Page 2 - TABLE OF CONTENTS; Page
i 326142000 TABLE OF CONTENTS Page GENERAL INFORMATION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL DESCRIPTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT DESCRIPTION 1 . . . . . ...
Page 8 - GENERAL INFORMATION; GENERAL DESCRIPTION
326142000 1 GENERAL INFORMATION IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, andmaintaining this equipment. Refer to Table of Contents for page location of information pertaining toquestions that arise during installation, operation, service and maintenan...
Page 11 - FIGURE 2. FLOW DIAGRAM
326142000 4 PRODUCT SAMPLE VALVE (2) PRODUCT SHUTOFFVALVE (2) FREEZE CYLINDER (2) SYRUP FLOW REGULATOR (2) PRODUCT BLENDER TANK (2) CARBONATOR TANK CO 2 PRESSURE SWITCH CO 2 CHECK VALVE SECONDARY CO 2 REGULATOR TO CARBONATOR TANKS (100-PSI) SECONDARY CO 2 REGULATORS TO PRODUCT BLENDER TANKS (60-PSI)...
Page 12 - INSTALLATION; UNPACKING AND INSPECTION; Item; IDENTIFICATION OF LOOSE-SHIPPED PARTS
326142000 5 INSTALLATION This section covers unpacking and inspection, installing LOOSE-SHIPPED PARTS, selecting location, installingUnit, preparing for operation, and operation. UNPACKING AND INSPECTION (see Figure 5) NOTE: The Unit was thoroughly inspected before leaving the factory and the carrie...
Page 13 - ELECTRICAL POWER REQUIREMENTS; DOMESTIC UNIT; IMPORTANT: Power circuit voltage across L
326142000 6 2. SPANNER WRENCH, FLOW REGULATORS (item 2) is used to adjust flow regulators inside Unit. 3. SPANNER WRENCH, DISPENSING VALVE (item 3) is used to remove shank nuts securing dispensing valves to faceplates. 4. CLEANING BRUSH (item 4) is used to clean faceplate relief valves passages. 5. ...
Page 14 - FIGURE 3. FREEZE CYLINDER CUTAWAY VIEW
7 326142000 1. Product Inlet Fitting 2. Scraper Blade (2) 3. Evaporator Coi.l 4. Relief Valve Port 5. O-Ring 6. Flatwasher (4) 7. Hex Nut (4) 8. Faceplate 9. Relief Va;ve 10. Valve Lever 11. Knob 12. Dispensing Valve 13. Beater 14. Drive Shaft Seal Assembly 15. Allen Head Setscrew 16. Beater Shaft C...
Page 15 - FIGURE 4. BEATERS AND SCRAPER BLADES INSTALLATION; EXPORT UNIT; SELECTING LOCATION
8 326142000 KEY ON END OF POST BEATER KEY ON END OF POST KEY SLOT ON BLADE SCRAPER BLADES MUST BE MOUNTED TO THEBEATER BODY AS SHOWN USING THE PERFO-RATED EDGE AS THE LEADING EDGE. LINE UPKEY ON END OF POSTS WITH KEY SLOT INSCRAPER BLADES. FIGURE 4. BEATERS AND SCRAPER BLADES INSTALLATION A properly...
Page 16 - INSTALLING UNIT; INSTALLING DRIP TRAY SUPPORTS, DRIP TRAY, AND CUP REST; INSTALLING PRIMARY CO; cylinder in
9 326142000 1. Close to a plain water inlet supply line with a minimum pressure of 12-psig. NOTE: Circulating air, required to cool the refrigeration system’s condenser coil, is drawn in throughgrille on front and exhausted out through sides and back of Unit. Restricting air circulation through theU...
Page 17 - CONNECTING SOFT DRINK TANKS CO
10 326142000 WARNING: 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 t...
Page 18 - CONNECTING ELECTRICAL POWER CIRCUIT TO UNIT; PREPARATION FOR OPERATION; 0 OR 60 HZ OPERATION AND BEATER MOTOR SELECT
11 326142000 CONNECTING ELECTRICAL POWER CIRCUIT TO UNIT (see Figure 17) WARNING: Make sure Unit 30-amp minimum-rated disconnect switch (not provided) orequivalent HACR circuit breaker is in ‘‘OFF’’ position. Domestic Unit. IMPORTANT: Power circuit voltage across L 1 and L 2 terminals on contactor i...
Page 19 - IMPORTANT: Carbonator secondary CO; TURNING ON PLAIN WATER SUPPLY TO UNIT
12 326142000 TURNING ON ELECTRICAL POWER TO UNIT Turn on electrical power to Unit. Operational status of Unit is now being displayed as fault messages on controlpanel message display. The following fault messages will be continuously displayed at 2-second intervals untilnecessary operation requireme...
Page 21 - NOTE: Syrup systems may be sanitized at this time as instructed.
14 326142000 NOTE: Syrup systems may be sanitized at this time as instructed. FILLING FREEZE CYLINDERS WITH PRODUCT 1. Open product shutoff valves, located in lines leading from product blender tanks to freeze cylinders. 2. Press ‘‘AUTO BLEND 1’’ and ‘‘AUTO BLEND 2’’ switches to begin filling freeze...
Page 22 - DISPLAYED ERROR CONDITIONS
15 326142000 ADJUSTING ‘‘VIS SET’’ (PRODUCT VISCOSITY) OF DISPENSED PRODUCT Adjust ‘‘VIS SET’’ (PRODUCT VISCOSITY) determines what product consistency of the dispensed product willbe present in each freeze cylinder. Adjust ‘‘VIS SET’’ (PRODUCT VISCOSITY) of the dispensed product asinstructed in SERV...
Page 24 - OPERATORS INSTRUCTIONS; CONTROL PANEL SWITCHES AND DISPLAYED MESSAGES; CONTROL PANEL SWITCHES
17 326142000 OPERATORS INSTRUCTIONS This section describes operating controls and indicators, dispensed product conditions, operatingcharacteristics, Unit operation, replenishing syrup supply, product flavor change, checking CO supply, operatorsdaily cleaning of Unit, and sanitizing requirements. WA...
Page 25 - CONTROL PANEL DISPLAY MESSAGES
18 326142000 ‘‘ERROR RESET’’ Control Switch. ‘‘ERROR RESET’’ control switch, located on control panel (see Figure 5), is a touch-type switch and requiresonly pressing to activate. ‘‘ERROR RESET’’ switch is used to restore normal operation after error within Unit(indicated by ‘‘ERROR 1’’ or ‘‘ERROR 2...
Page 26 - FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS
19 326142000 ‘‘DEFROST 1’’ or ‘‘DEFROST 2’’ Display Messages. ‘‘DEFROST 1’’ or ‘‘DEFROST 2’’ display messages will appear on message display if either freeze cylinder is indefrost mode. ‘‘DEFROST 1’’ or ‘‘DEFROST 2’’ messages will remain on during defrost cycle and will disappearwhen cycle has ended...
Page 27 - ‘‘OVERRUN’’, AS APPLIED TO FROZEN CARBONATED BEVERAGES
20 326142000 NOTE: Automatic defrost, sleep time, and wake up time may be used in any combination together orseparately. FACEPLATE RELIEF VALVES The faceplate relief valves (see Figure 5), located in each faceplate, are spring-loaded valves that protect freezecylinders from accidental over-pressure....
Page 28 - OPERATING CHARACTERISTICS
21 326142000 Overrun is a Variable. The percentage or degree of overrun depends on a number of factors. The specific syrup, BRIX, low dispensingvolume, carbonation level in liquid product, and freezing, all affect overrun. After these factors have beenconsidered, desired viscosity (product consisten...
Page 29 - OPERATING UNIT; REPLENISHING SYRUP SUPPLY; CHECKING CO
22 326142000 1. If some time has elapsed since last drink was drawn from particular freeze cylinder and compressor has not cycled on, the drink dispensed will have a tendency to be wetter, have slightly less overrun than normalfor the setting, and will not mound up as high. See Drawing 1. NOTE: A cy...
Page 32 - gas could then back flow into water system and create health; CLEANING CO
25 326142000 ‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) Displayed voltage readout may be displayed on message display as instructed in SECTION IV SERVICE ANDMAINTENANCE PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) INTO UNIT ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) may be programmed into the Unit to chec...
Page 34 - SERVICE AND MAINTENANCE; PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING; DRIP TRAY
27 326142000 SERVICE AND MAINTENANCE This section describes service and maintenance to be performed on the Unit. WARNING: Disconnect electrical power to Unit to prevent personnel injury beforeattempting any internal maintenance. Only qualified personnel should service internalcomponents or electrica...
Page 35 - LUBRICATION; CARBONATOR WATER PUMP MOTOR
28 326142000 LOWER FRONT ACCESS PANEL Remove two screws securing lower front panel, then pull panel down to remove from Unit. CONDENSER COIL ACCESS PANEL Pull out on top of condenser coil access panel, then lift panel up and out to remove. LUBRICATION CARBONATOR WATER PUMP MOTOR (see Figure 12) Carb...
Page 37 - FIGURE 5. OPERATING CONTROLS
Page 38 - FIGURE 6. UNIT INTERNAL COMPONENTS
Page 39 - FIGURE 8. SERVICING BEATER DRIVE SHAFT SEAL ASSEMBLY; CLEANING CONDENSER COIL
32 326142000 SPRING HOUSING TORSION SPRING SPRING FITTING DISPENSING VALVE BODY CAGED O-RING VALVE LEVER SLEEVE SPRING KNOB RETAINING SCREW(2) HOLD-DOWN PLATE(2) FIGURE 7. SELF-CLOSING DISPENSING VALVE STATIONARY O-RING STATIONARY O-RING PLASTIC SLEEVE ”RUNNING” O-RINGS STAINLESS STEEL SEAL RETAINER...
Page 40 - ADJUSTMENTS; ADJUSTING PLAIN WATER PRESSURE REGULATOR
33 326142000 1. Press ‘‘OFF 1’’ and ‘‘OFF 2’’ switches on Unit control panel to stop refrigeration system and beaters motors. 2. Remove condenser coil access panel as instructed. 3. Clean condenser coil with vacuum cleaner, low pressure compressed air, or a soft brush. 4. Install condenser coil acce...
Page 41 - IMPORTANT: Carbonator tank secondary CO
34 326142000 14. Repeat steps 11 through 13 until desired carbonated water flow rate is achieved. 15. Remove added length of line from outlet side of carbonated water flow regulator. Connect carbonated water line, disconnected from carbonated water flow regulator in step 8 preceding, to regulator ou...
Page 42 - PRODUCT CARBONATION ADJUSTMENT
35 326142000 ADJUSTING BRIX (WATER-TO-SYRUP) ‘‘RATIO’’ OF DISPENSED PRODUCT (see Figures 2 and 6) 1. Remove Unit front lower access panel as instructed for access to product blender tanks secondary CO 2 regulators and product sample valves. 2. Check product blender tanks secondary CO 2 regulators, w...
Page 43 - ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE); NOTE: The Unit control panel switches are as shown in Figure 9.
36 326142000 1. Remove Unit front lower access panel as instructed for access to carbonator secondary CO 2 regulator with 100-psi gage. 2. Observe pressure setting on carbonator secondary CO 2 regulator gage. 3. To lower CO 2 pressure, loosen regulator adjusting screw lock nut. Turn adjusting screw ...
Page 44 - PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY
37 326142000 HIDDEN SECURITY SWITCH MESSAGE DISPLAY FIGURE 9. CONTROL PANEL PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY The MAIN MENU SELECTIONS (see Table 4) may be brought up on the message display as follows: 1. Press ‘‘AUTO 1’’, ‘‘WASH 1’’, and ‘‘BLEND 1’’ control switches (see Figure 9...
Page 45 - PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT; PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT
38 326142000 1. Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up ‘‘CLOCK’’ on display. Press ‘‘DEFROST’’ (SELECT) switch to lock in on selection. 2. Press ‘‘CANCEL DEFROST’’ (ADVANCE) switch to bring up flashing hour number on display. 3. Press ‘‘CANCEL DEFROST’’ (ADVANCE)...
Page 46 - PROGRAMMING ‘‘WAKE UP’’ (WAKE UP TIME) INTO UNIT; FIGURE 10. MASTER AND RELAY CIRCUIT BOARDS
39 326142000 5. Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS. 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(return to normal operation) after ‘‘sleep time’’ has occurred. Pro...
Page 48 - ) on message display indicates which set of numbers belongs to; ‘‘VIS READ’’ (ACTUAL VISCOSITY READOUT) OF PRODUCT IN FREEZE CYLINDERS
41 326142000 PROGRAMMING POINT OF SALE MESSAGE DISPLAY (see Figure 7 and 10) Note: Point of sales display messages may be turned off by placing No. 1 and No. 3 switches on mastercircuit board (see Figure 10 and Tables 5 and 7) assembly in appropriate positions. Three point of sales display messages ...
Page 49 - PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) INTO UNIT
42 326142000 1. Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up ‘‘SENSORS’’ (TEMPERATURES READOUT)on message display. 2. Press ‘‘DEFROST’’ (SELECT) switch to bring up evaporator refrigeration coils inlet and common outlet temperature readings in degrees Fahrenheit. 3. Press ‘ERR...
Page 52 - CLEANING AND SANITIZING; DAILY CLEANING OF UNIT
45 326142000 DISPLAYING ‘‘TOTALS’’ (DISPLAYED CYCLES AND HOURS TOTALS) ONTO MESSAGEDISPLAY (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 ‘‘...
Page 55 - FIGURE 11. LIQUID CHECK VALVE ASSEMBLY; YEARLY OR AFTER WATER SYSTEM DISRUPTION); SERVICING CARBONATOR WATER PUMP WATER STRAINER SCREEN
48 326142000 36. 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. 37. Open No. 2 product blender tank product shutoff valve. 38. Press both ‘‘AUTO...
Page 56 - SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE
49 326142000 4. Remove lower front access panel and left-side panel as instructed for access to the water pump water strainer screen. 5. Pull up on carbonator tank relief valve plastic cover to release CO 2 pressure from tank. 6. Loosen screen retainer in water pump port, then remove screen retainer...
Page 57 - REPLENISHING CO
50 326142000 REPLENISHING SYRUP SUPPLY NOTE: Sugar free diet syrup cannot be used with this Unit. Although syrup replenishing can be done anytime, syrup supply must be replenished when either ‘‘SYRUP 1’’ or‘‘SYRUP 2’’ fault messages are displayed on message display indicating either No. 1 or No. 2 s...
Page 58 - SYRUP FLAVOR CHANGE
51 326142000 2. Slowly loosen CO 2 regulator assembly coupling nut allowing CO 2 pressure to escape, then remove regulator assembly from empty CO 2 cylinder. 3. Unfasten safety chain and remove empty CO 2 cylinder. 4. Position full CO 2 cylinder and secure with safety chain. WARNING: To avoid person...
Page 59 - FIGURE 12. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE
52 326142000 FIGURE 12. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE
Page 60 - GAS CHECK VALVE; REPLACING FREEZE CYLINDER BEATER DRIVE SHAFT BEARING; SHUTTING UNIT DOWN
53 326142000 CLEANING CO 2 GAS CHECK VALVES (see Figures 2 and 13) The CO 2 gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO 2 system. ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED. FI...
Page 61 - NOTE: Items in parentheses are in reference to Figure 3.; INSTALLING BEATER DRIVE SHAFT BEARING ASS’Y; FIGURE 14. BEATER DRIVE MOTOR AND SHAFT SEAL ASS’Y REPLACEMENT
54 326142000 NOTE: Items in parentheses are in reference to Figure 3. 5. Remove HEX NUTS (item 7) and FLATWASHERS (item 6) securing FACEPLATE (item 8) to freeze cylinder, then remove faceplate. 6. Remove beater shaft and scraper blades from inside freeze cylinder. 7. Pull beater drive shaft seal ass...
Page 63 - REPLACING FREEZE CYLINDER BEATER MOTOR
56 326142000 2. Sanitize syrup system as instructed in CLEANING AND SANITIZING. REPLACING FREEZE CYLINDER BEATER MOTOR (see Figure 6 and 14 ) NOTE: Use Beater Drive Shaft Assembly Alignment Tool Kit (P/N 0726) when installing beater driveshaft assembly. 1. Press ‘‘OFF 1’’ and ‘‘OFF 2’’ control switc...
Page 64 - ADJUSTING CARBONATOR TANK LIQUID LEVEL
57 326142000 ADJUSTING CARBONATOR TANK LIQUID LEVEL The carbonator tank liquid level (pump cut-in and cutout was adjusted at the factory and should require nofurther adjustment. However, if incorrect setting is suspected, check and make necessary adjustments asfollows: 1. Remove Unit back and side p...
Page 65 - FIGURE 15. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT
58 326142000 RELIEF VALVE CARBONATED WATER TANK LEVEL CONTROL SWITCHES(2) SWITCHES ACTUATOR BRACKET ACTUATOR BRACKET ADJUSTMENT SCREW FIGURE 15. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT
Page 66 - FIGURE 16. REFRIGERATION FLOW DIAGRAM
Page 67 - FIGURE 17. WIRING DIRGRAM
Page 68 - TROUBLESHOOTING
61 326142000 WARNING: If repairs are to be made to a product system, remove quick disconnects fromthe applicable product tank, then relieve the system pressure before proceeding. If repairsare to be made to the CO 2 system, stop dispensing, shut off the CO 2 supply, then relieve the system pressure ...
Page 71 - TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATORS
64 326142000 Trouble Remedy Probable Cause DEFROST CYCLE DOES NOTCANCEL AFTER PRESSING‘‘CANCEL DEFROST ’’SWITCH. A. Flat cable not properlyconnected to control switchmodule or master circuitboard. A. Properly connect flat cable tocontrols switch module or mastercircuit board. B. Flat cable connected...
Page 72 - TROUBLESHOOTING DISPENSED PRODUCT
65 326142000 Trouble Remedy Probable Cause ERRATIC CARBONATORWATER PUMP CYCLING. A. Insufficient water supplypressure. ‘‘H 2 O OUT’’ fault message goes on and offintermittently and water pumpcycles on and off duringcarbonator tank fill cycle. A. Increase water inlet supply linepressure. Water inlet ...
Page 77 - FIGURE 20. FCB FLOW DIAGRAM
326142000 70 4 5 6 7 8 11 12 14 15 79 84 85 87 88 115 117 118 4 FIGURE 20. FCB FLOW DIAGRAM
Page 85 - WARRANTY; IMI Cornelius Offices
326142000 78 WARRANTY IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship un-der normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire prod-uct, in your country, please write, fax or telephone the IM...
