Cornelius R-404A REFRIGERANT Service Manual
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Cornelius R-404A REFRIGERANT Service Manual

Cornelius R-404A REFRIGERANT Service Manual

Fcb overcounter post-mix dispenser with v3+features (r-404a refrigerant)
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Service Manual
FCB
OVERCOUNTER
POST-MIX DISPENSER
WITH
V3+FEATURES
(R-404A REFRIGERANT)
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.
312028000
November 14, 1994
Revised: March 11, 1997
Control Code A–B–C–D
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Service Manual must be read and understood before starting to install or operate this equipment.
IMI CORNELIUS INC; 1994-97
IMI CORNELIUS INC.
One Cornelius Place
Anoka, MN 55303–6234
Telephone (800) 238–3600
Facsimile (612) 422–3232
Printed in U.S.A.

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Summary of Contents for Cornelius R-404A REFRIGERANT

  • Page 1 Revised: March 11, 1997 Control Code A–B–C–D THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Service Manual must be read and understood before starting to install or operate this equipment. IMI CORNELIUS INC; 1994-97 IMI CORNELIUS INC. One Cornelius Place Anoka, MN 55303–6234 Telephone (800) 238–3600...

  • Page 2: Table Of Contents

    GENERAL DESCRIPTION ..........GENERAL DESCRIPTION .
  • Page 3 TABLE OF CONTENTS (cont’d) ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS, COMPONENTS “DIAGNOSE’’ (DIAGNOSTIC MODE), AND ‘‘TOTALS”(DISPLAYED CYCLES AND HOURS TOTALS) INTO UNIT PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY SETTING CLOCK (TIME OF DAY) PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT PROGRAMMING ‘‘SLEEP’’...
  • Page 4 TABLE OF CONTENTS (cont’d) REPLENISHING SYRUP SUPPLY PRODUCT FLAVOR CHANGE CHECKING CO2 SUPPLY ..........CLEANING AND SANITIZING DAILY CLEANING .
  • Page 5 TABLE OF CONTENTS (cont’d) SIDE PANELS ........... . FRONT ACCESS PANEL OPENING AND CLOSING FRONT ACCESS DOOR OPENING FRONT ACCESS DOOR...
  • Page 6 TABLE OF CONTENTS (cont’d) FREEZE CYLINDER AUTOMATIC DEFROST CYCLE DOES NOT OPERATE............UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE.
  • Page 7 TABLE OF CONTENTS (cont’d) FIGURE 19. CONTROL BOX COMPONENTS FIGURE 20. SECONDARY CO2 REGULATOR ASS’Y FIGURE 21. TUBE ASSEMBLY FIGURE 22. TUBE ASSEMBLY FIGURE 23. CO2 REGULATOR ASSEMBLY FIGURE 24. CHECK VALVE ASSEMBLY FIGURE 25. BLENDER AND TUBING COMPONENTS FIGURE 26. TUBING ASSEMBLY (CARB WATER) FIGURE 27.

  • Page 8: 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 troubleshoo musting this equipment. These Units must be installed and serviced by a qualified Service Person.

  • Page 9: Generic Flavor Tabs

    Refrigeration System: Compressor Horsepower Refrigerant Type And Charge Ambient Operating Temperature Electrical Requirements: Operating Voltage Operating Current ACCESSORIES Installation kits Cup Holder Cup Holder Changeover Kit GENERIC FLAVOR TABS Cola Cherry Orange Grape Lemon-Lime Strawberry Banana SERVICE TOOLS 3-gallon Sanitizing Tank Spanner Wrench, Dispensing Valve Refractometer, 0-30 Scale Wrench, Rear Seal Housing...

  • Page 10: Defrost Systems

    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 CO gas pressure from the freeze cylinder to atmosphere when filling the cylinder with product. Electronic sens- ing on each freeze cylinder motor provides a means of adjusting viscosity (consistency) of the dispensed product to suit customer preference.

  • Page 11: 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 cyl- inders 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.

  • Page 12: Figure 2. Flow Diagram

    *WATER PRESSURE REGULATOR IS FACTORY ADJUSTED TO 45-PSI AND SHOULD NOT BE READJUSTED. **SYRUP SOLD-OUT SWITCHES ARE FACTORY ADJUSTED AND SHOULD NOT BE READJUSTED. LINE LEGEND PLAIN WATER CARB WATER SYRUP PRODUCT CARBONATOR TANK PRODUCT BLENDER TANK(2) PRODUCT SHUTOFF VALVE(2) FREEZE CYLINDER(2) CARBONATED WATER...
  • Page 13 THIS PAGE LEFT BLANK INTENTIONALLY 312028000...

  • Page 14: Installation

    Request a written inspection report from a Claims Inspector to substantiate any necessary claim. File claim with the delivering carri- er, not with IMI Cornelius Inc. 1. After Unit has been unpacked, remove shipping tape and other packing material.

  • Page 15: Electrical Power Requirements

    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) are to be installed on front of Unit (See Figure 5) and secured with thread cutting screws (item 6) and thread cutting screw (item 16).

  • Page 16: Installing Unit

    Locate the Unit so the following requirements are satisfied. 1. 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.

  • Page 17: Cylinder

    INSTALLING PRIMARY CO (see Figure 2) WARNING: To avoid personal injury and/or property damage, always secure CO upright position with a safety chain to prevent it from falling over. Should the valve become accidentally damaged or broken off, CO personal injury. WARNING: CO displaces oxygen.

  • Page 18: 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 313867000) are recommended.

  • Page 19: Preparation For Operation

    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.

  • Page 20: Starting Fcb And Adjusting Water-To-Syrup "Ratio" (Brix) Of Dispensed Product

    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. ‘‘H O OUT’’ fault message should have gone out but ‘‘SYRUP 1’’, and ‘‘SYRUP 2’’ fault mes- sages will continue to be displayed.

  • Page 21: Filling Freeze Cylinders With Product

    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.

  • Page 22: Placing Unit In Operating Location

    PLACING UNIT IN 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.

  • Page 23: Adjustment And Programming Main Menu Selections, Components "Diagnose'' (Diagnostic Mode), And ''Totals"(Displayed Cycles And Hours Totals) Into Unit

    CAUTION: IF NO. 4 ‘‘BEATER MOTOR CURRENT READOUT’’ SWITCH ON DIP SWITCH 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 the beater motor current has just been reset at A155 B145.

  • Page 24: Programming ''Defrost'' (Automatic) Settings Into Unit

    MENU SELECTIONS “CLOCK” (TIME OF DAY) see note below “DEFROST” (AUTOMATIC) “SLEEP” (SLEEP TIME) “WAKE UP” (WAKE UP TIME) “VIS SET” (PRODUCT VISCOSITY SETTING) “VIS READ” (ACTUAL VISCOSITY READOUT) “SENSORS” (TEMPERATURES READOUT) “VOLTAGE” (DISPLAYED VOLTAGE READOUT) “DIAGNOSE” (DIAGNOSTIC MODE) “TOTALS” “MOTORS”...

  • Page 25: Programming ''Sleep'' (Sleep Time) Into Unit

    6. Repeat step 5 as many times as necessary to program desired number of defrost time settings into the Unit. 7. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS. PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT ‘‘SLEEP’’ (SLEEP TIME) may be programmed into Unit to occur any time of the day after Unit automatic defrost cycle has occurred.

  • Page 26: Programming ''Wake Up'' (Wake Up Time) Into Unit

    DISPLAYED MODEL KLBER Klauber – FASV3 60 Fasco/VW FASCWR 60 Fasco/VW VW/GE 60 Fasco/VW EMRSN 60 Emerson BODINE 60 Bodine KLBER Klauber – FASV3 Fasco/VW FASCWR 50 Fasco/VW VW/GE 50 Fasco/VW EMRSN 50 Emerson DIP SWITCH DIP SWITCH NO. 1 NO.

  • Page 27: Adjusting "Vis Set" (Product Viscosity) Of Dispensed Product

    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 4, 5, and 7) on the DIP SWITCH ASSEMBLY in the appropriate positions.

  • Page 28: Figure 4. Master And Relay Circuit Board

    DIP SWITCH ASS’Y Note: Switch No. 3 must be in “OFF” position for standard Units with pulse expan- sion valves. Switch No. 3 must be in “ON” position for Units with mechanical expansion valves. MOTOR CURRENT ADJUSTMENT RELAY CIRCUIT BOARD NO. 2 RELAY CIRCUIT BOARD NO.

  • Page 29: Voltage'' (Displayed Voltage Readout)

    ‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) Displayed voltage readout may be displayed on message display as follows: 1. Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up ‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) on message display. 2. Press ‘‘DEFROST’’ (SELECT) switch to bring up voltage readout on message display. 3.

  • Page 30: Displaying ''Totals'' (Displayed Cycles And Hours Totals) Onto Message Display

    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 ‘‘H 25.

  • Page 31: Table 8 "Totals" (Displayed Cycles And Hours Totals) Menu

    TOTALS MENU COMMANDS COMP HRS COMP CYC DFSTYC1 DFSTYC2 BLDRCYC1 BLDRCYC2 SOLDOUT 1 SOLDOUT 2 BMTRHRS1 BMTRHRS2 PWR ON AUTO ON 1 AUTO ON 2 ERR HRS 1 ERR HRS 2 SLEEP HRS SYR MIN 1 (see note) SYR MIN 2 (see note) NOTE: Displaying “SYR MIN 1”...

  • Page 32: Programming Proper Refrigerant Type Into Unit Electronics

    MESSAGE 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 > 255, Sensed on Motor Two REFRIG **Maximum Run Time on Compressor SYRUP 1...

  • Page 33: Displayed Error Conditions

    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). “R404A3HP” (V3+ Dispenser with 3 H.P. Copeland Compressor and R-404A refrigerant).

  • Page 34: Operator's Instructions

    OPERATOR’S INSTRUCTIONS This section describes operating controls and indicators, dispensed product conditions, operating characteris- tics, Unit operation, replenishing syrup supply, product flavor change, checking CO cleaning of Unit, and sanitizing requirements. CAUTION: Do not place or store anything on top of the Unit. WARNING: Disconnect electrical power to the Unit to prevent personal injury before attempting any internal maintenance.

  • Page 35: Control Panel Assembly Display Messages

    ’’AUTO 1’’ and ‘‘AUTO 2’’ Control Switches. ‘‘AUTO 1’’ and ‘‘AUTO 2’’ control switches, located on control panel assembly, are touch-type switches and require only pressing to activate. These switches are used to operate freeze cylinders beaters and refrigeration system after cylinders have been filled with product. Freeze cylinders beaters and refrigeration system may be stopped by pressing ‘‘OFF 1’’...

  • Page 36: Freeze Cylinders Manual Or Automatic Defrost Systems

    ‘‘CO OUT’’ Fault Message. ‘‘CO OUT’’ fault message will appear on message display when CO pressure drops below 50-psi. A minimum CO ‘‘CO OUT’’ fault message. ‘‘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.

  • Page 37: Sleep'' (Sleep Time) Operation

    ‘‘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 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 38: Syrup Flow Regulators

    SYRUP FLOW REGULATORS The syrup flow regulators located behind the front access door (see Figure 2 and Figure 12), 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. DISPENSING VALVES Self-closing dispensing valves (see Figure 5)), located on faceplates on front of Unit, are operated one at a time or simultaneously to deliver product to the customer.

  • Page 39: 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 Freezing Affects Overrun.

  • Page 40: 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 2.

  • Page 41: Adjustments

    ADJUSTMENTS CARBONATED WATER FLOW RATE The carbonated water flow regulators (see Figure 2 and 12), 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. WATER-TO-SYRUP “RATIO”...

  • Page 42: 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 opera- tion) until programmed ‘‘WAKE UP’’...

  • Page 43: Programming Freeze Cylinders Beater "Motors" Into Unit Electronics

    PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT ELECTRONICS Note in Table 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. A replacement freeze cylinder beater motor is also manufactured by one of these manufacturer’s listed.

  • Page 44: 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 personal 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 45: Front Access Panel

    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 PANEL, 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 5), then...

  • Page 46: Figure 5. Operating Controls

    CONTROL PANEL TOP PANEL RETAINING SCREW (2) CONTROL PANEL FACEPLATE RELIEF VALVE (4) CUP REST DISPENSING VALVE (2) DRIP TRAY BRACKET RETAINING SCREW (ITEM 6) ACCESS PANEL RETAINING SCREW LOWER FRONT (ITEM 16) ACCESS PANEL HIDDEN “SECURITY SWITCH” TOP PANEL FACEPLATE (2) DRIP TRAY BRACKET...

  • Page 47: Figure 6. Unit Internal Components

    REFRIGERATION CONDENSER COIL COMPRESSOR RELIEF VALVE (2) PRODUCT BLENDER TANK (2) FREEZE CYLINDER (2) BEATER DRIVE MOTOR (2) ACCUMULATOR SECONDARY CO REGULATOR (3) FIGURE 6. UNIT INTERNAL COMPONENTS 312028000...

  • Page 48: Figure 7. Self-Closing Dispensing Valve

    SPRING HOUSING TORSION SPRING SPRING KNOB FIGURE 7. SELF-CLOSING DISPENSING VALVE 3. Carefully remove large O-RING (item 5) from FACEPLATE (item 8). 4. Unscrew RELIEF VALVE (item 9) from FACEPLATE (item 8). 5. Disassemble dispensing valve (see Figure 7) as follows: Remove two screws and hold-down plates securing spring housing to dispensing valve body, then re- move housing.
  • Page 49 Carefully install valve with caged O-ring in dispensing valve body. Install spring fitting, knob and lever parts, torsion spring, and spring housing assembly by reversing removal procedure. Do not tighten hold-down plates securing spring housing at this time. 10. Thoroughly clean RELIEF VALVE (item 9), then screw relief valve into FACEPLATE (item 8). 11.

  • Page 50: Cleaning Condenser Coil

    15. Position SCRAPER BLADES (item 2) on BEATER (item 13) as shown in Figure 8. Slide beater into freeze cylinder so slotted hooks engage DRIVE PIN (item 17) on DRIVE SHAFT (item 19). Turn beater to the right (clockwise) to lock in place. 16.

  • Page 51: Figure 8. Freeze Cylinder Cutaway View

    Product Inlet Fitting Scraper Blade (2) Evaporator Coil Relief Valve Port O-Ring Flatwasher (4) Hex Nut (4) Faceplate Relief Valve FIGURE 8. FREEZE CYLINDER CUTAWAY VIEW Valve Lever Knob Dispensing Valve Beater Allen Head Setscrew Beater Shaft Coupling Drive Pin Bearing Housing Locking Tab (4) Bearing Retainer Beater Motor Drive Shaft...

  • Page 52: Figure 9. Servicing Beater Motor Drive Shaft/Seal Assembly

    BEATER DRIVE MOTOR DRIVE SHAFT/SEAL ASS’Y BEATER DRIVE BEATER MOTOR SHAFT ALLEN-HEAD ALLEN-HEAD SET SCREW SET SCREW COUPLING PLASTIC 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 9.

  • Page 53: Figure 10. Beaters And Scraper Blades Installation

    BEATER Key on End of Post FIGURE 10. BEATERS AND SCRAPER BLADES INSTALLATION 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. 3.

  • Page 54: Adjusting Co2 Regulators

    11. Press applicable ‘‘AUTO BLEND 1’’ or ‘‘AUTO BLEND 2’’ switch to activate the electrically operated car- bonated water solenoid. 12. 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.

  • Page 55: Adjusting Brix (Water-To-Syrup) ''Ratio'' Of Dispensed Product

    Carbonator Secondary CO Regulator. (see Figure 2 and 6) 1. Remove the Unit lower front access panel as instructed for access to the carbonator(s) secondary CO regulator(s). IMPORTANT: The carbonator tank secondary CO above the product blender tanks secondary CO 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.

  • Page 56: Product Carbonation Adjustment

    PRODUCT CARBONATION ADJUSTMENT (see Figures 2 and 6) Carbonation of dispensed product can also be varied to suit consumer preference by adjusting Unit carbonator secondary CO regulator as follows: IMPORTANT: Carbonator tank secondary CO product blender tanks secondary CO pressures must be able to overcome and vent product blender tanks head pressures while tanks are filling with carbonated water and syrup.
  • Page 57 4. Remove right-hand side panel as instructed for access to No. 2 product blender tank product shutoff valve. 5. Close No. 2 product blender tank product shutoff valve to prevent product bleeding back into No. 1 product blender tank during sanitizing procedure. IMPORTANT: The following CO soft drink tank replacement or filling soft drink tank in place must be performed in order as follows: 6.
  • Page 58 19. 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. 20. 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.

  • Page 59: Yearly Or After Water System Disruption

    38. After carbonator water pump cycles off, intermittently pull and release No. 1 freeze cylinder faceplate relief valve. This bleeds CO from freeze cylinder and allows product to enter and fill cylinder. 39. Open No. 2 product blender tank product shutoff valve. 40.

  • Page 60: Servicing Carbonator Water Pump Double Liquid Check Valve

    Index Part 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 SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE (see Figures 2 and 12) 1.

  • Page 61: Replenishing Syrup Supply

    10. Open CO cylinder 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.

  • Page 62: Replenishing Co2 Supply

    REPLENISHING CO SUPPLY WARNING: CO displaces oxygen. Strict attention must be observed in the prevention of (carbon dioxide) gas leaks in the entire CO suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO tremors which are followed rapidly by loss of consciousness and suffocation.

  • Page 63: Figure 12. Water Strainer Screen And Double Liquid Check Valve

    O-RING (P/N 315349000) SCREEN RETAINER SCREEN (P/N 315348000) WATER PUMP MOTOR WATER PUMP WATER PRESSURE SWITCH CARBONATED WATER FLOW REGULATOR (2) SYRUP FLOW REGULATOR (2) LIQUID CHECK VALVE (4) FIGURE 12. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE 312028000 CHECK VALVE ASS’Y WHITE TAPERED WATER PRESSURE...

  • Page 64: Cleaning Co2 Gas Check Valves

    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.

  • Page 65: Adjusting Carbonator Tank Liquid Level

    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 instructed. 4. Remove one bolt and two hex nuts and two lockwashers securing motor to Unit frame. 5.

  • Page 66: Figure 14. Carbonator Liquid Level Control Switch Adjustment

    RELIEF VALVE CARBONATED WATER TANK SWITCHES ACTUATOR BRACKET LEVEL CONTROL SWITCHES(2) ACTUATOR BRACKET ADJUSTMENT SCREW FIGURE 14. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT 312028000...

  • Page 67: Figure 15. Refrigeration Flow Diagram

    ELECTRONIC EXPANSION VALVE (2) HOT-GAS DEFROST SOLENOID VALVE ASS’Y (2) CONDENSER COIL FAN ASS’Y FREEZE CYLINDER (2) EVAPORATOR STRAINER/DRYER COMPRESSOR RECEIVER TANK ACCUMULATOR FIGURE 15. REFRIGERATION FLOW DIAGRAM 312028000...

  • Page 68: Figure 16. Wiring Diagram

    FIGURE 16. WIRING DIAGRAM...
  • Page 69 THIS PAGE LEFT BLANK INTENTIONALLY 312028000...

  • Page 70: 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 pressure before proceeding.

  • Page 71: Control Panel Switches Cannot Be Deactivated

    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. 312028000 Probable Cause Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire...

  • Page 72: Co2 Out'' Fault Message Goes On During Operation

    Trouble ALL FAULT MESSAGE NOT OPERATING (cont’d) ‘‘CO OUT’’ FAULT MESSAGE GOES ON DURING OPERATION. ‘‘H O 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.

  • Page 73: Manual Defrost Cycle Does Not Operate When ''Defrost'' Switch Is Pressed. (Cont'd)

    Trouble MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN ‘‘DEFROST’’ SWITCH IS PRESSED. (cont’d) DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING ‘‘CANCEL DEFROST ’’ SWITCH. TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE. 312028000 Probable Cause Master circuit board not operating properly.

  • Page 74: Carbonator Water Pump Will Not Shut Off

    Trouble CARBONATOR WATER PUMP WILL NOT SHUT OFF. ERRATIC CARBONATOR WATER PUMP CYCLING. 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.

  • Page 75: Frozen Product Consistency Varies Excessively

    Trouble FREEZE CYLINDER DOES NOT REFILL AT ALL TIMES WHEN DISPENSING. (cont’d) FROZEN PRODUCT CONSISTENCY VARIES EXCESSIVELY. CYLINDER FREEZE-UP. 312028000 Probable Cause Lines restricted. Dispensed product BRIX varying because: Syrup and/or water flow regulator sticking. Primary CO regulator pressure insufficient. Cylinder freeze-up causing ice formation in center of cylinder and liquid product...

  • Page 76: Illustrated Parts Breakdown

    OVERCOUNTER POST-MIX DISPENSER WITH V3+FEATURES (R-404A REFRIGERANT) UNIT PART NUMBERS: 416136xxxx 496136xxxx ILLUSTRATED PARTS BREAKDOWN 312028000...

  • Page 77: Figure 17. Overcounter Fcb Post-Mix Dispenser

    FIGURE 17. OVERCOUNTER FCB POST-MIX DISPENSER 312028000...
  • Page 78 Item Part No. Name 325457000 Blade, Scraper 3432 Body, Beater 326002000 Tube Kit, Drain Tube (Not Shown; See Figure 39) 2613 Bracket, Receiver and Accumulator Secondary CO Regulator Components (See Figure 18) Control Box Components (See Figure 1317 Filter, Solenoid Blender and Tubing Components (See Figure 25) 2392...
  • Page 79 Item Part No. Name 325069000 Machine Screw, Sl Truss Hd., No. 10-24 By 1/2-In. Long 3898 Compressor Kit, 2HP 230V 60Hz (Domestic) 3899 Compressor Kit, 2HP 230V 50Hz (Export) 3832 Cover, Control Box 311304000 Tapered Gasket, Black 3557 Dryer 326071000 Expansion Valve, Refrigeration 2672 Panel, Back...

  • Page 80: Figure 18. Secondary Co2 Regulator Components

    Item Part No. Name Secondary CO Regulator Components 324218000 Tube, .156 I.D. By 3-In. Long 324219000 Tube, .156 I.D. By 1-In. Long 324220000 Tube, .156 I.D. By 11-In. Long 317528000 Fitting, Tee, 1/8-Barb 300393000 Fitting, Tee, 1/8-Barb By 3/8-Barb 178025100 Tapered Gasket, White 187462000 Tube, .312 I.D.

  • Page 81: Figure 20. Secondary Co2 Regulator Ass'y

    Item Part No. Name 3049 Secondary CO Regulator Ass’y 183287000 Gage, 60-PSI 183449000 Regulator Ass’y, 30-PSI (See Figure 183412000 Regulator Ass’y, 100-PSI (See Figure 23) 183286000 Gage, 100-PSI 183047000 Fitting, 1/4-NPT 130066ooo Fitting, Plug, 1/4-NPT 183061000 Fitting, 1/4-NPT By 7/16-20 183301100 Check Valve Ass’y (See Figure 24) 183068000...

  • Page 82: Figure 23. Co2 Regulator Assembly

    Item Part No. Name 183449000 Regulator Ass’y, 60-PSI, Orange (Includes 1-16) 183412000 Regulator Ass’y, 100-PSI, Gold (Includes 1-16) 183040000 Machine Screw, Phil Fill Hd., No. 10-32 By 7/8-In. Long 183233059 Cover Kit (Includes Nonremovable Adjusting Screw) 183021000 Retainer, Spring 315424000 Adjusting Spring, 60-PSI 183020000 Adjusting Spring, 100-PSI...

  • Page 83: Figure 25. Blender And Tubing Components

    FIGURE 25. BLENDER AND TUBING COMPONENTS Item Part No. Name Blender and Tubing Components 31701500 O-Ring, .239 I.D. By .070 C.S. 2657 Base 316963000 Bushing, 2-In. Dia. 2469 Retainer, Module 200498003 Hex Nut, No. 8-32 319941000 Thread Rolling Screw, Hex Washer Hd., No.

  • Page 84: Figure 26. Tubing Assembly (Carb Water)

    Item Part No. Name 2780 Tube Ass’y, Carb Water Outlet 77060200 Fitting, Cross, 1/4-Barb 77050100 Fitting, Elbow, Valve 325012000 Shut-Off Valve 174103000 Tube, .250 I.D. By 3-In. Long 174103000 Tube, .250 I.D. By 10-In. Long 174103000 Tube, .250 I.D. By 22-In. Long 176001000 Ferrule, .425 O.D.

  • Page 85: Figure 29. Tubing Assembly (Water Solenoid To Blender)

    Item Part No. Name 2779 Tube Ass’y, Water Solenoid to Blender 311742000 Connector, Barb 176001000 Ferrule, .375 O.D. Tube 174103000 Tube, .250 I.D. By 11-In. Long 309854000 Clamp, .400 O.D. Tube 77900500 Turnaround, Barb 77040100 Fitting, Elbow, Swivel, 7/16-20 FIGURE 29. TUBING ASSEMBLY (WATER SOLENOID TO BLENDER) Item Part No.

  • Page 86: Figure 32. Solenoid Valve Assembly

    FIGURE 32. SOLENOID VALVE ASSEMBLY Item Part No. Name 2486 Solenoid Valve Ass’y, Water 2487 Solenoid Valve Ass’y, Syrup 2356 Block, Valve 1319 Body, Valve 0837 Thread Rolling Screw, Phil Pan Hd., No. 6-32 By 5/8-In. Long 310754011 Piston, Water 310480011 Piston, Syrup 317431011...

  • Page 87: Figure 33. Blender Components

    FIGURE 33. BLENDER COMPONENTS Item Part No. Name Blender Components 2625 Support, Blender 188206000 Thread Rolling Screw, Phil Truss Hd., No. 10-24 By 3/4-In. Long 324116000 Washer, .625 I.D. 324047000 Tank, Blender 186570000 Strain Relief 315925000 O-Ring, 1.609 I.D. By .139 C.S. 312028000 Item Part No.

  • Page 88: Figure 34. Control Box And Display Panel Components

    FIGURE 34. CONTROL BOX AND DISPLAY PANEL COMPONENTS Item Part No. Name Control Box and Display Panel Components 326079000 Cable, Ribbon 326078000 P.C. Board, Display 2763 Housing, Display 2897 Hinge, Display 2895 Latch, Display 2704 Panel, Back, Display 319941000 Thread Rolling Screw, Hex Washer Hd., No.

  • Page 89: Figure 35. Faceplate Assembly

    FIGURE 35. FACEPLATE ASSEMBLY Item Part No. Name 326106000 Door, Freeze Cylinder Ass’y 325918000 Door, Freeze Cylinder 325954088 Relief Valve Ass’y 320678000 O-Ring, 4.60 I.D. By .210 C.S. 1557 Valve Head Ass’y (See Figure 36) 312028000 Item Part No. 321652000 325936000 321269001 322441000...

  • Page 90: Figure 36. Dispensing Valve Assembly

    FIGURE 36. DISPENSING VALVE ASSEMBLY Item Part No. Name 1557 Dispensing Valve Ass’y 1556 Body and Shank 1554 Valve 1576 Housing 1575 Fitting 325305000 Spring 321651000 Lever, Valve 1555 Knob Item Part No. 325647000 317784000 2818 321653000 1544 1543 Name Plate Thread Cutting Screw, Phil Truss Hd., Stainless Steel, No.

  • Page 91: Figure 37. Carbonator Components

    Item Part No. Name Carbonator Components 2682 Bracket, Motor 320767000 Machine Screw, Phil Pan Hd., No. 10-24 By 3/8-In. Long 309854000 Clamp, .409 O.D. Tube 326136000 Carbonator Tank Ass’y (See Figure 3159 Switch, Pressure 2833 Pump and Motor Ass’y, Domestic (See Figure 41) 2814 Pump and Motor Ass’y, Export (See...

  • Page 92: Figure 40. Carbonator Tank And Linkage Assembly

    FIGURE 40. CARBONATOR TANK AND LINKAGE ASSEMBLY Item Part No. Name 326136000 Carbonator Tank and Linkage Ass’y 326135000 Tank, Carbonator 317746000 Link, Pivot 317772000 318036000 Push-on Nut 317747000 Pivot Housing 317752000 Spring Item Part No. 318037000 Insulation, Switch 317771000 Level Control Switch 315961000 Machine Screw, Sl.

  • Page 93: Figure 41. Pump And Motor Ass'y

    FIGURE 41. PUMP AND MOTOR ASS’Y Item Part No. Name 2833 Pump and Motor Ass’y, 230/220V. 60/50HZ (Domestic) 2814 Pump and Motor Ass’y, 230V. 50HZ (Export) 320626000 Motor, 230/220V. 60/50HZ (Domestic) 199020000 Motor, 230V 50HZ (Export) 312996000 Pump, Water, 90GPH 178025100 Tapered Gasket, White 187483000...

  • Page 94: Figure 42. Beater Motor Drive Shaft/Seal Ass'y

    FIGURE 42. BEATER MOTOR DRIVE SHAFT/SEAL ASS’Y Item Part No. Name 3193 Rear Seal Ass’y 3156 Drive Shaft 2463 Bearing with Setscrews Item Part No. 2360 O-Ring, 1.86 I.D. By .139 C.S. 2583 Retaining Ring 2731 O-Ring, .671 I.D. By .139 C.S. 2591 Housing Name...

  • Page 95: Warranty

    IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workman- ship 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.
  • Page 96 THIS PAGE LEFT BLANK INTENTIONALLY 312028000...
  • Page 97 IMI CORNELIUS INC. CORPORATE HEADQUARTERS: One Cornelius Place Anoka, Minnesota 55303-6234 (612) 421-6120 (800) 238-3600...

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