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Installation/Service Manual

FCB POST-MIX DISPENSER

W/HOT-GAS DEFROST AND V4 ELECTRONICS

(DEFROST/ERROR INDICATOR LIGHTS)

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

Codes.

PRINTED IN U.S.A

IMI CORNELIUS INC

www.cornelius.com

Part No. 560001279SER

February 20, 2004

Revised: December 6, 2006

Revision: E

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION

This Manual must be read and understood before installing or operating this equipment

Summary of content (92 pages)

PAGE 1
IMI CORNELIUS INC www.cornelius.com Installation/Service Manual FCB POST-MIX DISPENSER W/HOT-GAS DEFROST AND V4 ELECTRONICS (DEFROST/ERROR INDICATOR LIGHTS) 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.
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TABLE OF CONTENTS SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECOGNIZE SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDERSTAND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOLLOW SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO2 (CARBON DIOXIDE) WARNING . . . . . . . . . . . . . . .
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CHECKING UNIT FOR SYRUP, CO2 AND PLAIN WATER LEAKS . . . . . . . . . . . ADJUSTING “WATER-COOLED” UNIT REFRIGERATION SYSTEM VARIABLE WATER REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS AND PROGRAMMING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . SETTING CLOCK (TIME OF DAY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROGRAMMING DEFROST (AUTOMATIC) INTO UNIT ELECTRONICS . . . . .
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‘‘FILL 1’’ AND ‘‘FILL 2’’ FAULT MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ‘‘ERROR 1’’ AND ‘‘ERROR 2’’ FAULT MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . ‘‘OFF 1’’ AND ‘‘OFF 2’’ FAULT MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ‘‘H2O OUT’’ FAULT MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ‘‘CO2 OUT’’ FAULT MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE CYLINDERS DRIVE SHAFT/ SEAL ASSEMBLIES . . . . . . . . . . . . . . . . . SERVICING DISPENSING VALVES CAGED O-RINGS. (SEE FIGURE 10) . . . . SERVICING FREEZE CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES. . . . . . CLEANING CONDENSER COIL (SEE FIGURE 23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT WITH AIR-COOLED REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . UNIT WITH WATER-COOLED REFRIGERATION SYSTEM . . . . . . . . . . . . . . .
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FIGURE 1. TWO–FLAVOR FLOOR MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FIGURE 2. TWO–FLAVOR OVERCOUNTER (OC2) UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FIGURE FIGURE FIGURE FIGURE FIGURE FIGURE FIGURE 3. FOUR–FLAVOR FLOOR MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. FLOW DIAGRAM. 3 H.P. DISPENSER (TWO–FLAVOR MODEL SHOWN) . . . . 5. FLOW DIAGRAM (2 AND 3 H.P. OVERCOUNTER OC2 DISPENSER) . . .
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SAFETY INFORMATION Recognize Safety Information This is the safety-alert symbol. When you see this symbol on our machine or in this manual, be alert to the potentially of personal injury. Follow recommended precautions and safe operating practices. Understand Signal Words A signal word - DANGER, WARNING, OR CAUTION is used with the safety-alert symbol. DANGER identifies the most serious hazards. Safety signs with signal word DANGER or WARNING are typically near specific hazards.
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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.
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UNIT DESCRIPTION 2 AND 3 H.P. TWO–FLAVOR OVERCOUNTER (OC2) UNITS The 2 and 3 H.P.
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FOUR–FLAVOR FLOOR MODEL The 2 H.P. Four–Flavor Floor Model FCB Dispenser (see Figure 3 and 4) consists basically of four freeze cylinders each containing an internal beater driven by an electric motor, two refrigeration systems, four product blender tanks, four carbonator tanks which feed the product blender tanks, a timer-controlled automatic hot-gas defrost system to defrost the freeze cylinders, and interconnecting tubing, components, and fittings necessary to regulate, transfer, and dispense product.
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Table 1. Design Data Unit Part Numbers: Two-Flavor 3 H.P. Floor Model (Air-Cooled), 230 VAC, 60 Hz Two-Flavor 3 H.P. Floor Model (Water-Cooled) 230 VAC, 60 Hz Two-Flavor 2 H.P. Overcounter (OC2) Air-Cooled 230 VAC, 60 Hz Two-Flavor 3 H.P. Overcounter (OC2) Air-Cooled (Top Condensing) 230 VAC, 60 Hz Two-Flavor 3 H.P. Overcounter (OC2) Water-Cooled 230 VAC, 60 Hz Four-Flavor 2 H.P.
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Table 2.
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THEORY OF OPERATION (see applicable Figure 4 or 5) A CO2 cylinder or a bulk CO2 supply delivers carbon dioxide (CO2) gas to an adjustable primary CO2 regulator assembly attached to the cylinder. The primary CO2 regulator assembly in turn delivers CO2 gas to an adjustable secondary CO2 regulators inside the Unit and also to the soft drink tanks. CO2 is delivered from the adjustable secondary CO2 regulator(s) to the carbonator tank(s) and also to the product-blender tanks inside the Unit.
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AUTOMATIC DEFROST SYSTEM NOTE: The following paragraph describes the Automatic Hot-Gas Defrost system operation for the Two-Flavor FCB Dispenser No. 1 and No. 2 freeze cylinders. This paragraph also describes the Automatic Hot-Gas Defrost system operation for the Four-Flavor FCB Dispenser No. 11 and No. 22 freeze cylinders, which is identical to the No. 1 and No. 2 freeze cylinders.
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PRODUCT SAMPLE VALVE(2) *WATER PRESSURE REGULATOR IS FACTORY ADJUSTED TO 45–PSI AND SHOULD NOT BE READJUSTED. **SYRUP SOLD–OUT SWITCHES ARE FACTORY ADJUSTED AND SHOULD NOT BE READJUSTED.
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*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.
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INSTALLATION This section covers unpacking and inspection, installing LOOSE-SHIPPED PARTS, selecting location, installing Unit, preparing for operation, and operation. UNPACKING AND INSPECTION NOTE: The Unit was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it. Any damage or irregularities should be noted at time of delivery (or not later than 15 days from date of delivery) and immediately reported to the delivering carrier.
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Table 3. Loose-Shipped Parts (Cont’d) Item No. Part No. Name Qty. OC2 Model Qty. Qty. (Air Cooled Top 4–FL Qty. 2–fl Floor Model OC2 Model Condensing) Model 14 3221 Front Access Panel 560003645 Front Access Panel X X 1 X X 1 X X 15 3108 X 2 X X 16 319941000 Thread Rolling Screw, Hex Washer Hd; No. 8-32 by 3/8-in.
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SELECTING LOCATION CAUTION: This Unit is intended for indoor installation only. Do not install this Unit in an outdoor environment which would expose it to the outside elements. IMPORTANT: Unit operating ambient temperature MUST NOT EXCEED 100° F. Operating ambient in excess of 100° F will automatically void the factory warranty and will eventually result in Unit failure.
PAGE 20
INSTALLING DRIP TRAY SUPPORTS Overcounter (OC2) Model 2 and 3 H.P. Units 1. Install DRIP TRAY SUPPORT, LEFT and DRIP TRAY SUPPORT, RIGHT (item 6) on front of the Unit and secure with THREAD CUTTING SCREWS (item 5). 2. Place DRIP TRAY (item 7) on drip tray supports. 3. Place CUP REST (item 4) in drip tray. Floor Model 3 H.P. Unit 1. Install DRIP TRAY SUPPORTS (item 6) on front of the Unit and secure with THREAD ROLLING SCREWS (item 16). 2. Place DRIP TRAY (item 7) on drip tray supports. 3.
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INSTALLING PRIMARY CO2 REGULATOR ASSEMBLY ON CO2 CYLINDER (see applicable Figure 4 or 5) WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder in upright position with a safety chain to prevent it from falling over. Should the valve become accidentally damaged or broken off, CO2 cylinder can cause serious personal injury. WARNING: CO2 displaces oxygen.
PAGE 22
Connecting City Plain Water Source Line to Unit Post-Mix System. (see applicable Figure 4 or 5) 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 4 or 5) that provides plain water to the Dispenser post-mix system. A Cornelius Water Filter (P/N 313860000) and Quick Disconnect Set (P/N 313867000) are recommended. 1.
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Electrical Requirements Refer to the nameplate to determine the power requirements before connecting electrical power to the unit. Voltage across contactor terminals L1 and L2, with the compressor running, must be within voltage limits described in Table .
PAGE 24
Overcounter (OC2) 2 and 3 H.P. Units. 1. Remove cover from electrical box located inside the Unit. WARNING: This Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator. A ground lug is located inside the electrical box to connect the power circuit ground wire which will electrically ground the Unit. 2.
PAGE 25
PREPARATION FOR OPERATION NOTE: Two-flavor Unit- The No. 1 freeze cylinder is the left-hand cylinder facing the front of the Unit. No. 2 freeze cylinder is to the right of the No. 1 freeze cylinder. Four-flavor Unit- The No. 1 freeze cylinder is the left-hand cylinder facing the front of the Unit. The other three freeze cylinders, to the right of the No.1 freeze cylinder, are labeled 2, 11, and 22.
PAGE 26
ADJUSTING CO2 REGULATORS (see applicable Figure 4 or 5) Adjusting CO2 Source Primary CO2 Regulator. Unit Connected to a Bag-In-Box Syrup Source System. Adjust CO2 source (CO2 cylinder or bulk CO2) primary CO2 regulator to read not less then 80 psi. Unit Connected to a Syrup Tanks Syrup Source System. Adjust CO2 source (CO2 cylinder or bulk CO2) primary CO2 regulator to read 80 to 100 psi. Adjusting Unit Secondary CO2 Regulators. Product Blender Tanks Secondary CO2 Regulators.
PAGE 27
ACTIVATING SYRUP SOURCE SYSTEM IMPORTANT: The product shutoff valves, located in the product lines leading from the product blender tanks to the freeze cylinders (see applicable Figure 4 or 5), must be closed at this time. Closing the valves prevents product from filling the freeze cylinders while checking BRIX of the product in the product blender tanks. 1.
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8. Repeat steps 5 through 7 preceding until proper BRIX adjustment is achieved. 9. Repeat steps 1 through 8 preceding to adjust BRIX of dispensed product on No. 2 system. After completing BRIX adjustment on No. 2 system, only the ‘‘OFF 1’’ and ‘‘OFF 2’’ fault messages should continue to be displayed. NOTE: Syrup systems should be sanitized at this time before putting Dispenser into operation. Refer to SERVICE AND MAINTENANCE section of this manual for sanitizing instructions.
PAGE 29
SETTING CLOCK (TIME OF DAY) NOTE: The CLOCK (TIME OF DAY) must be programmed into the Unit before “DEFROST” (AUTOMATIC), “SLEEP” (SLEEP TIME), and “WAKE UP” (WAKE UP TIME) can be programmed into the Unit. The time of day (hour AM or PM and minutes) and the day of the week may be programmed into the Unit electronics to appear on the message “DISPLAY” when desired. Refer to PROGRAMMING/ADJUSTMENTS section of this manual for programming instructions.
PAGE 30
“VIS READ” (ACTUAL VISCOSITY READOUT) OF PRODUCT IN FREEZE CYLINDERS “VIS READ” (ACTUAL VISCOSITY READOUT) may be displayed on the message “DISPLAY” to actually read the viscosity (product consistency) of product in the freeze cylinders while the Unit is in operation. Refer to PROGRAMING/ADJUSTMENTS section of this manual for instruction to display “VIS READ” (ACTUAL VISCOSITY READOUT) on the message display.
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“OPTIONS” (DIP SWITCHES 1 THROUGH 10) (see PROGRAMMING/ADJUSTMENTS section of this manual) The “OPTIONS” (DIP SWITCHES 1 THROUGH 10) are used to: 1. Program one of three POINT OF SALE display messages to appear on the message display. 2. Program one of three POINT OF SALE display messages to appear on the message display. 3. Program in applicable pulse expansion valves or mechanical expansion valves the Unit is equipped with. 4. To adjust beater motor current (either side). 5.
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DISPLAYED ERROR CONDITIONS Displayed error conditions, associated errors, and items affected by the errors may be found in Table 6. ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE) IMPORTANT: Any current adjustments or preventative maintenance current readings check on the beater motor current (either side) must be performed with both freeze cylinders fully defrosted. A partially defrosted freeze cylinder will cause false current readings to be displayed on the message display. 1.
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3. Use “MENU/SELECT” (M/S) switch to toggle to “DIP4 OFF” (beater motor current readout switch) which will appear on the message “DISPLAY”. 4. Use “CANCEL DEFROST” (FORWARD) switch to change “DIP4 OFF” to “DIP4 ON” on which will appear on the message “DISPLAY” (“DIP4 ON” will be flashing on the display). Press “ERROR RESET”. Both freeze cylinders beater motors will start and operate and beaters motors current ratings will be displayed on the message “DISPLAY”.
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MOTOR CURRENT ADJUSTMENT TOUCH SWITCH ASS’Y CABLE DISPLAY CABLE DIAMOND SYMBOL MASTER CIRCUIT BOARD RELAY CIRCUIT BOARD NO. 2 PIN CONNECTOR PERSONALITY MODULE RELAY CIRCUIT BOARD NO. 1 PIN CONNECTOR SOCKET CONNECTOR FIGURE 7. MASTER AND RELAY CIRCUIT BOARD DISPLAYED MODEL HZ MOTOR DESCRIPTION KLBER–60 Klauber 60 Over/under gear box with a GE wide-range voltage motor. FASV3+60 Fasco/VW 60 Over/under gear box with a Fasco wide-range voltage motor.
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PROGRAMMING/ADJUSTMENTS OPTIONS: (DIP SWITCHES 1 THROUGH 10) QUICK REFERENCE GUIDE FCB V4 PROGRAMMING BLEND ON/OFF ON ERROR SYRUP PRIME RESET ER MOTOR OFF ÍÍÍÍ ÍÍÍÍ DIP1 (POS MESSAGE) Used to program POINT OF SALE display messages into Unit electronics. DIP2 (POS MESSAGE) Used to program POINT OF SALE display messages into Unit electronics. DIP3 (EXPANSION VALVES) Display Side 1 Switch No. 3 must be in the “OFF” position for standard Units with pulse expansion valves. Switch No.
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ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ Defrost Same One Defrost Per Setting Time Every Day Press 5 seconds M/S CLOCK M/S M/S su FORWARD> CTU1015P mo SELECT HOUR AM OR PM M/S M/S 1MO 315A FORWARD> M/S SELECT DAY OF WEEK 1MO 415A FORWARD> M/S ER Operating mode ER SELECT HOUR AM OR PM 1MO 415A CTU1015P M/S LOCK FORWARD> SELECT MINUTES M/S FORWARD> SELECT DAY OF WEEK 1MO 315A CTU1015P ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ FORWARD> FORWARD> FORWA
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ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ One Sleep Per Setting Sleep Same Time Every Day M/S M/S FORWARD> su SELECT DAY OF WEEK FORWARD> mo LOCK M/S SMO SMO FORWARD> FORWARD> SMO 1200A SELECT HOUR SMO 1200A SELECT HOUR AM OR PM FORWARD> SMO 100A M/S SMO 100A SMO 100A SELECT MINUTES FORWARD> SMO 115A LOCK M/S ER Operating mode ER
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ÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍ ÍÍÍ ÍÍÍ ÍÍÍÍ >> FORWARD> << FORWARD> FORWARD> M/S ER Operating mode ER SELECT VISCOSITY NO. ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ VIS READ M/S ACTUAL VISCOITY READĆ OUT OF PRODUCT IN EACH FREEZE CYLINDER ER ÍÍÍ ÍÍÍ ÍÍÍ ÍÍÍ SENSORS M/S 35 78 123 M/S Operating mode VOLTAGE READOUT ER ER Operating mode VOLTAGE READOUT RIGHT-SIDE VISCOSITY BLINKING M/S
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ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ DIAGNOSE M/S MOTOR 1 M/S NO. 1 BEATER MOTOR WILL OPERATE WHILE SWITCH IS PUSHED ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍ FORWARD> MOTOR 2 M/S NO.
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ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ TOTALS M/S COMP HRS PRESS AND HOLD M/S, FOR ALL M/S ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ FORWARD> AUTO ON 2 COMPRESSOR RUN HOURS ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ FORWARD> COMP CYC M/S FORWARD> ERR HRS 1 COMPERSSOR CYCLES X 100 FORWARD> ERR HRS 2 DEFROST SIDE 1 CYCLES M/S FORWARD> SLEEP HRS DEFROST SIDE 2 CYCLES M/S M/S FORWARD> SYR MIN 1 BLENDER SIDE 1 CYCLES X 100
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ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ M/S MOT_1MFG1 M/S OPTIONS DIP 1 ON/OFF REPRESENTS NO.1 FREEZE CYLINDER BEATER MOTOR. M/S MANUFACTURERS NAME. ON ÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍ ÍÍÍÍ ÍÍÍ MOTOR NAME CHANGES TO ANOTHER MOTOR M/S ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ M/S MOT_MFG1 MANUFACTUREERS NAME AND WILL BE BLINKING.
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ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ LOCK IN MO DAY YR LOCK IN SELECT MONTH MO FRST/LST SELECT DAY FORWARD> FORWARD> MO FRST/LST SELECT YEAR M/S M/S ER LOCK IN FLASHING MO (MONTH) PUSH FORWARD TO SELECT MO (10) FLASHING FIRST/LAST PUSH FORWARD" TO SELECT "FIRST" 0R LAST" ER Operating mode ER ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ NOT FLASHING FORWARD> FORWARD> Operating mode PROGRAMMING STANDARD TIME (WINTER). DIP NO.
PAGE 43
OPERATOR’S INSTRUCTIONS This section describes operating controls and indicators, dispensed product conditions, operating characteristics, Unit operation, replenishing syrup supply, product flavor change, checking CO2 supply, operators daily cleaning of Unit, and sanitizing requirements. WARNING: Disconnect electrical power to the Unit to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring.
PAGE 44
2. Programmed Defrost Scheduling The control system in Cornelius FCB equipment includes a function to automatically defrost product in the barrel at programmed times. Programmed defrosts must be scheduled frequently to ensure that product quality within the barrel is maintained. Failure to defrost regularly during periods of low throughput will allow increased ice crystal growth, with a possible decrease in product quality.
PAGE 45
FOUR–FLAVOR UNITS NOTE: Four indicator lights are located on front of the Unit front access door (see Figure 8). The indicator light on the left side monitors conditions of the No. 1 freeze cylinder and the indicator light on the right side monitors conditions on the No. 2 freeze cylinder. A flashing red indicator light indicates a freeze cylinder is in the defrost mode. A flashing green indicator light indicates “OUT OF SYRUP”, “OUT OF WATER”, “OUT OF CO2”, or an “ERROR” condition has occured.
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‘‘SYRUP PRIME’’ SWITCHES The ‘‘SYRUP PRIME’’ switches, located on the control panel, are touch-type switches and require only pressing to activate. The ‘‘SYRUP PRIME’’ switches are used only when filling the syrup systems sold-out floats during syrup replenishing, syrup flavor changeover, or sanitizing the syrup systems. ‘‘BLEND ON/OFF’’ SWITCHES The ‘‘BLEND ON/OFF” switches, located on the control panel, are touch-type switches and require only pressing to activate.
PAGE 47
CONTROL PANEL DISPLAY MESSAGES ‘‘FILL 1’’ and ‘‘FILL 2’’ FAULT MESSAGES ‘‘FILL 1’’ and ‘‘FILL 2’’ fault messages will appear on the message display only after the “SYRUP PRIME” switches have been pressed and the syrup systems sold-out floats have been filled with product. ‘‘FILL 1’’ and ‘‘FILL 2’’ fault messages will continue to be displayed until the “BLEND ON/OFF” switches have been pressed to fill the product blender tanks with product.
PAGE 48
DEFROST SYSTEMS NOTE: The automatic defrost, “SLEEP” (SLEEP TIME), and “WAKE UP” (WAKE UP TIME) should be programmed into the Unit electronics by a qualified Service Person. The Units are equipped with both manual and automatic hot-gas defrost systems. The automatic defrost system may be programmed into the Unit to occur up to nine different times a day with a minimum of two hours between defrost time settings or the system may be completely turned off. MANUAL DEFROST SYSTEM Two-Flavor FCB Dispenser.
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FACEPLATE RELIEF VALVES The faceplate relief valves, located in each freeze cylinder faceplate (see Figure 11), are spring-loaded valves that protect the freeze cylinders from accidental over-pressure. The relief valve is also used to manually bleed CO2 gas from the freeze cylinder to atmosphere during filling with product and if gas pockets form in the cylinder during operation.
PAGE 50
Specific Product Ingredients Affect Overrun. Each syrup has its own specific formulation of makeup. Baume, an important ingredient factor, may fall within an extremely wide range. Fruit flavors contain citric acids that colas do not. Colas also differ in ingredients from one brand to another. Each product formulation has its own peculiarities regarding the way the product will absorb carbonation and the way it will release carbonation. BRIX Affects Overrun.
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OPERATING CHARACTERISTICS The product viscosity (product consistency) can be varied by adjustment and secondary CO2 regulator setting from a high overrun light drink to a wet heavy drink. The length of the freezing cycle and the amount of CO2 present in the product combine to create the drink dispensed. The dispensed product will have a normal variance due to the following conditions: 1.
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ADJUSTING BRIX (WATER-TO-SYRUP “RATIO”) OF DISPENSED PRODUCT BRIX is the Water-to-Syrup “Ratio” of the dispensed product and should be periodically checked and if necessary, be adjusted by a qualified Service Person. REPLENISHING SYRUP SUPPLY NOTE: Sugar-free diet syrup cannot be used with this Unit. Although syrup replenishing can be done anytime, the syrup supply must be replenished when either the ‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages are displayed on the message display indicating either No.
PAGE 53
SERVICE AND MAINTENANCE This section describes service and maintenance to be performed on the Unit. WARNING: Disconnect electrical power to Unit to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring. PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING CAUTION: Before shipping, storing, or relocating Unit, syrup systems must be sanitized and all sanitizing solution must be purged from syrup systems.
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OPENING AND CLOSING FRONT ACCESS DOOR TWO–FLAVOR MODELS AND OVERCOUNTER (OC2) MODELS 1. Pull out on bottom right side of the front access door to disengage it’s latch, then open door to the left. 2. Close the front access door by carefully pushing the door shut until it’s latch engages. FOUR–FLAVOR FLOOR MODEL 1. Pull out on bottom of the front access door to disengage it’s latch, then lift door up to open.. 2. Close the front access door by carefully lowering the door the until it’s latch engages.
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13. If adjustment is necessary, turn the carbonated water flow regulator adjusting screw to the left (counterclockwise) to reduce carbonated water flow rate or turn the screw to the right (clockwise) to increase the flow rate. 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.
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SERVICING DISPENSING VALVES CAGED O-RINGS AND FREEZE CYLINDERS DRIVE SHAFT/ SEAL ASSEMBLIES SERVICING DISPENSING VALVES CAGED O-RINGS. (see Figure 10) NOTE: Dispensing valves caged O-Rings should be serviced (lubricated) every six months and O-Rings should be replaced once a year. 1.
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6. Wash all parts in warm water. Remove all traces of syrup and lubricant, especially from faceplate, O-rings, and dispensing valve. If parts are excessively coated, wipe clean with paper towel to remove syrup and lubricant, especially from caged O-ring and dispensing valve. Use BRUSH (provided with the Unit) to clean the faceplates relief valve passages. 7. Submerge all parts in 4-percent solution of approved sanitizing agent for time recommended by the sanitizer manufacturer. 8.
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C. Install spring fitting, knob and lever parts, torsion spring, and spring housing assembly by reversing removal procedure. Do not tighten down hold-down plates securing spring housing at this time. 10. Thoroughly clean RELIEF VALVE (item 9), then screw relief valve into FACEPLATE (item 8). 11. Proceed to SERVICING FREEZE CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES. SERVICING FREEZE CYLINDERS DRIVE SHAFT/SEAL ASSEMBLIES.
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BEATER KEY ON END OF POST 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 12. BEATERS AND SCRAPER BLADES INSTALLATION 15. Position SCRAPER BLADES (item 2) on BEATER (item 13) as shown in Figure 12. Slide beater into freeze cylinder so slotted hooks engage DRIVE PIN (item 16) on DRIVE SHAFT (item 21) as shown in Figure 9.
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BEATER DRIVE MOTOR DRIVE SHAFT/SEAL ASS’Y BEATER DRIVE MOTOR SHAFT BEATER ALLEN-HEAD SET SCREW COUPLING PLASTIC COUPLER PIN ALLEN-HEAD SET SCREW COUPLING DRIVE COUPLER DRIVE COUPLER DRIVE SHAFT GAUGE, DRIVE/COUPLER (ITEM 10) PLASTIC HOUSING LOCK RING O-RING BEARING O-RING SHAFT ALLEN-HEAD SET SCREW (2) DRIVE SHAFT/ SEAL ASSEMBLY FIGURE 13.
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CLEANING CONDENSER COIL (SEE FIGURE 23) UNIT WITH AIR-COOLED REFRIGERATION SYSTEM NOTE: Circulating air, required to cool the refrigeration system condenser coil, is drawn in through louvers on front and exhausted out through louvers on sides and back of Unit. Restricting air circulation through Unit will decrease its cooling efficiency. Periodically clean condenser coil as follows: 1. Press ‘‘OFF 1’’ and ‘‘OFF 2’’ switches on Unit control panel to stop refrigeration system and beaters motors. 2.
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5. Close No. 2 product blender tank product shutoff valve to prevent product bleeding back into No. 1 product blender tank during sanitizing procedure. 6. Press SIDE 1 “BLEND ON/OFF” switch to prevent more product from entering the product blender tank. 7. Place waste container under No. 1 cylinder dispensing valve nozzle. Open dispensing valve and dispense all product from the freeze cylinder and the product blender tank.
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18. Press SIDE 1 “BLEND ON/OFF” switch to prevent more sanitizing solution from entering the product blender tank. 19. Place waste container under No. 1 dispensing valve nozzle. Open the dispensing valve and dispense all sanitizing solution from the freeze cylinder. As sanitizing solution level lowers in the freeze cylinder, partially close the valve to avoid spurting. 20. Place waste container under the No. 1 product blender tank product sample valve.
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29. Syrup Tank System. A. Disconnect empty syrup tank from No. 1 syrup system. B. Connect syrup tank containing syrup into No. 1 syrup system. Bag-in-Box Syrup System. A. Remove empty bag-in-box connector from No. 1 syrup pump syrup inlet line. B. Connect No. 1 syrup pump syrup inlet line to bag-in-box containing syrup. 30. Press SIDE 1 “SYRUP PRIME” switch to fill No. 1 syrup system syrup float switch with syrup. 31. Press SIDE 1 ‘‘BLEND ON/OFF’’ switch to fill No. 1 product blender tank with product.
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NOTE: A strainer screen should always be used otherwise particles could foul the double liquid check valve. 10. Install good or new strainer screen in the screen retainer, then screw the screen retainer into the water strainer port and tighten securely. 11. Proceed to SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE. REPLACING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE (see applicable Figure 4 or 5 and 14 or 15) 1.
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O-RING (P/N 315349000) DOUBLE LIQUID CHECK VALVE ASS’Y SCREEN RETAINER SCREEN (P/N 315348000) WHITE TAPERED GASKET WATER PUMP MOTOR WATER PUMP WATER PRESSURE REGULATOR WATER PRESSURE SWITCH FIGURE 15. DOUBLE LIQUID CHECK VALVE AND WATER STRAINER SCREEN (OVERCOUNTER OC2 UNIT) ADJUSTING CARBONATOR TANK LIQUID LEVEL The carbonator tank liquid level (pump cut-in and cutout) was adjusted at the factory and should require no further adjustment.
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REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR (SEE FIGURE13) IMPORTANT: Note in TABLE 7. MOTOR SELECT the number of freeze cylinders beater drive motors manufacturers that are listed. Your Unit was manufactured and equipped with freeze cylinders beater drive motors from one of these manufacturers. The replacement freeze cylinder beater drive motor is also manufactured by one of these manufacturers listed. WHEN REPLACING ONE OF THE BEATER MOTORS, NOTE THE MANUFACTURER’S NAME ON THE MOTOR.
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REPLENISHING SYRUP SUPPLY SYRUP TANKS SYSTEM NOTE: Sugar-free diet syrup cannot be used with this Unit. Although syrup replenishing can be done anytime, the syrup supply must be replenished when either the ‘‘SYRUP 1’’ or ‘‘SYRUP 2’’ fault messages are displayed on the message display indicating either No. 1 or No. 2 syrup system syrup tank is empty. NOTE: The following instructions are applicable only when replenishing the syrup supply. Refer to SYRUP FLAVOR CHANGE when changing syrup flavors. 1.
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To connect syrup tank into the Unit syrup system. First, connect CO2 quick disconnect to the syrup tank to pressurize the tank. Second, connect liquid quick disconnect to the syrup tank. 2. Disconnect inlet (CO2) and outlet (syrup) lines from the empty syrup tank. 3. Check syrup tank quick disconnects for sticky or restricted operation. Rinse the disconnects in warm water. 4. First, pressurize the full syrup tank by connecting CO2 line to the tank, then connect the Unit syrup inlet line to the tank. 5.
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REPLENISHING CO2 SUPPLY The Unit may be connected to either a bulk CO2 supply or to a CO2 cylinder. If your Unit is connected to a CO2 cylinder, proceed as follows to replenish the CO2 supply. RELIEF VALVE CARBONATED WATER TANK SWITCHES ACTUATOR BRACKET LEVEL CONTROL SWITCHES(2) ACTUATOR BRACKET ADJUSTMENT SCREW FIGURE 17. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT WARNING: CO2 displaces oxygen.
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1. Fully close (clockwise) CO2 cylinder valve. 2. Slowly loosen the primary CO2 regulator assembly coupling nut allowing CO2 pressure to escape, then remove regulator assembly from empty CO2 cylinder. 3. Unfasten safety chain and remove empty CO2 cylinder. 4. Position full CO2 cylinder and secure with safety chain. WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder in an upright position with safety chain to prevent it from falling over.
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FIGURE 19. WIRING DIAGRAM (3 H.P.
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FOR MODELS: 416126-XXX1 496126-XXX1 FIGURE 20. WIRING DIAGRAM (2 AND 3 H.P.
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FOR MODELS: 416126-XXX1 496126-XXX1 FIGURE 21.
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FOR MODELS: 416126-XXX1 496126-XXX1 FIGURE 22.
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ELECTRONIC EXPANSION VALVE (2) HOT-GAS DEFROST SOLENOID VALVE ASS’Y (2) FREEZE CYLINDER (2) EVAPORATOR STRAINER/DRYER ACCUMULATOR CONDENSER COIL FAN ASS’Y COMPRESSOR RECEIVER TANK NOTE: One refrigeration system is shown in this illustration. A two-flavor Unit has one refrigeration system. A four–flavor Unit has two refrigeration systems. FIGURE 23.
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ELECTRONIC EXPANSION VALVE (2) HOT GAS DEFROST 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.
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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 CO2 system, stop dispensing, shut off the CO2 supply, then relieve the system pressure before proceeding.
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Trouble Probable Cause ALL CONTROL PANEL A. SWITCHES NOT OPERATING. Electric power disconnected from Unit. Remedy A. Restore electric power to Unit. B. Control panel security enabled. B. Press and hold any one of the control panel switches for 5-seconds to override the control panel security. Control panel security will return 90-seconds after switches have not been pressed. C. Flat cable not properly connected to control switch module or master circuit board. C.
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Trouble ALL FAULT MESSAGES NOT OPERATING OPERATING. Probable Cause Remedy A. No electrical power to Unit. A. Connect electrical power to Unit. B. Flat cable not properly connected to fault message module or master circuit board. B. Properly connect flat cable to fault message module or master circuit board. C. Flat cable connected between fault message module and master circuit board pinched and shorted out or broken wire in cable. C.
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Trouble Probable Cause Remedy UNIT DOES NOT GO OFF AUTOMATIC DEFROST CYCLE. A. Automatic defrost timer stuck in automatic defrost cycle. A. Replace master circuit board. MANUAL DEFROST CYCLE DOES NOT OPERATE WHEN ‘‘MANUAL DEFROST’’ SWITCH IS PRESSED. A. Flat cable not properly connected to control switch module or master circuit board. A. Properly connect flat cable to control switch module or master circuit board. B.
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Trouble Probable Cause Remedy TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATORS CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE. A. No electrical power to Unit. A. Connect electrical power to Unit. Check power source. B. ‘‘BLEND ON/OFF’’ switches have not been pressed. B. Press ‘‘BLEND ON/OFF’’ switches. C. ‘‘H2O OUT’’ fault message is on. C. Restore water supply to Unit. D. ‘‘CO2 OUT’’ fault message is on. D. Restore CO2 supply to the Unit. E. Loose or broken electrical wires. E.
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Trouble BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ TOO HIGH. IMPROPER PRODUCT DISPENSED. Probable Cause A. Syrup flow regulators set too high. A. Adjust BRIX of dispensed product as instructed. B. Water flow regulator set too low. B. Water flow regulator must be set for 1.3 ± 0.05 oz/sec. C. Water flow regulator stuck. C. Clean regulator. D. Syrup Baume not in proper range. D. Change syrup supply as instructed. E. Restricted water filter. E. Replace water filter. A.
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Trouble Probable Cause Remedy TROUBLESHOOTING REFRIGERATION SYSTEM UNIT EQUIPPED WITH AIR-COOLED REFRIGERATION SYSTEM A. Dispenser refrigeration system overheating. A. Clean Unit condenser coil as instructed (see NOTE below) NOTE: The Dispenser condenser coil must be periodically cleaned to maintain proper cooling of the refrigeration system. UNIT EQUIPPED WITH WATER-COOLED REFRIGERATION SYSTEM A. Water supply to refrigeration cooling coil assembly disruppted. A.
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WARRANTY IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire product, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number, serial number and the date of purchase. IMI Cornelius Offices Locate your local office on www.cornelius.com under the contact menu.
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APPENDIX A VALVE TORQUE AND STAKING IMI Cornelius provided Service Bulletin number TSB–06–3 concerning the proper torquing and staking of FCB equipment using the Delta stainless steel dispensing valve. The procedures in the Service Bulletin ensured that the shank nut used to retain the Delta dispensing valve to the faceplate was tightened to the correct torque and then staked so that the shank nut could not be dislodged.
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2. Remove splash panel. 3. Remove nut and plastic pieces from rear of faceplate to obtain unobstructed access to shank nut. Do this for BOTH Motorman and Delta type valves (Delta not shown).
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Motorman Valve 1. Attach one nut finger tight to bottom, right of Barrel #1. Attach Faceplate to bottom, left of Barrel #2, as shown, with top edge of faceplate resting on first nut. Attach second nut finger tight to faceplate to hold it in place. 2. Place special spanner socket in two slots on shank nut, making sure slots are fully engaged. Tighten shank nut, as shown, with torque wrench and socket. Torque wrench setting is 10 lb–ft (or 120 lb–in).
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3. After applying torque, inspect the threads and shank nut to ensure proper thread engagement. Motorman Shank Nut This is what the Motorman shank nut clearance should look like. S Shank nut surface 0.1965 below valve shank surface.
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Delta Valve 1. Rotate faceplate, as shown, with valve facing barrel. Attach faceplate to two studs with nuts finger tight. This holds assembly in place for applying torque to shank nut. 2. Place special spanner socket in two slots on shank nut, making sure slots are fully engaged. Tighten shank nut, as shown, with torque wrench and spanner socket. Torque wrench setting is 10 lb–ft (or 120 lb–in). Socket part number is 620711709. NOTE: Do not use any other tool or method to tighten the shank nut.
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3. After torquing shank nut locate hammer and punch. The faceplate must be removed from the unit and secured to sustain impact from staking. NOTE: This procedure is used for the stainless steel Delta valve only. DO NOT use on plastic Motorman valve threads. 4. Place point of punch in slot on shank nut right against valve threads. 5. Strike end of punch with hammer.
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6. After applying torque and performing staking (stainless steel valve threads only) inspect the threads and shank nut to ensure proper thread engagement. Delta Shank Nut This is what the Delta shank nut clearance should look like. S Shank nut surface 0.1025 below valve shank surface. Shank Nut Surface Valve Shank Surface Staking mark on threads inside notch in shank nut.