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Service Manual/Parts List FCB Overcounter Post

1. YEL BLU 2 FLAVOR LEFT gt LEFT LEFT LEFT WITS 1 KS 2 1 Ka LEFT 1 LEFT 2 SYRUP BLENDER NC FLOATS NC FLOATS BEATER BEATER i Lr 1 ir MOTOR MOTOR YEL IC Ho S 1 SOLD OUT WIR PSI SWITCHES CERN oray 2 o LEFT 1 0 YEL 1 T z NC im m WHT BL gx Eis BLK EXE LEFT 2 BLK F NG cA IN ING RED FILTER BLK YE BLK YEL DATAS Di 1 aS REFR ier 193 SB 167 o 18 1 L a 1 MASTER BOARD BOARD 1 CO2 PSI SWT 2 cog eu leuc i8 1 152 1 16 a LEFT 2 e HRS H DEEN 182 2 LEFT 3 CO SC a ea sg 2 SOL so E 5 F 5 g 1 EFT FT L gt H D ei 2 LEFT 2 a WIR WIR HAH E amp so a le gt Bo SOL x L BOARD 7 T TOUCH SWT S GRAY J POWER SUPPLY i YEE amp MT BLU E AB WAT GRAY 9 YEL E x 1 a L4 1 aA CES x Ehu AYE cono 0520 3 IE zf FAN Re RELAY 1132 5 MOTOR A 410 BLK i T2L 2 FLAVOR UNITS ELECTRONICS 1 COOL ING FAN BLK E g d COMPRESSOR LEFT 4 8 d 1 2 ERAS EATE
2. DRIVE MOTOR DRIVE SHAFT SEAL 557 EE DRIVE BEATER MOTOR SHAFT ALLEN HEAD H ALLEN HEAD PIN SET SCREW EE MIT 22224 Be i aa Bl ze o4 yy q HH 04 d 2 COUPLING COUPLING COUPLER DRIVE SHAFT DRIVE COUPLER COUPLER TOOL DRIVE COUPLER ADJUSTMENT GAUGE ITEM 12 PLASTIC LOCK RING HOUSING O RING BEARING O RING gt al E ALLEN HEAD DRIVE SHAFT SEAL ASSEMBLY P N 3193 SET SCREW FIGURE 13 SERVICING BEATER MOTOR DRIVE SHAFT SEAL ASSEMBLY 59 2992 RELIEF VALVE CARBONATED WATER e SWITCHES ACTUATOR BRACKET LEVEL CONTROL SWITCHES 2 f b i ACTUATOR BRACKET ADJUSTMENT SCREW pL FIGURE 14 CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT 2992 60
3. ELECTRONIC e EXPANSION VALVE 2 v c Qm Cc camo Cc HOT GAS DEFROST B SOLENOID VALVE ocr RES ASS Y 2 T ra 4 H 5 CONDENSER COIL K ASS Y f J CYLINDER 2 ke au D Gp am 3 EVAPORATOR STRAINER DRYER COMPRESSOR RECEIVER TANK ACCUMULATOR FIGURE 15 REFRIGERATION FLOW DIAGRAM 61 2992 2666 c9
4. 13 ADJUSTING PRODUCT BLENDER TANKS SECONDARY CO2 13 ADJUSTING CARBONATOR SECONDARY CO2 REGULATOR 13 STARTING FCB AND ADJUSTING WATER TO SYRUP RATIO BRIX OF DISPENSED PRODUCT 14 FILLING FREEZE CYLINDERS WITH PRODUCT 15 CHECKING UNIT FOR SYRUP CO2 OR PLAIN WATER LEAKS 15 PLACING UNIT IN OPERATING LOCATION 16 ADJUSTING BEATER MOTOR CURRENT EITHER SIDE 16 2992 TABLE CONTENTS cont d Page ADJUSTMENT 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 MESSAGE DISPLAY 22 ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT bis ee eee En et Re ER CR G 22 VIS READ ACTUAL VISCOSITY READOUT OF PRODUCT IN FREEZE CYLINDERS te te ERA E e es 22 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES
5. S SYRUP SOLD OUT SWITCHES ARE FACTORY ADJUSTED AND SHOULD NOT BE READJUSTED doles 591 LINE LEGEND CO2 A PLAIN WATER CARB WATER SYRUP il m KN em PRODUCT BLENDER A 2 7 1 PRODUCT SHUTOFF VALVE 2 4 A FREEZE CYLINDER 2 d 1 CARBONATED WATER i j VOLUME SAMPLE VALVE Ss Y Zo xn DANT CARBONATED WATER Eds REO TUBE SOLENOID VALVE 2 N 1 4 CARBONATED WATER AIVE S FLOW REGULATOR 2 SYRUP SOLENOID L prep A jer TE SYRUP FLOW SOURCE PRIMARY CO REGULATOR 2 SHUTOF REGULATOR ASS Y A SYRUP SOLD OUT FLOAT SWITCH 2 Lon Bet A H SYRUP SOLD OUT SE 6 es Q SWITCH S S DOUBLE PRESSURE Y e LIQUID x SWITCH CARBONATOR Y WATER PUMP Nc CO ies PRESSURE CYLINDE Lj SWITCH SOFT DRINK SECONDARY CO REGULATORS TANK 2 TO PRODUCT BLENDER TANKS 60 PSI GAGE 2 CHECK SECONDARY CO REGULATOR VALVE 3 TO CARBONATOR TANK 100 PSI GAGE FIGURE 2 FLOW DIAGRAM 5 2992 THIS PAGE LEFT BLANK INTENTIONALLY 2992 6 INSTALLATION This section covers unpacking and inspection installing LOOSE SHIPPED PARTS selecting location installing Unit preparing for operation and operation UNPACKING AND INSPECTION see Figure 7 NOTE The Unit was thorou
6. 76 FIGURE 26 TUBING ASSEMBLY CARB WATER 77 FIGURE 27 TUBING ASSEMBLY 77 FIGURE 28 TUBING ASSEMBLY BLENDER TO FREEZE CYLINDER 77 FIGURE 29 TUBING ASSEMBLY WATER SOLENOID BLENDER 78 FIGURE 30 TUBING ASSEMBLY REGULATOR TO BLENDER 78 FIGURE 31 DOUBLE CHECK VALVE ASSEMBLY 78 FIGURE 32 SOLENOID VALVE ASSEMBLY 79 FIGURE 33 BLENDER COMPONENTS 80 FIGURE 34 CONTROL BOX AND DISPLAY PANEL COMPONENTS 81 FIGURE 35 FACEPLATE 82 FIGURE 36 DISPENSING VALVE ASSEMBLY 83 FIGURE 37 CARBONATOR COMPONENTS 84 FIGURE 38 TUBING ASSEMBLY 84 FIGURE 39 DRIP TRAY DRAIN KIT 84 FIGURE 40 CARBONATOR TANK AND LINKAGE ASSEMBLY 85 FIGURE 41 PUMP AND MOTOR ASS Y 86 FIGURE 42 BEATER MOTOR DRIVE SHAFT SEAL 65 87 LIST OF TABLES TABLE 1 DESIONIDATA ace aac acre ric 2 TABLE 2 ACCESSORIES AND TOOLS 3 TABLE LOOSE SHIPPED PARTS 7 TABLE 4 MAIN MENU SELECTIONS
7. 21 FIGURE 7 OPERATING CONTROLS 40 FIGURE 8 UNIT INTERNAL COMPONENTS 41 FIGURE 9 SELF CLOSING DISPENSING VALVE 43 FIGURE 10 LIQUID CHECK VALVE ASSEMBLY 52 FIGURE 11 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK INE a ual ad eee EE 55 FIGURE 12 CO2 GAS CHECK VALVE 56 FIGURE 13 SERVICING BEATER MOTOR DRIVE SHAFT SEAL ASSEMBLY 59 FIGURE 14 CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT xti xx AM RADO Rhe 60 FIGURE 15 REFRIGERATION FLOW 61 FIGURE 16 WIRING DIAGRAM 62 FIGURE 17 OVERCOUNTER FCB POST MIX DISPENSER 70 FIGURE 18 SECONDARY CO2 REGULATOR COMPONENTS 73 FIGURE 19 CONTROL BOX COMPONENTS 73 FIGURE 20 SECONDARY CO2 REGULATOR 55 74 FIGURE 21 TUBE 74 FIGURE 22 TUBE 74 FIGURE 23 CO2 REGULATOR ASSEMBLY 75 FIGURE 24 CHECK VALVE ASSEMBLY 75 2992 TABLE OF CONTENTS cont d Page LIST OF FIGURES CONT D FIGURE 25 BLENDER AND TUBING COMPONENTS
8. 18 TABLE 5 DIP SWITCH FUNCTIONS 20 TABLE 6 MOTOR SELECT 20 TABLE 7 POINT OF SALE DISPLAY MESSAGES 20 TABLE 8 TOTALS DISPLAYED CYCLES AND HOURS TOTALS MENU 24 TABLE 9 DISPLAYED ERROR CONDITIONS 25 2992 vi GENERAL DESCRIPTION IMPORTANT To the user of this manual This manual is a guide for installing operating and maintaining this equipment Refer to Table of Contents for page location of information pertaining to questions that arise during installation operation service and maintenance or troubleshooting this equipment Warranty Registration Date to be filled out by customer Model Number Serial Number Install Date Service Center GENERAL DESCRIPTION This section gives the description theory of operation and design data for the FCB Frozen Carbonated Bever age Overcounter Post Mix Dispenser with V3 Features hereafter referred to as a Unit UNIT DESCRIPTION The Unit See Figure 1 consists basically of two freeze cylinders each containing an internal beater driven by an electric motor one refrigeration system with a 2 horsepower compressor one carbonator which feeds both carbo nator blender tanks a timer controlled automatic hot gas defrost system to defrost the freeze cylinders and inter connecting tubing components and fittings necessar
9. tacta REPLENISHING SYRUP SUPPLY REPLENISHING CO2 SUPPLY edo ds SYRUP FEAVOR CHANGE 525 tox ck ht packer sa Db A UA es CLEANING CO2 GAS CHECK VALVES REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR ADJUSTING CARBONATOR TANK LIQUID LEVEL TROUBLESHOOTING oia TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGE SS nia aa e ad i at ONE OR MORE CONTROL PANEL SWITCHES OPERATING ALL CONTROL PANEL SWITCHES NOT OPERATING CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED PARTIAL MESSAGE OR DULL POORLY ILLUMINATED DISPLAY ONE OR MORE FAULT MESSAGES NOT OPERATING ALL FAULT MESSAGES NOT OPERATING CO2 OUT FAULT MESSAGE GOES ON DURING OPERATION 2 OUT FAULT MESSAGE GOES ON DURING OPERATION SYRUP 1 OR SYRUP 2 FAULT MESSAGE GOES ON DURING OPERATIONS 2 53en eR deng deh oh etre chanel P RE RE He repe tcd ERROR 1 OR ERROR 2 FAULT MESSAGE GOES ON DURING OPERATION cet b Deuce MEREER CURE IHR HOAN PRETIUM FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT 2 Set EE ana ang rab TM UNIT DOES GO OFF AUTOMATIC DEFROST CYCLE MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN DEFRO
10. FCB OVERCOUNTER POST MIX DISPENSER Service Manual WITH V3 FEATURES IMPORTANT TO THE INSTALLER It is the responsibility of the Installer to ensure that the water supply to the dispensing equipment is provided with protection against backflow by an air gap as defined 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 2992 May 31 1994 Revised April 4 1995 THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment IMI CORNELIUS INC 1994 95 PRINTED IN U S A SOLUTIONS Part Corrections Update Document Unit Type Model Manual FCB OC2 POST MIX 2992 DISPENSER W V3 Unit Part Numbers 416136xxx 496136xxx Page Item Old Part Desc New Part Desc Agent Date Notes 71 53 2467 FOAM PACK 4467 FOAM PACK JLS 01 24 03 72 66 326000000 COMPRESSOR 560004343 COMPRESSOR JLS 01 24 03 Includes all KIT 2HP 230V 60 KIT 60H components and DOMESTIC instructions to convert from R502 to R404 72 66 324233000 COMPRESSOR 560004342 COMPRESSOR JLS 01 24 03 Includes all KIT 2HP 230 50
11. 22 VOLTAGE DISPLAYED VOLTAGE 23 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE INT UBND iui itor terc e reme m eee 23 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY 26 PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS 2 4 26 PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS uber iei 27 DISPLAYED ERROR CONDITIONS 27 OPERATOR S INSTRUCTIONS 29 CONTROL PANEL ASS Y SWITCHES AND DISPLAYED MESSAGES 29 CONTROL PANEL ASS Y SWITCHES 29 CONTROL PANEL ASSEMBLY DISPLAY MESSAGES 30 FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS 31 MANUAL DEFROST SYSTEM 31 AUTOMATIC DEFROST SYSTEM 31 SLEEP SLEEP TIME 31 WAKE UP WAKE UP 32 FACEPLATE RELIEF VALVES 1 32 PRODUCT SAMPLE VALVES 32 PRODUCT SHUTOFF VALVES 32 PRIMARY CO2 REGULATOR
12. 32 SECONDARY CO2 REGULATORS 32 CARBONATED WATER FLOW REGULATORS 32 SYRUP FLOW REGULATORS 32 DISPENSING VALVES 32 DISPENSED PRODUCT CONDITIONS 33 OVERRUN AS APPLIED TO FROZEN CARBONATED BEVERAGES 33 OPERATING CHARACTERISTICS 34 OPERATING HNH Zeene E E ats 34 2992 ii TABLE OF CONTENTS cont d Page REPLENISHING SYRUP SUPPLY 34 PRODUCT FLAVOR CHANGE 35 CHECKING CO2 SUPPLY 35 CLEANING AND SANITIZING 35 35 SANITIZING elt TAR 35 CLEANING CONDENSER COIL 35 DIE Edel kak a aa aa 35 ADJUSTMENTS eegene 35 CARBONATED WATER FLOW RATE 85 WATER TO SYRUP RATIO BRIX OF DISPENSED PRODUCT 36 2 REGULATORS i146 aceite tras Leti x tb Pon dd 36 ADJUSTING BEATERS MOTORS CURRENTS 36 PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY 36 SETTING CLOCK TIME DAY 36 PRO
13. CLEANING CO GAS CHECK VALVES see applicable 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 QUAD RING 183294000 BALL pe 10279000 SPRING 183297000 A RQa 183298000 BODY 183295100 QUAD RING SEAL MUST BE REPLACED EACH TIME CHECK VALVE IS SERVICED FIGURE 12 GAS CHECK VALVE 2992 56 REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR see Figures 8 and 13 IMPORTANT Note in 6 MOTOR SELECT the number of freeze cylinder beater drive motors Manufacturers that are listed Your Unit was manufactured and equipped with freeze cylinders beater drive motors from one of these Manufacturers The replacement freeze cylinder beater drive motor is also manufactured by one of these Manufacturer s listed WHEN REPLACING ONE OF THE BEATER MOTORS NOTE THE MANUFACTURER S NAME ON THE MOTOR THE BEATER MOTOR MANUFACTURER S NAME MUST BE PROGRAMMED INTO THE UNIT WHICH WILL MATCH THE MOTOR TO THE UNIT ELECTRONICS Proceed as follows to replace the freeze cylinder beater drive motor 1 Press OFF 1 and OFF 2 control switches to stop the refrigeration system and the beater drive motors 2 Disconnect electrical power to the Unit 3 Remove Unit back and both side panels as instru
14. SANITIZING The Unit syrup systems should be sanitized as instructed every 90 days and before and after storage periods following parent company requirements and sanitizer manufacturers recommendations Sanitize syrup systems as instructed CLEANING CONDENSER COIL The FCB Dispenser refrigeration system is equipped with a condenser coil see Figure 8 that is cooled by two condenser coil fans Circulating air required to cool the refrigeration system s condenser coil is drawn in through grilled panel on the right hand side and is exhausted out through the opposite side and back grilled pan els Restricting air circulation through the Unit will decrease its cooling efficiency THE CONDENSER COIL MUST BE CLEANED PERIODICALLY AS INSTRUCTED IN THE SERVICE AND MAINTENANCE SECTION LUBRICATION Carbonator pump motor must be lubricated as instructed on the motor ADJUSTMENTS CARBONATED WATER FLOW RATE The black carbonated water flow regulators see Figure 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 the SERVICE AND MAINTENANCE section 35 2992 WATER TO SYRUP RATIO BRIX OF DISPENSED PRODUCT Water To Syrup Ratio BRIX is the water to syrup ratio of the dispensed product Adjust BRIX as instructed in the SERVICE AND MAINTENANCE section REGULATORS
15. control switches have been pressed to fill product blender tanks with product ERROR 1 and ERROR 2 Fault Messages ERROR 1 and ERROR 2 fault messages will appear on message display only if error within Unit has devel oped interrupting normal operation Error will have to be located and corrected then press ERROR RESET to restore normal operation ERROR 1 or ERROR 2 fault message will disappear from display OFF 1 and OFF 2 Fault Messages OFF 1 and OFF 2 fault messages will appear on message display when either freeze cylinder beater is not operating H2O OUT Fault Message The Unit plain water inlet system contains a water pressure switch Should the plain water source to the Unit be disrupted or a water pressure drop occur this will cause the 2 OUT fault message to appear on the mes sage display The Unit will continue to operate for 1 1 2 minutes after HsO OUT fault message has appeared and if water pressure has not been restored or water pressure improved after 1 1 2 minutes Unit operation will shut down After plain water source has been restored or water pressure has improved Unit will resume opera tion and 2 OUT fault message will disappear from message display OUT Fault Message CO OUT fault message will appear on message display when supply to Unit has been turned off or if pressur
16. regulators 2 Adjust the product blender tanks secondary CO regulators with 60 psi gages by turning their regulator adjusting screws to the right clockwise until their gages read 25 to 30 psig for best textured product 3 Install the lower front access panel by reversing the removal procedure Carbonator Secondary CO Regulator see Figure 2 and 8 1 Remove the Unit lower front access panel as instructed for access to the carbonator s secondary regulator s IMPORTANT The Carbonator tank secondary CO regulator must be adjusted 25 psi higher or more above the product blender tanks secondary CO regulators pressure settings The Carbonated water and syrup pressures must be able to overcome and vent the product blender tanks head pressures while the tanks are filling with carbonated water and syrup Carbonator tank secondary regulator not adjusted high enough will cause a decreased flow of carbonated water into the blender tanks which will increase brix of the dispensed product 2 Adjust carbonator s secondary CO regulator s with 100 psi gage s by turning regulator s adjusting screw s to the right clockwise until gage s reads 50 to 60 psig 3 Install the lower front access panel by reversing the removal procedure ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT see Figures 2 and 8 1 Remove Unit lower front access panel as instructed for access to product blender tanks secon
17. see Figures 2 and 8 Carbonator s plain water inlet adjustable water pressure regulator is factory adjusted to 45 psi and should not be readjusted ADJUSTING CARBONATED WATER FLOW RATE The back carbonated water flow regulators see Figures 2 and 8 which control carbonated water flow rate into the product blender tanks are factory adjusted for a flow rate of 1 3 0 05 ounces per second and normally do not require adjustment However if adjustment is necessary proceed as follows 1 Press applicable OFF 1 or OFF 2 switch to prevent more product from entering the applicable product blender tank 2 Disconnect Unit syrup inlet line from the applicable soft drink tank 45 2992 10 11 12 13 14 15 16 17 18 19 20 21 22 Using flat blade screwdriver turn lock counterclockwise to unlock the front access door see Figure 7 then open the door Remove lower front access panel as instructed for access to the applicable carbonated water flow regula tor product shutoff valve and the product sample valve Close applicable product shutoff valve to prevent more product from entering the freeze cylinder Place container under applicable product sample valve Open the valve and allow all product to be purged from the product blender tank then close the valve Note pressure setting on the applicable secondary regulator with 60 psi gage for the applicable prod uct blender
18. AUTO MATIC SLEEP SLEEP TIME and WAKE UP WAKE UP TIME will function TABLE 4 MAIN MENU SELECTIONS Program CLOCK TIME OF DAY into Unit as follows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up CLOCK on display Press DEFROST SELECT switch to lock in on selection 2 Press CANCEL DEFROST ADVANCE switch to bring up flashing hour number on display 3 Press CANCEL DEFROST ADVANCE switch to advance hours on display to desired hour Press DE FROST SELECT switch to lock in hour on display 4 After hour time of day has been locked in on message display minute numbers will be flashing on display Press CANCEL DEFROST ADVANCE switch to advance minute numbers to desired minutes time of day Press DEFROST SELECT switch to lock in minute time of day on display 5 Press ERROR RESET switch two times to exit from MENU SELECTION PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT The automatic defrost system may be programmed into the Unit to occur up to nine different times during a day with a minimum of two hours between defrost time settings Program automatic defrost time settings into the Unit as follows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ON TO MESSAGE DISPLAY and bring up DE FROST on message display Press DEFROST SELECT switch to lock in on selection 2 Press CANCEL DEFROST AD
19. 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 the message display as instructed in the INSTALLATION section 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 Program DIAGNOSE into Unit and check components for proper operation as instructed in the INSTAL LATION section DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY TOTALS DISPLAYED CYCLES AND HOURS TOTALS may be displayed on the message display as instructed in the INSTALLATION section 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 the INSTALLATION section for programming instructions DISPLAYED ERROR CONDITIONS Displayed error conditions associated errors and items affected by the errors are found in Table 9 DISPLAYED ERROR
20. Hd No 10 24 By 3 4 In Long 324116000 Washer 625 I D 3 Tank Blender Strain Relief 6 315925000 O Ring 1 609 I D By 139 C S 2992 80 315931000 O Ring 364 1 0 By 070 C S 325288000 Float Switch Ass y 324048000 Holder Float Switch 324115000 Retaining Ring 12 311751000 Machine Screw SI Hex Washer Hd No 4 40 By 1 4 In Long 326105000 Relief Valve Ass y FIGURE 34 CONTROL AND DISPLAY PANEL COMPONENTS Control Bok and Display Panel 10 325981069 Holder Flavor Tab Components 11 2716 Cover Control Box 326079000 Cable Ribbon 12 312251000 Thread Rolling Screw Phil Pan Hd 326078000 P C Board Display No 10 24 By 3 8 In Long 2897 Hinge Display 14 0150 Fan Cage 230V 9W 2895 Latch Display 15 324136000 Board Main 2704 Panel Back Display 16 325998000 Cable Ribbon 319941000 Thread Rolling Screw Hex Washer 17 325925000 Support P C Board Hd No 8 32 By 3 8 In Long 18 326076000 P C Board Motor No 1 19 326077000 P C Board Motor No 2 325962040 Switch Touch 20 320389000 Bushing 875 Dia 21 1020 Wire Harness Not Shown 81 2992 FIGURE 35 FACEPLATE ASSEMBLY EI 326106000 Door Freeze Oylinder Ass y 321652000 Shank Nut 325918000 Door Freeze Oylinder 325936000 325954088 Relief Valve Ass y 320678000 O Ring 4 60 LD By 210 C S 1557 Valve Head Ass y See Figure 36
21. OFF 1 OFF 2 Control Switches OFF 1 and OFF 2 control switches located on control panel are touch type switches and require only pressing to activate These switches are used to stop freeze cylinders beaters and refrigeration system ERROR RESET Control Switch ERROR RESET control switch located on control panel assembly is a touch type switch and requires only pressing to activate ERROR RESET switch is used to restore normal operation after error within Unit indi cated by ERROR 1 or ERROR 2 on message display has been corrected SECURITY SWITCH The Unit is equipped with a hidden SECURITY SWITCH located between FILL 1 switch and ERROR RE SET switch on the control panel assembly Pressing in and holding the SECURITY SWITCH for 3 seconds deactivates the control switches preventing tampering with Unit is normal operation To reactivate control switches press in and hold SECURITY SWITCH for 3 seconds CONTROL PANEL ASSEMBLY DISPLAY MESSAGES see Figure 5 FILL 1 and FILL 2 Fault Messages FILL 1 and FILL 2 fault messages will appear on message display only when FILL 1 and FILL 2 control switches have been pressed and syrup systems 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
22. See Figure 23 eo s Josi Fitting Plug 1 4 174061196 Ass y Regulator Ass y Secondary Regulator 309379000 Tube Ass y Pump to Carb 174103001 Tube 250 1 0 By 60 In Long 174103001 Tube 250 1 0 By 22 In Long 2 176001000 Ferrule For 425 O D Tube 770104 Nipple For 250 1 0 Tube 4 176017000 Swivel Nut 7 16 20 FIGURE 22 TUBE ASSEMBLY 2992 74 183449000 Regulator Ass y 60 51 130167000 Orange Includes 1 16 183412000 Regulator Ass y 100 PSI Gold EN Machine Screw Phil Fill Hd No 10 183008000 O Ring 489 I D By 070 C S 2 183233059 Cover Kit Includes Non Removable 12 183006000 Spring Poppet EL Adjusting Screw 12 183006000 Spring Poppet Tp 183021000 Retainer Spring Manes Poppet 315424000 _ Adjusting Spring 60 PSI 30168000 a Redueing Valve egt 1 183020000 Adjusting Spring 100 PSI 93003000 EE 130174000 Diaphram 83001015 ody EE 324211000 Fitting 1 16 NPT 5 32 Barb FIGURE 23 CO REGULATOR ASSEMBLY Wana name _ Te oeer vane assy van d 2 pe s mmm a FIGURE 24 CHECK VALVE ASSEMBLY 75 2992 319941000 Thread Rolling Screw Hex Washer Hd No 8 32 By 3 8 In Long 2780 Tube Ass y Carb Water Outlet See Figure 26 2815 Tube A
23. T lee TABLE 6 MOTOR SELECT DIP SWITCH DIP SWITCH NO 1 NO 2 MESSAGE OFF OFF ENJOY A FROZEN BEVERAGE OFF NOT USED BLANK OFF HAVE A NICE DAY DISFRUTE UNA BEBIDA CONGELADA CARBONATADA For special messages contact your local sales representative TABLE 7 POINT OF SALE DISPLAY MESSAGES 2992 20 1 2 EVAPORATOR COILS REFRIGERATION COMMON OUTLET TEMPERATURES NO 2 EVAPORATOR REFRIGERATION COIL INLET TEMPERATURE NO 1 EVAPORATOR REFRIGERATION COIL INLET TEMPERATURE MOTOR CURRENT ADJUSTMENT RELAY CIRCUIT BOARD NO 1 MASTER CIRCUIT BOARD 9 RELAY CIRCUIT BOARD NO 2 POINT OF SALE MESSAGE DISPLAY SELECT 1 2 SEE Table 5 3 SEE NOTE BEATER MOTORS CURRENT READOUT SEE Note in Table 5 DIP SWITCH 6 MOTOR CURRENT SELF CALIBRATION SEE Table 5 ASS Y 7 NOT USED 8 9 APPLICABLE ELECTRIC OR GAS DEFROST SEE Table 5 SERVICE USE ONLY FIGURE 6 MASTER AND RELAY CIRCUIT BOARD 21 2992 PROGRAMMING POINT SALE MESSAGE DISPLAY see Figure 6 7 NOTE Point of sale display messages be turned off by placing No 1 DIP SWITCH on master circuit board in OFF position and No 2 DIP SWITCH in ON positi
24. gt 255 OFF OFF Sensed on motor one Motor 2 High current gt 255 OFF OFF Sensed on motor two amer mem mengen Is Tenor mon 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 25 minutes on Standard System 30 minutes on Remote System TABLE 9 DISPLAYED ERROR CONDITIONS 25 2992 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY see Tables 4 and 8 1 TOTALS DISPLAYED CYCLES AND HOURS TOTALS may be displayed on message display as follows 2 Refer to PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY and bring up the word CLOCK on message display 3 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 4 Press and hold DEFROST SELECT switch Compressor run hours will appear on message display 5 Press CANCEL DEFROST ADVANCE switch to advance and bring up CYC on message dis play 6 Press and hold DEFROST SELECT switch Compressor cycles x 100 will appear on message display 7 Use CANCEL DEFROST
25. 2 TORSION SPRING HOLD DOWN SPRING icd i PLATE 2 DISPENSING E O VALVE BODY CAGED O RING LEVER ED SLEEVE SPRING KNOB FIGURE 9 SELF CLOSING DISPENSING VALVE 4 Unscrew RELIEF VALVE item 9 from FACEPLATE item 8 5 Disassemble dispensing valve see Figure 9 as follows A Remove two screws and hold down plates securing spring housing to dispensing valve body then re move housing Remove torsion spring from dispensing valve Remove knob spring sleeve and lever from dispensing valve Remove spring fitting from dispensing valve Press valve with caged O ring down and out of dispensing valve body W Carefully remove caged O ring from valve 6 Wash all parts in warm water Remove all traces of syrup and lubricant especially from faceplate O rings and dispensing valve If parts are excessively coated wipe clean with paper towel to remove syrup and lubricant especially from caged O ring and dispensing valve Use BRUSH item 3 Table 3 to clean face plates relief valve passages 7 Submerge all parts in 4 percent solution of approved sanitizing agent for time recommended by sanitizer manufacturer 8 Remove parts from sanitizing solution and place on clean paper towels NOTE Use Dow Corning DC 111 P N 321471000 light grade silicone lubricant 9 Assemble dispensing valve as follows A Lubricate caged O ring Carefully install caged O ring on valve from straight
26. 265 1 0 By 3 In Long NS LD 770698 Fitting Tee Barb 770460 Fitting Elbow Swivel 5 8 18 5 2 1 uc pet 2781 Tube Ass y Blender to Freeze A oe XO Cylinder weg 1 174103000 Tube 250 D By 3 In Long 2 2 1 gt Be 6 174103000 Tube 250 1 0 22 In Long 174103000 Tube 250 I D By 38 In Long i c vA oe 6 SH 2 176001000 For 375 O D Tube gt 176016000 Nut Swivel 1 2 16 Ke 2 770204 Nipple For 250 LD Tube s ue gt e 325012000 Shut Off Valve b 770601 Fitting Tee 1 4 Barb FIGURE 28 TUBING ASSEMBLY BLENDER TO FREEZE CYLINDER 77 2992 2779 Tube Ass y Water Solenoid to Blender Ce rroo Funa Eron samen Teen Tune ssy Relat Boner FIGURE 30 TUBING ASSEMBLY REGULATOR TO BLENDER na 311764001 Single Check Valve Ass y Le meeue FIGURE 31 DOUBLE CHECK VALVE ASSEMBLY 2992 78 Solenoid Valve Ass y Water Solenoid Valve Ass y Syrup es fev emm No 6 32 By 5 8 In Long Piston Water Piston Syrup 317431011 Oylinder 317816000 O Ring 676 I D By 070 C S 79 Hd No 8 16 By 1 2 In Long 8 32 By 1 4 In Long 311355000 Inlet Valve 2992 12 lt SC ai E or FIGURE 33 BLENDER COMPONENTS 2625 Support Blender Blender Components 2 188206000 Thread Rolling Screw Phil Truss
27. 39 FRONT ACCESS PANEL tob Ras 42 OPENING AND CLOSING FRONT ACCESS DOOR 42 OPENING FRONT ACCESS DOOR 42 CLOSING FRONT ACCESS DOOR 42 2992 TABLE CONTENTS cont d EUBRICATION coe acini ade et ees Ne eres CARBONATOR WATER PUMP SERVICING DISPENSING VALVES CAGED O RINGS AND FREEZE CYLINDERS DRIVE SHAFT SEAL ASSEMBLIES CLEANING CONDENSER COIL ADJUSTMEN FS ek Exe xx exe e ex ex Rc ee af ae kaa eh Eet ADJUSTING PLAIN WATER PRESSURE REGULATOR ADJUSTING CARBONATED WATER FLOW RATE ADJUSTING CO2 REGULATORS ADJUSTING BRIX WATER TO SYRUP RATIO OF DISPENSED PRODUCT ae ofi Clu td Ar bata ting pct oue PRODUCT CARBONATION ADJUSTMENT CLEANING AND SANITIZING DAILY CLEANING OF UNIT SANITIZING SYRUP 5 YEARLY OR AFTER WATER SYSTEM DISRUPTION SERVICING CARBONATOR WATER PUMP WATER STRAINER SCREEN rek et Reve a VOCARE De En WEN SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK iiu inii mene rete ERE
28. ADVANCE switch to advance through remaining TOTALS DISPLAYED CYCLES AND HOURS TOTAL MENU See Table 8 Press DEFROST SELECT switch to obtain mes sage display readings of the individual menu selections 8 Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING FREEZE CYLINDERS BEATER MOTORS INTO UNIT ELECTRONICS IMPORTANT Note in Table 6 MOTOR SELECT the number of freeze cylinders beater motors Manufacturers that are listed Your Unit was manufactured and equipped with motors from one of these Manufacturers A replacement freeze cylinder beater motor is also manufactured by one of these Manufacturers listed DURING NEW UNIT INSTALLATION OR WHEN REPLACING ONE OF THE BEATER MOTORS NOTE THE MANUFACTURER S NAME ON THE MOTOR S THE BEATER MOTOR S MANUFACTURER S NAME S MUST BE PROGRAMMED INTO THE UNIT WHICH WILL MATCH THE MOTOR S TO THE UNIT ELECTRONICS Proceed as follows to program the beater motors into the Unit electronics 1 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up MO TORS on the message display Press The DEFROST SELECT switch to lock in on the selection 1 MFG 1 represents No 1 freeze cylinder beater motor will appear on the message display 2 Press The 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 The CANCEL DEFROST ADV
29. 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 present 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 the last drink was drawn from a particular freeze cylinder and the compres sor has not cycled on the drink dispensed will have a tendency to be wetter have slightly less overrun than normal for the setting and will not mound up as high See Drawing 1 NOTE A cylinder freeze up may be expected under casual draw conditions if an attempt is made to eliminate drink described above by adjusting viscosity 2 If product is drawn from freeze cylinder quite regularly its viscosity product consistency will be maintained at whatever viscosity adjustment was made within the normal variance of the compressor off and on cycle See Drawing 2 3 If product is drawn continuously from freeze cylinder and rate is approaching capacity of the dispensing unit overrun of drink will increase
30. CONDITIONS 37 2992 WATER STRAINER SCREEN DOUBLE LIGUID CHECK VALVE MAINTENANCE see Figures 2 and 11 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 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 Service water strainer screen and double liquid check valve as instructed in the SERVICE AND MAINTE NANCE section CLEANING GAS CHECK VALVES see Figure 2 and 12 The gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO system as instructed in the SERVICE AND MAINTENANCE section 2992 38 SERVICE This section describes service and maintenance to be performed on the Unit WARNING Disconnect electrical power to Unit to prevent personnal injury before attempting any internal maintenance Only qualified personnel should service internal components or electrical wiring PREPARING UNIT FOR SHIPPING STORING OR RELOCATING CAUTION Before shipping storing or relocating Unit syrup systems must be sanitized and all sanit
31. INSTRUCTIONS This section describes operating controls and indicators dispensed product conditions operating characteris tics Unit operation replenishing syrup supply product flavor change checking supply operators daily cleaning of Unit and sanitizing requirements WARNING Disconnect electrical power to the Unit to prevent personnel injury before attempting any internal maintenance Only qualified personnel should service internal components or electrical wiring NOTE The No 1 freeze cylinder see Figure 7 is the left hand cylinder facing the front of the Unit No 2 freeze cylinder is to the right of the No 1 freeze cylinder CONTROL PANEL ASS Y SWITCHES AND DISPLAYED MESSAGES CONTROL PANEL ASS Y SWITCHES see Figure 5 NOTE The Unit control panel assembly is equipped with a hidden SECURITY SWITCH located be tween FILL 1 and ERROR RESET control switches see Figure 5 Pressing in and holding SE CURITY SWITCH for 3 seconds deactivates the control switches preventing tampering with Unit nor mal operation To reactivate the control switches press in and hold the SECURITY SWITCH for 3 seconds FILL 1 and FILL 2 Control Switches FILL 1 and FILL 2 control switches located on control panel assembly are touch type switches and require only pressing to activate FILL 1 and FILL 2 control switches are used when filling syrup systems sold out floats during syrup replenishing syrup f
32. KIT 50H components and EXPORT instructions to convert from R502 to R404 72 78 324120000 GEAR MOTOR 324120088 GEAR MOTOR JLS 01 24 03 Klauber motor for 1 4HP 220V 1 4HP 240V 60 OC1 only 72 78 2472 GEAR MOTOR 4210 GEAR MOTOR JLS 01 24 03 Includes 1 AHP 220 240V KIT 230 50 60 components and 50H KLAUBER EMERSON instructions to replace Klauber with Emerson motor 72 78 3471 GEAR MOTOR 4689 GEAR MOTOR JLS 1 01 24 03 Use Emerson motor 1 8HP 208 240 230 50 60 4689 when 50 60H EMERSON replacing an EMERSON existing Emerson motor 72 78 2108 MOTOR 1 4HP JLS 01 24 03 Obsolete 220 240 50H FASCO 74 3 183412000 REGULATOR 183412016 REGULATOR JLS 01 24 03 ASSY 100PSI SECONDARY 100PSI 80 4 324047000 BLENDER TANK 324194888 BLENDER TANK JLS 01 24 03 FOR SINGLE FLOAT USE OR 324205888 BLENDER TANK FOR DOUBLE FLOAT USE 87 n a 3232 DRIVE SHAFT JLS 01 24 03 TABLE OF CONTENTS Page GENERAL DESCRIPTION 22 22 See e dee 1 GENERAL DESCRIPTION x e 1 UNIT DESCRIPTION tar a aa aga 1 THEORY OF OPERATION An ag a tta a an fita KA Lad 2 DEFROST SYSTEMS adito Rad e Date civ relies ad eie De es ed iet 3 MANUAL DEFROST SYSTEM 3 AUTOMATIC DEFROST SYSTEM E 3 SLEEP SLEEP TIME Ate 4 WAKE UP WAKE
33. Primary Regulator The primary CO regulator see Figure 2 and Table 8 regulates pressure to the soft drink tanks also to the bag in box syrup system if used and also to the secondary regulators located inside the Unit neces sary to adjust the primary regulator adjust as instructed in the SERVICE AND MAINTENANCE section Secondary Regulators The secondary regulators see Figure 2 and 8 regulate pressure to the carbonator and product blend er tanks If necessary to adjust secondary CO regulators adjust as instructed in the SERVICE AND MAINTE NANCE section ADJUSTING BEATERS MOTORS CURRENTS Beaters motors currents must be adjusted as instructed in THE INSTALLATION section PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS see Table 4 may be brought up on the message display as instructed in the INSTALLATION section SETTING CLOCK TIME OF DAY NOTE CLOCK TIME OF DAY must be programmed into Unit before DEFROST AUTOMATIC SLEEP SLEEP TIME and WAKE UP WAKE UP TIME can be programmed into the Unit Program CLOCK TIME OF DAY into Unit as instructed in the INSTALLATION section PROGRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT The automatic defrost system may be programmed into the Unit to occur up to nine different times during a day with a minimum of two hours between defrost time settings Program aut
34. Reading Common Outlet 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 Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up the word CLOCK on display Press CANCEL DEFROST ADVANCE switch to bring up DIAGNOSE menu on message display Press DEFROST SELECT switch to lock in place The word MOTOR 1 will appear on message display Press DEFROST SELECT switch No 1 beater motor will start and operate while switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up the word MOTOR 2 on message display Press DEFROST SELECT switch No 2 beater motor will start and operate while switch is pressed Press CANCEL DEFROST ADVANCE switch to advance and bring up DEFR
35. SERVICING CARBONATOR WATER PUMP WATER STRAINER SCREEN see Figure 11 1 Press OFF 1 and OFF 2 switches to stop freeze cylinders beaters and refrigeration systems 2 Disconnect electrical power from Unit 3 Close CO cylinder and water inlet supply line shutoff valve 4 Using a flat blade screwdriver turn lock counterclockwise to unlock the front access door see Figure 7 then open the door 5 Remove back panel as instructed for access to the water pump water strainer screen 51 2992 6 Pull up on carbonator tank relief valve plastic cover to release pressure from tank 7 Loosen screen retainer in water pump port then remove screen retainer and strainer screen from port 8 Pull strainer screen from screen retainer Clean any sediment from screen retainer and water pump port 9 Inspect strainer screen for holes restrictions corrosion and other damage Discard damaged strainer Screen 10 Check O ring on screen retainer Replace worn or damaged O ring P N 315349000 NOTE Strainer screen should always be used otherwise particles could foul double liquid check valve 11 Install good or new strainer screen P N 315348000 in screen retainer then screw retainer into water pump port and tighten securely 12 Proceed to SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE 317965000 Retainer 312196000 Spring 312419000 Ball 312415000 Washer 300 I D 312418000 Quad Ring 317963000 Body Install new
36. UP 4 INSTALLATION codec ese 7 UNPACKING AND INSPECTION 7 IDENTIFICATION OF LOOSE SHIPPED PARTS 7 ELECTRICAL POWER REQUIREMENTS 8 zu ONIN 2 TT 8 SOTA TEN id aa aom is 8 SELECTING LOCATION NEE 8 INSTALLING UNIT Ae oer nl tinta 9 INSTALLING LEVELING LEGS 0 9 INSTALLING DRIP TRAY SUPPORTS 9 INSTALLING DRIP TRAY DRAIN HOSE KIT 9 PREPARING UNIT FOR CONNECTION TO SYRUP CO2 AND CITY PLAIN WATER EE tem Pads 9 INSTALLING PRIMARY CO2 REGULATOR ASSEMBLY ON CO2 CVINDERS ias ee 9 CONNECTING SOFT DRINK TANKS 2 LINES TO PRIMARY CO2 REGULATOR ASSEMBLY ah deele tual 11 PREPARING UNIT SYRUP INLET LINES FOR CONNECTION TO SOFT DRINK TANKS tasti taam ien eter 12 CONNECTING CO2 SOURCE LINE TO UNIT CO2 INLET LINE 12 CONNECTING CITY PLAIN WATER SOURCE LINE TO UNIT 12 CONNECTING ELECTRICAL POWER CIRCUIT TO THE UNIT 12 PREPARATION FOR 13 TURNING ON ELECTRICAL POWER TO UNIT 13 TURNING ON CO2 SUPPLY THE UNIT 13 ADJUSTING PRIMARY CO2 REGULATOR
37. ball seat after each servicing FIGURE 10 LIQUID CHECK VALVE ASSEMBLY SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE see Figure 2 and 11 1 Service water pump water strainer screen before servicing water pump double liquid check valve 2 Disconnect carbonator tank water line from double liquid check valve assembly outlet 3 Remove double liquid check valve assembly from elbow in water pump outlet port Retain white tapered gasket inside inlet female end of double liquid check valve 2992 52 4 Disassemble each check valve as shown Figure 10 5 Wipe each part with clean lint free cloth Inspect each part especially ball for burrs nicks corrosion deteri oration 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 10 ALWAYS INSTALL NEW BALL SEAT QUAD RING P N 312418000 NOTE Make sure when assembling check valves together check valve female end with white tapered gasket inside is on inlet side of double liquid check valve assembly 7 Assemble check valves together DO NOT OVERTIGHTEN 8 Make sure white tapered gasket is in place inside female end of double liquid check valve assembly then install check valve assembly on elbow in water pump outlet port 9 Connect carbonator tank water line to double liquid check valve assembly outlet DO NOT OVERTIGH TEN 10 Open CO cylinder
38. 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 NOTE When indicator on primary CO cylinder regulator assembly 1800 psi gage is in shaded change CO cylinder portion of the dial cylinder is almost empty and should be changed 1 Fully close clockwise CO cylinder valve 2 Slowly loosen CO regulator assembly coupling nut allowing CO pressure to escape then remove regula tor assembly from empty CO cylinder 3 Unfasten safety chain and remove empty cylinder 4 Position full CO cylinder and secure with safety chain WARNING To avoid personal injury and or property damage always secure CO cylinder in upright position with safety chain to prevent it from falling over Should valve become accidentally damaged or broken off CO cylinder can cause serious personal injury 5 Make sure gasket is in place inside CO regulator coupling nut then install regulator on CO cylinder 6 Open counterclockwise CO cylinder valve slightly to allow lines to slowly fill with gas then open valve fully to back seat valve Back seating valve prevents leakag
39. carbonated water solenoid relay will click when switch is pressed 16 Press CANCEL DEFROST ADVANCE switch to advance and bring up WATER 2 on message display 17 Press DEFROST SELECT switch No 2 carbonated water solenoid relay will click when switch is pressed 18 Press CANCEL DEFROST ADVANCE switch to advance and bring up RF SOL 1 on message display 19 Press DEFROST SELECT switch Refrigeration relay clicks when switch is pressed 20 Press CANCEL DEFROST ADVANCE switch to advance and bring up RF SOL 2 on message display 21 Press DEFROST SELECT switch No 2 refrigeration solenoid clicks when switch is pressed 22 Press CANCEL DEFROST ADVANCE switch to advance and bring up COMPRESS on Message dis play 23 Press DEFROST SELECT switch Compressor and condenser fan motor will start and operate while switch is pressed 24 Press CANCEL DEFROST ADVANCE switch to advance and bring up HO PUMP on message display 25 Press DEFROST SELECT switch Carbonator water pump relay on master circuit board clicks when switch is pressed 26 Press ERROR RESET switch two times to exit from MENU SELECTIONS ITEMS AFFECTED BY ERROR MESSAGE BEATER BEATER DISPLAYED ERROR MOTOR 1 MOTOR 2 Motor 1 Low Current lt 109 OFF OFF Sensed on motor one Motor 2 Low Current lt 109 OFF OFF Sensed on motor two Motor 1 High current
40. 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 antifreeze in water The higher the BRIX in a product the greater resistance the product has to freezing Conversely in products with lower BRIX freezing takes place at higher tempera tures than for high BRIX products Thus BRIX affects overrun because the amount of sugar in a drink has a direct bearing on the product s freezing characteristics gt DRAWING 1 DRAWING 2 DRAWING 3 Low Dispensing Volume Affects Overrun When Unit sits idle for a period of time and no drinks are dispensed gas in the system takes a set When first few drinks are drawn off after an idle period gas has less tendency to break out as drink is dispensed The result is these casual drinks have less overrun than drinks dispensed during peak use periods Carbonation Level in Liquid Product Affects Overrun The higher the specific carbonation level in a given product the greater the potential for carbonation breakout in frozen carbonated form of that drink For example drinks with 3 0 volume of carbonation will have more gas breakout in frozen carbonated form and more overrun than will drinks that contain 2 0 volumes of gas 33 2992 Freezing
41. end opposite tapered end Lubricate grooves in which O ring rides to fill in all void areas around O ring Carefully install valve with caged O ring in dispensing valve body 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 43 2992 10 11 Thoroughly clean RELIEF VALVE item 9 then screw relief valve into FACEPLATE item 8 Proceed to Servicing Beater Motor Drive Shaft Seal Assemblies Servicing Freeze Cylinders Drive Shaft Seal Assemblies see Figure 13 IMPORTANT The freeze cylinders drive shaft seal assemblies must be removed and inspected every four months Their shafts and bearings must be inspected and replaced if necessary All O Ring seals must be replaced at this time NOTE Use Dow Corning DC 111 P N 321471000 light grade silicone lubricant 1 2 Pull BEATER item 13 and SCRAPER BLADES item 2 from freeze cylinder Using WRENCH item 11 LOOSE SHIPPED PARTS reach into the freeze cylinder and turn the drive shaft seal assembly to the right clockwise to unlock its four locking tabs from the notches in the freeze cylinder retainer Pull the assembly out of the freeze cylinder retainer using the beater as a puller Remove the coupling end fitting from the shaft by loosening the set screw in the coupling then slide cou pling off the shaft Remove
42. has occurred Unit will shut down go into sleep time and will not wake up return to normal operation until programmed WAKE UP WAKE UP TIME has occurred Program SLEEP SLEEP TIME into Unit as follows 1 Refer to PROGRAMMING MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up SLEEP on message display Press DEFROST SELECT switch to lock in on selection 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 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 Press ERROR RESET switch two times to exit from MENU SELECTIONS PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT WAKE UP WAKE UP TIME may be programmed into Unit to occur any time of the day to wake Unit up return to normal operation after sleep time has occurred Program WAKE 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 Press CANCEL DEFROST ADVANCE switch to bring up flashing hour n
43. more concentrated form because it will be diluted approximately four to one in product blender tank 16 17 18 19 20 21 22 23 24 25 26 Using clean empty soft drink tank prepare full tank of sanitizing solution using Chlor Tergent Oakite Prod uct Inc or equivalent sanitizer Mix sanitizing solution by using 70F to 100F max plain water and 2 65 oz gallon sanitizer This mixture will provide 800 ppm of chlorine Sanitizing solution will be diluted to approximately 200 ppm inside product blender tank after carbonated water has been mixed with sanitizing solution Shake sanitizing solution tank to thoroughly mix solution then connect tank into No 1 syrup system Press FILL 1 switch to fill No 1 syrup system syrup float switch with sanitizing solution SYRUP 1 fault message on message display will go out indicating syrup float switch has been filled with sanitizing solu tion Press AUTO BLEND 1 switch to fill No 1 product blender tank with sanitizing solution Carbonator water pump will start and begin pumping carbonated water into product blender tank which will dilute sanitizing solution also entering tank After carbonator water pump cycles off completely fill No 1 freeze cylinder with sanitizing solution by re peatedly pulling and releasing relief valve knob on freeze cylinder faceplate and until sanitizing solution comes out of relief valve port Open dispensing valve until sanitizing so
44. pump strainer screen as instructed Replace water pressure switch Replenish syrup supply as instructed Locate and correct error then press ERROR RESET switch to restore normal operation Repair electrical wires Replace master circuit board Replace master circuit board Properly connect flat cable to control switch module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace control panel switch module Repair wire Replace master circuit board 2992 Trouble DEFROST CYCLE DOES A CANCEL AFTER PRESSING CANCEL DEFROST SWITCH TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR Probable Cause Flat cable not properly connected to control switch module or master circuit board Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Inoperable CANCEL DEFROST switch on control panel switch module Master circuit board not operating properly 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 2992 B AUTO BLEND 1 or AUTO BLEND 2 switches have not been pressed H2O OUT fault message is on COs OUT fault message is on Loose or broken electrical wires Overheated water pump motor
45. tank Turn regulator adjusting screw out counterclockwise until gage reads 0 Pull up on the applicable product blender tank relief valve to release CO pressure from the tank Disconnect carbonated water line from the outlet side of the applicable carbonated water flow regulator Connect line long enough to reach to the outside of the Unit to the water flow regulator outlet then route the line to the outside of the Unit Place end of the carbonated water line routed to the outside of the Unit in the container Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to activate the electrically operated car bonated water solenoid When a steady stream of water is flowing from the added length of line catch carbonated water in a con tainer graduated in ounces for exactly 10 seconds Press applicable FILL 1 or FILL 2 switch to deacti vate the carbonated water solenoid In 10 seconds 12 to 14 ounces of water should have been dispensed If adjustment is necessary turn the regulator adjusting screw to the left counterclockwise to reduce car bonated water flow rate or turn the screw to the right clockwise to increase the flow rate Repeat steps 11 through 13 until the desired carbonated water flow rate is achieved Remove added length of line from the outlet side of the carbonated water flow regulator Connect the car bonated water line disconnected from the carbonated water flow regulator in step 8 precedi
46. up to the Unit 2 Before connecting the city plain water source line to the Unit open shutoff valve in city plain water source line for a period of time to flush out any metal shavings then close valve 3 Connect the city plain water source line to the Unit plain water inlet line Seal connection with TAPERED GASKET BLACK item 4 DO NOT OPEN THE CITY PLAIN WATER SOURCE LINE SHUTOFF VALVE AT THIS TIME CONNECTING ELECTRICAL POWER CIRCUIT TO THE UNIT see Figure 16 WARNING Make sure Unit 30 amp 60 Hz Unit or 50 amp 50 Hz Unit minimum rated disconnect switch not provided or equivalent HACR circuit breaker is in OFF position 60 HZ Unit IMPORTANT Power circuit voltage across L4 and Ls terminals on the contactor inside the lower electrical control box with refrigeration compressor operating must be in the range of 198 253 VAC 60 Hz single phase for proper operation Use No 10 AWG copper wire or larger depending upon line length in suitable conduit or BX sheath POWER CIRCUIT TO UNIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES 50 HZ Unit IMPORTANT Power circuit voltage across L4 and Ls terminals on the contactor inside the lower electrical control box with refrigeration compressor operating must be in the operating range of 209 253 VAC 50 Hz single phase for proper operation 2992 12 1 Remove cover from electrical box located in lower back side of t
47. 17771000 Level Level Control Switch Switch 315961000 Machine Screw Sl Rd 4 40 CETT 1 1 8 In Long 318123000 Switch Actuator Actuator 342663000 Thread Cutting Screw Phil Pan Hd Sems No 8 32 3 8 In Long 318362000 Relief Vave Valve 85 2992 FIGURE 41 PUMP AND MOTOR ASS Y Pump and Motor Ass y 230 220V 187502000 Fitting Eloow 3 8 MPT By 7 16 20 60 50HZ Domestic 311765001 Double Check Valve Ass y See Pump and Motor Ass y 230V 50HZ Figure 31 Export 311855000 J Nut 1 4 20 320626000 Motor 230 220V 60 50HZ 199020000 Motor 230V 50HZ Export 9 312062000 Fitting 1 4 NPT By 58 18 4 187483000 Clamp Pump to Motor 2992 86 FIGURE 42 BEATER MOTOR DRIVE SHAFT SEAL ASS Y O Ring 1 86 1 0 By 139 C S 2583 Retaining Ring 2731 O Ring 671 1 0 By 139 C S 87 2992 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 12
48. 22 VIENNA AUSTRIA 43 1 233 520 FAX 43 1 2335 2930 BELGIUM BOSKAPELLEI 122 e B 2930 BRAASCHAAT BELGIUM 32 3 664 0552 FAX 32 3 665 2307 BRAZIL RUA ITAOCARA 97 TOMAS COELHO RIO DE JANEIRO BRAZIL 55 21 591 7150 FAX 55 21 593 1829 ENGLAND TYTHING ROAD ALCESTER WARWICKSHIRE B49 6 EU ENGLAND 44 789 763 101 FAX 44 789 763 644 FRANCE 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 6 49 2173 7930 FAX 49 2173 77 438 GREECE e 488 MESSOGION AVENUE AGIA PARASKEVI e 153 42 ATHENS GREECE 30 1 600 1073 FAX 30 1 601 2491 HONG KONG 1104 TAIKOTSUI CENTRE 11 15 CHEUNG ST TAIKOKTSUE HONG KONG 852 789 9882 FAX 852 391 6222 ITALY VIA PELLIZZARI 11 1 20059 e VIMARCATE ITALY 39 39 608 0817 FAX 39 39 608 0814 NEW ZEALAND 20 LANSFORD CRES BOX 19 044 AVONDALE AUCKLAND 7 NEW ZEALAND e 64 9 8200 357 FAX 64 9 8200 361 SINGAPORE e 16 TUAS STREET SINGAPORE 2263 65 862 5542 FAX 65 862 5604 SPAIN POLIGONO INDUSTRAIL RIERA DEL FONOLLAR E 08830 SANT BOI DE LLOBREGAT BARCELONA SPAIN 34 3 640 2839 FAX 34 3 654 3379 USA ONE CORNELIUS PLACE ANOKA MINNESOTA 612 421 6120 FAX 612 422 3255 LD004 4 21 98 2992 88 THIS PAGE LEFT BLANK INT
49. 2992 82 11 FIGURE 36 DISPENSING VALVE ASSEMBLY 1 1556 Body and Shank 317784000 Thread Cutting Screw Phil Truss Hd Stainless Steel No 8 32 By 1854 ong 1576 321514000 O Ring Caged 562 I D By 325305000 11 321653000 862 I D 103 C S 321651000 12 Den 7 1698 Baja 83 2992 Carbonator Components 2682 Bracket Motor 309854000 Clamp 409 O D Tube 2 320767000 Machine Screw Phil Pan Hd No 10 24 By 3 8 In Long 4 326136000 Carbonator Tank Ass y See Figure 40 325777000 Switch Pressure 2833 Pump and Motor Ass y Domestic See Figure 41 2814 Pump and Motor Ass y Export See Figure 41 7 318976000 Machine Screw SI Hex Washer Hd 1 4 20 By 1 2 In Long EM 311855000 J Nut 1 4 20 317974000 Deflector Relief Valve 309379000 Tube Ass y See Figure 22 FIGURE 37 CARBONATOR COMPONENTS name Iesse Tae 375 10 Bye Lora 8 Tube 375 1 0 By 96 In Long 3 55 Q 5 3 FIGURE 38 TUBING ASSEMBLY 326002000 Drain Kit Drip Tray 2 170423000 Nut 5 8 32 151281000 Washer 640 I D 140133000 Clamp 687 8 113500039 Tube 500 LD By 60 In Long FIGURE 39 DRIP TRAY DRAIN KIT 2992 84 Termen canonar Tan ana usage er ww EH 318037000 2 Switch Ex 3
50. 67 70 71 72 73 74 75 76 7 7 2992 72 324120000 2472 Motor 1 4H P 220V 60HZ Klauber Motor 1 4H P 220 240V 50HZ Klauber 3471 Motor 1 8H P 208 240V 50 60HZ Emerson 2091 2108 Motor 1 4H P 220 240V 50HZ Fasco S 84 176272396 Tube Ass y 375 1 0 By 96 In Long Water Inlet See Figure 38 T T 92 324171000 Relay 230V 50 60HZ 10 Klauber only 93 320106000 Thread Rolling Screw Phil Pan Hd No 6 32 By 1 In Long 95 300200000 Motor 1 4H P 220V 60HZ Fasco EE Components z Tapered Gasket White 11 3049 Regulator Ass y See Figure 20 12 2684 Bracket Regulator 13 174061196 Tube Ass y Secondary Regulator See Figure 21 14 2827 Ass y Regulator See Figure 22 FIGURE 18 SECONDARY REGULATOR COMPONENTS BE EE Control Box Components 1 3310 Jump Cord Control Box to Electrical Box 325192 Snap Bushing 1 093 Dia 3 325940 Relay Start Domestic 197466 Relay Start Export 5 5 325939 Capacitor Run Domestic 2162 Capacitor Run Export s uo 8 32 By 1 4 In Long SERGE Cpe rad No 8 32 By 3 8 In Long FIGURE 19 CONTROL BOX COMPONENTS 73 2992 3049 Secondary Regulator Ass y 1 183287000 Gage 60 PSI 2 183449000 Regulator Ass y 30 PSI See Figure 23 183412000 Regulator Ass y 100 PSI
51. 8 i Um 71 35 36 37 320539000 343304000 319941000 Washer 191 1 0 Washer 204 1 0 Thread Rolling Screw Washer No 8 32 By 3 8 In Long Machine Screw Hex Washer Hd No 8 18 By 1 2 In Long 38 325282000 39 2685 Panel Top 3104 Panel Top Stainless Steel 40 3221 Panel Splash 42 186770000 Machine Screw Phil Rd Hd No 10 24 By 5 8 In Long 43 2671 Panel Side Right Side 3102 Panel Side Right Side Stainless Steel 44 2670 Panel Side Left Side 3101 Panel Side Left Side Stainless Steel 320754000 Tube Drain 2 1 4 In Long Stainless Steel 46 320776000 Strap Tube 47 325701000 Extension Foam Pack 48 0831 Retainer Syrup Lines 49 326106000 Door Ass y Freeze Cylinder See Figure 35 309316000 Motor Fan 230V 60HZ 35W Domestic 300835000 Motor Fan 230V 50HZ 35W Export 3113 Fan 5 Blade 45 50 51 52 53 a A 55 56 57 58 59 2944 Bracket Fan Motor 2844 Wire Harness Input Not Shown 2845 Wire Harness Output Not Shown 186154000 Machine Screw Phil Pan Hd No 8 36 By 3 8 In Long 62 63 64 325776000 325644000 325145000 Fe 2992 FCB POST MIX DISPENSER 325069000 Machine Screw SI Truss Hd No 10 24 By 1 2 In Long 326000000 Compressor Kit 2HP 230V 60HZ Domestic 65 324233000 Compressor Kit 2HP 230V 50HZ Export 10 16 By 5 8 In Long 3238 Bracket Beater Motor
52. ANCE 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 5 Keep pressing and releasing the CANCEL DEFROST ADVANCE switch until the applicable blinking Manufacturer s name appears on the message display This indicates the Manufacturer s name of the No 1 freeze cylinder beater motor new Unit installation or the new installed replacement motor 6 After applicable beater motor Manufacturer s name has been selected press the DEFROST SELECT switch which will match the beater motor to the Unit electronics The motor Manufacturer s name will no longer be blinking 7 Press the DEFROST SELECT switch to return to MOT MFG1 8 Press the CANCEL DEFROST ADVANCE switch to go from MOT to MFG represents No 2 freeze cylinder beater motor which will appear on the message display 2992 26 9 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 Refe
53. ATORS ARE ADJUSTED TO SEE PRECEDING IMPORTANT NOTE Tighten adjusting screw lock nut after each adjustment 4 Observe pressure setting on carbonator secondary CO regulator gage 5 To raise CO pressure turn regulator adjusting screw to the right clockwise until gage reads desired pres sure DO NOT SET PRESSURE HIGHER THAN 60 PSI Make sure primary CO regulator on CO cylin der is set at 80 to 100 psi Tighten adjusting screw lock nut after each adjustment 6 Install lower front access panel on Unit CLEANING AND SANITIZING DAILY CLEANING OF UNIT Daily or more often if necessary wash all external surfaces of Unit with a mild soap solution Rinse with clean water then wipe dry with a clean soft cloth DO NOT USE ABRASIVE CLEANERS Remove and wash drip tray in mild soap solution rinse with clean water then install drip tray on Unit 2992 48 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 parent company re quirements 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 identi
54. CE 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 3 Press ERROR RESET switch two times to exit fom MENU SELECTIONS DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be 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 2992 22 2 3 Press DEFROST SELECT switch to bring up evaporator refrigeration coils inlet and common outlet tem perature readings in degrees Fahrenheit Left Reading Refrigeration Coils Inlet No 1 Middle Reading Refrigeration Coils Inlet No 2 Right
55. DISPENSING VALVE item 2 is used to remove shank nuts securing dispensing valves to faceplates 3 CLEANING BRUSH item 3 is used to clean faceplate relief valves passages 4 TAPERED GASKET BLACK item 4 is used to seal connection when connecting plain water source line to Unit water inlet line 5 DRIP TRAY SUPPORTS item 7 and item 8 to be installed on front of Unit See Figure 7 and secured with Thread Cutting SCREWS item 6 and THREAD CUTTING SCREWS 18 6 CUP REST item 5 to be installed in DRIP TRAY item 9 then drip tray to be installed on drip tray sup ports 7 DRIP TRAY DRAIN HOSE KIT item 10 to be installed on drip tray as instructed in Instructions provided in the Kit 8 WRENCH REAR SEAL HOUSING item 11 used to remove the drive shaft seal assembly from inside the freeze cylinder 9 TOOL DRIVE COUPLER ADJUSTMENT GAUGE item 12 is used for servicing the beater motor drive shaft seal assembly See Figure 13 10 LEVELING LEGS item 13 are to be installed on bottom of the Unit 11 FRONT ACCESS PANEL item 15 to be installed on front of the Unit See Figure 7 and secured with WHITE SPACERS item 14 and SCREWS item 16 SPACERS TO BE INSTALLED BETWEEN THE FRONT PANEL AND THE UNIT FRAME ELECTRICAL POWER REQUIREMENTS IMPORTANT Before connecting electrical power to the Unit refer to nameplate and Note if Unit is to be operated with 50 or 60 Hz power source 50 HZ UNIT IMPORTANT Pow
56. DOES NOT OPERATE UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN DEFROST SWITCH IS PRESSED Probable Cause Master circuit board not operating Fault message display module not operating properly supply turned off or exhausted Primary regulator set too low Inoperable pressure switch Water supply turned off or water pressure inadequate Plugged water filter or water pump strainer screen Inoperative water pressure switch Soft drink tank empty Error within Unit has developed interrupting normal operation Loose or broken electrical wires Inoperable automatic defrost timer Automatic defrost timer stuck in automatic defrost cycle Flat cable not properly connected to control switch module or master circuit board Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Inoperable DEFROST switch on control panel switch module Loose or broken wire Master circuit board not operating properly 65 Remedy Replace master circuit board Replace fault message display module Open CO cylinder shutoff valve or replenish supply as instructed Adjust primary regulator as instructed Replace pressure switch Turn on water supply or check water supply line pressure Change water filter or clean water
57. EL TO REINSTALL THE PLASTIC SPACERS IN BETWEEN THE PANEL AND THE UNIT FRAME OPENING AND CLOSING FRONT ACCESS DOOR OPENING FRONT ACCESS DOOR Using a flat blade screwdriver turn lock counterclockwise to unlock the front access door see Figure 7 then open the door CLOSING FRONT ACCESS DOOR Close front access door then use a flat blade screwdriver to turn lock clockwise to lock the door LUBRICATION CARBONATOR WATER PUMP MOTOR see Figure 8 Carbonator water pump motor bearings must be lubricated periodically Refer to oiling instructions on motor DO NOT OVER OIL SERVICING DISPENSING VALVES CAGED O RINGS AND FREEZE CYLINDERS DRIVE SHAFT SEAL ASSEMBLIES Servicing Dispensing Valves Caged O Rings see Figure 9 NOTE Dispensing valves caged O Rings should be serviced lubricated every six months and O Rings should be replaced once a year 1 Defrost freeze cylinders shut Unit down disconnect electrical power from Unit close product shutoff valves in lines leading from the product blender tanks to the freeze cylinders then drain product from the freeze cylinders NOTE numbers in parentheses in this paragraph are in reference to Figure 3 2 Remove HEX NUTS item 7 and FLATWASHERS item 6 securing FACEPLATE item 8 to freeze cylin der then remove faceplate from cylinder 3 Carefully remove large O RING item 5 from FACEPLATE item 8 2992 42 RETAINING SPRING HOUSING 4 SCREW
58. ENTIONALLY 89 2992 CORNELIUS EECHER CORPORATE HEADQUARTERS One Cornelius Place Anoka Minnesota 55303 6234 612 421 6120 800 238 3600
59. GRAMMING DEFROST AUTOMATIC SETTINGS INTO UNIT 36 PROGRAMMING SLEEP SLEEP TIME INTO 36 PROGRAMMING WAKE UP WAKE UP TIME INTO UNIT 37 PROGRAMMING POINT OF SALE MESSAGE DISPLAY 37 ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT Me MIC CES MONROE EHE GEHE PP Tan 37 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES 37 VOLTAGE DISPLAYED VOLTAGE 37 PROGRAMMING COMPONENTS DIAGNOSE DIAGNOSTIC MODE INTO UNIT EE 37 DISPLAYING TOTALS DISPLAYED CYCLES AND HOURS TOTALS ONTO MESSAGE DISPLAY tay anv ec ace scent 37 PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS EE 37 DISPLAYED ERROR CONDITIONS 37 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE MAINTENANCE 2 6 Sa en adt apa aui ns tef 38 CLEANING CO2 GAS CHECK VALVES 38 SERVICE AND MAINTENANCE 39 PREPARING UNIT FOR SHIPPING STORING OR RELOCATING 39 PERIODIC INSPECTIONS ae ERUNT EErEE 39 REMOVAL OF TOP PANEL BACK PANEL SIDE PANELS AND FRONT ACCESS PANG Ls eo Latus tele a an E DRE 39 el TEE 39 BACK PANED olia avente bote 39 SIDE PANELS Sot ninth a on Kn A ti
60. ND 1 switch to fill No 1 product blender tank with product Carbonator water pump will start and begin pumping carbonated water into the product blender tank along with syrup to make product After carbonator water pump cycles off completely fill No 1 freeze cylinder with product by repeatedly pull ing and releasing faceplate relief valve and until product comes out of relief valve port Open dispensing valve until product flows from valve then close valve Open No 1 system product sample valve until prod uct flows from valve then close valve 2992 50 30 Press WASH 1 switch to start No 1 freeze cylinder beater Allow beater to operate for five minutes then press OFF 1 switch to stop beater 31 Disconnect soft drink tank containing syrup from No 1 syrup system 32 Connect clean empty soft drink tank into No 1 syrup system 33 Hold appropriate container under dispensing valve and dispense until all product has been dispensed from freeze cylinder As product level lowers in freeze cylinder partially close valve to avoid spurting 34 Place waste container under No 1 system product sample valve Slowly open valve and purge remaining product out of product blender tank 35 Disconnect empty soft drink tank from No 1 syrup system and install tank containing syrup 36 Press FILL 1 switch to fill No 1 syrup system syrup float switch with syrup SYRUP 1 fault message on message display will go out indicat
61. ON DIP SWITCH ANY TIME THE NO 4 BEATER MOTOR CURRENT READOUT SWITCH ON DIP SWITCH ASSEMBLY IS PLACED IN ON POSITION THE BEATER MOTOR CURRENT READINGS MUST BE READJUSTED TO A150 B150 2 AS INSTRUCTED THEN SWITCH MUST BE PLACED BACK IN THE OFF POSITION 6 Close front access door then use a flat blade screwdriver to turn lock clockwise to lock the door 7 Install FRONT ACCESS PANEL item 15 and SPACERS item 14 and secure with THREAD CUTTING SCREWS item 16 MAKE SURE SPACERS ARE INSTALLED BETWEEN THE FRONT ACCESS PANEL AND THE UNIT FRAME SEE FIGURE 7 ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS COMPONENTS DIAGNOSE DIAGNOSTIC MODE AND TOTALS DISPLAYED CYCLES AND HOURS TOTALS INTO UNIT NOTE The Unit control panel switches are as shown in Figure 5 The following instructions outline adjustments and programming main menu selections components DIAG NOSE DIAGNOSTIC MODE and TOTALS DISPLAYED CYCLES AND HOURS TOTALS into the Unit NOTE Plain water CO and syrup supplies to Unit must be satisfied to turn off OUT 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 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 sa
62. OST 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 23 2992 Displaying SYR MIN 1 SYR 2 message display will indicate time minutes syrup actually has been dispensed Refer to table and formula below to calculate how much syrup has been dispensed BRIK GALLONS x SYRUP MINUTES Note A numbers are based upon a 4 4 to 1 water to syrup ratio Using the table to the above choose the A num ber that corresponds to your BRIX setting Multiply the A number by the syrup minutes reading to ob tain the amount gallons of syrup used TABLE 8 TOTALS DISPLAYED CYCLES AND HOURS TOTALS MENU 2992 24 15 Press DEFROST SELECT switch No 1
63. R BEATER RELAY i MOTOR NOTOR pens o_o i 2 0 2 H 1 x amp 1 x I BRN BRN Ge Ee t HI PRESSURE WHT ATL E 3 2 CUTOUT Sr SIRE 1 ME CERE RELAY RELAY I RED WHT fo 23 23 pt 01 b anti EE 5 S WIRING FOR WATER COOLED UNIT ONLY 2 FLAVOR SHOWN T CONDENSER FAN WIRES REMOVED FIGURE 16 WIRING DIAGRAM KLAUBER MOTOR 2426 REV D 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 CO supply then relieve the System pressure before proceeding If repairs are to be made to the refrigeration system make sure electrical power is disconnected from the unit WARNING If repairs to be made 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 disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustm
64. RBONATOR TANK LIQUID LEVEL The carbonator tank liquid level pump cut in and cut out was adjusted at the factory and should require no fur ther adjustment However if incorrect setting is suspected check and make necessary adjustments as follows 1 Remove Unit back and side panels as instructed for access to carbonator and carbonated water volume sample valve see Figure 2 2 To check carbonator tank total fill allow carbonator water pump motor to operate and fill tank with carbon ated water After pump cycles off disconnect electrical power from Unit 57 2992 Using container graduated ounces open carbonator carbonated water sample valve and completely drain carbonator tank into container Total carbonated water volume dispensed should be 40 to 58 ounces maximum If total carbonated water dispensed is below 40 ounces loosen screw securing level control switches ac tuator bracket see Figure 14 and move actuator bracket up slightly If more than 58 ounces maximum of carbonated water was dispensed move actuator bracket down then tighten screw MAKE ADJUST MENTS IN SMALL INCREMENTS Connect electrical power to Unit and allow carbonator tank to fill with water until water pump cycles off Repeat steps 2 through 5 preceding as many times as necessary until correct carbonated water volume adjustment is achieved 2992 58
65. ST SWITCEH IS PRESSED x rre RR ohana Rie usas 2992 iv 63 64 64 64 64 65 65 TABLE CONTENTS cont d DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING CANCEL DEFROST SWITCH 66 TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR 66 CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE 66 CARBONATOR WATER PUMP WILL NOT SHUT 66 ERRATIC CARBONATOR WATER PUMP CYCLING 66 TROUBLESHOOTING DISPENSED PRODUCT 67 BRIX WATER TO SYRUP RATIO TOO LOW 67 BRIX WATER TO SYRUP RATIO TOO 67 IMPROPER PRODUCT DISPENSED 67 PRODUCT WILL NOT DISPENSE OUT OF DISPENSING VALVE IN ONLY SMALL AMOUNTS OR ONLY LIQUID 67 FREEZE CYLINDER DOES REFILL AT ALL TIMES WHEN DISPENSING Ne nae EE 67 FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY 67 CYLINDER FREEZE UP 68 E EEN 88 LIST FIGURES FIGURE 1 FCB OVERCOUNTER POST MIX DISPENSER 1 FIGURE 2 FLOW DIAGRAM E EEE 5 FIGURE 3 FREEZE CYLINDER CUTAWAY VIEW 10 FIGURE 4 BEATERS AND SCRAPER BLADES INSTALLATION 11 FIGURE 5 CONTROL PANEL ASS Y 15 FIGURE 6 MASTER AND RELAY CIRCUIT BOARD
66. VANCE switch to bring up flashing hour number on display 3 Press CANCEL DEFROST ADVANCE switch to advance hours on display to desired hour Press DE FROST SELECT switch to lock in hour on display 4 After hour time of day has been locked in on message display minute numbers will be flashing on display Press CANCEL DEFROST ADVANCE switch to advance minute numbers to desired minutes time of day Press DEFROST SELECT switch to lock in minute time of day on display 2992 18 Press DEFROST SELECT switch then repeat steps 2 3 and 4 to program next defrost time setting MAKE SURE A MINIMUM OF TWO HOURS IS MAINTAINED BETWEEN DEFROST TIME SETTINGS IF A TIME SETTING OF LESS THAN TWO HOURS IS PROGRAMMED INTO THE UNIT A MOMENTARY ERROR MESSAGE WILL APPEAR ON THE MESSAGE DISPLAY WHEN OPERATOR TRIES TO EXIT DEFROST THE PROGRAM WILL NOT ALLOW THE OPERATOR TO EXIT THE DEFROST SETTING UNTIL THE LESS THAN 2 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 Repeat step 5 as many times as necessary to program desired number of defrost time settings into the Unit 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
67. VES The two product shutoff valves located in lines leading from the product blender tanks to the freeze cylinders see Figure 2 and 8 are manually operated lever type ball valves and are used to prevent product from enter ing and filling freeze cylinders while adjusting BRIX of dispensed product Shutoff valves may also be used to shut off product to individual freeze cylinder for service and maintenance without disrupting operation of other freeze cylinder PRIMARY REGULATOR The primary regulator see Figure 2 controls pressure to the soft drink tanks and the Unit secondary regulators located behind the lower front access panel If necessary to adjust the primary CO regulator adjust as instructed in the SERVICE AND MAINTENANCE section SECONDARY CO REGULATORS The secondary CO regulators located behind the lower front access panel see Figure 2 and 8 control pressure to the carbonator and the product blender tanks If necessary to adjust the secondary CO regulators adjust as instructed in the SERVICE AND MAINTENANCE section CARBONATED WATER FLOW REGULATORS The adjustable carbonated water flow regulators see Figure 2 and 8 located behind the front access panel control carbonated water flow rate to the product blender tanks The water flow regulators are factory adjusted at 1 3 0 05 oz sec and should not normally require adjustment If adjustment is necessary adjust as instructed in t
68. X NUTS 17 Turn dispensing valve spring housing to the left counterclockwise to put tension on torsion spring then tighten hold down plates to secure spring housing 18 Test dispensing valve to make sure it closes by itself when lever is released If not readjust torsion spring tension 19 Sanitize syrup system as instructed in CLEANING AND SANITIZING then return Unit to operation CLEANING CONDENSER COIL see Figure 8 NOTE The FCB Dispenser refrigeration system is equipped with a condenser coil see Figure 8 that is cooled by two condenser coil fans Circulating air required to cool the refrigeration system s condens er coil is drawn in through grilled panel on the right hand side and is exhausted out through the oppo site side and back grilled panels Restricting air circulation through the Unit will decrease its cooling efficiency THE CONDENSER COIL MUST BE CLEANED PERIODICALLY AS INSTRUCTED Periodically clean condenser coil as follows 1 Press OFF 1 and OFF 2 switches on Unit control panel to stop refrigeration system and beaters mo tors Remove Unit right side panel as instructed Clean condenser coil with vacuum cleaner low pressure compressed air or a soft brush PG ws Install Unit right side panel as instructed 5 Press AUTO 1 and AUTO 2 switches on Unit control panel to start refrigeration system and beaters motors ADJUSTMENTS ADJUSTING PLAIN WATER PRESSURE REGULATOR
69. and water inlet supply lines shutoff valves Check for water leaks and tighten any loose connections 11 Close front access door then use a flat blade screwdriver to turn lock clockwise to lock the door 12 Install back panel by reversing the removal procedure 13 Connect electrical power to Unit 14 Press both AUTO BLEND 1 and AUTO BLEND 2 switches 15 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 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 sys tem IMPORTANT The following and liquid disconnect and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows 2 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 thr
70. cal to No 1 syrup system with exception of using applicable system switches Proceed as follows 1 Press OFF 2 switch to stop beater motor and refrigeration in No 2 freeze cylinder which is not to be de frosted OFF 2 fault message will appear on message display Press DEFROST switch to start defrost cycle on No 1 freeze cylinder DEFROST 1 message will ap pear on message display as long as defrost cycle is in progress Immediately press AUTO 2 control switch to restart beater in No 2 freeze cylinder Refrigeration in No 2 cylinder will not be operating Remove right hand side panel as instructed for access to No 2 product blender tank shutoff valve Close No 2 product blender tank shutoff valve to prevent product bleeding back into the No 1 product blender tank during sanitizing procedure IMPORTANT The following and liquid disconnects disconnecting and connecting procedures for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows 6 13 14 To disconnect soft drink tank from Unit syrup system A Disconnect liquid disconnect soft drink tank NOTE Disconnecting liquid quick disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustments Second disconnect quick disconnect from soft drink tank To connect soft drink tank into Unit syrup syst
71. ch control switch module or master module or master circuit circuit board board 63 2992 Trouble ALL CONTROL PANEL SWITCHES NOT OPERATING cont d CONTROL PANEL SWITCHES CANNOT BE DEACTIVATED PARTIAL MESSAGE OR DULL POORLY ILLUMINATED DISPLAY ONE OR MORE FAULT MESSAGES NOT OPERATING ALL FAULT MESSAGES NOT OPERATING 2992 Probable Cause Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable Master circuit board not operating properly Not pressing and holding SECURITY SWITCH for 3 seconds to deactivate control switches SECURITY SWITCH inoperable Extremely low voltage Flat cable not properly connected to fault message module or master circuit board Flat cable connected between fault message module and master circuit board pinched and shorted out or broken wire in cable External sensing device failing to signal master circuit board which in turn signals fault message display External sensing devices cable connectors not securely connected to master circuit board connectors Disconnected or broken wire between master circuit board connector and external sensing device Master circuit board not operating properly Fault message display module not operating properly No electrical power to Unit Flat cable not properly connected to fault message module or master circuit board Flat cabl
72. cted 4 Remove one bolt and two hex nuts and two lockwashers securing motor to Unit frame 5 Very carefully pull motor back off two mounting studs and disengage motor shaft and plastic coupler from freeze cylinder drive shaft 6 Lower motor down to Unit bottom platform then turn motor for access to it s electrical wiring cover plate 7 Remove two screws securing the electrical wiring cover plate then remove plate for access to electrical terminals 8 Tag beater drive motor electrical wiring for identification then disconnect wiring from terminals 9 Remove old beater drive motor from inside Unit 10 Remove plastic coupler from the old beater drive motor shaft and install on the new motor shaft MAKE SURE THE ALLEN HEAD SET SCREWS ARE SECURELY TIGHTENED AND PROPERLY SEATED ON THE SHAFT FLAT SURFACE 11 Install new beater drive motor in the Unit by reversing removal procedure CAUTION The new beater drive motor has a screw in the vent hole on top of the gear box that must be removed before the motor is put into operation 12 Remove screw from the vent hole on top of the beater drive motor gear box 13 Install Unit back and both side panels by reversing removal procedures 14 Restore the Unit to operation 15 Refer to PROGRAMMING FREEZE CYLINDER BEATER MOTORS INTO UNIT ELECTRONICS in the INSTALLATION section to program the new replacement beater motor into the Unit to match the Unit elec tronics ADJUSTING CA
73. 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 2 OUT fault message goes on and off intermittently and water pump cycles on and off during carbonator tank fill cycle 66 B A B Remedy Properly connect flat cable to control switch module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace control panel switch module Replace master circuit board 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 ha
74. dary regulators and product sample valves 2 Check product blender tanks secondary CO regulators with 60 psi gages for proper pressure settings which are set at 25 to 30 psi for best textured dispensed product If adjustment is necessary adjust as instructed 3 Remove both Unit side panels as instructed for access to product shutoff valves located close to product blender tanks 4 Close product shutoff valve in line between applicable product blender tank and associated freeze cylinder BRIX adjustment will be performed on 5 Press applicable FILL 1 or FILL 2 switch to prevent more product from filling product blender tank 6 Open applicable product blender tank sample valve and take sample approximately 6 ounces of product in cup 47 2992 NOTE Temperature compensated hand type refractometers P N 511004000 are available from the Cornelius Company 7 Observe pressure setting on carbonator secondary CO regulator gage 8 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill product blender tank 1 4 full of new batch of product When product blender tank is 1 4 full of product press applicable FILL 1 or FILL 2 switch to prevent more product from entering product blender tank 9 Repeat steps 6 and 7 preceding to check product sample for BRIX 10 Repeat steps 7 through 10 preceding until proper BRIX adjustment is achieved 11 Open product shutoff valve in line between product blend
75. dispensed product Adjust dispensed product not properly adjusted viscosity as instructed 68 FCB OVERCOUNTER POST MIK DISPENSER WITH V3 FEATURES UNIT PART NUMBERS 416136 496136 ILLUSTRATED PARTS BREAKDOWN 2992 FIGURE 17 OVERCOUNTER FCB POST MIX DISPENSER 70 2992 FCB POST MIX DISPENSER 1 325457000 2 3432 3 326002000 Blade Scraper Body Beater Tube Kit Drain Tube Not Shown See Figure 39 2613 Bracket Receiver and Accumulator Secondary Regulator Components See Figure 18 Control Box Components See Figure 19 Filter Solenoid Blender and Tubing Components See Figure 25 2392 Bushing Flange 501 LD 10 178025100 11 Tapered Gasket White Control Box and Display Panel Components See Figure 34 Cup Rest Drip Tray 12 317660000 13 317659029 14 2623 15 150777000 16 186147000 3108 Thread Cutting Screw Phil Pan Hd No 10 32 By 1 In Long 3234 Plate Beater Motor Left Side Klauber 120227000 3236 Plate Beater Motor Left Side Emerson 3235 Plate Beater Motor Right Side Klauber 3237 Plate Beater Motor Right Side Emerson 33 200498003 Hex Nut No 8 32 34 3193 Drive Shaft Seal Ass y See Figure 42 4 2 7 ser 18
76. e around valve shaft 7 Check CO connections for leaks Tighten loose connections SYRUP FLAVOR CHANGE One or both syrup flavors can be changed at the same time Perform flavor change on one system as follows 1 Sanitizing procedure on syrup system and syrup flavor change will be made as instructed 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 2992 54 gt 5 gt ul ua oc Oe a qx wt tc tr 5 KO gt a NO I lt 4 2 JE ax o GE gt o Do Se 1 Y3 T SP 29 EG S 29 gu 25 ng VL 5 gt on gt ba f OL KON a CRE o Je e 2 S Ce WAN S S tc 2 ea E S S Xo 9 S E e 9 lt 3 gt 5 T LE o e 9 59 rg lt 5 5 6a od a 2 D lt a gt d gt o zg S ro Sz W tc tc 5 5 m o tc 2992 FIGURE 11 WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE 55 2 disconnect soft drink tank from Unit syrup system A Disconnect liquid disconnect from soft drink tank NOTE Disconnecting liquid disconnec
77. e connected between fault message module and master circuit board pinched and shorted out or broken wire in cable 64 Remedy Check cable for pinched or broken wire condition and repair or replace as necessary Replace master circuit board Press and hold SECURITY SWITCH for 3 seconds to deactivate control switches Replace control panel switch module Upgrade voltage Properly connect flat cable to fault message module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Replace or repair external sensing device Make sure external sensing devices cable connectors are securely connected to master circuit board connectors Connect or repair wire between master circuit board connector and external sensing device Replace master circuit board Replace fault message display module Connect electrical power to Unit Properly connect flat cable to fault message module or master circuit board Check cable for pinched or broken wire condition and repair or replace as necessary Trouble ALL FAULT MESSAGES OPERATING OUT FAULT MESSAGE GOES ON DURING OPERATION H20 OUT FAULT MESSAGE GOES ON DURING OPERATION SYRUP 1 OR SYRUP 2 FAULT MESSAGE GOES ON DURING OPERATION ERROR 1 OR ERROR 2 FAULT MESSAGE GOES ON DURING OPERATION FREEZE CYLINDER AUTOMATIC DEFROST CYCLE
78. e drops below 50 psi A minimum pressure of 75 psi must be available to Unit to extinguish COs OUT fault message 2992 30 SYRUP 1 or SYRUP 2 Fault Messages SYRUP 1 or SYRUP 2 fault messages will appear on message display if product tanks are not connected to Unit or product tanks are empty Syrup systems syrup float switches must be filled with syrup to extinguish SYRUP 1 or SYRUP 2 fault messages DEFROST 1 or DEFROST 2 Display Messages DEFROST 1 or DEFROST 2 display messages will appear on message display if either freeze cylinder is in defrost mode DEFROST 1 or DEFROST 2 messages will remain on during defrost cycle and will disappear when cycle has ended POINT OF SALE Display Message Three POINT OF SALE display messages are available to choose from and may be programmed into Unit as instructed to appear on message display Common Outlet Temperatures Evaporator refrigeration coils inlet 1 and inlet 2 and common outlet temperatures may be displayed on the con trol panel message display as instructed FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS The Unit is equipped with both manual and automatic hot gas defrost systems The automatic defrost system may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours be tween defrost time settings or the system may be completely t
79. em A First connect CO quick disconnect to soft drink tank to pressurize tank B Second connect liquid quick disconnect to soft drink tank Disconnect soft drink tank containing syrup from No 1 syrup system Connect clean empty soft drink tank into No 1 syrup system 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 Remove Unit lower front access panel as instructed for access to No 1 product blender tank product sam ple valve 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 Disconnect empty soft drink tank from No 1 syrup system Refer to SERVICING DISPENSING VALVES CAGED O RINGS AND FREEZE CYLINDERS DRIVE SHAFT SEAL ASSEMBLIES under LUBRICATION and perform procedure to lubricate dispensing valve caged O ring and drive shaft seal assembly WARNING To avoid possible injury or property damage do not attempt to remove soft drink tank cover until pressure has been released from tank 49 2992 15 Pull up empty soft drink tank cover relief valve to release pressure from tank prior to adding to soft drink tank WARNING If powder type sanitizer is used it must be thoroughly dissolved with water NOTE Sanitizing solution is used in a
80. em 9 on drip tray supports 3 Place CUP REST item 5 in drip tray INSTALLING DRIP TRAY DRAIN HOSE KIT ITEM 10 Install DRIP TRAY DRAIN HOSE KIT item 10 on Unit as instructed in Installation Instructions provided with the Kit PREPARING UNIT FOR CONNECTION TO SYRUP COs AND CITY PLAIN WATER SOURCES Route coiled up syrup CO and plain water lines out through hole provided in the Unit base INSTALLING PRIMARY REGULATOR ASSEMBLY ON CO CYLINDER see Figure 2 WARNING To avoid personal injury and or property damage always secure CO cylinder upright position with a safety chain to prevent it from falling over Should the valve become accidentally damaged or broken off CO cylinder can cause serious personal injury 9 2992 2666 Ol 18 26 20 7 22 23 5 10 13 16 19 22 25 Product Inlet Fitting Relief Valve Port Hex Nut 4 Valve Lever Beater Drive Pin Beater Motor Drive Shaft Viscosity Sensor Shaft Release d dei g ERN ULL tit 25 N P E 10 1 i 24 14 27 2 13 3 4 12 2 Scraper Blade 2 3 Evapo
81. ent B Second disconnect CO quick disconnect from soft drink tank 2 To connect soft drink tank into Unit syrup system A First connect CO quick disconnect to soft drink tank to pressurize tank B Second connect liquid quick disconnect to soft drink tank 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 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 es on C Replace control panel switch control 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 electric power to Unit SWITCHES NOT OPERATING from Unit B SECURITY SWITCH has B Press and hold SECURITY not 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 D Flat cable not properly D Properly connect flat cable to connected to control swit
82. er Secure tank quick disconnect Adjust BRIX of dispensed product as instructed Water flow regulator must be set at 1 3 0 05 oz sec Clean syrup flow regulators Sanitize Unit as instructed Change syrup supply as instructed Adjust BRIX of dispensed product as instructed Water flow regulator must be set for 1 3 0 05 oz sec Clean regulator Change syrup supply as instructed Replace water filter Adjust secondary CO regulators as instructed Replace CO supply as instructed Open and close dispensing valve repeatedly Defrost freeze cylinder as instructed If necessary check and adjust as instructed Adjust viscosity of dispensed product as instructed Refer to CYLINDER FREEZE UP Press AUTO BLEND 1 or AUTO BLEND 2 switch Check carbonator and restore to operation Sanitize Unit as instructed a Clean regulator s 2992 Trouble FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY CYLINDER FREEZE UP 2992 B Probable Cause Remedy Primary regulator b Primary regulator must be pressure insufficient adjusted from 80 to 100 psi Cylinder freeze up causing B Refer to CYLINDER ice formation in center of FREEZE UP cylinder and liquid product channels around ice formation NOTE DEFROST AFFECTED FREEZE CYLINDER AS INSTRUCTED Dispensed product BRIX too A Refer to BRIX Water to Syrup low Ratio too low Viscosity of
83. er circuit voltage across L4 and Ls terminals on contactor inside lower control box with refrigeration compressor operating must be in range of 209 253 VAC 50Hz single phase for proper operation A properly grounded 209 253 VAC 50Hz single phase electrical circuit connected through a 30 amp minimum rated disconnect switch not provided fused at 30 amps slow blow must be available to be connected to the electrical box located in the lower back side of the Unit 60 HZ UNIT IMPORTANT Power circuit voltage across L4 and Lo terminals on contactor inside lower electrical control box with refrigeration compressor operating must in range of 198 253 VAC 60 Hz single phase for proper operation A properly grounded 198 253 VAC 60Hz single phase electrical circuit connected through a 30 amp minimum rated disconnect switch not provided fused at 30 amps slow blow or circuit connected through an equivalent HACR circuit breaker must be available to be connected to the electrical box located in lower back side of the Unit ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES MAKE SURE UNIT IS PROPERLY GROUNDED SELECTING LOCATION IMPORTANT Unit operating ambient temperature MUST NOT EXCEED 100 F Operating ambient in excess of 100 F will automatically void the factory warranty and will eventually result in Unit failure Several means are available to achieve proper ambient temperature and air circulation around the Unit which are wall a
84. er tank and freeze cylinder 12 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch 13 Install Unit side panels and lower front access panel by reversing removal procedures 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 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 lower front access panel as instructed for access to carbonator secondary CO regulator with 100 psi gage 2 Observe pressure setting on carbonator secondary regulator gage 3 To lower pressure loosen regulator adjusting screw lock nut Turn adjusting screw to the left counter clockwise until pressure gage reads 15 psi below desired reading then turn screw to the right clockwise until gage reads desired pressure DO NOT SET REGULATOR PRESSURE BELOW 25 PSI ER THAN PRODUCT BLENDER TANKS REGUL
85. er 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 ADJUSTING PRIMARY co REGULATOR IMPORTANT If bag in box syrup supply system will be connected to the Unit instead of soft drink tanks primary regulator see Figure 2 must be adjusted to no less than 80 psi 1 Adjust primary CO regulator see Figure 2 by turning regulator adjusting screw to the right clockwise until regulator pressure reads 80 to 100 psig OUT OF warning light on control panel message display should have gone out 2 Using a flat blade screwdriver turn lock counterclockwise to unlock the front access door see Figure 7 then open the door for access to the product blender tanks relief valves see Figure 8 3 Pull up on product blender tanks relief valves see Figure 8 to purge air from tanks ADJUSTING PRODUCT BLENDER TANKS SECONDARY Check product blender tanks secondary CO regulators with 60 psi gages see Figures 2 and 8 for pressure set ting which should be set at 25 to 30 psi for best textured product If further adjustment is necessary adjust as instructed ADJUSTING CARBONATOR SECONDARY CO REGULATOR IMPORTANT The carbonator secondary regulator must be adjusted 25 psi higher or more above the product blender tanks secondary CO regulators pressure settings Carbonated water and syrup pressures must be able to ove
86. frost system may be activated at any time by pressing the DEFROST switch on front of the Unit Refrigeration compressor will operate for a short time then both freeze cylinders will go into defrost and defrost for approximately 60 seconds At the end of the manual defrost cycle the Unit will return to normal opera tion Manual defrost may be cancelled at any time by pressing the CANCEL DEFROST switch AUTOMATIC DEFROST SYSTEM The automatic hot gas defrost system may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours between defrost settings At the start of each automatic defrost cycle refrigeration compressor will operate for 30 seconds to pump freon out of the freeze cylinders evaporator coils After freon has been pumped out of the freeze cylinders evaporator coils No 1 freeze cylinders only will go into defrost cycle and defrost for approximately 7 minutes then will return to normal operation This ends the automatic defrost cycle of No 1 freeze cylinder No 2 freeze cylinder will defrost 30 minutes after the start of No 1 freeze cylinder The next automatic defrost cycle will occur according to the time programmed into the Unit Automatic defrost may be cancelled at any time by pressing the CANCEL DEFROST switch 3 2992 SLEEP SLEEP TIME SLEEP SLEEP TIME may be programmed into Unit to allow Unit to go into sleep time Unit shut down freeze cylinders beater
87. frozen Transparent faceplate attached to the front of each freeze cylinder includes a self closing dispensing valve and a spring loaded relief valve that protects freeze cylinder from accidental over pressure The relief valve is also used to bleed gas pressure from the freeze cylinder to the atmosphere when filling the cylinder with product Electronic sensing on each freeze cylinder motor provides a means of adjusting viscosity consistency of the dispensed product to suit customer preference 2992 2 Table 2 Accessories and Tools ACCESSORIES 115 51100500 51100600 51103500 up Holder up Holder O Changeover Kit OI OO 5 E gp m Ct 5 2 N ENERIC FLAVOR TABS ola herry range rape Lemon Lime trawberry Dues fn 1089 uji 2 Banana gt 0 D D ERVICE TOOLS gallon Sanitizing Tank panner Wrench Dispensing Valve 28188400 32285900 51100400 289 ool Drive Coupler Adjustment Gauge 381 D ECH Q ce 3 D D 2 0 2 D D Co D I o c o 2 DEFROST SYSTEMS The Unit is equipped with both manual and automatic hot gas defrost systems The automatic defrost system may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours between defrost time settings or the system may be completely turned off MANUAL DEFROST SYSTEM The Manual hot gas de
88. ghly inspected before leaving the factory and the carrier has accepted 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 After Unit has been unpacked remove shipping tape and other packing material 2 Remove Unit sides and back panels as instructed 3 Remove shipping bolts that secure Unit to skid then remove skid 4 Unpack LOOSE SHIPPED PARTS Make sure all items are present and in good condition Table 3 Loose Shipped Parts lt 1 78025100 Tapered Gasket White 1 Spanner Wrench Dispensing Valve 3 Cleaning Brush 4 Tapered Gasket Black 5 Cup Rest Thread Cutting Screw Hex Hd No 8 by 18 by 1 2 in long 7 Drip Tray Support Left Drip Tray Support Right Drip Tray 10 Kit Drip Tray Drain Hose Wrench Rear Seal Housing Tool Drive Coupler Adjustment Gauge 13 Leveling Leg 14 Spacer White Numbers in parentheses in reference to items in Figure 3 ech N IDENTIFICATION OF LOOSE SHIPPED PARTS 1 TAPERED GASKETS WHITE item 1 are used to seal connections when connecting Unit product inlet lines to product tanks and connecting Unit inlet line to source 7 2992 2 SPANNER WRENCH
89. he SERVICE AND MAINTENANCE section SYRUP FLOW REGULATORS The syrup flow regulators located behind the front access door see Figure 2 and Figure 8 are adjustable regu lators that control syrup flow rate to the product blender tanks for desired BRIX of dispensed product Adjust syrup flow regulators for desired BRIX as instructed in the SERVICE AND MAINTENANCE section DISPENSING VALVES Self closing dispensing valves see Figure 9 located on faceplates on front of Unit are operated one at a time or simultaneously to deliver product to the customer 2992 32 DISPENSED PRODUCT CONDITIONS OVERRUN AS APPLIED TO FROZEN CARBONATED BEVERAGES Overrun Defined Overrun is product expansion that takes place in the frozen carbonated drink is caused primarily by CO gas breakout and secondary by freezing Overrun is a Variable The percentage or degree of overrun depends on a number of factors The specific syrup BRIX low dispensing volume carbonation level in liquid product and freezing all affect overrun After these factors have been 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
90. he Unit WARNING The Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator A green screw with lock washer is provided inside the electrical box to connect power circuit ground wire which will electrically ground the Unit 2 Connect electrical power circuit from a 30 amp 60 Hz Unit or 30 amps 50 Hz Unit minimum rated discon nect switch not provided fused at 30 amps 60 Hz Unit or 30 amps 50 Hz Unit slow blow or through an equivalent HACR circuit breaker to electrical wires inside the electrical control box Secure the connections with red wire nuts MAKE SURE GROUND WIRE IS CONNECTED TO GREEN GROUND SCREW INSIDE THE ELECTRICAL BOX 3 Install the electrical box cover and secure with screws PREPARATION FOR OPERATION TURNING ON ELECTRICAL POWER TO UNIT Turn on electrical power to the Unit Operational status of the Unit is now being displayed as fault messages on the control panel message display The following fault messages will be continuously displayed at 2 second inter vals until necessary operation requirements are satisfied OFF 1 Beater Motor No 1 not operating OFF 2 Beater Motor No 2 not operating H2O OUT No water supply to Unit CO OUT No CO gas supply to Unit SYRUP 1 No syrup supply to Unit No 1 syrup system SYRUP 2 No syrup supply to Unit No 2 syrup system TURNING ON SUPPLY TO the UNIT 1 Open CO cylind
91. ift panel straight up to remove 39 2992 AUTO BLEND 1 CANCEL AUTO DEFROST DEFROST BLEND 2 SELECT ADVANCE FAULT MESSAGE DISPLAY CONTROL PANEL HIDDEN SECURITY SWITCH BACK PANEL TOP PANEL TOP PANEL RETAINING VENTILATION LOUVERS SCREW 2 A 227 222 22222 2 CONTROL PANEL S 2222 2222 FACEPLATE RELIEF 2 2222 22 VALVE 4 EA BA CUP REST 2 22 FRONT ACCESS ZDISPENSING VALVE 2 DRIP TRAY BRACKET SIDE 2 RETAINING SCREW 2 sp SE PANEL M FACEPLATE 2 DRIP TRAY BRACKET ACCESS PANEL SPACER ACCESS PANEL ITEM 14 RETAINING SCREW LOWER FRONT NOTE The No 1 freeze cylinder is the left hand ITEM 16 ACCESS PANEL cylinder facing the front of the Unit No 2 freeze cylinder is to the right of No 1 freeze cylinder FIGURE 7 OPERATING CONTROLS 2992 40 REFRIGERATION MPRESSOR co SSO CONDENSER COIL PRODUCT BLENDER TANK 2 FREEZE CYLINDER 2 BEATER DRIVE MOTOR 2 ACCUMULATOR SECONDARY CO REGULATOR 3 FIGURE 8 UNIT INTERNAL COMPONENTS 41 2992 FRONT ACCESS PANEL Remove two screws securing front access panel then remove panel and plastic spacers from the Unit MAKE SURE WHEN REINSTALLING THE FRONT ACCESS PAN
92. ing air intake to the inside of the Unit Air flow through the Unit must be present to provide adequate cooling for the refrigeration system Refer to SELECTING LOCATION for sides top and front clearances to be observed when placing Unit in operating position 2 Referring to the preceding NOTE very carefully place the Unit in operating location 3 Make sure the Unit is sitting level The Unit may be leveled by using a carpenter s level and adjusting the four leveling legs installed on the Unit during installation 4 Restore Unit to operation by connecting electrical power at the electrical power source disconnect switch ADJUSTING BEATER MOTOR CURRENT EITHER SIDE Adjusting beater motor current either side procedure is very important and must be performed as instructed Be sure you fully understand the instructions before performing the current adjustments or doing any preventative maintenance current readings check IMPORTANT Any current adjustments or preventative maintenance current readings check on the beater motor current either side must be performed with both freeze cylinders fully defrosted A partially defrosted freeze cylinder will cause false current readings to be displayed on the message display Adjust beater motor current either side as follows 1 Using a flat blade screwdriver turn lock counterclockwise to unlock the front access door see Figure 7 then open the door 2 Remove four screws securing the upper e
93. ing syrup float switch has been filled with syrup 37 Press AUTO BLEND 1 switch to fill No 1 product blender tank with product Carbonator water pump will start and begin pumping carbonated water into product blender tank along with syrup to make product in cylinder and lose carbonation CAUTION Do not relieve freeze cylinder pressure too fast or product will foam excessively 38 After carbonator water pump cycles off intermittently pull and release No 1 freeze cylinder faceplate relief valve This bleeds from freeze cylinder and allows product to enter and fill cylinder 39 Open No 2 product blender tank product shutoff valve 40 Press both AUTO 1 and AUTO 2 switches to start both freeze cylinders beaters and refrigeration sys tem Product will be ready for dispensing in approximately 10 minutes 41 Install right hand side panel and lower front access panel by reversing removal procedure YEARLY OR AFTER WATER SYSTEM DISRUPTION valve must be Inspected and serviced after any disruptions plumbing work earthquake WARNING The carbonator water pump water strainer screen and double liquid check 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 gas could then back flow into water system and create a health hazard in the water system
94. ir intake grilles and ceiling exhaust fans air conditioning etc Consult local codes 2992 8 Locate the Unit so the following requirements are satisfied 1 Locate close to a filtered plain water inlet supply line with a minimum water pressure of 12 psig NOTE The FCB Dispenser refrigeration system is equipped with a condenser coil that is cooled by two condenser coil fans Circulating air required to cool the refrigeration system s condenser coil is drawn in through the grilled panel on the right hand side and is exhausted out through the opposite side grilled panel Restricting air circulation through the Unit will decrease its cooling efficiency 2 When installing Unit in it s operating position do not allow obstructions to block sides top and front of the Unit which will block off cooling air intake to the inside of the Unit Air flow through the Unit must be present to provide adequate cooling for the refrigeration system Locate the Unit to provide the following clearances Top of unit Open 24 inches Back side 0 inches Sides 6 inches min Front Open INSTALLING UNIT INSTALLING LEVELING LEGS Very carefully tilt Unit up and install LEVELING LEGS item 13 on four corners of the Unit base INSTALLING DRIP TRAY SUPPORTS ITEM 7 AND ITEM 8 1 Install DRIP TRAY SUPPORT LEFT item 7 and DRIP TRAY SUPPORT RIGHT item 8 on front of the Unit and secure with SCREWS item 6 See Figure 7 2 Place DRIP TRAY it
95. izing solution must be purged from syrup systems All water must also be purged from plain and carbonated water systems A freezing ambient environment will cause residual sanitizing solution or water remaining inside Unit to freeze resulting in damage to internal components PERIODIC INSPECTION 1 Make sure CO cylinder valve is fully opened and primary CO cylinder regulator assembly 1800 psi gage indicator is not in shaded change CO cylinder portion of dial If so CO cylinder is almost empty and must be replaced 2 Make sure soft drink tanks contain sufficient amount of syrup for Unit operation 3 The FCB Dispenser refrigeration system is equipped with a condenser coil see Figure 8 that is cooled by two condenser coil fans Circulating air required to cool the refrigeration system s condenser coil is drawn in through grilled panel on the right hand side and is exhausted out through the opposite side and back grilled panels Restricting air circulation through the Unit will decrease its cooling efficiency THE CON DENSER COIL MUST BE CLEANED PERIODICALLY AS INSTRUCTED IN THE SERVICE AND MAIN TENANCE SECTION REMOVAL OF TOP PANEL BACK PANEL SIDE PANELS AND FRONT ACCESS PANEL see Figure 7 TOP PANEL Remove two screws securing the top panel then lift panel up off Unit BACK PANEL Remove one screw securing back panel then lift panel straight up to remove SIDE PANELS Remove screw securing side panel then l
96. just prior to point capacity is exceeded and drink dispensed will turn slightly wetter see Drawing 3 OPERATING UNIT NOTE The No 1 freeze cylinder see Figure 7 is the left hand cylinder facing the front of the Unit No 2 freeze cylinder is to the right of No 1 freeze cylinder 1 Make sure H2O 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 not displayed on message display This indicates no syrup supply to Unit 4 Make sure AUTO BLEND 1 AUTO BLEND 2 AUTO 1 and AUTO 2 control switches are pressed for normal operation 5 Place cup under dispensing valve then dispense until cup is full of product 6 Make sure viscosity product consistency is as desired If not adjust as instructed REPLENISHING SYRUP SUPPLY IMPORTANT The following CO and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows 1 To disconnect soft drink tank from Unit syrup system A Disconnect liquid disconnect from soft drink tank NOTE Disconnecting liquid quick discon nect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regu lator which may alter regulat
97. k 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 discon nect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regula tor 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 CO quick disconnect to soft drink tank to pressurize the tank D Second connect liquid quick disconnect to the soft drink tank 3 Pressurize soft drink tanks containing syrup then connect tanks into Unit syrup systems OFF 1 OFF 2 SYRUP 1 and SYRUP 2 fault messages will continue to be displayed 4 The following steps A through J are instructions for adjusting the Water to Syrup Ratio Brix of the dis pensed product on on of the systems NOTE The Unit control panel assembly is equipped with a hidden SECURITY SWITCH located be tween FILL 1 and ERROR RESET control switches see Figure 5 Pressing in and holding SECURITY SWITCH for 3 seconds deactivates the control switches preventing tampering with Unit normal operation To reactivate the control switches press in and hold the SECURITY SWITCH for 3 seconds NOTE The adjustable carbonated water flow regulators see Figure 2 and 11 located in their res
98. lavor changeover or sanitizing syrup systems After syrup systems sold out floats have been filled FILL 1 and FILL 2 switches be used to prevent more product entering prod uct blender tanks during the BRIX test AUTO BLEND 1 and AUTO BLEND 2 Control Switches AUTO BLEND 1 and AUTO BLEND 2 control switches located on control panel assembly are touch type Switches and require only pressing to activate These switches are used to fill product blender tanks after sol out floats have been filled using FILL 1 and FILL 2 switches AUTO BLEND 1 and AUTO BLEND 2 and AUTO 1 and AUTO 2 switches must be pressed to operate freeze cylinders beaters and refrigeration sys tem during normal operation WASH 1 and WASH 2 Control Switches WASH 1 and WASH 2 control switches located on control panel assembly are touch type switches and re quire 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 assembly are touch type switches and re quire only pressing to activate These switches are used to operate freeze cylinders beaters and refrigeration system after cylinders have been filled with product Freeze cylinders beaters and refrigeration system may be stopped by pressing OFF 1 or OFF 2 switches 29 2992
99. lectrical control box cover control box located on back of the front access door Remove cover for access to the master circuit board see Figure 6 3 Place 4 BEATER MOTOR CURRENT READOUT switch on DIP SWITCH assembly on master circuit board see Figure 6 in ON position Both freeze cylinders beater motors will start and operate and beaters motors current ratings will be displayed on message display 2992 16 4 Display should be adjusted to read A150 B150 2 by adjusting MOTOR CURRENT ADJUSTMENTS lo cated on No 1 and No 2 relay circuit boards see Figure 6 These figures will fluctuate slightly with varia tions in line voltage and motor loads 5 After completion of adjusting beater motor current to A150 150 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 electronics to automatically self calibrate the beaters motors currents at completion of each defrost cycle assembly is placed in ON position and beater motor current readings were A155 B145 and switch was then placed back in OFF position without readjusting to A150 B150 2 beater motor current has just been reset at A155 B145 Operating the FCB Dispenser at these current readings may have serious effects on its operation CAUTION IF NO 4 BEATER MOTOR CURRENT READOUT SWITCH
100. lin ders faceplates relief valves to bleed air from cylinders while filling with product then close valves Do not relieve freeze cylinder pressure too fast or product will foam excessively in cylinder and lose carbonation CHECKING UNIT FOR SYRUP OR PLAIN WATER LEAKS 1 Inspect the entire Unit and the entire system for syrup plain water leaks and repair if evident 2 Install the Unit back and side panels 3 Install Unit front access panel see Figure 7 and secure with THREAD CUTTING SCREWS item 16 and WHITE SPACERS ITEM 14 4 Close front access door then use a flat blade screwdriver to turn lock clockwise to lock the door 15 2992 PLACING UNIT OPERATING LOCATION IMPORTANT NOTICE The FCB Dispensers manufactured prior to the models documented in this manual were elevated in the front dispensing valve side 1 4 to 3 8 inch higher than the back when placing the Unit in operating position to eliminate gas pockets being trapped inside the freeze cylinders Due to a redesign of the foam pack in the models documented in this manual elevating the front of the Dispenser is no longer required The Dispenser must be leveled at time of placing in operating location 1 Disconnect electrical power from Unit at the electrical power source disconnect switch IMPORTANT When installing Unit in it s operating position do not allow obstructions to block sides top and front of the Unit which will block off cool
101. ling end fitting on end of the drive shaft Insert COUPLER end of the adjustment gauge be tween coupling end fitting and the plastic housing The adjustment gauge in place places the coupling end fitting 0 750 inch away from the plastic housing Make sure Allen Head set screw in the coupling end fitting is securely tightened and properly seated on the shaft flat surface Lubricate the two outer O Ring seals on the outside of the plastic housing with a generous amount of spe cial light grade silicone grease Reinstall the drive shaft seal assembly in the freeze cylinder Push in and turn the drive shaft seal assembly to the left counterclockwise to lock its four locking tabs into four notches in the freeze cylinder retainer Position SCRAPER BLADES item 2 on BEATER item 13 as shown in Figure 3 Slide beater into freeze cylinder so slotted hooks engage DRIVE PIN item 16 on DRIVE SHAFT item 21 Turn beater to the right clockwise to lock in place 2992 44 16 Lubricate O RING item 5 with water to facilitate faceplate installation Position O RING item 5 FACE PLATE item 8 Install faceplate on Unit so dispensing valve spout faces down MAKE SURE FEMALE END OF THE BEATER IS PLACED OVER THE FACEPLATE STAINLESS STEEL STUD AND BUSHING BEFORE PUSHING THE FACEPLATE INTO POSITION ON ITS FOUR THREADED MOUNTING STUDS Tighten hex nuts until faceplate touches freeze cylinder all around flange CAUTION DO NOT OVERTIGHTEN HE
102. lution 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 Connect soft drink tank containing syrup into No 1 syrup system solution left in system could create a health hazard WARNING Flush residual sanitizing solution from syrup system as instructed Residual 27 28 29 Press FILL 1 switch to fill No 1 syrup system syrup float switch with syrup SYRUP 1 fault message message display will go out indicating syrup float switch has been filled with syrup Press AUTO BLE
103. me time and hold them pressed for a minimum of 1 2 second to bring up MAIN MENU SELECTIONS on message display The word CLOCK will appear on display You are now in the MAIN MENU SELECTIONS as shown in 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 return to MAIN MENU SELECTIONS press ERROR 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 be programmed into the Unit 17 2992 EE 1 0 w Io N I IO fie Mn In fis IO Io gt IO gt 1 mi IN NII TIN IO 0 Jl no DIAGNOSE DIAGNOSTIC MODE SE 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
104. mpressor will operate for 30 seconds to pump freon out of freeze cylinders evaporator coils Then No 1 freeze cylinder will go into defrost for and defrost 60 seconds After No 1 freeze cylinder has defrosted No 2 freeze cylinder will go into defrost and defrost for 60 seconds At end of No 2 freeze cylinder defrost Unit will shut down and go into sleep time 31 2992 WAKE WAKE UP TIME WAKE UP WAKE UP TIME may be programmed into the Unit to allow Unit to resume normal operation at a desired time When programmed wake up time is reached an alarm will sound for a short duration then Unit will resume normal operation NOTE Automatic defrost sleep time and wake up time may be used in any combination together or separately FACEPLATE RELIEF VALVES The faceplate relief valves see Figure 7 located in each freeze cylinder faceplate are spring loaded valves that protect freeze cylinders from accidental over pressure The relief valve is also used to manually bleed gas from freeze cylinder to atmosphere during filling with product and if gas pockets form in cylinder during op eration PRODUCT SAMPLE VALVES The two product sample valves are located behind the lower front access panel see Figure 2 and Figure 8 are manually operated lever type ball valves used to check product BRIX Turn valve lever to line up with at tached line to open valve and at 90 angle with line to close valve PRODUCT SHUTOFF VAL
105. ng to the reg ulator outlet Turn the product blender tanks CO regulator with 60 psi gage adjusting screw in clockwise until gage registers pressure noted in step 7 preceding Pull relief valve on the applicable product blender tank to purge air from the tank then close the valve Connect Unit syrup inlet line to the soft drink tank Press the applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill the product blender tank with product Open the product shutoff valve that was closed in step 4 preceding Close front access door then use a flat blade screwdriver to turn lock clockwise to lock the door Install the lower front access panel by reversing the removal procedure ADJUSTING CO REGULATORS NOTE To readjust regulator to a lower setting loosen the adjusting screw lock nut then turn the screw to the left counterclockwise until the pressure gage reads 5 psi lower than the new setting will be Turn the adjusting screw to the right clockwise until the gage registers new setting then tighten the lock nut 2992 46 Primary Regulator see Figure 2 Adjust the primary COs regulator by turning the regulator adjusting screw to the right clockwise until the regu lator pressure reads 80 to 100 psig Product Blender Tanks Secondary Regulators see Figures 2 and 8 1 Remove the Unit lower front access panel as instructed for access to the product blender tanks secondary
106. omatic defrost time settings into the Unit as instructed in the 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 the INSTALLATION section 2992 36 PROGRAMMING WAKE WAKE UP TIME INTO UNIT WAKE UP WAKE UP TIME May be programmed into Unit to occur any time of the day to wake Unit up re turn to normal operation after sleep time has occurred Program WAKE into Unit as instructed in the the INSTALLATION section PROGRAMMING POINT OF SALE MESSAGE DISPLAY Three point of sale display messages are available to choose from and may be programmed into Unit by placing No 1 and No 2 switches on DIP SWITCH assembly on master circuit board in appropriate positions Program point of sale display messages into Unit as instructed in the INSTALLATION section ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT Adjusting VIS SET PRODUCT VISCOSITY determines what product consistency of the dispensed product will be present in each freeze cylinder Adjust VIS SET PRODUCT VISCOSITY of the dispensed product as instructed in the INSTALLATION section
107. on see Figure 6 and 5 and 7 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 and Table 5 and 7 on the DIP SWITCH AS SEMBLY in the appropriate positions ADJUSTING VIS SET PRODUCT VISCOSITY OF DISPENSED PRODUCT Adjusting VIS SET PRODUCT VISCOSITY determines what product consistency of the dispensed product will be present in each freeze cylinder Adjust VIS SET PRODUCT VISCOSITY of the dispensed product as fol lows 1 Refer to PROGRAMMING MAIN MENU SELECTIONS INTO MESSAGE DISPLAY and bring up VIS SET on message display 2 Press DEFROST SELECT switch to bring up numbers on message display NOTE The direction of arrows lt lt gt gt on message display indicates which set of numbers belongs to which freeze cylinder A No 4 setting indicates the thinnest product consistency of dispensed product and a No 12 setting indicates the thickest consistency of product dispensed 3 Press CANCEL DEFROST ADVANCE switch The left side freeze cylinder viscosity number will be flash ing on message display 4 Press CANCEL DEFROST ADVANCE switch to advance viscosity number to desired setting Press DE FROST SELECT switch to lock in viscosity setting The right side freeze cylinder viscosity number will now be flashing 5 Press CANCEL DEFROST ADVAN
108. or adjustment B Second disconnect CO quick disconnect from soft drink tank 2992 34 2 To connect soft drink tank into Unit syrup system A First connect quick disconnect to soft drink tank to pressurize tank B Second connect liquid quick disconnect to soft drink tank Syrup supply should be checked daily and if necessary replenished as instructed PRODUCT FLAVOR CHANGE Perform syrup flavor change as instructed CHECKING SUPPLY WARNING displaces oxygen Strict attention must be observed in the prevention of carbon dioxide gas leaks in the entire and soft drink system If a gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak 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 change CO cylinder portion of dial If so CO cylinder is almost empty and must be replaced as instructed CLEANING AND SANITIZING DAILY CLEANING Daily or more often if necessary wash all external surfaces of Unit rinse with clean water then wipe dry with clean soft cloth DO NOT USE ABRASIVE CLEANERS Wash the drip tray and cup rest with warm water and mild detergent then rinse with clean water
109. ough Unit syrup flow regu lator which may alter regulator adjustment B Second disconnect CO quick disconnect from soft drink tank 3 To connect soft drink tank into Unit syrup system A First connect CO quick disconnect to soft drink tank to pressurize tank B Second connect liquid quick disconnect to soft drink tank 4 Disconnect inlet CO2 and outlet syrup lines from empty soft drink tank 53 2992 5 Check soft drink tank quick disconnects for sticky or restricted operation Rinse disconnects in warm water 6 First pressurize full soft drink tank by connecting line to tank then connect Unit syrup inlet line to tank 7 Press applicable FILL 1 or FILL 2 switch to fill applicable No 1 or No 2 syrup system syrup float switch with syrup 8 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill applicable No 1 or No 2 system product blender tank with product 9 Press applicable AUTO 1 or AUTO 2 switch to start refrigeration system and beater in applicable No 1 or No 2 freeze cylinder 10 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 REPLENISHING SUPPLY WARNING displaces oxygen Strict attention must
110. pective systems control carbonated water flow rate to the product blender tanks The water flow regulators are factory adjusted at 1 3 0 05 oz sec and should not normally require adjustment If adjustment is nec essary adjust as instructed A Press FILL 1 switch to fill No 1 syrup system sold out float SYRUP 1 fault message will go out and FILL 1 fault message will come on OFF 1 OFF 2 and SYRUP 2 fault messages will continue to be displayed B Press AUTO BLEND 1 switch to fill No 1 system product blender tank with product FILL 1 fault message will go out when AUTO BLEND 1 switch is pressed When product blender tank is full press FILL 1 switch to prevent more product from entering tank OFF 1 OFF 2 and SYRUP 2 fault messages will continue to be displayed C Open 1 product blender tank product sample valve see Figure 2 and 8 and take a sample approx imately 6 ounces of product in a cup or glass 2992 14 NOTE Temperature compensated refractometers P N 511004000 are available from Cor nelius Company D Check product BRIX with a temperature compensated hand type refractometer BRIX should read 13 1 If BRIX is not within tolerance adjust white syrup flow regulator for No 1 syrup system as follows E Turn regulator adjusting screw to the left counterclockwise no more than 1 8 turn at a time to reduce syr
111. primary CO regulator assembly which is at tached to the cylinder The primary regulator assembly in turn delivers gas to adjustable secondary regulators inside the Unit and also to two soft drink tanks is delivered from the adjustable secondary regulators to the carbonator tank and also to product blender tanks inside the Unit gas pressure pushes syrup out of the soft drink tanks through the syrup sold out switches through adjustable syrup flow regu lators through electrically operated syrup solenoid valves and on to the product blender tanks At the same time plain water passes through the water pressure regulator and is pumped into the carbonated water tank by the water pump and is carbonated by gas pressure also entering the tank Carbonated water is pushed by CO gas pressure from the carbonated water tank through adjustable carbonated water flow regula tors through electrically operated carbonated water solenoid valves and on to the product blender tanks Car bonated water and syrup enter the tanks properly proportioned blended for desired BRIX of dispensed product by adjustment of the syrup flow regulators From product blender tanks product is pushed by the gas into the freeze cylinders The beater in each freeze cylinder is driven by an electric motor Scraper blades attached to the beaters scrape product from the cylinder walls as product enters the freeze cylinders and is
112. r 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 R404A2HP V3 Dispenser with 2 H P Copeland Compressor and R 404A Refrigerant B R404A3HP V3 Dispenser with 3 H P Copeland Compressor and R 404A refrigerant 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 2 Refer to Dispenser serial plate to identify the type of refrigerant gas installed in the refrigeration system 3 Press the CANCEL DEFROST ADVANCE switch as many times as necessary to bring up applicable re frigerant type from sub menu of REF TYPE REFRIGERANT TYPE on MESSAGE DISPLAY 4 Press the DEFROST SELECT switch to lock in on the selection This programs the proper refrigeration pulse rate into the Dispenser electronics 5 Press the 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 27 2992 THIS PAGE LEFT BLANK INTENTIONALLY 2992 28 OPERATOR S
113. rator Coil 5 O Ring 6 Flatwasher 4 8 Faceplate 9 Relief Valve 11 Knob 12 Dispensing Valve 14 Allen Head Setscrew 15 Beater Shaft Coupling 17 Bearing Housing Locking Tab 4 18 Bearing Retainer 20 Beater Drive Motor 21 Drive Shaft Assembly 23 Spinner 24 Spring 26 Bearing 27 Bearing Housing FIGURE 3 FREEZE CYLINDER CUTAWAY VIEW END BLADE SCRAPER BLADES MUST BE MOUNTED TO THE BEATER BODY AS SHOWN USING THE PERFORATED EDGE AS THE LEADING EDGE LINE UP KEY ON END OF POSTS WITH KEY SLOT IN SCRAPER BLADES FIGURE 4 BEATERS AND SCRAPER BLADES INSTALLATION WARNING displaces oxygen Strict attention must be observed in the prevention of carbon dioxide gas leaks in the entire and soft drink system If a gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of gas will experience tremors which are followed rapidly by loss of consciousness and suffocation 1 Unscrew protector cap with chain attached from CO cylinder valve Open CO cylinder valve slightly coun terclockwise to blow any dirt or dust from outlet fitting before installing primary CO regulator then close valve 2 Remove shipping plug from primary regulator assembly coupling nut and make sure gasket is in place inside nut Install regulator assembly on CO c
114. rcome and vent product blender tanks head pressures while tanks are filling with carbonated water and syrup Carbonator tank secondary regulator not adjusted high enough will cause decreased flow of carbonated water into the blender tanks which will increase brix of the dispensed product 13 2992 1 Adjust carbonator secondary CO regulator with 100 psi gage by turning regulator adjusting screw to the right clockwise until gage reads 50 to 60 psi 2 Pull up on carbonator tank relief valve plastic cover to purge air from tank STARTING FCB AND ADJUSTING WATER TO SYRUP RATIO BRIX OF DISPENSED PRODUCT 1 Open shutoff valve in city plain water line connected to the Unit Check for water leaks and tighten or repair leaks if evident H2O OUT fault message should have gone out but SYRUP 1 and SYRUP 2 fault mes sages will continue to be displayed IMPORTANT Product shutoff valves located in lines leading from product blender tanks to freeze cylinders see Figure 2 and 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 and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drin
115. s and refrigeration systems not operating At start of sleep time refrigeration compressor will operate for 30 seconds to pump freon out of freeze cylinders evaporator coils then No 1 freeze cylinder will go into defrost and defrost for 60 seconds After No 1 freeze cylinder has defrosted No 2 freeze cylinder will go into defrost and defrost for 60 seconds At end of No 2 freeze cylinder defrost Unit will shut down and go into sleep time WAKE UP WAKE UP TIME WAKE UP WAKE UP TIME may be programmed into the Unit to allow Unit to 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 2992 4 WATER PRESSURE REGULATOR IS FACTORY ADJUSTED TO 45 PSI AND SHOULD NOT BE READJUSTED PRODUCT SAMPLE ue VALVE 2 t
116. ss y Syrup Source to Syrup Solenoid See Figure 27 326111000 Soldout Switch 311764001 Check Valve Ass y See Figure 31 343487000 Machine Screw Phil Pan No 8 32 Ka a 1 2 In Long 315925000 O Ring 1 609 1D By 139 6 8 1 609 I D By 139 C S 315931000 O Ring 364 I D By 070 C S 2992 76 2487 Solenoid Valve Ass y Syrup See Figure 32 15 2781 Tube Ass y Product Blender to Freeze Cylinder See Figure 28 16 2779 Tube Ass y Water and Syrup Solenoid to Blender See Figure 29 17 326098000 Tube Ass y Regulator to Blender See Figure 30 183008000 O Ring 489 I D By 070 C S 325576000 Tube Syphon 12 In Long 2486 Solenoid Valve Ass y Water See Figure 32 Jm Blender Components See Figure 2780 Tube Ass y Carb Water Outlet 4 6 da TE EF RW 44 4 174103000 Tube 250 1 0 By 3 In Long race 174103000 Tube 250 LD By 10 In Long AUT 4 5 174103000 Tube 250 1 0 22 In Long 5 4 z 5 176001000 Ferrule 425 O D Tube NS 5 5 174103001 Tube 250 I D By 40 In Long FIGURE 26 TUBING ASSEMBLY CARB WATER 2815 Tube Ass y Syrup 6 ee 1 176017000 Nut Swivel 7 16 20 PT ae 3 770104 Nipple 265 LD Tube 5 PR s p 176000000 Ferrule 500 O D Tube 4 Ss oF 4 174478000 Tube 265 LD 92 In Long 1 2 55 174478000 Tube
117. t from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment Second disconnect quick disconnect from soft drink tank 3 To connect soft drink tank into Unit syrup system A First connect CO quick disconnect to soft drink tank to pressurize tank B Second connect liquid quick disconnect to soft drink tank 4 First pressurize soft drink tank containing new flavor syrup by connecting CO line to tank then connect Unit syrup inlet line to tank 5 Press applicable FILL 1 or FILL 2 switch to fill applicable No 1 or No 2 syrup system syrup float switch with syrup 6 Press applicable AUTO BLEND 1 or AUTO BLEND 2 switch to fill applicable No 1 or No 2 system product blender tank with product 7 Press applicable AUTO 1 or AUTO 2 switch to start refrigeration system and beater in applicable No 1 or No 2 freeze cylinder CAUTION Do not relieve freeze cylinder pressure too fast or product will foam excessively in freeze cylinder and lose carbonation 8 After carbonator water pump cycles off intermittently pull and release applicable No 1 or No 2 freeze cyl inder faceplate relief valve This bleeds from freeze cylinder and allows product to enter and fill cylin der 9 If necessary adjust BRIX product viscosity product consistency and product carbonation of dispensed product as instructed
118. the lock ring bearing retainer from the end of the plastic housing Using a block of wood tap the drive shaft and both bearings out of the plastic housing Loosen bearings and remove shaft Remove two old inner drive shaft O Ring seals and two outer O Ring seals from the plastic housing Discard the old O Ring seals NOTE If old lubricant cannot be removed from the plastic housing by washing use a nylon pot and pan scrubber 3M Company Scotchbrite or equivalent to remove the residue Do not scrape plastic housing Replace any housing that has rough edges in O Ring sealing areas 7 10 11 12 13 14 15 Remove old lubricant from the plastic housing with paper towel DO SCRAPE THE PLASTIC HOUSING Wash the housing and the back of the freeze cylinder with warm water Lubricate two new drive shaft O Ring seals with a generous amount of special light grade silicone grease then install O Rings inside the plastic housing Inspect the drive shaft and both bearings Replace the drive shaft if worn and bearing s if found to be rough Reassemble the drive shaft seal assembly Using TOOL DRIVE COUPLER ADJUSTMENT GAUGE item 12 insert DRIVE end of adjustment gauge between drive pin and housing see Figure 13 to set the shaft end at 1 542 inches out of the plastic housing Make sure Allen Head set screw in each bearing is securely tightened and properly seated on the shaft flat surface Install coup
119. umber 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 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 Press ERROR RESET switch two times to exit from MENU SELECTIONS 19 2992 SWITCH NO FUNCTION POINT OF SALE MESSAGE SELECT See Table 7 POINT OF SALE MESSAGE SELECT See Table 7 See NOTE BEATER MOTOR CURRENT READOUT ON Display current readout OFF No displayed current readout 5 MOTOR CURRENT SELF CALIBRATION ON Disabled OFF Operating 6 NOTUSED NOT USED 8 NOTUSED DEFROST ON Hot gas OFF Electric SERVICE USE NOTE Switch No 3 must be in OFF position for standard Units with pulse expansion valves Switch No 3 must be in ON position for older Units with mechanical expansion valves TABLE 5 DIP SWITCH FUNCTIONS meus wer Tei mmm O aer Wie oo Grrr gear bor win a GE vale ee Faris Fasc eo gear boc ha Fasea waerenga agendi so Fasc oo gear boc usg a alge oe es meng Emerson oo Overuncergear boc wit an Emerson wastane eme
120. up flow rate or turn screw to the right clockwise no more than 1 8 turn to increase flow rate F Place container under No 1 product sample valve Open valve to purge product out of product blender tank line and valve then close valve OFF 1 OFF 2 and SYRUP 2 will continue to be displayed 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 L Repeat steps F through H preceding until proper BRIX adjustment is achieved J Repeat steps A through preceding to adjust BRIX of dispensed product on No 2 system After com pleting BRIX adjustment on No 2 system only the OFF 1 and OFF 2 fault messages should contin ue to be displayed NOTE Syrup systems may be sanitized at this time as instructed HIDDEN SECURITY SWITCH MESSAGE DISPLAY AUTO BLEND 1 CANCEL AUTO DEFROST DEFROST BLEND 2 SELECT ADVANCE FIGURE 5 CONTROL PANEL ASS Y FILLING FREEZE CYLINDERS WITH PRODUCT 1 Open product shutoff valves located in lines leading from product blender tanks to freeze cylinders 2 Press AUTO BLEND 1 and AUTO BLEND 2 switches to begin filling freeze cylinders Open freeze cy
121. urned off MANUAL DEFROST SYSTEM The Manual hot gas defrost system may be activated at any time by pressing DEFROST switch on front of the Unit Refrigeration compressor will operate for a short time then both freeze cylinders will go into defrost for approximately 60 seconds At the end of the manual defrost cycle the Unit will return to normal operation Manual defrost may be cancelled at any time by pressing CANCEL DEFROST switch AUTOMATIC DEFROST SYSTEM The automatic hot gas defrost system may be programmed into the Unit of occur up to nine different times a day with a minimum of two hours between defrost settings At start of each automatic defrost cycle refrigeration compressor will operate for 30 seconds to pump freon out of freeze cylinders evaporator coils After freon has been pumped out of freeze cylinders evaporator coils No 1 freeze cylinder only will go into defrost and defrost for approximately 7 minutes then will return to normal operation This ends automatic defrost cycle of No 1 freeze cylinder No 2 freeze cylinder will defrost 30 minutes after the start of No 1 freeze cylinder The next automatic defrost cycle will occur according to time programmed into the Unit SLEEP SLEEP TIME 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 co
122. ve large enough I D Trouble ERRATIC CARBONATOR WATER PUMP CYCLING cont d B Probable Cause Water filter restricted 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 FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY 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 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 gas in same way as clean gas This can also cause off taste problems Dispensing valve has ice particles in it Cylinder freeze up AUTO BLEND 1 or AUTO BLEND 2 switch not pressed Carbonator water pump not operating Lines restricted Dispensed product BRIX varying because Syrup and or water flow regulator sticking 67 Remedy Replace water filt
123. y to regulate transfer and dispense the product The components are attached to a steel frame and are enclosed in a steel cabinet The cabinet sides and back panels are easily removed and the front access door may be opened 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 drip tray with cup rest is located directly below the dispensing valves FIGURE 1 FCB OVERCOUNTER POST MIX DISPENSER and all sanitizing solution must be purged from syrup systems All water must also be CAUTION Before shipping storing or relocating Unit syrup systems must be sanitized purged from plain and carbonated water systems A freezing ambient environment will cause residual sanitizing solution or water remaining inside Unit to freeze resulting in damage to internal components 1 2992 Table 1 Design Data nit Part Numbers 60 HZ Unit 50 HZ Unit verall Dimensions Height Width Depth W O Drip tray Depth W Drip Tray Shipping Weight approx 420 pounds Refrigeration System Compressor Horsepower 2 H P Refrigerant Type And Charge See Unit Nameplate Ambient Operating Temperature 40 F to 100 Electrical Requirements Operating Voltage Operating Current THEORY OF OPERATION see Figure 2 A CO cylinder delivers carbon dioxide COs gas to an adjustable
124. ylinder so gages can be easily read then tighten coupling nut DO NOT OPEN CO CYLINDER VALVE AT THIS TIME CONNECTING SOFT DRINK TANKS CO LINES TO PRIMARY REGULATOR ASSEMBLY see Figure 2 1 Connect soft drink tanks CO lines to primary CO regulator manifold assembly as shown in Figure 2 2 Install gas quick disconnects on ends of soft drink tanks CO lines DO NOT CONNECT LINES TO TANKS AT THIS TIME 11 2992 PREPARING UNIT SYRUP INLET LINES FOR CONNECTION SOFT DRINK TANKS see Figure 2 1 Route Unit syrup inlet lines labeled No 1 and No 2 to soft drink tanks location 2 Install liquid quick disconnects on ends of Unit syrup inlet lines DO NOT CONNECT SYRUP LINES TO SOFT DRINK TANKS AT THIS TIME CONNECTING SOURCE LINE TO UNIT CO INLET LINE see Figure 2 1 Connect and route a CO source line from the primary CO regulator up to the Unit 2 Connect the CO source line to the Unit inlet line DO NOT TURN ON THE SOURCE AT THIS TIME CONNECTING CITY PLAIN WATER SOURCE LINE TO UNIT NOTE The Units require connection to a city plain water source line with a minimum water pressure of 12 psig IMI Cornelius Inc recommends that a water shutoff valve and water filter be installed in the City plain water source line see Figure 2 A Cornelius Water Filter P N 313860000 and Quick Disconnect Set P N 313867 000 are recommended 1 Connect and route city plain water source line

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