Cornelius FCB OVERCOUNTER POST-MIX DISPENSER Service Manual
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Cornelius FCB OVERCOUNTER POST-MIX DISPENSER Service Manual

Cornelius FCB OVERCOUNTER POST-MIX DISPENSER Service Manual

Fcb overcounter post-mix dispenser with v3+features
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Service Manual
IMPORTANT:
TO THE INSTALLER.
It is the responsibility of the Installer to
ensure that the water supply to the
dispensing equipment is provided with
protection against backflow by an air gap
as defined in ANSI/ASME A112. 1.2-1979; or
an approved vacuum breaker or other such
method as proved effective by test.
Water pipe connections and fixtures
directly connected to a potable water
supply shall be sized, installed, and
maintained according to federal, state, and
local laws.
Part No. 2992
May 31, 1994
Revised: April 4, 1995
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 1994–95
FCB OVERCOUNTER
POST-MIX DISPENSER
WITH V3+FEATURES
PRINTED IN U.S.A

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  • Page 1 Part No. 2992 May 31, 1994 Revised: April 4, 1995 THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment  IMI CORNELIUS INC; 1994–95 PRINTED IN U.S.A...
  • Page 2 Part # Corrections/Update Document Unit Type/Model # Manual # FCB OC2 POST MIX 2992 DISPENSER W/V3+ Unit Part Numbers: 416136xxx 496136xxx Page Item Old Part Desc. New Part Desc. Agent Date Notes 2467 FOAM PACK 4467 FOAM PACK 01/24/03 326000000 COMPRESSOR 560004343 COMPRESSOR 01/24/03 Includes all KIT 2HP 230V/60...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Page GENERAL DESCRIPTION ..........GENERAL DESCRIPTION .
  • Page 5 TABLE OF CONTENTS (cont’d) Page 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) .
  • Page 6 TABLE OF CONTENTS (cont’d) Page REPLENISHING SYRUP SUPPLY ........PRODUCT FLAVOR CHANGE .
  • Page 7 TABLE OF CONTENTS (cont’d) Page LUBRICATION ............CARBONATOR WATER PUMP MOTOR .
  • Page 8 ............. . LIST OF FIGURES FIGURE 1. FCB OVERCOUNTER POST-MIX DISPENSER ....
  • Page 9 TABLE OF CONTENTS (cont’d) Page LIST OF FIGURES(CONT’D) FIGURE 25. BLENDER AND TUBING COMPONENTS ..... FIGURE 26. TUBING ASSEMBLY (CARB WATER) .

  • Page 10: General Description

    A drip tray, with cup rest, is located directly below the dispensing valves. FIGURE 1. FCB OVERCOUNTER POST-MIX DISPENSER 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.

  • Page 11: Theory Of Operation

    Table 1. Design Data Unit Part Numbers: 60 HZ Unit 416136XXX 50 HZ Unit 496136XXX Overall Dimensions: Height 32 inches Width 19 inches Depth W/O Drip tray 31 1/8 inches Depth W/Drip Tray 36 inches Shipping Weight (approx) 420 pounds Refrigeration System: Compressor Horsepower 2 H.P.

  • Page 12: Defrost Systems

    Table 2. Accessories and Tools ACCESSORIES Installation Kits 1155 Cup Holder 511005000 Cup Holder 511006000 Changeover Kit 511035000 GENERIC FLAVOR TABS Cola 1085 Cherry 1086 Orange 1087 Grape 1088 Lemon-Lime 1089 Strawberry 1090 Banana 1091 SERVICE TOOLS 3-gallon Sanitizing Tank 281884000 Spanner Wrench, Dispensing Valve 322859000...

  • Page 13: 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 14: Figure 2. Flow Diagram

    *WATER PRESSURE REGULATOR IS PRODUCT SAMPLE FACTORY ADJUSTED TO 45-PSI AND VALVE(2) 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...
  • Page 15 THIS PAGE LEFT BLANK INTENTIONALLY 2992...

  • Page 16: 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 17: Electrical Power Requirements

    2. SPANNER WRENCH, DISPENSING VALVE (item 2) is used to remove shank nuts securing dispensing valves to faceplates. 3. CLEANING BRUSH (item 3) is used to clean faceplate relief valves passages. 4. TAPERED GASKET, BLACK (item 4) is used to seal connection when connecting plain water source line to Unit water inlet line.

  • Page 18: Installing Unit

    Locate the Unit so the following requirements are satisfied. 1. Locate close to a filtered plain water inlet supply line with a minimum water pressure of 12-psig. NOTE: The FCB Dispenser refrigeration system is equipped with a condenser coil that is cooled by two condenser coil fans.

  • Page 19: Figure 3. 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 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 Beater Drive Motor Drive Shaft Assembly...

  • Page 20: Regulator Assembly

    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 4.

  • Page 21: Preparing Unit Syrup Inlet Lines For Connection To Soft Drink Tanks

    NOTE: The Units require connection to a city plain water source line with a minimum water pressure of 12-psig. IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the City plain water source line (see Figure 2). A Cornelius Water Filter (P/N 313860000) and Quick Disconnect Set (P/N 313867-000) are recommended.

  • Page 22: Preparation For Operation

    1. Remove cover from electrical box located in lower back side of the Unit. WARNING: The Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator. A green screw, with lock washer, is provided inside the electrical box to connect power circuit ground wire which will electrically ground the Unit.

  • Page 23: Starting Fcb And Adjusting Water-To-Syrup "Ratio" (Brix) Of Dispensed Product

    1. Adjust carbonator secondary CO regulator, with 100-psi gage, by turning regulator adjusting screw to the right (clockwise) until gage reads 50 to 60-psi. 2. Pull up on carbonator tank relief valve plastic cover to purge air from tank. STARTING FCB AND ADJUSTING WATER-TO-SYRUP “RATIO” (BRIX) OF DISPENSED PRODUCT 1.

  • Page 24: Filling Freeze Cylinders With Product

    NOTE: Temperature compensated hand-type refractometers (P/N 511004000) are available from The Cor- nelius Company. 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 25: 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. Due to a redesign of the foam pack in the models documented in this manual, elevating the front of the Dispenser is no longer required.

  • Page 26: Adjustment And Programming Main Menu Selections, Components "Diagnose'' (Diagnostic Mode), And (''Totals" Displayed Cycles And Hours Totals) Into Unit

    4. Display should be adjusted to read A150 B150 ± 2 by adjusting MOTOR CURRENT ADJUSTMENTS lo- cated on No. 1 and No. 2 relay circuit boards (see Figure 6). These figures will fluctuate slightly with varia- tions in line voltage and motor loads. 5.

  • Page 27: Programming ''Defrost'' (Automatic) Settings 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 28: Programming ''Sleep'' (Sleep Time) Into Unit

    5. Press ‘‘DEFROST’’ (SELECT) switch, then repeat steps 2, 3, and 4 to program in next defrost time setting. MAKE SURE A MINIMUM OF TWO HOURS IS MAINTAINED BETWEEN DEFROST TIME SETTINGS. IF A TIME SETTING OF LESS THAN TWO HOURS IS PROGRAMMED INTO THE UNIT, A MOMENTARY ‘‘ERROR’’...

  • Page 29: Table 5. Dip Switch Functions

    SWITCH FUNCTION POINT OF SALE MESSAGE SELECT See Table 7 POINT OF SALE MESSAGE SELECT See Table 7 See NOTE. BEATER MOTOR CURRENT READOUT ON- Display current readout. OFF- No displayed current readout. MOTOR CURRENT SELF-CALIBRATION ON- Disabled. OFF- Operating. NOT USED NOT USED NOT USED...

  • Page 30: Figure 6. 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 5) SEE NOTE...

  • Page 31: Programming Point Of Sale Message Display

    PROGRAMMING POINT OF SALE MESSAGE DISPLAY (see Figure 6 and 7) NOTE: Point of sale display messages may be turned off by placing No. 1 DIP SWITCH on master circuit board in “OFF” position and No. 2 DIP SWITCH in “ON” position (see Figure 6 and 5 and 7). Three point of sales display messages are available and the desired one may be programmed in to appear on the message display by placing No.

  • Page 32: Voltage'' (Displayed Voltage Readout)

    2. Press ‘‘DEFROST’’ (SELECT) switch to bring up evaporator refrigeration coils inlet and common outlet tem- perature readings in degrees Fahrenheit. Left Reading–Refrigeration Coils Inlet No. 1 Middle Reading–Refrigeration Coils Inlet No. 2 Right Reading–Common Outlet 3. Press “ERROR RESET’’ switch two times to exit from MENU SELECTIONS. ‘‘VOLTAGE’’...

  • Page 33: 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 34: Table 9. Displayed Error Conditions

    15. Press ‘‘DEFROST’’ (SELECT) switch. No. 1 carbonated water solenoid relay will click when switch is pressed. 16. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to advance and bring up ‘‘WATER 2’’ on message display. 17. Press “DEFROST” (SELECT) switch. No. 2 carbonated water solenoid relay will click when switch is pressed.

  • Page 35: Displaying ''Totals'' (Displayed Cycles And Hours Totals) Onto Message Display

    DISPLAYING ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS) ONTO MESSAGE DISPLAY (see Tables 4 and 8). 1. ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS) may be displayed on message display as follows: 2. Refer to PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY and bring up the word ‘‘CLOCK’’...

  • Page 36: Programming Proper Refrigerant Type Into Unit Electronics

    9. Repeat steps 2 through 6 to program in the correct beater motor Manufacturer’s name for No. 2 freeze cylin- der. PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS The Dispenser electronics must be programmed for the proper refrigeration pulse rate according to the type of refrigerant gas that has been installed in the refrigeration system.
  • Page 37 THIS PAGE LEFT BLANK INTENTIONALLY 2992...

  • Page 38: 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 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 39: Control Panel Assembly Display Messages

    ‘‘OFF 1’’ and ‘‘OFF 2’’ Control Switches. ‘‘OFF 1’’ and ‘‘OFF 2’’ control switches, located on control panel, are touch-type switches and require only pressing to activate. These switches are used to stop freeze cylinders beaters and refrigeration system. ‘‘ERROR RESET’’ Control Switch. ‘‘ERROR RESET’’...

  • Page 40: Freeze Cylinders Manual Or Automatic Defrost Systems

    ‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ Fault Messages. ‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages will appear on message display if product tanks are not connected to Unit or product tanks are empty. Syrup systems syrup float switches must be filled with syrup to extinguish ‘‘SYRUP 1’’...

  • Page 41: Wake Up'' (Wake Up Time)

    ‘‘WAKE UP’’ (WAKE UP TIME) ‘‘WAKE UP’’ (WAKE UP TIME) may be programmed into the Unit to allow Unit to resume normal operation at a desired time. When programmed wake up time is reached, an alarm will sound for a short duration, then Unit will resume normal operation.

  • Page 42: Dispensed Product Conditions

    DISPENSED PRODUCT CONDITIONS ‘‘OVERRUN’’, AS APPLIED TO FROZEN CARBONATED BEVERAGES Overrun Defined. Overrun is product expansion that takes place in the frozen carbonated drink. It is caused primarily by CO breakout and secondary by freezing. Overrun is a Variable. The percentage or degree of overrun depends on a number of factors. The specific syrup, BRIX, low dispensing volume, carbonation level in liquid product, and freezing, all affect overrun.

  • Page 43: Operating Characteristics

    Freezing Affects Overrun. Freezing causes approximately a 10 percent expansion in dispensed frozen carbonated drink. The degree of freezing is limited because finished drink is intended to be sipped through a straw. This is not possible if product is too ‘‘solid’’. OPERATING CHARACTERISTICS The product viscosity (product consistency) can be varied by adjustment and secondary CO regulator setting...

  • Page 44: Product Flavor Change

    2. 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. Syrup supply should be checked daily and if necessary, replenished as instructed. PRODUCT FLAVOR CHANGE Perform syrup flavor change as instructed.

  • Page 45: Water-To-Syrup "Ratio" (Brix) Of Dispensed Product

    WATER-TO-SYRUP “RATIO” (BRIX) OF DISPENSED PRODUCT Water-To-Syrup “Ratio” (BRIX) is the water-to-syrup “ratio” of the dispensed product. Adjust BRIX as instructed in the SERVICE AND MAINTENANCE section. REGULATORS Primary CO Regulator. The primary CO regulator (see Figure 2 and Table 8) regulates CO pressure to the soft drink tanks (also to the bag-in-box syrup system if used) and also to the secondary CO regulators located inside the Unit.

  • Page 46: Programming ''Wake Up'' (Wake Up) Time Into Unit

    PROGRAMMING ‘‘WAKE UP’’ (WAKE UP) TIME INTO UNIT ‘‘WAKE UP’’ (WAKE UP TIME) May be programmed into Unit to occur any time of the day to wake Unit up (re- turn to normal operation) after ‘‘sleep time’’ has occurred. Program ‘‘WAKE UP’’ into Unit as instructed in the the INSTALLATION section.

  • Page 47: Water Strainer Screen And Double Liquid Check Valve Maintenance

    WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE MAINTENANCE (see Figures 2 and 11) WARNING: The carbonator water pump water strainer screen and double liquid check valve must be inspected and serviced after any disruptions (plumbing work, earthquake, etc.) to the water supply system, and at least once a year under normal circumstances.

  • Page 48: 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 personnal injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring. PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING CAUTION: Before shipping, storing, or relocating Unit, syrup systems must be sanitized and all sanitizing solution must be purged from syrup systems.

  • Page 49: Figure 7. Operating Controls

    FAULT MESSAGE DISPLAY CONTROL PANEL HIDDEN “SECURITY SWITCH” BACK PANEL TOP PANEL VENTILATION LOUVERS TOP PANEL RETAINING SCREW (2) CONTROL PANEL FACEPLATE RELIEF VALVE (4) CUP REST FRONT ACCESS DOOR LOCK DISPENSING VALVE (2) DRIP TRAY BRACKET SIDE PANEL (2) RETAINING SCREW (ITEM 6) SIDE PANEL...

  • Page 50: Figure 8. Unit Internal Components

    REFRIGERATION COMPRESSOR CONDENSER COIL RELIEF VALVE (2) PRODUCT BLENDER TANK (2) FREEZE CYLINDER (2) BEATER DRIVE MOTOR (2) ACCUMULATOR SECONDARY CO REGULATOR (3) FIGURE 8. UNIT INTERNAL COMPONENTS 2992...

  • Page 51: 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 7), then...

  • Page 52: Figure 9. 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 9. SELF-CLOSING DISPENSING VALVE 4. Unscrew RELIEF VALVE (item 9) from FACEPLATE (item 8). 5. Disassemble dispensing valve (see Figure 9) as follows: Remove two screws and hold-down plates securing spring housing to dispensing valve body, then re- move housing.
  • Page 53 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 13) IMPORTANT: The freeze cylinders drive shaft/seal assemblies must be removed and inspected every four months.

  • Page 54: Cleaning Condenser Coil

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

  • Page 55: Adjusting Co2 Regulators

    3. Using a flat blade screwdriver, turn lock counterclockwise to unlock the front access door (see Figure 7), then open the door. Remove lower front access panel as instructed for access to the applicable carbonated water flow regula- tor, product shutoff valve, and the product sample valve. 5.

  • Page 56: Adjusting Brix (Water-To-Syrup) ''Ratio'' Of Dispensed Product

    Primary CO Regulator. (see Figure 2) Adjust the primary CO regulator by turning the regulator adjusting screw to the right (clockwise) until the regu- lator pressure reads 80 to 100-psig. Product Blender Tanks Secondary CO Regulators. (see Figures 2 and 8) 1.

  • Page 57: Product Carbonation Adjustment

    NOTE: Temperature compensated hand-type refractometers (P/N 511004000) are available from the Cornelius Company. 7. Observe pressure setting on carbonator secondary CO regulator gage. 8. Press applicable ‘‘AUTO BLEND 1‘’ or ‘‘AUTO BLEND 2’’ switch to fill product blender tank 1/4-full of new batch of product.

  • Page 58: Sanitizing Syrup Systems

    SANITIZING SYRUP SYSTEMS NOTE: The Unit should be sanitized every 90 days following Sanitizer Manufacturer’s recommendation. Use Chlor-Tergent (Oakite Products, Inc.) or equivalent sanitizer. The Unit should be sanitized every 90 days and before and after storage periods following parent company re- quirements and sanitizer manufacturer’s recommendations.
  • Page 59 15. Pull up on empty soft drink tank cover relief valve to release CO pressure from tank. WARNING: If powder type sanitizer is used, it must be thoroughly dissolved with water prior to adding to soft drink tank. NOTE: Sanitizing solution is used in a more concentrated form because it will be diluted approximately four-to-one in product blender tank.

  • Page 60: Yearly Or After Water System Disruption

    30. Press ‘‘WASH 1’’ switch to start No. 1 freeze cylinder beater. Allow beater to operate for five minutes, then press ‘‘OFF 1’’ switch to stop beater. 31. Disconnect soft drink tank containing syrup from No. 1 syrup system. 32. Connect clean empty soft drink tank into No. 1 syrup system. 33.

  • Page 61: Servicing Carbonator Water Pump Double Liquid Check Valve

    6. Pull up on carbonator tank relief valve plastic cover to release CO pressure from tank. 7. Loosen screen retainer in water pump port, then remove screen retainer and strainer screen from port. 8. Pull strainer screen from screen retainer. Clean any sediment from screen retainer and water pump port. 9.

  • Page 62: Replenishing Syrup Supply

    4. Disassemble each check valve as shown in Figure 10. 5. Wipe each part with clean lint-free cloth. Inspect each part, especially ball for burrs, nicks, corrosion, deteri- oration, and other damage. Discard ball seat and any damaged or suspicious parts and replace with new parts during reassemble.

  • Page 63: Replenishing Co2 Supply

    5. Check soft drink tank quick disconnects for sticky or restricted operation. Rinse disconnects in warm water. 6. First, pressurize full soft drink tank by connecting CO line to tank, then connect Unit syrup inlet line to tank. 7. Press applicable ‘‘FILL 1’’ or ‘‘FILL 2’’ switch to fill applicable No. 1 or No. 2 syrup system syrup float switch with syrup.

  • Page 64: Figure 11. Water Strainer Screen And Double Liquid Check

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

  • Page 65: Cleaning Co2 Gas Check Valves

    2. To disconnect soft drink tank from Unit syrup system. Disconnect liquid disconnect from soft drink tank. NOTE - Disconnecting liquid 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 66: Replacing Freeze Cylinder Beater Drive Motor

    REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR (see Figures 8 and 13 ) IMPORTANT: Note in 6 “MOTOR SELECT” the number of freeze cylinder beater drive motors Manufacturers that are listed. Your Unit was manufactured and equipped with freeze cylinders beater drive motors from one of these Manufacturers.
  • Page 67 3. Using container graduated in ounces, open carbonator carbonated water sample valve and completely drain carbonator tank into container. Total carbonated water volume dispensed should be 40 to 58-ounces maximum. 4. If total carbonated water dispensed is below 40 ounces, loosen screw securing level control switches ac- tuator bracket (see Figure 14) and move actuator bracket up slightly.

  • Page 68: Figure 13. 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 TOOL, DRIVE/COUPLER ADJUSTMENT GAUGE (ITEM 12) PLASTIC HOUSING LOCK RING O-RING BEARING O-RING ALLEN-HEAD DRIVE SHAFT/ SEAL ASSEMBLY (P/N 3193) SET SCREW FIGURE 13.

  • Page 69: 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 2992...

  • Page 70: 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 2992...

  • Page 71: Figure 16. Wiring Diagram

    2426 REV: D FIGURE 16. WIRING DIAGRAM...

  • Page 72: 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 73: 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 74: 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 75: 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 control 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 76: Troubleshooting Dispensed Product

    Trouble Probable Cause Remedy ERRATIC CARBONATOR Water filter restricted. Replace water filter. WATER PUMP CYCLING. (cont’d) 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.

  • Page 77: Cylinder Freeze-Up

    Trouble Probable Cause Remedy FROZEN PRODUCT Primary CO regulator b. Primary CO regulator must be CONSISTENCY VARIES pressure insufficient. adjusted from 80 to 100-psi. EXCESSIVELY. (cont’d) Cylinder freeze-up causing Refer to CYLINDER ice formation in center of FREEZE-UP. cylinder and liquid product channels around ice formation.
  • Page 78 OVERCOUNTER POST-MIX DISPENSER WITH V3+FEATURES UNIT PART NUMBERS: 416136XXX 496136XXX ILLUSTRATED PARTS BREAKDOWN 2992...

  • Page 79: Figure 17. Overcounter Fcb Post-Mix Dispenser

    FIGURE 17. OVERCOUNTER FCB POST-MIX DISPENSER 2992...
  • Page 80 FCB POST-MIX DISPENSER Item Item Part No. Name Part No. Name 325457000 Blade, Scraper 320539000 Washer, .191 I.D. 3432 Body, Beater 343304000 Washer, .204 I.D. 326002000 Tube Kit, Drain Tube (Not Shown; See 319941000 Thread Rolling Screw, Hex Washer Hd., Figure 39) No.
  • Page 81 FCB POST-MIX DISPENSER (cont’d) Item Item Part No. Name Part No. Name 325069000 Machine Screw, Sl Truss Hd., No. 10-24 324120000 Motor, 1/4H.P. 220V. 60HZ (Klauber) By 1/2-In. Long 2472 Motor, 1/4H.P. 220/240V 50HZ (Klauber) 326000000 Compressor Kit, 2HP 230V 60HZ 3471 Motor, 1/8H.P.

  • Page 82: 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 324221000 Tube, .312 I.D.

  • Page 83: 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 130066000 Fitting, Plug, 1/4-NPT 183061000 Fitting, 1/4-NPT By 7/16-20 183301100 Check Valve Ass’y (See Figure 24) 183068000...

  • Page 84: Figure 23. Co2 Regulator Assembly

    Item Item Part No. Name Part No. Name 183449000 Regulator Ass’y, 60-PSI, 130167000 Guide Orange (Includes 1-16) 183010000 Gasket 183412000 Regulator Ass’y, 100-PSI, Gold 183009007 Retainer, Seat (Includes 1-16) 183008000 O-Ring, .489 I.D. By .070 C.S. 183040000 Machine Screw, Phil Fill Hd., No. 10-32 By 7/8-In.

  • Page 85: Figure 25. Blender And Tubing Components

    FIGURE 25. BLENDER AND TUBING COMPONENTS Item Item Part No. Name Part No. Name Blender and Tubing Components 2487 Solenoid Valve Ass’y, Syrup (See Figure 32) 317015000 O-Ring, .239 I.D. By .070 C.S. 2781 Tube Ass’y, Product, Blender to 2657 Base Freeze Cylinder (See Figure 28) 316963000...

  • Page 86: Figure 26. Tubing Assembly (Carb Water)

    Item Part No. Name 2780 Tube Ass’y, Carb Water Outlet 770602 Fitting, Cross, 1/4-Barb 770501 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 87: 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 779005 Turnaround, Barb 770401 Fitting, Elbow, Swivel, 7/16-20 FIGURE 29. TUBING ASSEMBLY (WATER SOLENOID TO BLENDER) Item Part No.

  • Page 88: Figure 32. Solenoid Valve Assembly

    FIGURE 32. SOLENOID VALVE ASSEMBLY Item Item Part No. Name Part No. Name 2486 Solenoid Valve Ass’y, Water 310632001 Adjusting Screw 2487 Solenoid Valve Ass’y, Syrup 1318 Flow Control, Top 2356 Block, Valve 180025000 O-Ring, .364 I.D. By .070 C.S. 1319 Body, Valve 1545...

  • Page 89: Figure 33. Blender Components

    FIGURE 33. BLENDER COMPONENTS Item Item Part No. Name Part No. Name Blender Components 315931000 O-Ring, .364 I.D. By .070 C.S. 2625 Support, Blender 325288000 Float Switch Ass’y 188206000 Thread Rolling Screw, Phil Truss 324048000 Holder, Float Switch Hd., No. 10-24 By 3/4-In. Long 324115000 Retaining Ring 324116000...

  • Page 90: Figure 34. Control Box And Display Panel Components

    FIGURE 34. CONTROL BOX AND DISPLAY PANEL COMPONENTS Item Item Part No. Name Part No. Name Control Box and Display Panel 325981069 Holder, Flavor Tab Components 2716 Cover, Control Box 326079000 Cable, Ribbon 312251000 Thread Rolling Screw, Phil Pan Hd., No.

  • Page 91: Figure 35. Faceplate Assembly

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

  • Page 92: Figure 36. Dispensing Valve Assembly

    FIGURE 36. DISPENSING VALVE ASSEMBLY Item Item Part No. Name Part No. Name 1557 Dispensing Valve Ass’y 325647000 Plate 1556 Body and Shank 317784000 Thread Cutting Screw, Phil Truss Hd., Stainless Steel, No. 8-32 By 1554 Valve 3/8-In. long 1576 Housing 321514000 O-Ring, Caged, .562 I.D.

  • Page 93: 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 40) 325777000 Switch, Pressure 2833 Pump and Motor Ass’y, Domestic (See Figure 41) 2814 Pump and Motor Ass’y, Export...

  • Page 94: Figure 40. Carbonator Tank And Linkage Assembly

    FIGURE 40. CARBONATOR TANK AND LINKAGE ASSEMBLY Item Item Part No. Name Part No. Name 326136000 Carbonator Tank and Linkage Ass’y 318037000 Insulation, Switch 326135000 Tank, Carbonator 317771000 Level Control Switch 317746000 Link, Pivot 315961000 Machine Screw, Sl. Rd. Hd., No. 4-40 By 1-1/8-In.

  • Page 95: Figure 41. Pump And Motor Ass'y

    FIGURE 41. PUMP AND MOTOR ASS’Y Item Item Part No. Name Part No. Name 2833 Pump and Motor Ass’y, 230/220V. 187502000 Fitting, Elbow, 3/8-MPT By 7\16-20 60/50HZ (Domestic) 311765001 Double Check Valve Ass’y (See 2814 Pump and Motor Ass’y, 230V. 50HZ Figure 31) (Export) 311855000...

  • Page 96: Figure 42. Beater Motor Drive Shaft/Seal Ass'y

    FIGURE 42. 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 2992...
  • Page 97 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 98 THIS PAGE LEFT BLANK INTENTIONALLY 2992...
  • Page 99 IMI CORNELIUS INC. CORPORATE HEADQUARTERS: One Cornelius Place Anoka, Minnesota 55303-6234 (612) 421-6120 (800) 238-3600...

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