IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234 Telephone (800) 238-3600 Facsimile (612) 422-3246 FCB (SOLID-STATE) POSTMIX DISPENSER TWO-FLAVOR/HOT-GAS DEFROST WITH V3 ELECTRONICS Service Manual Part No. 326142000 April 24, 1989 Revised: February 10, 1992 THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment IMI CORNELIUS INC; 1989–92 PRINTED IN U.S.
TABLE OF CONTENTS Page GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (cont’d) Page ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES . . . . . . . . . . . . . . . . . . . . 15 ‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) . . . . . . . . . . . . . . . . . . . . . . 15 PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) INTO UNIT . . . . . . . .
TABLE OF CONTENTS (cont’d) Page PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT . . 24 PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT . . . . . . . . . . . . . . . . . 24 PROGRAMMING ‘‘WAKE UP’’ (WAKE UP) TIME INTO UNIT . . . . . . . . . . . . 24 PROGRAMMING POINT OF SALE MESSAGE DISPLAY . . . . . . . . . . . . . . . 24 ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (cont’d) Page PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT . . . . . . . . . . . . . . . . . 38 PROGRAMMING ‘‘WAKE UP’’ (WAKE UP TIME) INTO UNIT . . . . . . . . . . . . 39 PROGRAMMING POINT OF SALE MESSAGE DISPLAY . . . . . . . . . . . . . . . 41 ADJUSTING “VIS SET” (PRODUCT VISCOSITY) OF DISPENSED PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (cont’d) Page ALL FAULT MESSAGES NOT OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . 62 ‘‘CO2 OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. . . . . . . . 63 ‘‘H2O OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. . . . . . . . 63 ‘‘SYRUP 1’’ OR ‘‘SYRUP 2’’ FAULT MESSAGE GOES ON DURING OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 ‘‘ERROR 1’’ OR ‘‘ERROR2’’ FAULT MESSAGE GOES ON DURING OPERATION. . .
TABLE OF CONTENTS (cont’d) Page LIST OF FIGURES (CONT’D) FIGURE 12. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 FIGURE 13. CO2 GAS CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 FIGURE 14. BEATER DRIVE MOTOR AND SHAFT SEAL ASS’Y REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, and maintaining this equipment. Refer to Table of Contents for page location of information pertaining to questions that arise during installation, operation, service and maintenance, or troubleshooting this equipment.
Table 1. Design Data (cont’d) Overall Dimensions: Height Width Depth Without Drip Tray Depth With Drip Tray Table 1. Design Data (cont’d) Overall Dimensions: 60-1/2 inches 19-1/4 inches 32-1/2 inches 38 inches Shipping Weight (approx.) 466 pounds Compressor Horsepower 2 H.P.
MANUAL DEFROST SYSTEM The Manual hot-gas defrost system may be activated at any time by pressing ‘‘DEFROST’’ switch on front of Unit. Refrigeration compressor will operate for a short time, then both freeze cylinders will go into defrost and defrost for approximately 60-seconds. At end of manual defrost cycle, Unit will return to normal operation. Manual defrost may be cancelled at any time by pressing ‘‘CANCEL DEFROST’’ switch.
PRODUCT SAMPLE VALVE (2) PRODUCT BLENDER TANK (2) CARBONATOR TANK PRODUCT SHUTOFF VALVE (2) SYRUP FLOW REGULATOR (2) FREEZE CYLINDER (2) CARBONATED WATER FLOW REGULATOR (2) FREEZE CYLINDER OVERFLOW TUBE CARBONATED WATER SOLENOID VALVE (2) LIQUID CHECK VALVE (4) SYRUP SOLENOID VALVE (2) CARBONATED WATER VOLUME SAMPLE VALVE PRIMARY CO2 REGULATOR ASS’Y SYRUP SOLD-OUT FLOAT SWITCH (2) SECONDARY CO2 REGULATOR TO CARBONATOR TANKS (100-PSI) *WATER PRESSURE REGULATOR CO2 CHECK VALVE CARBONATOR WATER PU
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 5) NOTE: The Unit was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it. Any damage or irregularities should be noted at time of delivery (or not later than 15 days from date of delivery) and immediately reported to the delivering carrier.
2. SPANNER WRENCH, FLOW REGULATORS (item 2) is used to adjust flow regulators inside Unit. 3. SPANNER WRENCH, DISPENSING VALVE (item 3) is used to remove shank nuts securing dispensing valves to faceplates. 4. CLEANING BRUSH (item 4) is used to clean faceplate relief valves passages. 5. TAPERED GASKET, BLACK (item 5) is used to seal connection when connecting plain water source line to Unit water inlet line. 6.
7 1. Product Inlet Fitting 2. Scraper Blade (2) 3. Evaporator Coi.l 4. Relief Valve Port 5. O-Ring 6. Flatwasher (4) 7. Hex Nut (4) 8. Faceplate 9. Relief Va;ve 10. Valve Lever 11. Knob 12. Dispensing Valve 13. Beater 14. Drive Shaft Seal Assembly 15. Allen Head Setscrew 16. Beater Shaft Coupling 17. Drive Pin 18. Bearing Guide Pin (4) 326142000 FIGURE 3. FREEZE CYLINDER CUTAWAY VIEW 19. 20. 21. Power Coupler (plastic) Beater Motor Drive Shaft Beater Drive Motor Shaft Coupling 22. 23. 24. 25. 26. 27.
BEATER KEY ON END OF POST KEY ON END OF POST KEY SLOT ON BLADE SCRAPER BLADES MUST BE MOUNTED TO THE BEATER BODY AS SHOWN USING THE PERFORATED EDGE AS THE LEADING EDGE. LINE UP KEY ON END OF POSTS WITH KEY SLOT IN SCRAPER BLADES. FIGURE 4.
1. Close to a plain water inlet supply line with a minimum pressure of 12-psig. NOTE: Circulating air, required to cool the refrigeration system’s condenser coil, is drawn in through grille on front and exhausted out through sides and back of Unit. Restricting air circulation through the Unit will decrease its cooling efficiency. 2. When installing Unit, do not allow obstruction to block grille on front which will block off air intake to inside of Unit.
WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 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 CO2 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation. 1.
CONNECTING ELECTRICAL POWER CIRCUIT TO UNIT (see Figure 17) WARNING: Make sure Unit 30-amp minimum-rated disconnect switch (not provided) or equivalent HACR circuit breaker is in ‘‘OFF’’ position. Domestic Unit. IMPORTANT: Power circuit voltage across L1 and L2 terminals on contactor inside lower control box, with refrigeration compressor operating, must be in operating range of between 219 and 242 VAC, 60Hz single-phase range for proper operation. If voltage is below or above this range, a .
TURNING ON ELECTRICAL POWER TO UNIT Turn on electrical power to Unit. Operational status of Unit is now being displayed as fault messages on control panel message display. The following fault messages will be continuously displayed at 2-second intervals until necessary operation requirements are satisfied. ‘‘OFF 1’’ (Beater Motor No. 1 not operating) ‘‘OFF 2’’ (Beater Motor No.
IMPORTANT: The following CO2 and liquid disconnects disconnecting and connecting procedure for soft drink tank replacement or filling soft drink tank in place must be performed in order as follows: To disconnect soft drink tank from Unit syrup system. A. Disconnect liquid disconnect from soft drink tank. NOTE - Disconnecting liquid quick disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator which may alter regulator adjustment. B.
NOTE: Syrup systems may be sanitized at this time as instructed. FILLING FREEZE CYLINDERS WITH PRODUCT 1. Open product shutoff valves, located in lines leading from product blender tanks to freeze cylinders. 2. Press ‘‘AUTO BLEND 1’’ and ‘‘AUTO BLEND 2’’ switches to begin filling freeze cylinders. Open freeze cylinders faceplates relief valves to bleed air from cylinders while filling with product, then close valves.
ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED PRODUCT Adjust ‘‘VIS SET’’ (PRODUCT VISCOSITY) determines what product consistency of the dispensed product will be present in each freeze cylinder. Adjust ‘‘VIS SET’’ (PRODUCT VISCOSITY) of the dispensed product as instructed in SERVICE AND MAINTENANCE SECTION.
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OPERATORS INSTRUCTIONS This section describes operating controls and indicators, dispensed product conditions, operating characteristics, Unit operation, replenishing syrup supply, product flavor change, checking CO supply, operators daily cleaning of Unit, and sanitizing requirements. WARNING: Disconnect electrical power to Unit to prevent personnel injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring. NOTE: No.
‘‘ERROR RESET’’ Control Switch. ‘‘ERROR RESET’’ control switch, located on control panel (see Figure 5), is a touch-type switch and requires only pressing to activate. ‘‘ERROR RESET’’ switch is used to restore normal operation after error within Unit (indicated by ‘‘ERROR 1’’ or ‘‘ERROR 2’’ on message display) has been corrected. ‘‘SECURITY SWITCH.’’ The Unit is equipped with a hidden ‘‘SECURITY SWITCH’’ located between ‘‘FILL 1’’ switch and ‘‘ERROR RESET’’ switch on control panel (see Figure 5).
‘‘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. Five ‘‘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.
NOTE: Automatic defrost, sleep time, and wake up time may be used in any combination together or separately. FACEPLATE RELIEF VALVES The faceplate relief valves (see Figure 5), located in each faceplate, are spring-loaded valves that protect freeze cylinders from accidental over-pressure. The relief valve is also used to manually bleed CO2 gas from freeze cylinder to atmosphere during filling with product and if gas pockets form in cylinder during operation.
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 considered, desired viscosity (product consistency) adjustment may be made on the Unit. The viscosity adjustment adjusts product texture from very wet to light. Specific Product Ingredients Affect Overrun. Each syrup has its own specific formulation of makeup.
1. If some time has elapsed since last drink was drawn from particular freeze cylinder and compressor has not cycled on, the drink dispensed will have a tendency to be wetter, have slightly less overrun than normal for the setting, and will not mound up as high. See Drawing 1. NOTE: A cylinder freeze-up may be expected under casual draw conditions if an attempt is made to eliminate drink described above by adjusting viscosity. 2.
Make sure CO2 cylinder shutoff valve is fully opened and regulator assembly 1800-psi gage indicator is not in shaded (‘‘change CO2 cylinder’’) portion of dial. If so, CO2 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.
PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS (see Table 4) may be brought up on message display as instructed in SERVICE AND MAINTENANCE SECTION. SETTING ‘‘CLOCK’’ (TIME OF DAY) NOTE: ‘‘CLOCK’’ (TIME OF DAY) must be programmed into Unit before ‘‘DEFROST’’ (AUTOMATIC), ‘‘SLEEP’’ (SLEEP TIME), and ‘‘WAKE UP’’ (WAKE UP TIME) can be programmed into the Unit. Program ‘‘CLOCK’’ (TIME OF DAY) into Unit as instructed in SERVICE AND MAINTENANCE SECTION.
‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) Displayed voltage readout may be displayed on message display as instructed in SECTION IV SERVICE AND MAINTENANCE PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) INTO UNIT ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) may be programmed into the Unit to check certain components for operation. Program ‘‘DIAGNOSE’’ into Unit and check components for proper operation as instructed in SERVICE AND MAINTENANCE SECTION.
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SERVICE AND MAINTENANCE This section describes service and maintenance to be performed on the Unit. WARNING: Disconnect electrical power to Unit to prevent personnel injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring. PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING CAUTION: Before shipping, storing, or relocating Unit, syrup systems must be sanitized and all sanitizing solution must be purged from syrup systems.
LOWER FRONT ACCESS PANEL Remove two screws securing lower front panel, then pull panel down to remove from Unit. CONDENSER COIL ACCESS PANEL Pull out on top of condenser coil access panel, then lift panel up and out to remove. LUBRICATION CARBONATOR WATER PUMP MOTOR (see Figure 12) Carbonator water pump motor bearings must be lubricated periodically. Refer to oiling instructions on motor. DO NOT OVER OIL.
7. Remove parts from sanitizing solution and place on clean paper towels. NOTE: Use Dow-Corning DC-111 (P/N 321471000) light grade silicone lubricant. 8. Assemble dispensing valve as follows: A. Lubricate caged O-ring. Carefully install caged O-ring on valve from straight end (opposite tapered end). Lubricate grooves in which O-ring rides to fill in all void areas around O-ring. B. Carefully install valve with caged O-ring in dispensing valve body. C.
326142000 FIGURE 5.
FIGURE 6.
RETAINING SCREW(2) SPRING HOUSING TORSION SPRING HOLD-DOWN PLATE(2) SPRING FITTING DISPENSING VALVE BODY CAGED O-RING VALVE LEVER SLEEVE SPRING KNOB FIGURE 7. SELF-CLOSING DISPENSING VALVE ”RUNNING” O-RINGS STATIONARY O-RING STATIONARY O-RING PLASTIC SLEEVE 1 VIEW A STAINLESS STEEL SEAL RETAINER 4 LOCKING TABS 90_ APART 2 4 2 SLOTS 180_ APART 3 VIEW B FIGURE 8. SERVICING BEATER DRIVE SHAFT SEAL ASSEMBLY 11.
1. Press ‘‘OFF 1’’ and ‘‘OFF 2’’ switches on Unit control panel to stop refrigeration system and beaters motors. 2. Remove condenser coil access panel as instructed. 3. Clean condenser coil with vacuum cleaner, low pressure compressed air, or a soft brush. 4. Install condenser coil access panel by reversing removal procedure. 5. Press ‘‘AUTO 1’’ and ‘‘AUTO 2’’ switches on Unit control panel to start refrigeration system and beaters motors.
14. Repeat steps 11 through 13 until desired carbonated water flow rate is achieved. 15. Remove added length of line from outlet side of carbonated water flow regulator. Connect carbonated water line, disconnected from carbonated water flow regulator in step 8 preceding, to regulator outlet. 16. Turn product blender tanks CO2 regulator, with 60-psi gage, adjusting screw in (clockwise) until gage registers pressure noted in step 7 preceding. 17.
ADJUSTING BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ OF DISPENSED PRODUCT (see Figures 2 and 6) 1. Remove Unit front lower access panel as instructed for access to product blender tanks secondary CO2 regulators and product sample valves. 2. Check product blender tanks secondary CO2 regulators, with 60-psi gages, for proper pressure settings which is set at 30-psi for best textured dispensed product. If adjustment is necessary, adjust as instructed. 3.
1. Remove Unit front lower access panel as instructed for access to carbonator secondary CO2 regulator with 100-psi gage. 2. Observe pressure setting on carbonator secondary CO2 regulator gage. 3. To lower CO2 pressure, loosen regulator adjusting screw lock nut. Turn adjusting screw to the left (counterclockwise) until pressure gage reads 15-psi below desired reading, then turn screw to the right (clockwise) until gage reads desired pressure.
HIDDEN SECURITY SWITCH MESSAGE DISPLAY FIGURE 9. CONTROL PANEL PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS (see Table 4) may be brought up on the message display as follows: 1. Press ‘‘AUTO 1’’, ‘‘WASH 1’’, and ‘‘BLEND 1’’ control switches (see Figure 9) at the same time and hold them pressed for a minimum of 1/2 second to bring up MAIN MENU SELECTIONS on message display. The word ‘‘CLOCK’’ will appear on display.
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 ‘‘DEFROST’’ (SELECT) switch to lock in hour on display. 4. After hour (time of day) has been locked in on message display, minute numbers will be flashing on display.
5. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS. PROGRAMMING ‘‘WAKE UP’’ (WAKE UP TIME) INTO UNIT ‘‘WAKE UP’’ (WAKE UP TIME) may be programmed into Unit to occur any time of the day to wake Unit up (return to normal operation) after ‘‘sleep time’’ has occurred. Program ‘‘WAKE UP’’ into Unit as follows: 1. Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up ‘‘WAKE UP’’ on message display. Press ‘‘DEFROST’’ (SELECT) switch to lock in on selection. 2.
SWITCH NO. FUNCTION 1 POINT OF SALE MESSAGE SELECT See Table 7 2 POINT OF SALE MESSAGE SELECT See Table 7 3 POINT OF SALE MESSAGE SELECT See Table 7 4 BEATER MOTOR CURRENT READOUT ON–DISPLAY CURRENT READOUT OFF–NO DISPLAYED CURRENT READOUT 5 MOTOR CURRENT SELF CALIBRATION NO–DISABLED OFF–OPERATING 6 BEATER MOTOR SELECT See Table 6 7 BEATER MOTOR SELECT See Table 6 8 BEATER MOTOR SELECT See Table 6 9 DEFROST NO–HOT GAS OFF–ELECTRIC 10 SERVICE USE ONLY TABLE 5.
PROGRAMMING POINT OF SALE MESSAGE DISPLAY (see Figure 7 and 10) Note: Point of sales display messages may be turned off by placing No. 1 and No. 3 switches on master circuit board (see Figure 10 and Tables 5 and 7) assembly in appropriate positions. Three point of sales display messages are available to choose from and may be programmed by placing switch No. 1 No. 2 and No. 3 on DIP SWITCH assembly on master circuit board in appropriate positions.
1. Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up ‘‘SENSORS’’ (TEMPERATURES READOUT)on message display. 2. Press ‘‘DEFROST’’ (SELECT) switch to bring up evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit. 3. Press ‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS. ‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) Displayed voltage readout may be displayed on message display as follows: 1.
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.
BRIX “A” 11.0 0.1358 11.5 0.1420 12.0 0.1481 12.5 0.1543 13.0 0.1605 13.5 0.1667 14.0 0.1728 14.5 0.1790 15.0 0.1852 15.5 0.1914 16.0 0.1975 GALLONS = “A” x SYRUP MINUTES Using the above table, choose the “A” number that corresponds to your BRIX setting. Multiply the “A” number by the syrup minutes reading to obtain the amount (gallons) of syrup used. TABLE 8.
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.
4. Remove right-hand side panel as instructed for access to No. 2 product blender tank product shutoff valve. 5. Close No. 2 product blender tank product shutoff valve to prevent product bleeding back into No. 1 product blender tank during sanitizing procedure.
17. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 product blender tank with sanitizing solution. Carbonator water pump will start and begin pumping carbonated water into product blender tank which will dilute sanitizing solution also entering tank. 18. After carbonator water pump cycles off, completely fill No. 1 freeze cylinder with sanitizing solution by repeatedly pulling and releasing relief valve knob on freeze cylinder faceplate and until sanitizing solution comes out of relief valve port.
36. After carbonator water pump cycles off, intermittently pull and release No. 1 freeze cylinder faceplate relief valve. This bleeds CO2 from freeze cylinder and allows product to enter and fill cylinder. 37. Open No. 2 product blender tank product shutoff valve. 38. Press both ‘‘AUTO 1’’ and ‘‘AUTO 2‘’ switches to start both freeze cylinders beaters and refrigeration system. Product will be ready for dispensing in approximately 10-minutes. 39.
4. Remove lower front access panel and left-side panel as instructed for access to the water pump water strainer screen. 5. Pull up on carbonator tank relief valve plastic cover to release CO2 pressure from tank. 6. Loosen screen retainer in water pump port, then remove screen retainer and strainer screen from port. 7. Pull strainer screen from screen retainer. Clean any sediment from screen retainer and water pump port. 8. Inspect strainer screen for holes, restrictions, corrosion, and other damage.
REPLENISHING SYRUP SUPPLY NOTE: Sugar free diet syrup cannot be used with this Unit. Although syrup replenishing can be done anytime, syrup supply must be replenished when either ‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages are displayed on message display indicating either No. 1 or No. 2 syrup system soft drink tank is empty. NOTE: The following instructions are applicable only when replenishing syrup supply. Refer to SYRUP FLAVOR CHANGE when changing syrup flavors. 1.
2. Slowly loosen CO2 regulator assembly coupling nut allowing CO2 pressure to escape, then remove regulator assembly from empty CO2 cylinder. 3. Unfasten safety chain and remove empty CO2 cylinder. 4. Position full CO2 cylinder and secure with safety chain. WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder in upright position with safety chain to prevent it from falling over.
326142000 FIGURE 12.
CLEANING CO2 GAS CHECK VALVES (see Figures 2 and 13) The CO2 gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO2 system. ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED. FIGURE 13. CO2 GAS CHECK VALVE REPLACING FREEZE CYLINDER BEATER DRIVE SHAFT BEARING (see Figures 3, 8, and 14) SHUTTING UNIT DOWN 1. Press ‘‘DEFROST’’ switch to defrost product in freeze cylinders. 2.
NOTE: Items in parentheses are in reference to Figure 3. 5. Remove HEX NUTS (item 7) and FLATWASHERS (item 6) securing FACEPLATE (item 8) to freeze cylinder, then remove faceplate. 6. Remove beater shaft and scraper blades from inside freeze cylinder. 7. Pull beater drive shaft seal assembly from socket in back of freeze cylinder using Cornelius Puller (P/N 322063000). 8. Pull beater drive shaft assembly out back of freeze cylinder.
INSTALLING BEATER DRIVE SHAFT ASS’Y AND BEATER DRIVE MOTOR ON UNIT NOTE: Use Beater Drive Shaft Assembly Alignment Tool Kit (P/N 0726) when installing beater drive shaft assembly. 1. Lubricate beater drive shaft bearing boot with DOW-CORNING DC-111 (P/N 321471000) light grade silicone lubricant. 2. Install beater drive shaft assembly in freeze cylinder. 3. Place plastic power coupler in beater drive motor shaft coupling.
2. Sanitize syrup system as instructed in CLEANING AND SANITIZING. REPLACING FREEZE CYLINDER BEATER MOTOR (see Figure 6 and 14 ) NOTE: Use Beater Drive Shaft Assembly Alignment Tool Kit (P/N 0726) when installing beater drive shaft assembly. 1. Press ‘‘OFF 1’’ and ‘‘OFF 2’’ control switches to stop refrigeration system and beaters motors. 2. Disconnect electrical power from Unit. 3. Remove back and side panels as instructed. 4.
ADJUSTING CARBONATOR TANK LIQUID LEVEL The carbonator tank liquid level (pump cut-in and cutout was adjusted at the factory and should require no further adjustment. However, if incorrect setting is suspected, check and make necessary adjustments as follows: 1. Remove Unit back and side panels as instructed for access to carbonator and carbonated water volume sample valve (see Figures 2 and 6). 2.
RELIEF VALVE CARBONATED WATER TANK SWITCHES ACTUATOR BRACKET LEVEL CONTROL SWITCHES(2) ACTUATOR BRACKET ADJUSTMENT SCREW 326142000 FIGURE 15.
FIGURE 16.
326142000 60 FIGURE 17.
TROUBLESHOOTING IMPORTANT: Only qualified personnel should service internal components or electrical wiring. WARNING: If repairs are to be made to a product system, remove quick disconnects from the applicable product tank, then relieve the system pressure before proceeding. If repairs are to be made to the CO2 system, stop dispensing, shut off the CO2 supply, then relieve the system pressure before proceeding.
Trouble Probable Cause ALL CONTROL PANEL E. SWITCHES NOT OPERATING. (cont’d) Remedy Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable. E. Check cable for pinched or broken wire condition and repair or replace as necessary. F. Master circuit board not operating properly. F. Replace master circuit board. A. Not pressing and holding ‘‘SECURITY SWITCH’’ for 3-seconds to deactivate control switches. A.
Trouble ALL FAULT MESSAGES NOT OPERATING. (cont’d) Probable Cause Remedy D. Master circuit board not operating. D. Replace master circuit board. E. Fault message display module not operating properly. E. Replace fault message display module. A. CO2 supply turned off or exhausted. A. Open CO2 cylinder shutoff valve or replenish CO2 supply as instructed. B. Primary CO2 regulator set too low. B. Adjust primary CO2 regulator as instructed. C. Inoperable CO2 pressure switch. C.
Trouble DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING ‘‘CANCEL DEFROST ’’ SWITCH. Probable Cause Remedy A. Flat cable not properly connected to control switch module or master circuit board. A. Properly connect flat cable to controls switch module or master circuit board. B. Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable. B. Check cable for pinched or broken wire condition and repair or replace as necessary. C.
Trouble ERRATIC CARBONATOR WATER PUMP CYCLING. Probable Cause Remedy A. Insufficient water supply pressure. ‘‘H2O OUT’’ fault message goes on and off intermittently and water pump cycles on and off during carbonator tank fill cycle. A. Increase water inlet supply line pressure. Water inlet supply line must have large enough I.D. B. Water filter restricted. B. Replace water filter. TROUBLESHOOTING DISPENSED PRODUCT BRIX (WATER–TO–SYRUP) ‘‘RATIO’’ TOO LOW. BRIX (WATER–TO–SYRUP) ‘‘RATIO’’ TOO HIGH.
Trouble FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY. Probable Cause A. Remedy Dispensed product BRIX varying because: A. Syrup and/or water flow regulator sticking. a.Clean regulator(s). Primary CO2 regulator pressure insufficient. b.Primary CO2 regulator must be adjusted from 80 to 100-psi. B. Cylinder freeze–up causing ice formation in center of cylinder and liquid product channels around ice formation. B. Refer to CYLINDER FREEZE–UP. NOTE: DEFROST AFFECTED FREEZE CYLINDER AS INSTRUCTED.
FCB (SOLID-STATE) POST-MIX DISPENSER TWO–FLAVOR/HOT-GAS DEFROST WITH V3+ ELECTRONICS MODEL NO.
31 32 33 100 29 45 104 107 101 102 107 108 103 120 107 109 106 90 97 37 126 29 22 62 24 119 29 29 29 29 25 70 36 13 52 53 9 43 16 35 17 2 23 57 94 39 93 26 56 54 40 44 29 47 1 65 48 41 46 20 18 29 51 19 21 38 29 71 42 34 FIGURE 18.
89 99 95 91 99 96 116 49 122 57 30 10 92 86 25 50 81 78 124 98 73 74 113 110 75 29 114 67 112 68 80 76 83 69 64 111 58 55 59 82 29 66 60 29 63 29 121 FIGURE 19.
88 11 14 12 15 7 8 87 117 118 85 4 5 6 79 4 FIGURE 20.
FCB POST-MIX DISPENSER Item No. Part No. Item No. Name 1 325457000 Blade, Scraper 2 2353 Body, Beater 3 326002000 Tube Kit, Drain Tube (Not Shown; See Figure 4 324218000 Tube, .156 I.D. By 3-In. Long, CO2 Regulator to Tee 324219000 5 34 Part No. Name 3004 Access Door (Domestic) 325726000 Access Door (Export) 35 325962040 Touch Switch 36 398024603 Hex Nut, No. 10-24 37 3062 Frame Tube, .156 I.D. By 1-In.
Item No. 67 Part No. Name 325940000 Relay, Start, Compressor, 230V. 60HZ. 35 Amp (Domestic) 197466000 Relay, Start, Compressor, 230V. 50HZ. 35 Amp (Export) 68 325938000 69 Item No. Part No. Name 93 325619000 Support, Motor 94 325620000 Spacer 95 309338011 Clip, Sensor Expansion Valve Capacitor, Start, 250V. 60HZ 96 309338012 Clip, Sensor, Thermostat 325939000 Capacitor, Run, 440V. 60HZ (Domestic) 97 2162 Capacitor, Run, 370V.
7 8 9 1 2 6 5 4 3 FIGURE 21. FACEPLATE ASSEMBLY Item No. Part No. Item No. Name Part No. Name 326106000 Door, Freeze Cylinder Ass’y 5 325954088 Relief Valve Ass’y 1 320678000 O-Ring, 4.60 I.D. By .210 C.S.
8 7 1 9 10 11 4 5 6 3 13 12 2 FIGURE 22. DISPENSING VALVE ASSEMBLY Item No. Part No. Name Item No. Part No. Name 1557 Dispensing Valve Ass’y 7 325647000 Plate 1 321653000 O-Ring, .862 I.D. By .103 C.S. 8 317784000 2 1553 Knob Thread Cutting Screw, Phil Truss Hd., Stainless Steel, No. 8-32 By 3/8-In. Long 3 321651000 Lever, Knob 9 1576 Housing 4 1556 Body and Shank 10 325305000 Spring 5 321514000 O-Ring, Caged, .562 I.D. By .210 C.S.
13 11 12 25 14 26 27 28 31 30 15 10 29 32 24 23 8 22 6 21 20 2 4 7 5 3 19 17 18 9 16 1 33 FIGURE 23. CO2 REGULATOR ASSEMBLY Item No. 1 Part No. Item No. Name Part No. Name 326097000 CO2 Regulator Ass’y, and Bracket 17 183040000 183301100 Check Valve Ass’y With Adaptor (Includes 2-8) Machine Screw, Phil Fil Hd., No. 10-32 By 7/8-In.
FIGURE 24. CARBONATOR ASSEMBLY Item No. Part No. Name Part No. Name Carbonator and Motor Ass’y 7 174103000 Tube, .250 I.D. By 4-In. Long 8 770104000 Nipple, For .250 I.D. Tube 9 176017000 Swivel Nut, 7/16-20 10 770602000 Fitting, Cross, 1/4-Barb 11 325558000 Tube Ass’y (Includes 12-15) 12 174103001 Tube, .250 I.D. By 30-In. Long 13 176001000 Ferrule, For .395 O.D.
Item No. Part No. Item No. Name Part No. Name 14 770104 Nipple, For .250 I.D. Tube 52 311855000 J-Nut, 1/4-20 15 176017000 Swivel Nut, 7/16-20 53 176272396 Tube Ass’y (Includes 54-57) 16 318045000 Tube Ass’y (Includes 17-20) 54 174292000 Tube, .375 I.D. By 96-In. Long 17 174103001 Tube, .250 I.D. By 12-3/4-In. Long 55 176204000 Ferrule, For .610 O.D. Tube, 61 Jaw 18 176001000 Ferrule, For .395 O.D. Tube, 40 Jaw 56 176205000 Nipple, For .375 I.D.
WARRANTY IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire product, 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 D P.O.
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IMI CORNELIUS INC.
