlor Tergent Oakite Products Inc or equivalent sanitizer The Unit should be sanitized every 90 days and before and after storage periods following par
94. leeve that has rough edges in O ring sealing areas RETAINING SPRING HOUSING SCREW 2 TORSION SPRING HOLD DOWN SPRING PLATE 2 DISPENSING 9 25 LEVER SLEEVE NG SPRING KNOB 2 CAGED O RING SCH VALVE S FIGURE 9 SELF CLOSING DISPENSING VALVE C Remove old lubricant from plastic sleeve and stainless steel seal retainer with paper towels Do not scrape the sleeve Wash sleeve retainer and socket and back of freeze cylinder in warm water 43 324229000 D Install No 1 stationary O ring in groove of plastic sleeve and No 2 stationary O ring in inner groove of stainless steel seal retainer Lubricate both O rings E Install new running O rings No 3 and No 4 in outer grooves of stainless steel seal retainer then lubricate O rings with generous amount of special light grade silicone grease F Slide stainless steel seal retainer in plastic sleeve until running O ring No 3 is just covered by plastic sleeve as shown in View B of Figure 10 G Carefully place shaft seal assembly over beater drive shaft and locate slots of seal retainer on drive shaft pin Then carefully and simultaneously push and turn plastic sleeve to locate locking tabs on sleeve in notches of freeze cylinder retainer When tabs are seated in notches press assembly firmly in place H Position SCRAPER BLADES item 2 on BEATER item 13 as shown in Figure 3 Sli
95. m DIAGNOSE into Unit and check components for proper operation as instructed in INSTALLA TION section DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY TOTALS DISPLAYED CYCLES AND HOURS TOTALS may be displayed on the message display as instructed in INSTALLATION section PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS Note in TABLE 6 BEATER MOTOR SELECT the number of freeze cylinders beater motors Manufacturer s that are listed Your Unit was manufactured and equipped with motors from one of these Manufacturer s A re placement freeze cylinder beater motor is also manufactured by one of these Manufacturer s listed NOTE THE MANUFACTURER S ON THE MOTOR S THE BEATER MOTOR S MANUFACTURER S NAME S MUST BE PROGRAMMED INTO THE UNIT WHICH WILL MATCH THE MOTOR S TO THE UNIT ELEC TRONICS as instructed in INSTALLATION section DISPLAYED ERROR CONDITIONS Displayed error conditions associated errors and items affected by the errors are found in Table 9 DIS PLAYED ERROR CONDITIONS PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS The Dispenser electronics must be programmed for the proper refrigeration pulse rate according to the type of refrigerant gas that has been installed in the refrigeration system Note Dispenser serial plate for the type of re frigerant gas that has been installed then proceed to INSTALLATION section for programming ins
96. n message display Press DEFROST SELECT switch to lock in on selection 2 Press CANCEL DEFROST ADVANCE switch to bring up flashing hour number on display 3 Press CANCEL DEFROST ADVANCE switch to advance hours on display to desired hour Press DE FROST SELECT switch to lock in hour on display 4 After hour time of day has been locked in on message display minute numbers will be flashing on display Press CANCEL DEFROST ADVANCE switch to advance minute numbers to desired minutes time of day Press DEFROST SELECT switch to lock in minutes time of day on display 5 Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT WAKE UP TIME may be programmed into Unit to occur any time of the day to wake Unit up return to normal operation after sleep time has occurred Program WAKE UP into Unit as follows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up WAKE UP on message display Press DEFROST SELECT switch to lock in on selection 2 Press CANCEL DEFROST ADVANCE switch to bring up flashing hour number on display 3 Press CANCEL DEFROST ADVANCE switch to advance hours on display to desired hour Press DE FROST SELECT switch to lock in hour on display 4 After hour time of day has been locked in on message display minute numbers will be flashing on display Press
97. n electrical power to Remote Refrigeration Assembly at disconnect switch 2 Turn on electrical power to FCB Overcounter Dispenser at disconnect switch Operational status of Unit is now being displayed as fault messages on control panel message display The following fault messages will be continuously displayed at 2 second intervals until necessary operation requirements are satisfied OFF 1 Beater Motor No 1 not operating OFF 2 Beater Motor No 2 not operating H2O OUT No water supply to Unit CO OUT No gas supply to Unit SYRUP 1 No syrup supply to Unit No 1 syrup system SYRUP 2 No syrup supply to Unit No 2 syrup system ADJUSTING PRIMARY AND SECONDARY CO REGULATORS NOTE to readjust CO regulator to a lower setting loosen adjusting screw lock nut then turn screw to the left counterclockwise until pressure gage reads 5 psi lower than new setting will be Turn adjusting Screw to the right clockwise until gage register new setting then tighten lock nut Adjusting Primary CO Regulator IMPORTANT If bag n box syrup supply system will be connected to Unit instead of soft drink tanks primary regulator see Figure 2 must be adjusted no higher than 80 psi maximum 1 Open CO cylinder valve slightly to allow lines to slowly fill with gas then open valve fully to back seat valve Back seating valve prevents leakage around valve shaft 2 Adjust primary COs regulator see Figure 2 by tur
98. n off CO cylinder can cause serious personal injury 5 Make sure gasket is in place inside CO regulator coupling nut then install regulator on CO cylinder 6 Open counterclockwise cylinder valve slightly to allow lines to slowly fill with gas the open valve fully to back seat valve Back seating valve prevents leakage around valve shaft 7 Check CO connections for leaks Tighten loose connections CLEANING CO GAS CHECK VALVES see figures 2 and 12 The CO gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO system ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED REPLACING FREEZE CYLINDER BEATER DRIVE SHAFT BEAR see Figures 3 10 and 14 SHUTTING UNIT DOWN 1 Press DEFROST switch to defrost product in freeze cylinders 2 After defrost cycle is completed press OFF 1 and OFF 2 control switches to stop refrigeration system beaters motors 3 Disconnect electrical power to Unit 4 Remove back and side panels as instructed 5 Close product shutoff valve leading from product blender tank to freeze cylinder beater drive shaft will be removed from 6 Drain product from freeze cylinder REMOVING BEATER DRIVE MOTOR AND BEATER DRIVE SHAFT ASS Y FROM UNIT 1 Tag beater drive motor electrical wiring for identification then disconnect wiring from motor terminal block on Unit fram
99. nd install LEVELING LEGS item 14 in four corners of the Unit base INSTALLING BEATERS item 7 AND SCRAPER BLADES item 8 see Figures 3 and 4 1 Remove four HEX NUTS and FLATWASHERS that secure each faceplate to freeze cylinders Pull face plates off freeze cylinders 2 Position two SCRAPER BLADES item 8 on BEATER item 7 as shown in Figure 4 3 Slide beater assembly into one of the freeze cylinders so beater slotted hooks engage DRIVE PIN on DRIVE SHAFT as shown in Figure 3 4 Repeat procedure outlined in step 3 preceding to assemble and install beater assembly in other freeze cylin der 5 Lubricate each faceplate O RING see Figure 3 with Dow Corning DC 111 light grade silicone to facilitate installing faceplates on freeze cylinders Position each FACEPLATE On freeze cylinders so dispensing valves faucets face down MAKE SURE FEMALE END OF THE BEATER IS PLACED OVER THE FACE PLATE STAINLESS STEEL STUD AND BUSHING BEFORE PUSHING FACEPLATE INTO POSITION ON IT S FOUR THREADED MOUNTING STUDS Secure each faceplate to freeze cylinders with four HEX NUTS and FLATWASHERS removed in step 1 preceding Tighten HEX NUTS until faceplates touch all the way around on freeze cylinder flanges CAUTION DO NOT OVERTIGHTEN HEX NUTS PLACING UNIT IN OPERATING LOCATION 1 Place Unit in operating location meeting requirements of SELECTING LOCATION 2 After Unit has been placed in operating location make sure front dispensing valve side
100. nder tanks during BRIX test AUTO BLEND 1 and AUTO BLEND 2 Control Switches AUTO BLEND 1 and AUTO BLEND 2 control switches located on control panel see Figure 7 are touch type switches and require only pressing to activate These switches are used to fill product blender tanks after sold out floats have been filled using FILL 1 and FILL 2 switches AUTO BLEND 1 and AUTO BLEND 2 switches must be pressed to operate freeze cylinders beaters and refrigeration system during normal operation WASH 1 and WASH 2 Control Switches WASH 1 and WASH 2 control switches located on control panel see Figure 7 are touch type switches and require only pressing to activate These switches are used to operate freeze cylinders beaters with no refrigera tion during sanitizing AUTO 1 and AUTO 2 Control Switches AUTO 1 and AUTO 2 control switches located on control panel see Figure 7 are touch type switches and require only pressing to activate These switches are used to operate freeze cylinders beaters and refrigeration system after cylinders have been filled with product Freeze cylinders beaters and refrigeration system may be stopped by pressing OFF 1 and OFF 2 switches OFF 1 and OFF 2 Control Switches OFF 1 and OFF 2 control switches located on control panel see Figure 7 are touch type switches and require only pressing to activate These switches are used to stop freeze cylin
101. ning regulator adjusting screw to the right clockwise until regulator gage reads 80 to 100 psig OUT OF warning light on control panel message display should have gone out 3 Pull up on product blender tanks relief valve to purge air from tanks Adjusting Product Blender Tanks Secondary CO Regulators 1 Remove Unit front lower access panel as instructed for access to product blender tanks secondary CO reg ulators with 60 psi gages see Figure 2 and 8 2 Product blender tanks secondary CO regulators with 60 psi gages have been factory set at 27 2 psi for best textured dispensed products If desired regulators may be reset to change texture of dispensed pro duct Adjusting Carbonator Secondary Regulator IMPORTANT Carbonator secondary regulator must be adjusted 25 psi higher or more above product blender tanks secondary CO regulators pressure settings Carbonated water and syrup pressures must be able to overcome and vent product blender tanks head pressures while tanks are filling with carbonated water and syrup Carbonator tank secondary regulator not adjusted high enough will cause decreased flow of carbonated water into blender tanks which will increase brix of dispensed product 324229000 14 1 Carbonator secondary CO regulator with 100 psi gage is factory set at 55 3 psi Carbonation of dis pensed product can be varied to suit consumer preference by readjusting the CO regulato
102. nt drain Place CUP REST item 6 in drip tray PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT DRINK TANKS see Figure 2 1 2 Remove back sides and top panel from Unit as instructed in SERVICE AND MAINTENANCE Route Unit syrup inlet lines labeled No 1 and No 2 out through hole provided in Unit base to soft drink tanks location Install liquid disconnects on ends of Unit syrup inlet lines DO NOT CONNECT SYRUP LINES TO TANKS AT THIS TIME CONNECTING 24 VAC ELECTRICAL CIRCUIT FROM REMOTE REFRIGERATION ASS Y TO FCB OVERCOUNTER DISPENSER 1 2 Route 24 VAC electrical circuit from Remote Refrigeration Assembly up through hole in Dispenser base to inside of Dispenser Connect 24 VAC power circuit electrical wires to labeled 24 V grey and red wires hanging out of Dispenser electrical control box CONNECTING REMOTE REFRIGERATION ASS Y REFRIGERATION LINES TO FCB OVERCOUNTER DISPENSER Connect refrigeration lines from Remote Refrigeration Assembly to refrigeration connectors on bottom of FCB Overcounter Dispenser 324229000 10 INSTALLING PRIMARY CO REGULATOR ASS Y ON CO CYLINDER see Figure 2 WARNING To avoid personal injury and or property damage always secure CO cylinder in upright position with a safety chain to prevent it from falling over Should the valve become accidentally damaged or broken off cylinder can cause serious personal injury WARNING CO displaces oxygen
103. oduct sample valve see Figures 2 and 8 and take sample approxi mately 6 ounces of product in cup NOTE Temperature compensated hand type refractometers P N 511004000 are available from The Cor nelius Company 15 324229000 D Check product BRIX with a temperature compensated hand type refractometer BRIX should read 14 3 If BRIX is not within tolerance adjust white syrup flow regulator for No 1 syrup system as follows E Loosen jamb nut on syrup flow regulator Turn regulator adjusting screw to the left counterclockwise no more than 1 8 turn at a time to reduce syrup flow rate or turn screw to the right clockwise no more than 1 8 turn to increase flow rate Tighten jamb nut on syrup flow regulator then lightly tap regulator to register adjustment F Place container under No 1 product sample valve Open valve and purge product out of product blend er tank line and valve then close valve OFF 1 OFF 2 and SYRUP 2 will continue to be dis played G Press AUTO BLEND 1 switch to run new batch of product into product blender tank When Product blender tank is full press FILL 1 switch to prevent more product from entering product blender tank OFF 1 OFF 2 and SYRUP 2 fault messages will continue to be displayed H Repeat steps c and d preceding to check product sample for BRIX Repeat steps f through h preceding until proper BRIX adjustment is achieved J Repeat steps a through i preceding to ad
104. r 1 Gs 2 IN 174103 Tube 250 1 0 by 8 in Long 3 174103 Tube 250 I D by 15 in Long EES lt aH 176001 Ferrule 40 Jaw for 395 O D Tube ES 176017 Swivel Nut 7 16 20 170104 Nipple for 250 1 0 Tube jee 770652 Fitting 1 4 Barb 7 16 20 85 324229000 WARRANTY IMI Cornelius Inc warrants that all equipment and parts are free from defects in material and workmanship un der normal use and service For a copy of the warranty applicable to your Cornelius Remcor or Wilshire prod uct in your country please write fax or telephone the IMI Cornelius office nearest you Please provide the equipment model number serial number and the date of purchase IMI Cornelius Offices AUSTRALIA 210 RIVERWOOD NSW 2210 AUSTRALIA e 61 2 533 3122 FAX 61 2 534 2166 AUSTRIA LANGEN FELDE 32 A 1222 VIENNA AUSTRIA e 43 1 233 520 FAX 43 1 2335 2930 BELGIUM BOSKAPELLEI 122 e 2930 BRAASCHAAT BELGIUM e 32 3 664 0552 FAX 32 3 665 2307 BRAZIL RUA ITAOCARA 97 TOMAS COELHO e RIO DE JANEIRO BRAZIL 55 21 591 7150 FAX 55 21 593 1829 ENGLAND TYTHING ROAD ALCESTER WARWICKSHIRE B49 6 EU ENGLAND e 44 789 763 101 FAX 44 789 763 644 FRANCE e 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 GERMANY e 49 2173
105. r as instructed in PRODUCT CARBONATION ADJUSTMENT 2 Pull up on carbonator tank relief valve plastic cover to purge air from tank STARTING FCB AND ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT 1 Open Plain water inlet supply line shutoff valve Check for water leaks and tighten or repair if evident H20 OUT fault message should have gone out but OFF 1 OFF 2 SYRUP 1 and SYRUP 2 fault mes sage will continue to be displayed IMPORTANT Product shutoff valves located in lines leading from product blender tanks to freeze cylinders see Figure 2 and 8 must be closed at this time Closing valves prevents product from filling freeze cylinders while checking BRIX of product in product blender tanks 2 Close product shutoff valves located in lines leading from product blender tanks to freeze cylinders to pre vent product from entering cylinders IMPORTANT The following CO and liquid disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows To disconnect soft drink tank from Unit syrup system A Disconnect liquid disconnect from soft drink tank NOTE Disconnecting liquid quick disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment B Second disconnect CO quick disconnect from soft drink tank To connect soft drink t
106. r tank liquid level pump cut in and cut out was adjusted at the factory and should require no further adjustment However if incorrect setting is suspected check and make necessary adjustments as follows 1 Remove Unit back and side panels as instructed for access to carbonator and carbonated water volume sample valve see Figures 2 and 8 2 To check carbonator tank total fill allow carbonator water pump motor to operate and fill tank with carbonated water After pump cycles off disconnect electrical power from Unit 3 Using container graduated in ounces open carbonator carbonated water sample valve and completely drain carbonator tank into container Total carbonated water volume dispensed should be 40 to 58 ounces maximum 4 If total carbonated water dispensed is below 40 ounces loosen screw securing level control switches actuator bracket see Figure 15 and move actuator bracket up slightly If more than 58 ounces maximum of carbonated water was dispensed move actuator bracket down then tighten screw MAKE ADJUSTMENTS IN SMALL INCREMENTS 5 Connect electrical power to Unit and allow carbonator tank to fill with water and until water pump cycles off 6 Repeat steps 2 through 5 preceding as many times as necessary until correct carbonated water volume adjustment is achieved 7 To check differential using container graduated in ounces open carbonated water volume sample valve and dispense into container until carbonator wat
107. rd clicks when switch is pressed 26 Press ERROR RESET switch two times to exit from MENU SELECTIONS DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY see Tables 4 and 8 TOTALS DISPLAYED CYCLES AND HOURS TOTALS may be displayed on message display as follows 1 Refer to PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY and bring up the word CLOCK on message display 2 Repeatedly press and release CANCEL DEFROST ADVANCE switch to advance through main menu until TOTALS menu appears on message display Press DEFROST SELECT switch to lock TOTALS menu in place The word COMP HRS will appear on message display 3 Press and hold DEFROST SELECT switch Compressor run hours will appear on message display 4 Press CANCEL DEFROST ADVANCE switch to advance and bring up COMP CYC on message dis play 5 Press and hold DEFROST SELECT switch Compressor cycles x 100 will appear on message display 6 Use CANCEL DEFROST ADVANCE switch to advance through remaining TOTALS DISPLAYED CYCLES AND HOURS TOTAL MENU see Table 8 Press DEFROST SELECT switch to obtain message display readings of the individual menu selections 7 Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS IMPORTANT Note in Table 6 the number of freeze c
108. rd no operating Fault message display module not operating properly supply turned off or exhausted Primary regulator set too low Inoperable CO pressure switch Water supply turned off or water pressure inadequate Plugged water filter or water pump strainer screen Inoperative water pressure switch Soft drink tank empty Error within Unit has developed interrupting normal operation Inoperable SENSOR or electrical wires disconnected from SENSOR Heater relay on relay circuit board not operating properly Refrigeration system operates over thirty minutes and does not cycle off Error within Unit has developed interrupting normal operation 65 Remedy Connect electrical power to Unit Properly connect flat cable to fault message module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace master circuit board Replace fault message display module Open CO cylinder shutoff valve or replenish supply as instructed Adjust primary CO regulator as instructed Replace CO pressure switch Turn on water supply or check water supply line pressure Change water filter or clean water strainer as instructed Replace water pressure switch Replenish syrup supply as instructed Locate and correct error then press ERROR RESET switch to restore normal operation Replace inoper
109. ress ERROR RESET to restore normal op eration Error fault message will disappear from display OFF 1 and OFF 2 Fault Messages OFF 1 and OFF 2 fault messages will appear on message display when either freeze cylinder beater is not oper ating H2O OUT Fault Message The Unit plain water inlet system contains a water pressure switch Should the plain water source to the Unit be disrupted or a water pressure drop occur will cause H20 OUT fault message to appear on message display Unit will continue to operate for 1 1 2 minutes after 2 OUT fault message has appeared and if water pressure has been restored or water pressure improved after 1 1 2 minutes Unit operation will shut down After plain water source has been restored or water pressure has improved Unit will resume operation and OUT fault message will disappear from message display COs OUT Fault Message CO OUT fault message will appear on message display when CO supply to Unit has been turned off or if CO pressure drops below 50 psi A minimum CO pressure of 75 psi must be available to Unit to extinguish CO OUT fault message 29 324229000 SYRUP 1 SYRUP 2 Fault Messages SYRUP 1 or SYRUP 2 fault messages will appear on message display if product tanks are not connected to Unit or product tanks are empty Syrup systems syrup float switches must be
110. ring carbonator tank fill cycle Water filter restricted 67 A Remedy Connect electrical power to Unit Check power source Press AUTO BLEND 1 or AUTO BLEND 2 switch Restore water supply to Unit Replenish supply as instructed Tighten connections or replace wires Check for proper line voltage Check restricted pump discharge Remove water pump from motor Rotate pump coupling shaft 180 degrees then reinstall pump Replace pump and or motor Replace level control switches Clean repair or replace balance mechanism Replace water pump and or motor Clean repair or replace balance mechanism Increase water inlet supply line pressure Water inlet supply line must have large enough I D Replace water filter 324229000 Trouble Probable Cause TROUBLESHOOTING DISPENSED PRODUCT BRIX WATER TO SYRUP RATIO TOO LOW BRIX WATER TO SYRUP RATIO TOO HIGH IMPROPER PRODUCT DISPENSED PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE IN ONLY SMALL AMOUNTS OR ONLY LIQUID FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING 324229000 A gt Quick disconnect not secure on soft drink tank Syrup flow regulator set too low Water flow regulator set too High Syrup flow regulators stuck Restriction in syrup line Syrup Baume not in proper range Syrup flow regulators set too high Water flow regulator set too low
111. rm water Remove all traces of syrup and lubricant especially from faceplate O rings and dispensing valve If parts are excessively coated wipe clean with paper towel to remove syrup and lubricant especially from caged O ring and dispensing valve Use BRUSH item 11 TABLE 3 to clean faceplates relief valve passages 6 Submerge all parts in four percent solution of approved sanitizing agent for time recommended by sanitizer manufacturer 324229000 40 AUTO BLEND 1 CANCEL ang DEFROST DEFROST BLEND 2 SELECT ADVANCE HIDDEN SECURITY SWITCH FAULT MESSAGE DISPLAY CONTROL PANEL SO TOP PANEL RETAINING SCREW 2 UPPER CONTROL BOX MASTER CIRCUIT L TOP PANEL BOARD S Co RELAY CIRCUIT BOARD NO 1 RELAY CIRCUIT BOARD NO 2 CONTROL PANEL FACEPLATE RELIEF VALVE 2 SIDE PANEL 2 FACEPLATE 2 DISPENSING VALVE 2 LOWER ACCESS PANEL CUP REST j Ss 2 SIDE PANEL RETAINING SCREW DRIP TRAY 4 FIGURE 7 OPERATING CONTROLS 41 324229000 RELIEF VALVE 2 RELIEF VALVE CARBONATOR TANK BEATER MOTOR 2 CARBONATOR WATER PUMP SECONDARY REGULATOR 3 FREEZE CYLINDER 2 FIGURE 8 UNIT INTERNAL COMPONENTS 324229000 42 7 Remove parts from sanitizing solution and place on clean paper towels NOTE Use Dow Corning DC 111 P N 321471000 light grade silicone lubricant 8 Assemble dispensing valve as follows A Lu
112. s been filled with syrup 44 Press AUTO BLEND 1 switch to fill No 1 product blender tank with product Carbonator water pump will start and begin pumping carbonated water into product blender tank along with syrup to make product CAUTION Do not relieve freeze cylinder pressure too fast or product will foam excessively in cylinder and lose carbonation 45 After carbonator water pump cycles off intermittently pull and release No 1 freeze cylinder faceplate relief valve This bleeds from freeze cylinder and allows product to enter and fill cylinder 46 Open No 2 Product blender tank product shutoff valve 47 Press both AUTO 1 and AUTO 2 switches to start both freeze cylinders beaters and refrigeration system Product will be ready for dispensing in approximately 10 Minutes 48 Install right hand side panel and front lower access panel by reversing removal procedure YEARLY OR AFTER WATER SYSTEM DISRUPTION SERVICING CARBONATOR WATER PUMP WATER STRAINER SCREEN see Figure 12 WARNING The carbonator water pump water strainer screen and double liquid check valve must be Inspected and serviced after any disruptions plumbing work earthquake etc to the water supply system and at least once a year under normal circumstances Water pump with no strainer screen or defective screen would allow foreign particles to foul the double liquid check valves CO gas could then back flow into water system and create
113. sce 31 PRIMARY CO2 REGULATOR 31 SECONDARY REGULATORS 31 CARBONATED WATER FLOW REGULATORS 81 SYRUP FLOW REGULATORS 32 DISPENSING VALVES ettet a ceti 32 DISPENSED PRODUCT CONDITIONS 32 OVERRUN AS APPLIED TO FROZEN CARBONATED BEVERAGES 32 324229000 ii TABLE OF CONTENTS cont d Page OVERRUN IS A VARIABLE 32 OPERATING CHARACTERISTICS 33 OPERATING UNLT Sa ata a dieters EE nie 33 REPLENISHING SYRUP SUPPLY 33 SYRUP FLAVOR CHANGE 34 CHECKING SUPPLY 34 CLEANING AND SANITIZING 34 DAILY CLEANING 34 SANIWIZING pee oneP CLER Ke RM MOERS 34 REMOTE REFRIGERATION ASS Y MAINTENANCE 34 LUBRICATION ie 34 CARBONATOR WATER PUMP 34 ADJUSTMENT Sec tne tedden upa pusa 35 CARBONATED WATER FLOW RATE 35 CO2 REGULATORS eee hei Seebeck Sea ei 35 BRIX WATER TO SYRUP RATIO OF DISPENSED PRO
114. sconnecting liquid quick disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustments B Second disconnect CO quick disconnect from soft drink tank To connect soft drink tank into Unit syrup system C First connect quick disconnect to soft drink tank to pressurize tank D Second connect liquid quick disconnect to soft drink tank 6 Disconnect soft drink tank containing syrup from No 1 syrup system 7 Connect clean empty soft drink tank into No 1 syrup system 8 Place waste container under No 1 cylinder dispensing valve nozzle Open dispensing valve and dispense all product from cylinder As product level lowers in cylinder partially close valve to avoid spurting 9 Remove Unit front lower access panel as instructed for access to No 1 product blender tank product sample valve 10 Place waste container under No 1 product blender tank product sample valve Slowly open valve and purge remaining product out of tank then close valve 11 Disconnect empty soft drink tank from No 1 syrup system 12 Refer to DISPENSING VALVES CAGED O RINGS AND DRIVE SHAFTS SEALS ASSEMBLIES under LUBRICATION and perform procedure to lubricate dispensing valve caged O ring and drive shaft seal assembly WARNING To avoid possible in jury or property damage do not attempt to remove soft drink tank cover until pressure has been released from tan
115. side the Unit gas pressure pushes syrup out of soft drink tanks through syrup sold out float switches through electrically operated syrup solenoid valves through adjustable syrup flow regulators and on to product blender tanks At the same time plain water passes through water pressure regulator and is pumped into carbonator tank by water pump and is carbonated by CO gas pressure also entering tank Carbonated water is pushed by CO gas pressure from carbonator tank through electrically operated carbonated water solenoid valves through adjustable carbonated water flow regulators and on to product blender tanks Carbonated water and syrup enter tanks properly proportioned blended for de sired BRIX of dispensed product by adjustment of syrup flow regulators From product blender tanks product is pushed by CO gas into freeze cylinders The beater in each freeze cylinder is driven by an electric motor Scraper blades attached to beaters scrapes product from cylinder walls as product enters freeze cylinders and is frozen Transparent faceplate attached to front of each freeze cylinder includes a self closing dispensing valve and a spring loaded relief valve that protects freeze cylinder from accidental over pressure The relief valve is also used to bleed CO gas pressure from freeze cylinder to atmosphere when filling cylinder with prod uct Electronic sensing on each freeze cylinder motor provides a means of adjusting viscosity consist
116. sing CANCEL DEFROST switch AUTOMATIC DEFROST SYSTEM The Automatic electric defrost system may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours between defrost settings At start of each automatic defrost cycle refrigeration compressor will operate for a short time No 1 freeze cylinder only will go into defrost cycle and defrost for approximately 15 minutes then it will return to normal operation This ends automatic defrost cycle of No 1 freeze cylinder No 2 freeze cylinder will defrost 30 minutes after the start of No 1 freeze cylinder The next automatic defrost cycle will occur according to time programmed into the Unit SLEEP SLEEP TIME OPERATION SLEEP SLEEP TIME may be programmed into Unit to allow Unit to go into sleep time Unit shut down freeze cylinders beaters and refrigeration systems not operating At start of sleep time refrigeration compres sor will operate for 30 seconds to pump freon out of freeze cylinders evaporator coils then both freeze cylinders will simultaneously go into defrost and defrost for approximately 15 minutes At end of defrost cycle Unit will go into sleep time 324229000 30 WAKE UP WAKE UP TIME WAKE UP WAKE UP TIME may be programmed into the Unit to allow Unit to resume normal operation at a desired time When the programmed WAKE time is reached an alarm will sound for a short duration then Unit
117. te beater drive shaft bearing boot with DOW CORNING DC 111 P N 321471000 light grade silicone lubricant Install beater drive shaft assembly in freeze cylinder Place plastic power coupler in beater drive motor shaft coupling TAPE POWER COUPLER TO MOTOR SHAFT COUPLING TO PREVENT COUPLER FROM FALLING OUT DURING INSTALLATION OF MOTOR IN UNIT Very Carefully slide beater drive motor shaft through hole in Unit frame up to coupling on end of beater drive shaft assembly Engage plastic coupler on end of beater drive motor shaft in coupling on end of beater drive shaft assembly Secure beater drive motor to Unit frame with hex nuts and lockwashers Connect beater drive motor electrical wiring to motor terminal block on Unit frame Refer to DISPENSING VALVES CAGED O RINGS AND BEATER DRIVE SHAFTS SEALS ASSEMBLIES under LUBRICATION and perform procedure to lubricate beater drive shaft seal assembly Carefully place shaft seal assembly over beater drive shaft and locate slots of seal retainer on drive shaft pin Then carefully and simultaneously push and turn plastic sleeve in notches of freeze cylinder retainer When tabs are seated in notches press assembly firmly in place Install beater shaft and scraper blades in freeze cylinder see Figure 4 Lubricate faceplate O ring with water to facilitate installation then install faceplate on Unit Secure faceplate with hex nuts and lockwashers DO NOT OVERTIGHTEN HEX NUTS RESTORING UNIT OPE
118. ted in step 7 preceding Pull relief valve on applicable product blender tank to purge air from tank then close valve Connect Unit syrup inlet line to soft drink tank Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill product blender tank with product Open product shutoff valve that was closed in step 4 preceding Install side panel and lower front access panel by reversing removal procedure ADJUSTING CO REGULATORS Primary CO Regulator The primary CO see Figure 2 regulator regulates CO pressure to soft drink tanks also to bag in box syrup system if used and secondary CO regulators located inside Unit If necessary to adjust primary CO regulator adjust as instructed in INSTALLATION SECTION 45 324229000 Secondary Regulators The three secondary CO regulators see Figures 2 and 8 regulate CO pressure to carbonator and product blender tanks If necessary to adjust secondary CO regulators adjust as instructed in INSTALLATION SECTION ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT see Figures 2 and 8 1 Remove Unit front lower access panel as instructed for access to product blender tanks secondary CO2 regulators and product sample valves Check product blender tanks secondary CO regulators with 60 psi gages for proper pressure settings which is set at 27 2 psi for best textured dispensed product If adjustment is necessary adjust as instructed
119. tency of dispensed product and a No 12 setting indicates the thickest consistency of product dispensed 3 Press CANCEL DEFROST ADVANCE switch The left side freeze cylinder viscosity number will be flash ing on message display 4 Press CANCEL DEFROST ADVANCE switch to advance viscosity number to desired setting Press DE FROST SELECT switch to lock in viscosity setting The right side freeze cylinder viscosity number will now be flashing 5 Press CANCEL DEFROST ADVANCE switch to advance viscosity number to desired setting Press DE FROST SELECT switch to lock in viscosity setting 6 Press ERROR RESET switch two times to exit from MENU SELECTIONS VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT IN FREEZE CYLINDERS VIS READ ACTUAL VISCOSITY READOUT may be brought up on message display to actually read the vis cosity product consistency of the product in the freeze cylinders while the Unit is in operation Bring VIS READ up on message display as follows 1 Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up VIS READ of product in freeze cylinders 2 Press DEFROST SELECT switch to bring up actual viscosity readout of product in each freeze cylinder Left Reading Refrigeration Coils Inlet No 1 Middle Reading Refrigeration Coils Inlet No 2 Right Reading Common Outlet 3 Press ERROR RESET switch two times to exit from MENU SELECTIO
120. this Unit the syrup systems must be sanitized and all sanitizing solution must be purged from the syrup systems All water must also be purged from the plain and carbonated water systems A freezing ambient environment will cause residual water in the Unit to freeze resulting in damage to internal components PERIODIC INSPECTION 1 sure CO cylinder valve is fully opened and primary CO cylinder regulator assembly 1800 psi gage indicator is not in shaded change CO cylinder portion of dial If so CO cylinder is almost empty and must be replaced 2 Make sure soft drink tanks contain sufficient amount of syrup for Unit operation 3 Make sure the Remote Refrigeration Assembly condenser coil is free from debris Restricting air through the condenser coil will decrease the refrigeration systems cooling efficiency REMOVAL OF DRIP TRAY BACK PANEL SIDE PANELS TOP PANEL AND LOWER FRONT ACCESS PANEL AND CONDENSER COIL ACCESS PANEL see Figure 7 DRIP TRAY Lift drip tray up and out of drip tray supports BACK PANEL Remove two screws securing bottom of back panel then lift panel straight up to remove SIDE PANELS Remove screw securing bottom of side panel then lift panel straight up to remove TOP PANEL Remove two screws securing top panel then lift panel up off Unit 39 324229000 LOWER FRONT ACCESS PANEL Remove two screws securing lower front panel then pull panel down to remove from Unit LUBRICATI
121. tructions WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE MAINTENANCE see Figures 2 and 12 must be inspected and serviced after any disruptions plumbing work earthquake etc to the water supply system and at least once a year under normal circumstances Water pump with no screen or defective screen in strainer would allow foreign particles to foul the double liquid check valve gas could then back flow into water system and create health hazard in system WARNING The carbonator water pump water strainer screen and double liquid check valve 37 324229000 Service water strainer screen and double liquid check valve as instructed in SERVICE AND MAINTENANCE SECTION CLEANING GAS CHECK VALVES see Figures 2 and 13 The CO gas check check valves must be inspected and serviced at least once a year under normal conditions and after any disruption on the system as instructed in SERVICE AND MAINTENANCE SECTION 324229000 38 SERVICE AND MAINTENANCE This section describes service and maintenance procedures to be performed on the FCB Overcounter Dispenser WARNING Disconnect electrical power to FCB Overcounter Dispenser to prevent personal injury before attempting any internal maintenance Only qualified personnel should service internal components or electrical wiring PREPARING FCB OVERCOUNTER DISPENSER FOR SHIPPING STORING OR RELOCATING CAUTION Before shipping storing or relocating
122. will cause residual water in the Unit to freeze resulting in damage to internal components CAUTION Before shipping storing or relocating this Unit the syrup systems must be FIGURE 1 FCB OVERCOUNTER POST MIX DISPENSER EVAPORATOR UNIT 1 324229000 Table 1 Design Data CB OVERCOUNTER DISPENSER DATA verall Dimensions Height Width Depth Without Drip Tray Depth With Drip Tray Table 2 Accessories and Tools ACCESSORIES Installation kits Cup Holder Cup Holder CO Changeover Kit Seal Kit Rear O Ring Housing and O Rings GENERIC FLAVOR TABS Cola Cherry Orange Lemon Lime Strawberry Banana SERVICE TOOLS Spanner Wrench Flow Regulator 3 gallon Sanitizing Tank Spanner Wrench Dispensing Valve Refractometer 0 30 Scale Shaft Seal Assembly Puller Alignment Tool Kit Beater Drive Shaft Ass y 324229000 2 1155 511005000 511006000 511035000 1040 1085 1086 1087 1089 1090 1091 151689000 281884000 322859000 511004000 322063000 0726 SYSTEM THEORY OF OPERATION see Figure 2 A CO cylinder delivers carbon dioxide CO gas to an adjustable primary CO regulator assembly attached to the cylinder Primary CO regulator assembly in turn delivers CO gas to adjustable secondary CO regulators inside the Unit and also to two soft drink tanks is delivered from adjustable secondary CO regulators to carbonator tank and also two product blender tanks in
123. ylinders beater motors Manufacturer s that are listed Your Unit was manufactured and equipped with motors from one of these Manufacturer s A replacement freeze cylinder beater motor is also manufactured by one of these Manufacturer s listed DURING NEW UNIT INSTALLATION OR WHEN REPLACING ONE OF THE BEATER MOTORS NOTE THE MANUFACTURER S NAME ON THE MOTOR S THE BEATER MOTOR S MANUFACTURER S NAME S MUST BE PROGRAMMED INTO THE UNIT WHICH WILL MATCH THE MOTOR S TO THE UNIT ELECTRONICS Proceed as follows to program the beater motors into the Unit electronics 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up MO TORS on the message display Press DEFROST SELECT switch to lock in on the selection MOT_1 MFG 1 represents No 1 freeze cylinder beater motor will appear on the message display 2 Press DEFROST SELECT switch again A motor Manufacturer s name see Table 6 will appear on the message display and will be non blinking 3 Press CANCEL DEFROST ADVANCE switch The motor Manufacturer s name will start blinking 4 Press the CANCEL DEFROST ADVANCE switch again which will change to another blinking Manufactur er s name 25 324229000 Keep pressing and releasing the CANCEL DEFROST ADVANCE switch until the applicable blinking Manufacturer s name appears on the message display This indicates Manufacturer s name of the No 1 freeze cyl

Service Manual FCB Overcounter Post-Mix Dispenser

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