Cornelius R-404A REFRIGERANT manual

IMPORT ANT : TO THE INST ALLER. 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 A1 12. 1.2-1979; or an approved vacuum breaker or other such method as proved effective by test. W ater pipe connections and fixtures[...]

i 312028000 T ABLE OF CONTENTS Page GENERAL DESCRIPTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL DESCRIPTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT DESCRIPTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

ii 312028000 T ABLE OF CONTENTS (cont’d) Page ADJUSTMENT AND PROGRAMMING MAIN MENU SELECTIONS, COMPONENTS “ DIAGNOSE ’’ (DIAGNOSTIC MODE), AND ‘‘ TOT ALS ” (DISPLAYED CYCLES AND HOURS TOT ALS) INTO UNIT 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE[...]

iii 312028000 T ABLE OF CONTENTS (cont ’ d) Page REPLENISHING SYRUP SUPPL Y 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT FLA VOR CHANGE 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING CO2 SUPPL Y 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

iv 312028000 T ABLE OF CONTENTS (cont ’ d) Page SIDE P ANELS 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT ACCESS P ANEL 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPENING AND CLOSING FRONT ACCESS DOOR 38 . . . . . . . . . . . . . . . . [...]

v 312028000 T ABLE OF CONTENTS (cont ’ d) Page FREEZE CYLINDER AUT OMA TIC DEFROST CYCLE DOES NOT OPERA TE. 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT DOES NOT GO OFF AUTOMA TIC DEFROST CYCLE. 65 . . . . . . . . . . . MANUAL DEFROST CYCLE DOES NOT OPERA TE WHEN ‘‘ DEFR[...]

vi 312028000 T ABLE OF CONTENTS (cont ’ d) Page LIST OF FIGURES (CONT ’ D) FIGURE 19. CONTROL BOX COMPONENTS 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 20. SECONDARY CO2 REGULA TOR ASS ’ Y7 4 . . . . . . . . . . . . . . . . . . . . . . FIGURE 21. TUBE ASSEMBL Y 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

1 312028000 GENERAL DESCRIPTION IMPORT ANT : T o the user of this manual – This manual is a guide for installing, operating, and maintaining this equipment. Refer to T able of Contents for page location of information pertaining to questions that arise during installation, operation, service and maintenance, or troubleshoo mus ting this equipment[...]

2 312028000 T able 1. Design Data (cont ’ d) Refrigeration System: Compressor Horsepower 2 H.P . Refrigerant T ype And Charge See Unit Nameplate Ambient Operating T emperature 40 ° F to 100 ° F Electrical Requirements: Operating V oltage See Unit Nameplate Operating Current See Unit Nameplate T able 2. Accessories and T ools ACCESSORIES Install[...]

3 312028000 T ransparent 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 2 gas pressure from the freeze cylinder to atmosphere when filling the cylinder with prod[...]

4 312028000 ‘‘ 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 evapora[...]

5 312028000 *W ATER PRESSURE REGULA TOR IS F ACTOR Y ADJUSTED TO 45-PSI AND SHOULD NOT BE READJUSTED. **SYRUP SOLD-OUT SWITCHES ARE F ACT OR Y ADJUSTED AND SHOULD NOT BE READJUSTED. PRODUCT BLENDER T ANK(2) PRODUCT SAMPLE V AL VE(2) SYRUP FLOW REGULA TOR(2) CARBONA TOR T ANK PRODUCT SHUTOFF V AL VE(2) CARBONA TED W A TER VOLUME SAMPLE V AL VE CARBO[...]

6 312028000 THIS P AGE LEFT BLANK INTENTIONALL Y[...]

7 312028000 INST ALLA TION This section covers unpacking and inspection, installing Loose-Shipped Parts, selecting location, installing Unit, preparing for operation, and operation. UNP ACKING AND INSPECTION (see Figure 5) NOTE: The Unit was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it. Any damage o[...]

8 312028000 3. Cleaning brush (item 3) is used to clean faceplate relief valves passages. 4. T apered 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[...]

9 312028000 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. Circulating air , required to cool the refrigeration system [...]

10 312028000 INST ALLING PRIMAR Y CO 2 REGULA TOR ASSEMBL Y ON CO 2 CYLINDER (see Figure 2) W ARNING: T o avoid personal injury and/or property damage, always secure CO 2 cylinder in upright position with a safety chain to prevent it from falling over . Should the valve become accidentally damaged or broken off, CO 2 cylinder can cause serious pers[...]

11 312028000 2. Connect the CO 2 source line to the Unit CO 2 inlet line. DO NOT TURN ON THE CO 2 SOURCE A T THIS TIME. CONNECTING CITY PLAIN W A TER 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 fi[...]

12 312028000 PREP ARA TION FOR OPERA TION TURNING ON ELECTRICAL POWER TO UNIT T urn 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[...]

13 312028000 ST ARTING FCB AND ADJUSTING W A TER-TO-SYRUP “ RA TIO ” (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 2 O OUT ’’ fault message should have gone out but ‘‘ SYRUP 1 ’’ , and ‘‘ SYRUP 2 ’’ faul[...]

14 312028000 B. 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 ’’ , ‘?[...]

15 312028000 PLACING UNIT IN OPERA TING LOCA TION IMPORT ANT 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 [...]

16 312028000 CAUTION: IF NO. 4 ‘‘ BEA TER MOT OR 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 ± 2, the beater motor current has just been reset at A155 B1[...]

17 312028000 MENU SELECTIONS MESSAGE DISPLA Y (EXAMPLE READOUTS) “ CLOCK ” (TIME OF DA Y) see note below C _ 1 2 - 0 0 A “ DEFROST ” (AUTOMA TIC) 3 D 1 0 - 0 0 A “ SLEEP ” (SLEEP TIME) S 1 2 - 3 0 A _ “ W AKE UP ” (W AKE UP TIME) W _ 0 7 - 1 5 A “ VIS SET ” (PRODUCT VISCOSITY SETTING) 12____10 “ VIS READ ” (ACTUAL VISCOSITY [...]

18 312028000 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) INT O UNIT ‘‘ SLEEP ’’ (SLEEP TIME) may be programmed into Unit to occur any time of the day[...]

19 312028000 DISPLA YED MODEL HZ MOTOR DESCRIPTION KLBER – 60 Klauber 60 Over/under gear box with a GE wide-range voltage motor . F ASV3 + 60 Fasco/VW 60 Over/under gear box with a Fasco wide-range voltage motor . F ASCWR 60 Fasco/VW 60 Standard gear box using a Fasco wide-range voltage motor . VW/GE 60 Fasco/VW 60 Standard gear box with a GE 219[...]

20 312028000 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 ASSEMBL Y in the appropriate positions. ADJUSTING “ VIS SET ” (PRODUCT VISCOSITY) OF DISPENSED PRODUCT Adjusting “ VIS SET ”[...]

21 312028000 NO. 1 AND NO. 2 EV APORA TOR COILS REFRIGERA TION COMMON OUTLET TEMPERA TURES NO. 2 EV APORA TOR REFRIGERA TION COIL INLET TEMPERA TURE NO. 1 EV APORA TOR REFRIGERA TION COIL INLET TEMPERA TURE MOT OR CURRENT ADJUSTMENT DIP SWITCH ASS ’ Y POINT OF SALE MESSAGE DISPLA Y SELECT (See T able 7) BEA TER MOTORS CURRENT READOUT (See T able [...]

22 312028000 ‘‘ VOL T AGE ’’ (DISPLA YED VOL T AGE READOUT) Displayed voltage readout may be displayed on message display as follows: 1. Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLA Y and bring up ‘‘ VOL T AGE ’’ (DISPLA YED VOL T AGE READOUT) on message display . 2. Press ‘‘ DEFROST ’’ (SELECT) switch to bring up [...]

23 312028000 22. Press ‘‘ CANCEL DEFROST ’’ (ADV ANCE) 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 ’’ (ADV ANCE) switch to advance and bring [...]

24 312028000 TOT ALS MENU COMMANDS DESCRIPTION COMP HRS COMPRESSOR RUN HOURS COMP CYC COMPRESSOR CYCLES X100 DFSTYC1 DEFROST SIDE 1 CYCLE DFSTYC2 DEFROST SIDE 2 CYCLES BLDRCYC1 BLENDER SIDE 1 CYCLE X100 BLDRCYC2 BLENDER SIDE 2 CYCLES X100 SOLDOUT 1 SOLDOUT SYRUP SIDE 1 SOLDOUT 2 SOLDOUT SYRUP SIDE 2 BMTRHRS1 BEA TER MOT OR 1 HOUR BMTRHRS2 BEA TER M[...]

25 312028000 ITEMS AFFECTED BY ERROR MESSAGE DISPLA YED ERROR BEA TER MOTOR 1 BEA TER MOTOR 2 REFRIG 1 REFRIG 2 Motor 1 Low Current, < 109, Sensed on Motor One OFF OFF Motor 2 Low Current, < 109, Sensed on Motor T wo OFF OFF Motor 1 High Current > 255, Sensed on Motor One OFF OFF Motor 2 High Current > 255, Sensed on Motor T wo OFF OFF [...]

26 312028000 1. Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLA Y and bring up “ REF TYPE ” (REFRIGERANT TYPE) on the message display . Press “ DEFROST (SELECT) switch to lock in on the selection. The sub menu of refrigerant types that may be brought up on the MESSAGE DISPLA Y from “ REF TYPE ” (REFRIGERANT TYPE) are as foll[...]

27 312028000 OPERA TOR ’ 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 2 supply , operators daily cleaning of Unit, and sanitizing requirements. CAUTION: Do not place or store anythin[...]

28 312028000 ’’ 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[...]

29 312028000 ‘‘ CO 2 OUT ’’ Fault Message. ‘‘ CO 2 OUT ’’ fault message will appear on message display when CO 2 supply to Unit has been turned of f or if CO 2 pressure drops below 50-psi. A minimum CO 2 pressure of 75-psi must be available to Unit to extinguish ‘‘ CO 2 OUT ’’ fault message. ‘‘ SYRUP 1 ’’ or ‘‘ S[...]

30 312028000 ‘‘ SLEEP ’’ (SLEEP TIME) OPERA TION ‘‘ 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 cylinde[...]

31 312028000 SYRUP FLOW REGULA T ORS 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 sectio[...]

32 312028000 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 [...]

33 312028000 1. T o disconnect soft drink tank from Unit syrup system. A. Disconnect liquid disconnect from soft drink tank. NOTE - Disconnecting liquid quick disconnect from soft drink tank first prevents syrup from backflowing through Unit syrup flow regulator, which may alter regulator adjustment. B. Second, disconnect CO 2 quick disconnect from[...]

34 312028000 ADJUSTMENTS CARBONA TED W A TER FLOW RA TE 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 sect[...]

35 312028000 PROGRAMMING ‘‘ SLEEP ’’ (SLEEP TIME) INT O 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 ’’ (W AKE[...]

36 312028000 PROGRAMMING FREEZE CYLINDERS BEA TER “ MOTORS ” INT O UNIT ELECTRONICS Note in T able 6 “ MOTOR SELECT ” the number of freeze cylinders beater motors manufacturer ’ s that are listed. Y our Unit was manufactured and equipped with motors from one of these manufacturer ’ s. A replacement freeze cylinder beater motor is also m[...]

37 312028000 SER VICE AND MAINTENANCE This section describes service and maintenance to be performed on the Unit. W ARNING: Disconnect electrical power to Unit to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring. PREP ARING UNIT FOR SHIPPING, ST ORIN[...]

38 312028000 FRONT ACCESS P ANEL Remove two screws securing front access panel, then remove panel and plastic spacers from the Unit. MAKE SURE WHEN REINST ALLING THE FRONT ACCESS P ANEL, TO REINST ALL THE PLASTIC SP ACERS IN BETWEEN THE P ANEL AND THE UNIT FRAME. OPENING AND CLOSING FRONT ACCESS DOOR OPENING FRONT ACCESS DOOR Using a flat blade scr[...]

39 312028000 CONTROL P ANEL HIDDEN “ SECURITY SWITCH ” T OP P ANEL T OP P ANEL RET AINING SCREW (2) CONTROL P ANEL F ACEPLA TE RELIEF V AL VE (4) LOWER FRONT ACCESS P ANEL CUP REST DRIP TRA Y SIDE P ANEL (2) F AUL T MESSAGE DISPLA Y DISPENSING V AL VE (2) F ACEPLA TE (2 ) BACK P ANEL SIDE P ANEL RET AINING SCREW VENTILA TION LOUVERS NOTE: The N[...]

40 312028000 RELIEF V AL VE (2 ) PRODUCT BLENDER T ANK (2) FREEZE CYLINDER (2) SECONDAR Y CO 2 REGULA TOR (3) ACCUMULA TOR CONDENSER COIL BEA TER DRIVE MOT OR (2) REFRIGERA TION COMPRESSOR FIGURE 6. UNIT INTERNAL COMPONENTS[...]

41 312028000 SPRING HOUSING T ORSION SPRING SPRING FITTING DISPENSING V AL VE BODY CAGED O-RING VA LV E LEVER SLEEVE SPRING KNOB RET AINING SCREW(2) HOLD-DOWN PLA TE(2) FIGURE 7. SELF-CLOSING DISPENSING V AL VE 3. Carefully remove large O-RING (item 5) from F ACEPLA TE (item 8). 4. Unscrew RELIEF V AL VE (item 9) from F ACEPLA TE (item 8). 5. Disas[...]

42 312028000 B. Carefully install valve with caged O-ring in dispensing valve body . C. 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 V AL VE (item 9), then screw relief valve [...]

43 312028000 15. Position SCRAPER BLADES (item 2) on BEA TER (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). T urn beater to the right (clockwise) to lock in place. 16. Lubricate O-RING (item 5) with water to facilitate faceplate installation. Position O-RING (i[...]

44 312028000 1 Product Inlet Fitting 2 Scraper Blade (2) 3 Evaporator Coil 4 Relief V alve Port 5 O-Ring 6 Flatwasher (4) 7 Hex Nut (4) 8 Faceplate 9 Relief V alve 10 V alve Lever 1 1 Knob 12 Dispensing V alve 13 Beater 14 Allen Head Setscrew 15 Beater Shaft Coupling 16 Drive Pin 17 Bearing Housing Locking T ab (4) 18 Bearing Retainer 19 Beater Mot[...]

45 312028000 BEA TER DRIVE M O T OR BEA TER DRIVE MOT OR SHAFT ALLEN-HEAD SET SCREW COUPLING PLASTIC COUPLER COUPLING ALLEN-HEAD SET SCREW DRIVE SHAFT/SEAL ASS ’ Y BEA TER DRIVE SHAFT LOCK RING BEARING ALLEN-HEAD SET SCREW (2) O-RING PLASTIC HOUSING O-RING SHAFT COUPLER DRIVE DRIVE COUPLER GAUGE, DRIVE/COUPLER (ITEM 14) PIN DRIVE SHAFT/ SEAL ASSE[...]

46 312028000 Key on End of Post BEA TER Key on End of Post Key Slot on Blade Scraper blades must be mounted to the beater body as shown using the perforated edge as the leading edge. Line up key on end of posts with key slot in scraper blades. FIGURE 10. BEA TERS AND SCRAPER BLADES INST ALLA TION 1. Press applicable ‘‘ OFF 1 ’’ or ‘‘ OF[...]

47 312028000 1 1. 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. Press applicable ‘‘ [...]

48 312028000 Carbonator Secondary CO 2 Regulator . (see Figure 2 and 6) 1. Remove the Unit lower front access panel as instructed for access to the carbonator(s) secondary CO 2 regulator(s). IMPORTANT : The carbonator tank secondary CO 2 regulator must be adjusted 25-psi higher or more above the product blender tanks secondary CO 2 regulators press[...]

49 312028000 PRODUCT CARBONA TION ADJUSTMENT (see Figures 2 and 6) Carbonation of dispensed product can also be varied to suit consumer preference by adjusting Unit carbonator secondary CO 2 regulator as follows: IMPORTANT : Carbonator tank secondary CO 2 regulator must be adjusted 25-psi higher or more above product blender tanks secondary CO 2 re[...]

50 312028000 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 2 and liquid disconnects disconnecting and con[...]

51 312028000 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 cylind[...]

52 312028000 38. After carbonator water pump cycles off, intermittently pull and release No. 1 freeze cylinder faceplate relief valve. This bleeds CO 2 from freeze cylinder and allows product to enter and fill cylinder . 39. Open No. 2 product blender tank product shutoff valve. 40. Press both ‘‘ AUTO 1 ’’ and ‘‘ AUTO 2 ‘’ switches [...]

53 312028000 1 2 3 4 5 6 Index No Part No Name 1 317965000 Retainer 2 312196000 Spring 3 312419000 Ball 4 312415000 W asher , .300 I.D. 5 312418000 Quad Ring 6 317963000 Body *Install new ball seat each servicing. FIGURE 1 1. LIQUID CHECK V AL VE ASSEMBL Y SER VICING CARBONA TOR W A TER PUMP DOUBLE LIQUID CHECK V AL VE (see Figures 2 and 12) 1. Ser[...]

54 312028000 10. Open CO 2 cylinder and water inlet supply lines shutof f valves. Check for water leaks and tighten any loose connections. 1 1. 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. Connect electrical power to Unit. 14. Pre[...]

55 312028000 REPLENISHING CO 2 SUPPL Y W ARNING: CO 2 displaces oxygen. Strict attention must be observed in the prevention of CO 2 (carbon dioxide) gas leaks in the entire CO 2 and soft drink system. If a CO 2 gas leak is suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Pers[...]

56 312028000 SCREEN R E T AINER O-RING (P/N 315349000) SCREEN (P/N 315348000) W A TER PUMP MOTOR DOUBLE LIQUID CHECK V AL VE ASS ’ Y WHITE T APERED GASKET W ATER PRESSURE SWITCH W ATER PRESSURE REGULA TOR W A TER PUMP SYRUP SOLD-OUT FLOA T SWITCH ( 2 ) SYRUP SOLENOID V AL VE (2) CARBONA TED W A TER FLOW REGULA T OR (2) LIQUID CHECK V AL VE (4) CA[...]

57 312028000 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. 7. Press applicable ‘‘ [...]

58 312028000 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. V ery carefully , pull motor[...]

59 312028000 RELIEF V AL VE CARBONA TED W A TER T ANK LEVEL CONTROL SWITCHES(2) SWITCHES ACTUA TOR BRACKET ACTUA TOR BRACKET ADJUSTMENT SCREW FIGURE 14. CARBONA TOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT[...]

60 312028000 HOT -GAS DEFROST SOLENOID V AL VE ASS ’ Y (2) ELECTRONIC EXP ANSION V AL VE (2) FREEZE CYLINDER (2) EV APORA TOR STRAINER/DR YER ACCUMULA TOR COMPRESSOR RECEIVER T ANK CONDENSER COIL F AN ASS ’ Y FIGURE 15. REFRIGERA TION FLOW DIAGRAM[...]

61 312028000 FIGURE 16. WIRING DIAGRAM[...]

62 312028000 THIS P AGE LEFT BLANK INTENTIONALL Y[...]

63 312028000 W ARNING: 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 2 system, stop dispensing, shut off the CO 2 supply , then relieve the system pressure before proceeding. If repairs are to be made t[...]

64 312028000 T rouble Remedy Probable Cause ALL CONTROL P ANEL SWITCHES NOT OPERA TING. (cont ’ d) E. Flat cable connected between control switch module and master circuit board pinched and shorted out or broken wire in cable. E. Check cable for pinched or broken wire condition and repair or replace as necessary . F . Master circuit board not ope[...]

65 312028000 T rouble Remedy Probable Cause ALL F AUL T MESSAGE NOT OPERA TING (cont ’ d) D. Master circuit board not operating. D. Replace master circuit board. E. Fault message display module not operating properly . E. Replace fault message display module. ‘‘ CO 2 OUT ’’ F AUL T MESSAGE GOES ON DURING OPERA TION. A. CO 2 supply turned [...]

66 312028000 T rouble Remedy Probable Cause MANUAL DEFROST CYCLE DOES NOT OPERA TE WHEN ‘‘ DEFROST ’’ SWITCH IS PRESSED. (cont ’ d) E. Master circuit board not operating properly . E. Replace master circuit board. DEFROST CYCLE DOES NOT CANCEL AFTER PRESSING ‘‘ CANCEL DEFROST ’’ SWITCH. A. Flat cable not properly connected to cont[...]

67 312028000 T rouble Remedy Probable Cause CARBONA TOR W A TER PUMP WILL NOT SHUT OFF . A. Binding, damaged, or dirty carbonated water tank balance mechanism. A. Clean, repair , or replace balance mechanism. ERRA TIC CARBONA TOR W A TER PUMP CYCLING. A. Insufficient water supply pressure. ‘‘ H 2 O OUT ’’ fault message goes on and off inter[...]

68 312028000 T rouble Remedy Probable Cause FREEZE CYLINDER DOES NOT REFILL A T ALL TIMES WHEN DISPENSING. (cont ’ d) C. Lines restricted. C. Sanitize Unit as instructed. FROZEN PRODUCT CONSISTENCY V ARIES EXCESSIVEL Y . A. Dispensed product BRIX varying because: Syrup and/or water flow regulator sticking. a. Clean regulator(s). Primary CO 2 regu[...]

69 312028000 FCB OVERCOUNTER POST -MIX DISPENSER WITH V3+FEA TURES (R-404A REFRIGERANT) 416136xxxx 496136xxxx UNIT P AR T NUMBERS: ILLUSTRA TED P ARTS BREAKDOWN[...]

70 312028000 FIGURE 17. OVERCOUNTER FCB POST -MIX DISPENSER 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 59 60 61 62 63 64 65 66 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 88 89 4 19 19 24 32 36 36 36 37 37 37 37 37 37 37 37 37 38[...]

71 312028000 FCB POST -MIX DISPENSER Item No. Part No. Name 1 325457000 Blade, Scraper 2 3432 Body , Be ater 3 326002000 Tube Kit, Drain T ube (Not Shown; See Figure 39) 4 2613 Bracket, Receiver and Accumulator 5 Secondary CO 2 Regulator Components (See Figure 18) 6 Control Box Components (See Figure 19) 7 1317 Filter , Solenoid 8 Blender and Tubin[...]

72 312028000 FCB POST -MIX DISPENSER (cont ’ d) Item No. Part No. Name 65 325069000 Machine Screw , Sl Truss Hd., No. 10-24 By 1/2-In. Long 66 3898 Compressor Kit, 2HP 230V 60Hz (Domestic) 3899 Compressor Kit, 2HP 230V 50Hz (Export) 67 3832 Cover , Control Box 68 31 1304000 T apered Gasket, Black 69 3557 Dryer 70 326071000 Expansion V alve, Refri[...]

73 312028000 Item No. Part No. Name Secondary CO 2 Regulator Components 1 324218000 Tube, .156 I.D. By 3-In. Long 2 324219000 Tube, .156 I.D. By 1-In. Long 3 324220000 Tube, .156 I.D. By 1 1-In. Long 4 317528000 Fitting, T ee, 1/8-Barb 5 300393000 Fitting, T ee, 1/8-Barb By 3/8-Barb 6 178025100 T apered Gasket, White 7 187462000 Tube, .312 I.D. By [...]

74 312028000 Item No. Part No. Name 3049 Secondary CO 2 Regulator Ass ’ y 1 183287000 Gage, 60-PSI 2 183449000 Regulator Ass ’ y , 30-PSI (See Figure 23) 3 183412000 Regulator Ass ’ y , 100-PSI (See Figure 23) 4 183286000 Gage, 100-PSI 5 183047000 Fitting, 1/4-NPT 6 130066ooo Fitting, Plug, 1/4-NPT 7 183061000 Fitting, 1/4-NPT By 7/16-20 8 18[...]

75 312028000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Item No. Part No. Name 183449000 CO 2 Regulator Ass ’ y , 60-PSI, Orange (Includes 1-16) 183412000 CO 2 Regulator Ass ’ y , 100-PSI, Gold (Includes 1-16) 1 183040000 Machine Screw , Phil Fill Hd., No. 10-32 By 7/8-In. Long 2 183233059 Cover Kit (Includes Nonremovable Adjusting Screw) 3 1830[...]

76 312028000 1 2 3 4 5 6 7 8 9 10 11 1 2 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 3 4 6 6 7 8 8 8 9 10 11 11 11 12 13 14 15 16 18 18 18 18 19 18 20 21 22 23 24 25 FIGURE 25. BLENDER AND TUBING COMPONENTS Item No. Part No. Name Blender and Tubing Components 1 31701500 O-Ring, .239 I.D. By .070 C.S. 2 2657 Base 3 316963000 Bushing, 2-In. Dia. 4 24[...]

77 312028000 Item No. Part No. Name 2780 T ube Ass ’ y, Carb W ater Outlet 1 77060200 Fitting, Cross, 1/4-Barb 2 77050100 Fitting, Elbow , V alve 3 325012000 Shut-Of f V alve 4 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 5 176001000 Ferrule, .425 O.D. Tube 6 174103001 T[...]

78 312028000 Item No. Part No. Name 2779 T ube Ass ’ y, W ater Solenoid to Blender 1 31 1742000 Connector , Barb 2 176001000 Ferrule, .375 O.D. Tube 3 174103000 Tube, .250 I.D. By 1 1-In. Long 4 309854000 Clamp, .400 O.D. Tube 5 77900500 Turnaround, Barb 6 77040100 Fitting, Elbow , Swivel, 7/16-20 1 2 2 2 3 3 4 5 6 FIGURE 29. TUBING ASSEMBL Y (W [...]

79 312028000 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 FIGURE 32. SOLENOID V AL VE ASSEMBL Y Item No. Part No. Name 2486 Solenoid V alve Ass ’ y , W ater 2487 Solenoid V alve Ass ’ y , Syrup 1 2356 Block, V alve 2 1319 Body , V alve 3 0837 Thread Rolling Screw , Phil Pan Hd., No. 6-32 By 5/8-In. Long 4 31075401 1 Piston, W ater 31048001 1 Pis[...]

80 312028000 1 2 3 4 5 6 7 8 9 10 11 12 13 2 FIGURE 33. BLENDER COMPONENTS Item No. Part No. Name Blender Components 1 2625 Support, Blender 2 188206000 Thread Rolling Screw , Phil T russ Hd., No. 10-24 By 3/4-In. Long 3 3241 16000 W asher , .625 I.D. 4 324047000 T ank, Blender 5 186570000 Strain Relief 6 315925000 O-Ring, 1.609 I.D. By .139 C.S. I[...]

81 312028000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 7 7 16 FIGURE 34. CONTROL BOX AND DISPLA Y P ANEL COMPONENTS Item No. Part No. Name Control Box and Display Panel Components 1 326079000 Cable, Ribbon 2 326078000 P .C. Board, Display 3 2763 Housing, Display 4 2897 Hinge, Display 5 2895 Latch, Display 6 2704 Panel, Back, Display 7 31[...]

82 312028000 1 2 3 4 5 6 7 8 9 10 FIGURE 35. F ACEPLA TE ASSEMBL Y Item No. Part No. Name 326106000 Door , Freeze Cylinder Ass ’ y 1 325918000 Door , Freeze Cylinder 2 325954088 Relief V alve Ass ’ y 3 320678000 O-Ring, 4.60 I.D. By .210 C.S. 4 1557 V alve Head Ass ’ y (See Figure 36) Item No. Part No. Name 5 321652000 Shank Nut 6 325936000 S[...]

83 312028000 1 2 7 3 4 5 6 8 9 10 11 12 13 FIGURE 36. DISPENSING V AL VE ASSEMBL Y Item No. Part No. Name 1557 Dispensing V alve Ass ’ y 1 1556 Body and Shank 2 1554 V alve 3 1576 Housing 4 1575 Fitting 5 325305000 Spring 6 321651000 Lever , V alve 7 1555 Knob Item No. Part No. Name 8 325647000 Plate 9 317784000 Thread Cutting Screw , P hi l T ru[...]

84 312028000 Item No. Part No. Name Carbonator Components 1 2682 Bracket, Motor 2 320767000 Machine Screw , Phil Pan Hd., No. 10-24 By 3/8-In. Long 3 309854000 Clamp, .409 O.D. Tube 4 326136000 Carbonator T ank Ass ’ y (See Figure 40) 5 3159 Switch, Pressure 6 2833 Pump and Motor Ass ’ y , Domestic (See Figure 41) 2814 Pump and Motor Ass ’ y [...]

85 312028000 1 2 3 4 5 6 7 7 8 9 10 11 12 FIGURE 40. CARBONA TOR T ANK AND LINKAGE ASSEMBL Y Item No. Part No. Name 326136000 Carbonator T ank and Linkage Ass ’ y 1 326135000 T ank, Carbonator 2 317746000 Link, Pivot 3 317772000 Pin 4 318036000 Push-on Nut 5 317747000 Pivot Housing 6 317752000 Spring Item No. Part No. Name 7 318037000 Insulation,[...]

86 312028000 1 2 3 4 5 6 7 8 9 10 11 5 9 FIGURE 41. PUMP AND MOTOR ASS ’ Y Item No. Part No. Name 2833 Pump and Motor Ass ’ y , 230/220V . 60/50HZ (Domestic) 2814 Pump and Motor Ass ’ y , 230V . 50HZ (Export) 1 320626000 Motor , 230/220V . 60/50HZ (Domestic) 199020000 Motor , 230V 50HZ (Export) 2 312996000 Pump, W ater , 90GPH 3 178025100 T a[...]

87 312028000 1 2 2 3 4 5 6 FIGURE 42. BEA TER MOT OR DRIVE SHAFT/SEAL ASS ’ Y Item No. Part No. Name 3193 Rear Seal Ass ’ y 1 3156 Drive Shaft 2 2463 Bearing with Setscrews Item No. Part No. Name 3 2360 O-Ring, 1.86 I.D. By .139 C.S. 4 2583 Retaining Ring 5 2731 O-Ring, .671 I.D. By .139 C.S. 6 2591 Housing[...]

88 312028000 W ARRANTY 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 W ilshire product, in your country , please write, fax or telephone the IMI Cornelius of fice nearest you. Please provide[...]

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IMI CORNELIUS INC. CORPORA TE HEADQUARTERS: One Cornelius Place Anoka, Minnesota 55303-6234 (612) 421-6120 (800) 238-3600[...]