Cornelius FCB 3 H.P. POST-MIX DISPENSER Installation & Service Manual
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Cornelius FCB 3 H.P. POST-MIX DISPENSER Installation & Service Manual

Cornelius FCB 3 H.P. POST-MIX DISPENSER Installation & Service Manual

Two-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 3 H.P. POST-MIX DISPENSER
TWO-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. 312026000
March 14, 1995
Revised: February 3, 1998
Control Code A–B–C
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 1995–98
Facsimile (612) 422-3246
PRINTED IN U.S.A

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Summary of Contents for Cornelius FCB 3 H.P. POST-MIX DISPENSER

  • 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 3 H.P. POST-MIX DISPENSER TWO-FLAVOR W/HOT-GAS DEFROST AND V3+ FEATURES IMPORTANT: TO THE INSTALLER. It is the responsibility of the Installer...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page GENERAL INFORMATION ..........GENERAL DESCRIPTION .
  • Page 3 TABLE OF CONTENTS (cont’d) Page ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED PRODUCT ............“VIS READ”...
  • Page 4 TABLE OF CONTENTS (cont’d) Page LUBRICATION ............ADJUSTMENTS .
  • Page 5 TABLE OF CONTENTS (cont’d) Page UNIT WITH WATER-COOLED REFRIGERATION SYSTEM ... . . ADJUSTMENTS ............ADJUSTING PLAIN WATER PRESSURE REGULATOR .
  • Page 6 TABLE OF CONTENTS (cont’d) Page TROUBLESHOOTING ............TROUBLESHOOTING CONTROL PANEL SWITCHES AND FAULT MESSAGES .
  • Page 7 TABLE OF CONTENTS (cont’d) Page LIST OF FIGURES FIGURE 1. FCB DISPENSER ......... . . FIGURE 2.

  • Page 8: General Information

    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. Warranty Registration Date (to be filled out by customer) Model Number:...

  • Page 9: Refrigeration Systems

    CAUTION: Before shipping, storing, or relocating Unit, syrup systems must be sanitized and all sanitizing solution must be purged from syrup systems. All water must also be purged from plain and carbonated water systems. A freezing ambient environment will cause residual sanitizing solution or water remaining inside Unit to freeze resulting in damage to internal components.

  • Page 10: Theory Of Operation

    THEORY OF OPERATION (see Figure 2) IMPORTANT: Before connecting electrical power to Unit, refer to nameplate and note if Unit is to be operated with 50 or 60 Hz power source. Note: The following paragraph describes the theory of operation for the Two-Flavor FCB Dispenser (see Figure 2).

  • 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 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 and defrost for 60-seconds.

  • Page 12: Figure 2. Flow Diagram

    *WATER PRESSURE REGULATOR IS FACTORY ADJUSTED TO 45–PSI AND SHOULD NOT BE READJUSTED. PRODUCT SAMPLE VALVE(2) **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...

  • Page 13: 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 14: Electrical Power Requirements

    7. CASTER KIT (item 7) to be installed on the Unit as instructed in Instructions provided in the Kit. 8. All parts for the SOUND BAFFLE/DRIP TRAY ASS’Y (item 8) are shipped with the Dispenser in a separate box and must be installed on the Dispenser during Dispenser installation. ELECTRICAL POWER REQUIREMENTS IMPORTANT: Before connecting electrical power to Unit, refer to nameplate and Note if Unit is to be operated with 50 or 60 Hz power source.

  • Page 15: Installing Sound Baffle/Drip Tray Ass'y On Unit

    Note: An alternate to sealing the Unit base to the floor would be to install the available 4-inch Caster Kit (P/N 309570000). 2. After Unit has been placed in operating location, make sure it is sitting in a level position. 3.

  • Page 16: Connecting City Plain Water Source Line (S) To Unit

    Connecting City Plain Water Source Line to Unit Post-Mix System. (see Figure 2) 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 NO TAG) that provides plain water to the Dispenser post-mix system.

  • Page 17: Connecting Electrical Power Circuit To Unit

    CONNECTING ELECTRICAL POWER CIRCUIT TO UNIT (see Figure 17) WARNING: Make sure disconnect switch (not provided) or equivalent HACR circuit breaker is in ‘‘OFF’’ position. IMPORTANT: Power circuit voltage across L and L terminals on the contactor inside the lower control box, with refrigeration compressor operating, must be in the range of 198-253 VAC, 60Hz single-phase for proper operation.

  • Page 18: Turning On City Plain Water Source Line To Unit

    3. Pull up on product blender tanks relief valves to purge air from tanks. 4. Remove Unit lower stainless steel access panel as instructed for access to carbonator secondary CO regulators (see Figure 4). 5. Check product blender tanks secondary CO regulators with 60-psi gages for pressure setting which should be set at 25 to 30-psi for best textured product.

  • Page 19: Adjusting Brix (Water-To-Syrup) ''Ratio'' Of Dispensed Product

    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. 1 syrup system as follows: Turn regulator adjusting screw to the left (counterclockwise) no more than 1/8-turn at a time to reduce syrup flow rate or turn screw to the right (clockwise) no more than 1/8-turn to increase flow rate.

  • Page 20: Adjusting "Water-Cooled" Unit Refrigeration System Variable Water Regulator

    ADJUSTING “WATER-COOLED” UNIT REFRIGERATION SYSTEM VARIABLE WATER REGULATOR IMPORTANT NOTICE Water-Cooled Refrigeration System Dispenser. Water flow rate through the refrigeration cooling coil varies due to pressure change on the high side of the refrigeration compressor which influences opening and closing of the variable water regula- tor (see Figure 16).

  • Page 21: Adjusting ''Vis Set'' (Product Viscosity) Of Dispensed Product

    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. “VIS READ”...

  • Page 22: Displayed Error Conditions

    DISPLAYED ERROR CONDITIONS Displayed error conditions, associated errors, and items affected by the errors are found in Table 8 DISPLAYED ERROR CONDITIONS. INSTALLING CONTROL BOX COVER AND BACK, SIDES LOWER ACCESS, AND TOP PANELS ON UNIT 1. Install upper electrical control box cover and secure with four screws. 2.
  • Page 23 THIS PAGE LEFT BLANK INTENTIONALLY 312026000...

  • Page 24: 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 25: Control Panel Display Messages

    ‘‘ERROR RESET’’ Control Switch. ‘‘ERROR RESET’’ control switch, located on control panel (see Figure 4), 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.’’...

  • Page 26: Freeze Cylinders Manual Or Automatic Defrost Systems

    ‘‘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.

  • Page 27: Faceplate Relief Valves

    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 4), located in each freeze cylinder faceplate, are spring-loaded valves that protect freeze cylinders from accidental over-pressure. The relief valve is also used to manually bleed CO gas from freeze cylinder to atmosphere during filling with product and if gas pockets form in cylinder during operation.

  • Page 28: Operating Characteristics

    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.

  • Page 29: Operating Unit

    1. If some time has elapsed since the last drink was drawn from a particular freeze cylinder and the 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.

  • Page 30: Cleaning And Sanitizing

    Make sure CO cylinder shutoff valve is fully opened and regulator assembly 1800-psi gage indicator is not in shaded (‘‘change CO cylinder’’) portion of dial. If so, CO cylinder is almost empty and must be replaced as instructed. CLEANING AND SANITIZING DAILY CLEANING Daily;...

  • Page 31: Adjusting Beaters Motors Currents

    ADJUSTING BEATERS MOTORS CURRENTS Beaters motors currents must be adjusted as instructed in SERVICE AND MAINTENANCE section. PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS (see Table 3) may be brought up on message display as instructed in SERVICE AND MAINTENANCE section.

  • Page 32: Displayed Evaporator Refrigeration Coils Inlets And Common Outlet Sensors Temperatures

    DISPLAYED EVAPORATOR REFRIGERATION COILS INLETS AND COMMON OUTLET SENSORS TEMPERATURES Evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit may be displayed on message display as instructed in SERVICE AND MAINTENANCE section. ‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) Displayed voltage readout may be displayed on message display as instructed in SERVICE AND MAINTENANCE section.

  • Page 33: Water Pump Double Liquid Check Valve Maintenance

    WATER PUMP DOUBLE LIQUID CHECK VALVE MAINTENANCE (see Figures 2 and 13) WARNING: The carbonator water pump 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. Foreign particles lodged in the double liquid check valve could cause CO gas to back flow into the water system and create a health hazard in the system.

  • Page 34: 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 35: Lower Front Access Panel

    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 13)

  • Page 36: Figure 4. Operating Controls

    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 (2) LOWER FRONT BACK PANEL ACCESS PANEL CUP REST FACEPLATE (2)

  • Page 37: Figure 5. Unit Internal Components

    CARBONATED WATER FLOW RELIEF VALVE (2) REGULATOR (2) PRODUCT BLENDER TANK UPPER CONTROL BOX COVER RETAINING SCREW (2) UPPER CONTROL BOX COVER SYRUP FLOW REGULATOR (2) FAULT MESSAGE DISPLAY FREEZE CYLINDER BEATER DRIVE MOTOR (2) SECONDARY CO REGULATOR (4) CARBONATED WATER TANK (2) RECEIVER TANK REFRIGERATION...
  • Page 38 1. Defrost freeze cylinders, shut Unit down, disconnect electrical power from Unit, close product shutoff valves in lines leading from the product blender tanks to the freeze cylinders, then drain product from the freeze cylinders. Note: Item numbers in parentheses in this paragraph are in reference to Figure 6 . 2.

  • Page 39: Figure 6. Freeze Cylinder Cutaway View

    Valve Lever Beater Drive Motor Product Inlet Fitting Knob Drive Shaft Assembly Scraper Blade (2) Dispensing Valve Evaporator Coi.l 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 Bearing Housing Locking Tab (4)

  • Page 40: Figure 7. 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 PLASTIC COUPLING COUPLER DRIVE SHAFT GAUGE, DRIVE/COUPLER (ITEM 6) PLASTIC HOUSING LOCK RING O-RING BEARING O-RING SHAFT ALLEN-HEAD DRIVE SHAFT/ SEAL ASSEMBLY SET SCREW (2) FIGURE 7.

  • Page 41: Figure 8. Beaters And Scraper Blades Installation

    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 8.

  • Page 42: Cleaning Condenser Coil

    10. Reassemble the drive shaft/seal assembly. Using TOOL, DRIVE/COUPLER ADJUSTMENT GAUGE (item 6), insert “DRIVE” end of adjustment gauge between drive-pin and housing (see Figure 7) to set the shaft end at 1.542-inches out of the plastic housing. Make sure Allen-Head set screw in each bearing is securely tightened and properly seated on the shaft flat surface.

  • Page 43: Unit With Water-Cooled Refrigeration System

    UNIT WITH WATER-COOLED REFRIGERATION SYSTEM The high-pressure cutout switch, located inside the lower control box (see Figure 16), will shut the Unit refrigeration system down when overheated (high head pressure) caused by lack of cooling water. After problem has been corrected and the head pressure has decreased, the reset button on the high-pressure cutout switch must be pressed to restart the refrigeration system.

  • Page 44: Adjusting Co2 Regulators

    14. Repeat steps 11 through 13 until the desired carbonated water flow rate is achieved. 15. Remove added length of line from the outlet side of the carbonated water flow regulator. Connect the carbonated water line, disconnected from the carbonated water flow regulator in step 8 preceding, to the regulator outlet.

  • Page 45: 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 46: Adjusting Beater Motor Current (Either Side)

    HIDDEN SECURITY SWITCH MESSAGE DISPLAY FIGURE 9. CONTROL PANEL 2. Observe pressure settings on the carbonated water tanks secondary CO regulators gages. 3. To lower CO pressure, loosen regulator adjusting screw lock nut. Turn adjusting screw to the left (counterclockwise) until pressure gage reads 15-psi below desired reading, then turn screw to the right (clockwise) until gage reads desired pressure.

  • Page 47: Adjustment And Programming Main Menu Selections Into Unit

    MESSAGE DISPLAY MENU SELECTIONS (EXAMPLE READOUTS) “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) See Programming Components Diagnose into “DIAGNOSE”...

  • Page 48: Programming ''Defrost'' (Automatic) Settings Into Unit

    Program ‘‘CLOCK’’ (TIME OF DAY) into Unit as follows: 1. Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up ‘‘CLOCK’’ on display. Press ‘‘DEFROST’’ (SELECT) switch to lock in on selection. 2. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to bring up flashing hour number on display. 3.

  • Page 49: Table 4. Dip Switch Settings

    SWITCH FUNCTION POINT OF SALE MESSAGE SELECT See Table 6 POINT OF SALE MESSAGE SELECT See Table 6 See Note BEATER MOTOR CURRENT READOUT ON- Display current readout. OFF- No displayed current readout. MOTOR CURRENT SELF CALIBRATION ON- Disabled. OFF- Operating. NOT USED NOT USED NOT USED...

  • Page 50: 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 51: Vis Read'' (Actual Viscosity Readout) Of Product In Freeze Cylinders

    5. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance viscosity number to desired setting. Press ‘‘DEFROST’’ (SELECT) switch to lock in viscosity setting. 6. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS. ‘‘VIS READ’’ (ACTUAL VISCOSITY READOUT) OF PRODUCT IN FREEZE CYLINDERS ‘‘VIS READ’’...

  • Page 52: Figure 10. Master And Relay Circuit Board

    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 TABLE 6) SEE NOTE...

  • Page 53: Displaying ''Totals'' (Displayed Cycles And Hours Totals) Onto Message Display

    10. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘SYRUP 1’’ on message display. 11. Press ‘‘DEFROST’’ (SELECT) switch. No. 1 syrup solenoid relay will click when switch is pressed. 12. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘SYRUP 2’’ on message display. 13.

  • Page 54: Table 7. "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 55: Programming Freeze Cylinders Beater "Motors" Into Unit Electronics

    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 56: Programming Proper Refrigerant Type Into Unit Electronics

    2. Press “DEFROST” (SELECT) switch again. A motor Manufacturer’s name (see TABLE 5) will appear on the message display and will be non-blinking. 3. Press “CANCEL DEFROST” (ADVANCE) switch. The motor Manufacturer’s name will start blinking. 4. Press the “CANCEL DEFROST” (ADVANCE) switch again which will change to another blinking Manufacturer’s name.

  • Page 57: Cleaning And Sanitizing

    CLEANING AND SANITIZING DAILY CLEANING OF UNIT Daily, or more often if necessary, wash all external surfaces of Unit with a mild soap solution. Rinse with clean water, then wipe dry with a clean soft cloth. DO NOT USE ABRASIVE-TYPE CLEANERS. Remove and wash drip tray in mild soap solution, rinse with clean water, then install drip tray on Unit.
  • Page 58 13. Disconnect empty soft drink tank from No. 1 syrup system. 14. Refer to SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES under LUBRICATION and perform procedure to lubricate dispensing valve caged O-ring and drive shaft seal assembly. WARNING: To avoid possible injury or property damage, do not attempt to remove soft drink tank cover until CO pressure has been released from tank.

  • Page 59: Yearly Or After Water System Disruption)

    27. Press ‘‘FILL 1’’ switch to fill No. 1 syrup system syrup float switch with syrup. ‘‘SYRUP 1’’ fault message on message display will go out indicating syrup float switch has been filled with syrup. 28. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 Product blender tank with product. Carbonator water pump will start and begin pumping carbonated water into product blender tank along with syrup to make product.

  • Page 60: Replenishing Syrup Supply

    2. Disconnect electrical power from Unit. 3. Close CO cylinder and water inlet supply line shutoff valve. 4. Remove lower front access panel and left-side panel as instructed for access to the water pump double liquid check valve assembly. 5. Pull up on carbonator tank relief valve plastic cover to release CO pressure from tank.

  • Page 61: Replenishing Co2 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 3. To connect soft drink tank into Unit syrup system. First, connect CO quick disconnect to soft drink tank to pressurize tank.

  • Page 62: Syrup Flavor Change

    NOTE: When indicator on primary CO cylinder regulator assembly 1800-psi gage is in shaded (‘‘change CO cylinder’’) portion of the dial, CO cylinder is almost empty and should be changed. 1. Fully close (clockwise) CO cylinder valve. 2. Slowly loosen CO regulator assembly coupling nut allowing CO pressure to escape, then remove regulator assembly from empty CO...

  • Page 63: Cleaning Co2 Gas Check Valves

    8. After carbonator water pump cycles off, intermittently pull and release applicable No. 1 or No. 2 freeze cylinder faceplate relief valve. This bleeds CO from freeze cylinder and allows product to enter and fill cylinder. 9. If necessary, adjust BRIX, product viscosity (product consistency), and product carbonation of dispensed product as instructed.

  • Page 64: Figure 13. Water Strainer Screen And Double Liquid Check Valve

    WATER PRESSURE REGULATOR DOUBLE LIQUID CHECK VALVE ASS’Y (2) WHITE TAPERED GASKET (2) WATER PUMP AND WATER PUMP MOTOR (2) SYRUP SOLD-OUT FLOAT SWITCH (2) CARBONATED WATER FLOW REGULATOR (2) SYRUP FLOW REGULATOR (2) LIQUID CHECK VALVE (4) CARBONATED WATER SOLENOID VALVE (2) SYRUP SOLENOID VALVE (2)

  • Page 65: Adjusting Carbonated Water Tanks Liquid Level

    7. Remove platic coupler from the old beater drive motor shaft and install on the new motor shaft. MAKE SURE THE ALLEN-HEAD SET SCREWS ARE SECURELY TIGHTENED AND PROPERLY SEATED ON THE SHAFT FLAT SURFACE. CAUTION: The new beater drive motor has a screw in the vent hole on top of the gear box that must be removed before the motor is put into operation.

  • 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 312026000...

  • Page 67: Figure 15. 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 CONDENSER COIL FAN ASS’Y COMPRESSOR ACCUMULATOR FIGURE 15. REFRIGERATION FLOW DIAGRAM (AIR-COOLED REFRIGERATION SYSTEM) 312026000...

  • Page 68: Figure 16. 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 240-PSI REFRIGERATION HIGH-SIDE PRESSURE.

  • Page 70: Figure 17. Wiring Diagram

    3584 Rev: C FIGURE 17. WIRING DIAGRAM...

  • Page 71: 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 72: Partial Message Or Dull (Poorly Illuminated) Display

    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 (cond’t) master circuit board pinched or replace as necessary. and shorted out or broken wire in cable.

  • Page 73: H2O Out'' Fault Message Goes On During Operation

    Trouble Probable Cause Remedy ALL FAULT MESSAGES NOT Master circuit board not Replace master circuit board. OPERATING. (cond’t) 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 74: 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 75: Brix (Water-To-Syrup) ''Ratio'' Too Low

    Trouble Probable Cause Remedy TROUBLESHOOTING DISPENSED PRODUCT BRIX (WATER–TO–SYRUP) Quick disconnect not secure Secure tank quick disconnect. ‘‘RATIO’’ TOO LOW. on soft drink tank. Syrup flow regulator set too Adjust BRIX of dispensed product low. as instructed. Water flow regulator set too Water flow regulator must be set at 1.3 ±...

  • Page 76: Troubleshooting Refrigeration System

    Trouble Probable Cause Remedy FROZEN PRODUCT Cylinder freeze-up causing ice Refer to CYLINDER CONSISTENCY VARIES formation in center of cylinder FREEZE–UP. EXCESSIVELY. (cont’d) and liquid product channels around ice formation. NOTE: DEFROST AFFECTED FREEZE CYLINDER AS INSTRUCTED. CYLINDER FREEZE–UP. Dispensed product BRIX too Refer to BRIX (Water–to–Syrup) low.

  • Page 77: Warranty

    IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship un- der normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire prod- uct, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number, serial number and the date of purchase.
  • Page 78 IMI CORNELIUS INC. CORPORATE HEADQUARTERS: One Cornelius Place Anoka, Minnesota 55303-6234 (612) 421-6120 (800) 238-3600...

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