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Cornelius FCB POST-MIX DISPENSER Installation & Service Manual

Two or four-flavor w/hot-gas defrost and v3+features
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IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234
Telephone (800) 238-3600
nstallation/Service
I
Manual
FCB POST-MIX DISPENSER
TWO OR FOUR-FLAVOR
W/HOT-GAS DEFROST
AND 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. 2813
October 13, 1993
Revised: March 28, 1995
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 1993–95
Facsimile (612) 422-3246
PRINTED IN U.S.A

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  • Page 1 IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234 Telephone (800) 238-3600 Facsimile (612) 422-3246 nstallation/Service Manual FCB POST-MIX DISPENSER TWO OR FOUR-FLAVOR W/HOT-GAS DEFROST AND V3+FEATURES IMPORTANT: TO THE INSTALLER It is the responsibility of the Installer...

  • Page 2: Table Of Contents

    GENERAL INFORMATION ..........GENERAL DESCRIPTION .
  • Page 3 TABLE OF CONTENTS Page PROGRAMMING POINT OF SALE MESSAGE DISPLAY ....ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED PRODUCT ............“VIS READ”...
  • Page 4 TABLE OF CONTENTS Page CLEANING CONDENSER COIL ......... UNIT WITH AIR-COOLED REFRIGERATION SYSTEM .
  • Page 5 TABLE OF CONTENTS Page CARBONATOR(S) WATER PUMP(S) MOTOR(S) ..... . SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE CYLINDERS DRIVE SHAFT/ SEAL ASSEMBLIES .
  • Page 6 TABLE OF CONTENTS Page SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE ............REPLENISHING SYRUP SUPPLY .
  • Page 7 ......... FIGURE 19. FCB POST-MIX DISPENSER (4-FLAVOR) .
  • Page 8 TABLE OF CONTENTS Page LIST OF FIGURES (CONT’D) FIGURE 37. TUBING ASSEMBLY (WATER SOLENOID TO BLENDER) ..FIGURE 38. TUBING ASSEMBLY (REGULATOR TO BLENDER) ... . FIGURE 39.

  • Page 9: General Information

    GENERAL INFORMATION IMPORTANT: 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. GENERAL DESCRIPTION This section gives the description, theory of operation, and design data for the Two or Four-Flavor FCB Post-Mix Dispenser with Hot-Gas Defrost and V3+ Features (hereafter referred to as a Unit).

  • Page 10: Figure 1. Four-Flavor Dispenser

    FIGURE 1. FOUR-FLAVOR DISPENSER Table 1. Design Data Unit Part Numbers: 60 HZ Units: Two-Flavor Unit (Air-Cooled) 416220 Two-Flavor Unit (Water-Cooled) 416222 Four-Flavor Unit (Air-Cooled) 416200 Four-Flavor Unit (Water-Cooled) 416202 50 HZ Units: Two-Flavor Unit (Air-Cooled) 496220 Two-Flavor Unit (Water-Cooled) 496222 Four-Flavor Unit (Air-Cooled) 496200...

  • Page 11: Refrigeration Systems

    Table 1. Design Data (cont’d) Refrigeration System: Refrigerant Type and Charge See Unit Nameplate 40° F to 100 ° F Ambient Operating Temp. Electrical Requirements: 60 HZ Two-Flavor Unit: Operating Voltage 198-253 VAC, 60 HZ, Single- Phase Current Draw 21.2 Amps 50 HZ Two-Flavor Unit: Operating Voltage 209-253 VAC, 50 HZ, Single-...

  • Page 12: Defrost Systems

    Note: The following paragraph describes the theory of operation for the Two-Flavor FCB Dispenser (see Figure 2 ). The Four-Flavor FCB Dispenser theory of operation is the same as the Two- Flavor Dispenser except the Four-Flavor (see Figure 3 ) has two carbonator tanks, four product-blender tanks, and is connected to four soft drink tanks.

  • Page 13: Sleep'' (Sleep Time)

    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.

  • Page 14: Figure 2. Flow Diagram (Two-Flavor Fcb Dispenser)

    *WATER PRESSURE REGULATOR IS FACTORY ADJUSTED TO 45 PSI AND SHOULD NOT BE READJUSTED. **SYRUP SOLD–OUT SWITCHES ARE FACTORY ADJUSTED AND SHOULD PRODUCT SAMPLE NOT BE READJUSTED. VALVE(2) LINE LEGEND PLAIN WATER CARB WATER SYRUP PRODUCT CARBONATOR TANK PRODUCT BLENDER TANK(2) PRODUCT SHUTOFF VALVE(2)

  • Page 15: Figure 3. Flow Diagram (Four-Flavor Fcb Dispenser)

    *WATER PRESSURE REGULATORS **SYRUP SOLD-OUT SWITCHES PRODUCT SAMPLE ARE FACTORY ADJUSTED TO 45-PSI ARE FACTORY ADJUSTED AND VALVE (4)) AND SHOULD NOT BE READJUSTED. SHOULD NOT BE READJUSTED. CARBONATED WATER CARBONATOR VOLUME SAMPLE VALVE PRODUCT BLENDER TANK (2) PRODUCT TANK (4) SHUTOFF VALVE (4) CARBONATED...
  • Page 16 THIS PAGE LEFT BLANK INTENTIONALLY 2813...

  • Page 17: Installation

    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.

  • Page 18: Electrical Power Requirements

    Table 3. Loose-Shipped Parts (cont’d) Item Qty. Qty. Part No. Name 2-Fl 4-Fl 326002 Kit, Drip Tray Drain Hose 2899 Wrench, Rear Seal Housing 3810 Tool, Drive/Coupler Adjustment Gauge 325018 Caster Kit, 4–inch diameter casters ∗ Νumbers in parentheses are in reference to items in Figure 4. 4.

  • Page 19: Installing Unit

    1. Close to a plain water inlet supply line with a minimum pressure of 12 psig. NOTE: “AIR-COOLED FCB DISPENSER The “air-cooled” FCB Dispenser refrigeration system is equipped with a condenser coil that is cooled by a condenser coil fan. 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.

  • Page 20: Figure 4. Freeze Cylinder Cutaway View

    Valve Lever Beater Drive Motor Product Inlet Fitting Knob Drive Shaft Assembly Scraper Blade (2) Dispensing Valve Evaporator Coil Viscosity Sensor Beater Relief Valve Port Spinner Allen Head Setscrew O-Ring Spring Beater Shaft Coupling Flatwasher (4) Shaft Release Drive Pin Hex Nut (4) Bearing Housing Locking Tab (4) Bearing...

  • Page 21: Cylinder

    BEATER KEY ON END KEY ON END OF POST 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 5.

  • Page 22: Connecting Soft Drink Tanks Co2 Lines To Primary Co2 Regulator Assembly

    (see applicable Figure 2 or 3 ) NOTE: IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the City plain water source line (see applicable Figure 2 or 3 ) that provides plain water to the Dispenser post-mix system.

  • Page 23: Connecting Electrical Power Circuit To Unit

    1. Route the refrigeration cooling coil(s) plain water inlet line(s) labeled “COOLING WATER IN” and line(s) labeled “ COOLING WATER OUT” out through hole in bottom of the Unit base. 2. Connect the refrigeration cooling coil(s) plain water inlet line(s) labeled “COOLING WATER IN” to the City plain water inlet line.

  • Page 24: Preparation For Operation

    PREPARATION FOR OPERATION 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.

  • Page 25: Connecting Soft Drink Tanks To Unit Syrup Systems

    (approximately 6-ounces) of product in a cup or glass. NOTE: Temperature compensated hand-type refractometers (P/N 511004000) are available from the Cornelius Company. 4. 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.

  • Page 26: Filling Freeze Cylinders With Product

    6. 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. 7.

  • Page 27: Programming ''Defrost'' (Automatic) Settings Into The Unit

    Program ‘‘CLOCK’’ (TIME OF DAY) into Unit as instructed in the SERVICE AND MAINTENANCE section. PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO the 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.

  • Page 28: Programming Components ''Diagnose'' (Diagnostic Mode) Into The Unit

    PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) INTO THE UNIT ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) may be programmed into the Unit to check certain components for operation. Program ‘‘DIAGNOSE’’ into the Unit and check components for proper operation as instructed in the SERVICE AND MAINTENANCE section. DISPLAYING ‘‘TOTALS’’...

  • Page 29: Operators Instructions

    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 the Unit to prevent personnel injury before attempting any internal maintenance.

  • Page 30: Control Panel Display Messages

    ’’AUTO 1’’ and ‘‘AUTO 2’’ Control Switches. ‘‘AUTO 1’’ and ‘‘AUTO 2’’ control switches, located on control panel (see Figure 6), are touch-type switches and require only pressing to activate. These switches are used to operate freeze cylinders beaters and refrigeration system after cylinders have been filled with product.

  • Page 31: Freeze Cylinders Manual Or Automatic Defrost Systems

    ‘‘CO OUT’’ Fault Message. ‘‘CO OUT’’ fault message will appear on message display when CO supply to the Unit has been turned off or if pressure drops below 50-psi. A minimum CO pressure of 75-psi must be available to the Unit to extinguish ‘‘CO OUT’’...

  • Page 32: Sleep'' (Sleep Time)

    ‘‘SLEEP’’ (SLEEP TIME) ‘‘SLEEP’’ (SLEEP TIME) may be programmed into Unit to allow Unit to go into sleep time (Unit shut down, freeze cylinders beaters and refrigeration systems not operating). At start of sleep time, refrigeration compressor will operate for 30-seconds to pump freon out of freeze cylinders evaporator coils. Then No. 1 freeze cylinder will go into defrost for 60-seconds.

  • Page 33: Syrup Flow Regulators

    SYRUP FLOW REGULATORS The syrup flow regulators (see applicable Figure 2 or 3 and Figure 7), located in their respective systems, are adjustable regulators that control syrup flow rate to the product blender tanks for desired BRIX of dispensed product. Adjust syrup flow regulators for desired BRIX as instructed in the SERVICE AND MAINTENANCE section.

  • Page 34: Operating Characteristics

    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 CO gas.

  • Page 35: Product Flavor Change

    1. To disconnect soft drink tank from Unit syrup system. 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. Second, disconnect CO quick disconnect from soft drink tank.

  • Page 36: Lubrication

    LUBRICATION Carbonator pump(s) motor(s) must be lubricated as instructed. ADJUSTMENTS CARBONATED WATER FLOW RATE The black carbonated water flow regulators (see applicable Figure 2 or 3 and 7 ), 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.

  • Page 37: Programming ''Sleep'' (Sleep Time) Into Unit

    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 operation) until programmed ‘‘WAKE UP’’...

  • Page 38: Displaying ''Totals'' (Displayed Cycles And Hours Totals) Onto Message Display

    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 SERVICE AND MAINTENANCE section. PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT ELECTRONICS Note in 6 “MOTOR SELECT” the number of freeze cylinders beater motors Manufacturer’s that are listed. Your Unit was manufactured and equipped with motors from one of these Manufacturer’s.

  • Page 39: Service And Maintenance

    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.

  • Page 40: Top Panel

    TOP PANEL Remove two screws securing top panel, then lift panel up off Unit. 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(S) WATER PUMP(S) MOTOR(S) (see Figure 12 )

  • Page 41: Figure 6. Operating Controls (Four-Flavor Unit)

    FAULT MESSAGE DISPLAY CONTROL PANEL HIDDEN “SECURITY SWITCH” TOP PANEL UPPER CONTROL BOX TOP PANEL RETAINING SCREW (2) RELAY CIRCUIT BOARD NO. 1 MASTER CIRCUIT BOARD RELAY CIRCUIT BOARD NO. 2 CONTROL PANEL FACEPLATE RELIEF VALVE (4) BACK PANEL LOWER FRONT ACCESS PANEL CUP REST FACEPLATE (4)

  • Page 42: Figure 7. Unit Internal Components

    SYRUP FLOW REGULATOR (2) RELIEF VALVE (2) CARBONATED WATER PRODUCT BLENDER FLOW REGULATOR (2) TANK (2) UPPER CONTROL BOX COVER RETAINING SCREW (4) UPPER CONTROL BOX COVER FAULT MESSAGE DISPLAY BEATER DRIVE FREEZE CYLINDER (2) MOTOR (2) SECONDARY CO REGULATOR (3) RECEIVER TANK REFRIGERATION CONDENSER COIL...

  • Page 43: Figure 8. Self-Closing Dispensing Valve

    RETAINING SPRING HOUSING SCREW(2) TORSION SPRING HOLD-DOWN SPRING FITTING PLATE(2) DISPENSING VALVE BODY CAGED O-RING VALVE LEVER SLEEVE SPRING KNOB FIGURE 8. SELF-CLOSING DISPENSING VALVE 4. Unscrew RELIEF VALVE (item 9) from FACEPLATE (item 8). 5. Disassemble dispensing valve (see Figure 8) as follows: Remove two screws and hold-down plates securing spring housing to dispensing valve body, then remove housing.
  • Page 44 10. Thoroughly clean RELIEF VALVE (item 9), then screw relief valve into FACEPLATE (item 8). 11. Proceed to Servicing Beater Motor Drive Shaft/Seal Assemblies. Servicing Freeze Cylinders Drive Shaft/Seal Assemblies. (see Figure 14) IMPORTANT: The freeze cylinders drive shaft/seal assemblies must be removed and inspected every four months.

  • Page 45: Cleaning Condenser Coil

    16. Lubricate O-RING (item 5) with water to facilitate faceplate installation. Position O-RING (item 5) on FACEPLATE (item 8). Install faceplate on Unit so dispensing valve spout faces down. (MAKE SURE FEMALE END OF THE BEATER IS PLACED OVER THE FACEPLATE STAINLESS-STEEL STUD AND BUSHING BEFORE PUSHING THE FACEPLATE INTO POSITION ON ITS FOUR THREADED MOUNTING STUDS).

  • Page 46: Adjusting Carbonated Water Flow Rate

    ADJUSTING CARBONATED WATER FLOW RATE The back carbonated water flow regulators (see applicable Figure 2 or 3 and 7), 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.

  • Page 47: Adjusting Water-Cooled Refrigeration System Variable Water Regulator

    Primary CO Regulator. (see applicable Figure 2 or 3) Adjust the primary CO regulator by turning the regulator adjusting screw to the right (clockwise) until the regulator pressure reads 80 to 100 psig. Product Blender Tanks Secondary CO Regulators. (see Figures 2 and 3) 1.

  • Page 48: Adjusting Brix (Water-To-Syrup) ''Ratio'' Of Dispensed Product

    NOTE: Temperature compensated hand-type refractometers (P/N 511004000) are available from the Cornelius Company. 7. Check product BRIX with a temperature compensated hand-type refractometer. BRIX should read 13 ± 1. If BRIX is not within tolerance, adjust applicable white syrup flow regulator as follows: Turn syrup flow regulator adjusting screw to the left (counterclockwise) no more than 1/8-turn at a time to reduce syrup flow rate or turn screw to the right (clockwise) no more than 1/8-turn to increase flow rate.

  • Page 49: Adjusting Beater Motor Current (Either Side)

    HIDDEN SECURITY SWITCH MESSAGE DISPLAY FIGURE 9. CONTROL PANEL 1. Remove Unit front lower stainless steel access panel as instructed for access to carbonator secondary regulator with 100-psi gage. 2. Observe pressure setting on carbonator secondary CO regulator gage. 3. To lower CO pressure, loosen regulator adjusting screw lock nut.

  • Page 50: Adjustment And Programming Main Menu Selections Into Unit

    ANY TIME THE NO. 4 ‘‘BEATER MOTOR CURRENT READOUT’’ SWITCH ON DIP SWITCH ASSEMBLY IS PLACED IN ‘‘ON’’ POSITION, THE BEATER MOTOR CURRENT READINGS MUST BE READJUSTED TO A150B150 ± 2 AS INSTRUCTED, THEN SWITCH MUST BE PLACED BACK IN THE ‘‘OFF’’ POSITION. ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS INTO UNIT NOTE: The Unit control panel switches are as shown in Figure 9.

  • Page 51: Programming ''Defrost'' (Automatic) Settings Into Unit

    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’’...

  • Page 52: Programming ''Wake Up'' (Wake Up Time) Into Unit

    4. After hour (time of day) has been locked in on message display, minute numbers will be flashing on display. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance minute numbers to desired minutes (time of day). Press ‘‘DEFROST’’ (SELECT) switch to lock in minutes (time of day) on display. 5.

  • Page 53: Adjusting "Vis Set" (Product Viscosity) Of Dispensed Product

    DISPLAYED MODEL MOTOR DESCRIPTION KLBER Klauber Over/under gear box with a GE wide-range voltage motor. – FASV3+60 Fasco/VW Over/under gear box with a Fasco wide-range voltage motor. FASCWR 60 Fasco/VW Standard gear box using a Fasco wide-range voltage motor. VW/GE 60 Fasco/VW Standard gear box with a GE 219/242 volt motor.

  • Page 54: Vis Read'' (Actual Viscosity Readout) Of Product In Freeze Cylinders

    NO. 1 AND NO. 2 EVAPORATOR COILS REFRIGERATION COMMON OUTLET TEMPERATURES NO. 2 EVAPORATOR REFRIGERATION COIL INLET TEMPERATURE NO. 1 EVAPORATOR REFRIGERATION COIL INLET TEMPERATURE MOTOR CURRENT ADJUSTMENT RELAY CIRCUIT BOARD NO. 1 MASTER CIRCUIT BOARD RELAY CIRCUIT BOARD NO. 2 POINT OF SALE MESSAGE DISPLAY SELECT (SEE 7) SEE NOTE...

  • Page 55: Displayed Evaporator Refrigeration Coils Inlets And Common Outlet Sensors Temperatures

    1. Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up ‘‘VIS READ’’ of product in freeze cylinders. 2. Press ‘‘DEFROST’’ (SELECT) switch to bring up actual viscosity readout of product in each freeze cylinder. 3. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS. DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES.

  • Page 56: Displaying ''Totals'' (Displayed Cycles And Hours Totals) Onto Message Display

    7. Press ‘‘DEFROST’’ (SELECT) switch. No. 1 defrost relay will click when switch is pressed. 8. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘DEFROST 2’’ on message display. 9. Press ‘‘DEFROST’’ (SELECT) switch. No. 2 defrost relay will click when switch is pressed. 10.

  • Page 57: Table 8. "Totals" (Displayed Cycles And Hours Totals) Menu

    TOTALS MENU COMMANDS DESCRIPTION COMP HRS COMPRESSOR RUN HOURS COMP CYC COMPRESSOR CYCLES X100 DFSTYC1 DEFROST SIDE 1 CYCLES DFSTYC2 DEFROST SIDE 2 CYCLES BLDRCYC1 BLENDER SIDE 1 CYCLES X100 BLDRCYC2 BLENDER SIDE 2 CYCLES X100 SOLDOUT 1 SOLDOUT SYRUP SIDE 1 SOLDOUT 2 SOLDOUT SYRUP SIDE 2 BMTRHRS1...

  • Page 58: Displaying ''Totals'' (Displayed Cycles And Hours Totals) Onto Message Display

    ITEMS AFFECTED BY ERROR BEATER BEATER MESSAGE MOTOR 1 MOTOR 2 REFRIG 1 REFRIG 2 DISPLAYED ERROR Motor 1 Low Current, < 109, Sensed on motor one Motor 2 Low Current, < 109, Sensed on motor two Motor 1 High Current, > 255, Sensed on motor one Motor 2 High Current, >...

  • Page 59: Programming Freeze Cylinders Beater "Motors" Into Unit Electronics

    PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT ELECTRONICS IMPORTANT: Note in “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.

  • Page 60: Displayed Error Conditions

    4. Press “DEFROST” (SELECT) switch to lock in on the selection. This programs the proper refrigeration pulse rate into the Dispenser electronics. 5. Press “ERROR RESET” switch two times to exit from “MAIN MENU SELECTIONS”. DISPLAYED ERROR CONDITIONS Displayed error conditions, associated errors, and items affected by the errors are found in 9 DISPLAYED ERROR CONDITIONS.
  • Page 61 7. To connect soft drink tank into Unit syrup system. First, connect CO quick disconnect to soft drink tank to pressurize tank. Second, connect liquid quick disconnect to soft drink tank. 8. Disconnect soft drink tank containing syrup from No. 1 syrup system. 9.
  • Page 62 23. 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.

  • Page 63: Yearly Or After Water System Disruption)

    YEARLY OR AFTER WATER SYSTEM DISRUPTION) WARNING: The carbonator water pump water strainer screen and double liquid check valve must be Inspected and serviced after any disruptions (plumbing work, earthquake, etc.) to the water supply system, and at least once a year under normal circumstances. Water pump with no strainer screen or defective screen would allow foreign particles to foul the double liquid check valves.

  • Page 64: Replenishing Syrup Supply

    index no part name 317965000 Retainer 312196000 Spring 312419000 Ball 312415000 Washer, .300 I.D. 312418000 Quad Ring 317963000 Body Install new ball seat each servicing. FIGURE 11. 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.

  • Page 65: Figure 12. Water Strainer Screen And Double Liquid Check

    SCREEN RETAINER O-RING (P/N 315349000) DOUBLE LIQUID CHECK VALVE ASS’Y SCREEN (P/N 315348000) WATER PUMP MOTOR WHITE TAPERED GASKET WATER PRESSURE SWITCH WATER PRESSURE REGULATOR WATER PUMP SYRUP SOLD-OUT FLOAT SWITCH (2) CARBONATED WATER FLOW REGULATOR (2) SYRUP FLOW REGULATOR (2) LIQUID CHECK VALVE (4) CARBONATED WATER...

  • Page 66: Replenishing Co2 Supply

    2. To disconnect soft drink tank from Unit syrup system. 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. Second, disconnect CO quick disconnect from soft drink tank.

  • Page 67: Syrup Flavor Change

    SYRUP FLAVOR CHANGE One or both syrup flavors can be changed at the same time. Perform flavor change on one system as follows: 1. Perform sanitizing procedure on syrup system syrup flavor change will be made on as instructed in the SERVICE AND MAINTENANCE SECTION.

  • Page 68: Replacing Freeze Cylinder Beater Drive Motor

    QUAD RING 183294000 BALL 183296000 SPRING 183297000 RETAINER 183298000 BODY 183295100 QUAD RING SEAL MUST BE REPLACED EACH TIME CHECK VALVE IS SERVICED. FIGURE 13. CO GAS CHECK VALVE REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR (see Figures 7 and 14) IMPORTANT: Note in “6 MOTOR SELECT”...

  • Page 69: Figure 14. Servicing Beater Motor Drive Shaft/Seal Assembly

    BEATER DRIVE SHAFT/SEAL ASS’Y DRIVE MOTOR BEATER DRIVE BEATER MOTOR SHAFT ALLEN-HEAD ALLEN-HEAD SET SCREW SET SCREW COUPLING RUBBER COUPLING COUPLER DRIVE SHAFT GAUGE, DRIVE/COUPLER (ITEM 14) PLASTIC HOUSING LOCK RING O-RING BEARING O-RING SHAFT ALLEN-HEAD DRIVE SHAFT/ SEAL ASSEMBLY SET SCREW (2) FIGURE 14.

  • Page 70: Figure 15. Carbonator Liquid Level Control Switch

    RELIEF VALVE CARBONATED WATER TANK SWITCHES ACTUATOR BRACKET LEVEL CONTROL SWITCHES(2) ACTUATOR BRACKET ADJUSTMENT SCREW FIGURE 15. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT 2813...

  • Page 71: Adjusting Carbonator Tank Liquid Level

    9. Very carefully, place the new beater drive motor into position in the Unit with the motor shaft engaged in the beater drive shaft large rubber coupler. 10. Secure beater drive motor to the Unit frame with bolt, hex nuts, and lockwashers. 11.

  • Page 72: Figure 16. Refrigeration Flow Diagram (Air-Cooled Refrigeration System)

    ELECTRONIC EXPANSION VALVE (2) HOT-GAS DEFROST SOLENOID VALVE ASS’Y (2) FREEZE CYLINDER (2) EVAPORATOR STRAINER/DRYER SCHREADER VALVE CONDENSER COIL FAN ASS’Y COMPRESSOR ACCUMULATOR RECEIVER TANK Note: One refrigeration system is shown in this illustration. A two-flavor Unit has one refrigera- tion system and a four-flavor Unit has two refrig- eration systems.

  • Page 73: Figure 17. Refrigeration Flow Diagram (Water-Cooled Refrigeration System)

    ELECTRONIC HOT GAS DEFROST EXPANSION VALVE (2) SOLENOID VALVE ASS’Y (2) FREEZE CYLINDER (2) *WATER FLOW RATE THROUGH COIL VARIES DUE TO PRESSURE CHANGE ON HIGH SIDE OF COMPRESSOR WHICH INFLUENCES OPENING AND CLOSING OF VARIABLE WATER REGULATOR. ADJUST VARIABLE WATER REGULATOR TO MAINTAIN 200 PSI REFRIGERATION HIGH-SIDE PRESSURE COOLING WATER IN...

  • Page 74: Figure 18. Wiring Diagram

    2426 REV: D FIGURE 18. WIRING DIAGRAM...

  • Page 75: Troubleshooting

    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 CO system, stop dispensing, shut off the CO supply, then relieve the...

  • Page 76: Control Panel Switches Cannot Be Deactivated

    Trouble Probable Cause Remedy ALL CONTROL PANEL Flat cable connected between Check cable for pinched or SWITCHES NOT OPERATING. control switch module and broken wire condition and repair (cont’d) master circuit board pinched or replace as necessary. and shorted out or broken wire in cable.

  • Page 77: Co2 Out'' Fault Message Goes On During Operation

    Trouble Probable Cause Remedy ALL FAULT MESSAGES NOT Master circuit board not Replace master circuit board. OPERATING. (cont’d) operating. Fault message display module Replace fault message display not operating properly. module. ‘‘CO OUT’’ FAULT MESSAGE supply turned off or Open CO cylinder shutoff valve GOES ON DURING exhausted.

  • Page 78: Defrost Cycle Does Not Cancel After Pressing ''Cancel

    Trouble Probable Cause Remedy DEFROST CYCLE DOES NOT Flat cable not properly Properly connect flat cable to CANCEL AFTER PRESSING connected to control switch controls switch module or master ‘‘CANCEL DEFROST ’’ module or master circuit circuit board. SWITCH. board. Flat cable connected between Check cable for pinched or control switch module and...

  • Page 79: Carbonator Water Pump Will Not Shut Off

    Trouble Probable Cause Remedy CARBONATOR WATER PUMP Binding, damaged, or dirty Clean, repair, or replace balance WILL NOT SHUT OFF. carbonated water tank balance mechanism. mechanism. ERRATIC CARBONATOR Insufficient water supply Increase water inlet supply line WATER PUMP CYCLING. pressure. ‘‘H O OUT’’...

  • Page 80: Freeze Cylinder Does Not Refill At All Times When Dispensing

    Trouble Probable Cause Remedy FREEZE CYLINDER DOES ‘‘AUTO BLEND 1’’ or ‘‘AUTO Press ‘‘AUTO BLEND 1’’ or NOT REFILL AT ALL TIMES BLEND 2’’ switch not pressed. ‘‘AUTO BLEND 2’’ switch. WHEN DISPENSING. Carbonator water pump not Check carbonator and restore to operating.
  • Page 81 FCB POST-MIX DISPENSER TWO OR FOUR-FLAVOR WITH HOT-GAS DEFROST AND V3+ ELECTRONICS UNIT PART NUMBERS: 416220-xxx 416222-xxx 416200-xxx 416202-xxx 496220-xxx 496222-xxx 496200-xxx 496202-xxx ILLUSTRATED PARTS BREAKDOWN 2813...

  • Page 82: Figure 19. Fcb Post-Mix Dispenser (4-Flavor)

    FIGURE 19. FCB POST-MIX DISPENSER (4-FLAVOR) 2813...

  • Page 83: Figure 20. Fcb Post-Mix Dispenser (4-Flavor)

    FIGURE 20. FCB POST-MIX DISPENSER (4-FLAVOR) 2813...

  • Page 84: Figure 21. Fcb Flow Diagram (4-Flavor)

    FIGURE 21. FCB FLOW DIAGRAM (4-FLAVOR) FCB POST-MIX DISPENSER 2813...
  • Page 85 FCB POST-MIX DISPENSER (cont’d) Item Item Part No. Name Part No. Name 325457 Blade, Scraper 189429 Hex Nut, 1/4-20 3432 Body, Beater 200498-003 Hex Nut, No. 8-32 326002 Tube Kit, Drain Tube (Not Shown; See 3108 Thread Rolling Screw, Phil Truss Hd., Figure 29) No.
  • Page 86 FCB POST-MIX DISPENSER (cont’d) Item Item Part No. Name Part No. Name 0157 Panel, Right-Hand Side 325938 Capacitor, Start, 250V. 60HZ. 1422 Panel, Right-Hand Side, Stainless Steel 325939 Capacitor, Run, 440V. 60HZ. 0156 Panel, Left-Hand Side 325776 Pressure Switch, CO...
  • Page 87 FCB POST-MIX DISPENSER (cont’d) Item Item Part No. Name Part No. Name 320940 Machine Screw, Hex Washer Hd., No. 186146 Hex Nut, 5/16-18 10-16 By 5/8-In. Long 318418 Washer, .312 I.D. 3238 Bracket, Beater Motor 176272-396 Tube Ass’y, .375 I.D. By 96-In. Long, Water Inlet (2-Flavor;...
  • Page 88 FCB POST-MIX DISPENSER (cont’d) Item Item Part No. Name Part No. Name 311743 Retainer, Blender 2342 Wire Harness, Upper Control Box (Not Shown) 311751 Machine Screw, Sl. Hex Hd., No. 4-40 By 1/4-In. Long 325577-010 Accumulator 325576 Syphon Tube 309524-011...

  • Page 89: Figure 22. Faceplate Assembly

    FIGURE 22. FACEPLATE ASSEMBLY Item Item Part No. Name Part No. Name 326106 Door, Freeze Cylinder Ass’y 321652 Shank Nut 325918 Door, Freeze Cylinder 325936 Spacer 325954-088 Relief Valve Ass’y 321269-001 Spinner 320678 O-Ring, 4.60 I.D. By .210 C.S. 322441 Sensor 1557 Valve Head Ass’y (See Figure 23)

  • Page 90: Figure 23. Dispensing Valve Assembly

    FIGURE 23. DISPENSING VALVE ASSEMBLY Item Item Part No. Name Part No. Name 1557 Dispensing Valve Ass’y 325647 Plate 1556 Body and Shank 317784 Thread Cutting Screw, Phil Truss Hd., Stainless Steel, No. 8-32 By 1554 Valve 3/8-In. long 1576 Housing 2818 O-Ring, Caged, .562 I.D.

  • Page 91: Figure 24. Co2 Regulator Assembly

    28 29 FIGURE 24. CO REGULATOR ASSEMBLY Item Item Part No. Name Part No. Name 326097 Regulator Ass’y and Bracket, 183007 Filter Screen Secondary (2-Flavor) 183006 Spring, Poppet 326099 Regulator Ass’y and Bracket, 130170 Valve, Poppet Secondary (4-Flavor) 130168 Reducing Valve Seat 183287 Gage, 60 PSI 183003...

  • Page 92: Figure 25. Carbonator Tank And Linkage Assembly

    FIGURE 25. CARBONATOR TANK AND LINKAGE ASSEMBLY Item Item Part No. Name Part No. Name 326136 Carbonator Tank and Linkage Ass’y 318037 Insulation, Switch 326135 Tank, Carbonator 317771 Level Control Switch 317746 Link, Pivot 315961 Machine Screw, Sl. Rd. Hd., No. 4-40 By 1-1/8-In.

  • Page 93: Figure 26. Pump And Motor Ass'y

    FIGURE 26. PUMP AND MOTOR ASS’Y Item Item Part No. Name Part No. Name 2494 Pump and Motor Ass’y, 115V. 60HZ 311437 Fitting, 3/8-NPT By 7/16-20 2493 Pump and Motor Ass’y, 230V. 50HZ 311765-001 Double Check Valve Ass’y (See Figure 27) 320626 Motor, 115V.

  • Page 94: Figure 27. Double Check Valve Assembly

    FIGURE 27. DOUBLE CHECK VALVE ASSEMBLY Item Item Part No. Name Part No. Name 311765-001 Double Check Valve Ass’y 312419 Ball 311764-001 Single Check Valve Ass’y 312415 Washer, .300 I.D. (Includes 2-7) 312418 Quad Ring, .329 I.D. 317965 Retainer 317963 Receptacle 312196 Spring...

  • Page 95: Figure 28. Solenoid Valve Assembly

    FIGURE 28. SOLENOID VALVE ASSEMBLY Item Item Part No. Name Part No. Name 2486 Solenoid Valve Ass’y, Water 310632-001 Adjusting Screw 2487 Solenoid Valve Ass’y, Syrup 1318 Flow Control, Top 2356 Block, Valve 180025 O-Ring, .364 I.D. By .070 C.S. 1319 Body, Valve 1545...

  • Page 96: Figure 29. Drip Tray Drain Kit

    Item Part No. Name 326002 Drain Kit, Drip Tray 170423 Hex Nut, 5/8-32 151281 Washer, .640 I.D. 140133 Clamp, .687 O.D. 170413 Fitting 113500-039 Tube, .500 I.D. By 60-In. Long FIGURE 29. DRIP TRAY DRAIN KIT Item Part No. Name 174061-196 Tube Ass’y, .265 I.D.

  • Page 97: Figure 32. Tubing Assembly (Carb Water)

    Item Part No. Name 2492 Tube Ass’y, Carb Water Outlet 770602 Fitting, Cross, Barb 770501 Fitting, Elbow, Valve 325012 Shut-Off Valve 174103 Tube, .250 I.D. By 52-In. Long 174103 Tube, .250 I.D. By 3-7/8-In. Long 176001 Ferrule, .425 O.D. Tube 174103-001 Tube, .250 I.D.

  • Page 98: Figure 35. Tubing Assembly (Syrup)

    Item Part No. Name 326113 Tube Ass’y, Syrup 176017 Nut, Swivel, 7/16-20 770104 Nipple, .265 I.D. Tube 176000 Ferrule, .500 O.D. Tube 174478 Tube, .265 I.D. By 92-In. Long 174478 Tube, .265 I.D. By 3-In. Long 770698 Fitting, Tee, Barb 176271 Nipple, .265 I.D.
  • Page 99 Item Part No. Name 2491 Tube Ass’y, Water Solenoid to Blender 311742 Connector, Barb 176001 Ferrule, .375 O.D. Tube 174103 Tube, .250 I.D. By 3 3/8-In. Long 174103 Tube, .250 I.D. By 1-3/4-In. Long 309854 Clamp, .400 O.D. Tube 779005 Turnaround, Barb 770104 Nipple, .250 I.D.
  • Page 100 FIGURE 39. BEATER MOTOR DRIVE SHAFT/SEAL ASS’Y Item Item Part No. Name Part No. Name 3193 Rear Seal Ass’y 2360 O-Ring, 1.86 I.D. By .139 C.S. 3156 Drive Shaft 2583 Retaining Ring 2463 Bearing with Setscrews 2731 O-Ring, .671 I.D. By .139 C.S. 2591 Housing 2813...
  • Page 101 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.
  • Page 103 IMI CORNELIUS INC. CORPORATE HEADQUARTERS: One Cornelius Place Anoka, Minnesota 55303-6234 (612) 421-6120 (800) 238-3600...

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