Page 2 - TABLE OF CONTENTS; Page
i 312028000 TABLE OF CONTENTS Page GENERAL DESCRIPTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL DESCRIPTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT DESCRIPTION 1 . . . . . ...
Page 8 - Warranty Registration Date; GENERAL DESCRIPTION; Height
1 312028000 GENERAL DESCRIPTION IMPORTANT: To the user of this manual – This manual is a guide for installing, operating, and maintainingthis equipment. Refer to Table of Contents for page location of information pertaining to questions that ariseduring installation, operation, service and maintenan...
Page 9 - Table 2. Accessories and Tools; THEORY OF OPERATION
2 312028000 Table 1. Design Data (cont’d) Refrigeration System: Compressor Horsepower 2 H.P. Refrigerant Type And Charge See Unit Nameplate Ambient Operating Temperature 40 ° F to 100 ° F Electrical Requirements: Operating Voltage See Unit Nameplate Operating Current See Unit Nameplate Table 2. Acce...
Page 10 - DISPENSER; DEFROST SYSTEMS; MANUAL DEFROST SYSTEM
3 312028000 Transparent faceplate, attached to the front of each freeze cylinder, includes a self-closing dispensing valve and aspring-loaded relief valve that protects freeze cylinder from accidental over pressure. The relief valve is also used tobleed CO 2 gas pressure from the freeze cylinder to ...
Page 12 - FIGURE 2. FLOW DIAGRAM
5 312028000 *WATER PRESSURE REGULATOR ISFACTORY ADJUSTED TO 45-PSI ANDSHOULD NOT BE READJUSTED. **SYRUP SOLD-OUT SWITCHES AREFACTORY ADJUSTED AND SHOULDNOT BE READJUSTED. PRODUCT BLENDER TANK(2) PRODUCT SAMPLE VALVE(2) SYRUP FLOW REGULATOR(2) CARBONATOR TANK PRODUCT SHUTOFF VALVE(2) CARBONATED WATER...
Page 13 - THIS PAGE LEFT BLANK INTENTIONALLY
Page 14 - INSTALLATION; UNPACKING AND INSPECTION; Item; IDENTIFICATION OF LOOSE-SHIPPED PARTS
7 312028000 INSTALLATION This section covers unpacking and inspection, installing Loose-Shipped Parts, selecting location, installing Unit,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 16 - CAUTION: Do not place or store anything on top of the Unit.; INSTALLING UNIT; INSTALLING LEVELING LEGS
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 twocondenser coil fans. Circulating...
Page 18 - CONNECTING CITY PLAIN WATER SOURCE LINE TO UNIT; Connect and route city plain water source line up to the Unit.; CONNECTING ELECTRICAL POWER CIRCUIT TO THE UNIT; Install the electrical box cover and secure with screws.
11 312028000 2. Connect the CO 2 source line to the Unit CO 2 inlet line. DO NOT TURN ON THE CO 2 SOURCE AT THIS TIME. CONNECTING CITY PLAIN WATER SOURCE LINE TO UNIT NOTE: The Units require connection to a city plain water source line with a minimum water pressure of12-psig. IMI Cornelius Inc. reco...
Page 19 - PREPARATION FOR OPERATION; IMPORTANT: The carbonator secondary CO
12 312028000 PREPARATION FOR OPERATION TURNING ON ELECTRICAL POWER TO UNIT Turn on electrical power to the Unit. Operational status of the Unit is now being displayed as fault messages onthe control panel message display. The following fault messages will be continuously displayed at 2-second inter-...
Page 21 - Repeat steps C and D preceding to check product sample for BRIX.; NOTE: Syrup systems may be sanitized at this time as instructed.; FILLING FREEZE CYLINDERS WITH PRODUCT; Inspect the entire Unit and the entire system for syrup, CO
14 312028000 B. Press ‘‘AUTO BLEND 1’’ switch to fill No. 1 system product blender tank with product. ‘‘FILL 1’’ faultmessage 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’’, ‘‘OFF 2’...
Page 22 - PLACING UNIT IN OPERATING LOCATION; IMPORTANT NOTICE; four leveling legs installed on the Unit during installation.; ADJUSTING BEATER MOTOR CURRENT (EITHER SIDE); Display should be adjusted to read A150 B150
15 312028000 PLACING UNIT IN OPERATING LOCATION IMPORTANT NOTICE The FCB Dispensers manufactured prior to the models documented in this manual wereelevated in the front (dispensing valve side) 1/4 to 3/8-inch higher than the back when placingthe Unit in operating position to eliminate gas pockets be...
Page 23 - AS INSTRUCTED. THEN, SWITCH MUST BE PLACED BACK IN THE ‘‘OFF’’ POSITION.; NOTE: The Unit control panel switches are as shown in Figure 3.; PROGRAMMING MAIN MENU SELECTION ONTO MESSAGE DISPLAY
16 312028000 CAUTION: IF NO. 4 ‘‘BEATER MOTOR CURRENT READOUT’’ SWITCH ON DIP SWITCHassembly is placed in ‘‘ON’’ position and beater motor current readings were A155 B145and switch was then placed back in ‘‘OFF’’ position without readjusting to A150 B150 ± 2, the beater motor current has just been r...
Page 24 - MENU SELECTIONS; MESSAGE DISPLAY; “TOTALS”; TABLE 4. MAIN MENU SELECTIONS; Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTION.; PROGRAMMING ‘‘DEFROST’’ (AUTOMATIC) SETTINGS INTO UNIT
17 312028000 MENU SELECTIONS MESSAGE DISPLAY (EXAMPLE READOUTS) “CLOCK” (TIME OF DAY) see note below C _ 1 2 - 0 0 A “DEFROST” (AUTOMATIC) 3 D 1 0 - 0 0 A “SLEEP” (SLEEP TIME) S 1 2 - 3 0 A _ “WAKE UP” (WAKE UP TIME) W _ 0 7 - 1 5 A “VIS SET” (PRODUCT VISCOSITY SETTING) 1 2 _ _ _ _ 1 0 “VIS READ” (A...
Page 25 - PROGRAMMING ‘‘SLEEP’’ (SLEEP TIME) INTO UNIT; SWITCH
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) INTO UNIT ‘‘SLEEP’’ (SLEEP TIME) may be programmed into Unit to occur ...
Page 27 - ADJUSTING “VIS SET” (PRODUCT VISCOSITY) OF DISPENSED PRODUCT; ) on message display indicates which set of numbers belongs to; ‘‘VIS READ’’ (ACTUAL VISCOSITY READOUT) OF PRODUCT IN FREEZE CYLINDERS
20 312028000 Three point of sales display messages are available and the desired one may be programmed in to appear on themessage display by placing No. 1 and No. 2 switches (see Figure 4, 5, and 7) on the DIP SWITCH ASSEMBLY inthe appropriate positions. ADJUSTING “VIS SET” (PRODUCT VISCOSITY) OF DI...
Page 28 - FIGURE 4. MASTER AND RELAY CIRCUIT BOARD
21 312028000 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 DIP SWITCH ASS’Y POINT OF SALE MESSAGE DISPLAY SELECT (See Table 7) BEATER MOTOR...
Page 29 - Press ‘‘ERROR RESET’’ switch two times to exit from MENU SELECTIONS.; PROGRAMMING COMPONENTS ‘‘DIAGNOSE’’ (DIAGNOSTIC MODE) INTO UNIT; ‘‘CLOCK’’ on display.
22 312028000 ‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) Displayed voltage readout may be displayed on message display as follows: 1. Refer to PROGRAMMING MENU SELECTIONS ON MESSAGE DISPLAY and bring up ‘‘VOLTAGE’’ (DISPLAYED VOLTAGE READOUT) on message display. 2. Press ‘‘DEFROST’’ (SELECT) switch to b...
Page 32 - PROGRAMMING PROPER REFRIGERANT TYPE INTO UNIT ELECTRONICS
25 312028000 ITEMS AFFECTED BY ERROR MESSAGE DISPLAYED ERROR BEATER MOTOR 1 BEATER 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 Two OFF OFF Motor 1 High Current > 255, Sensed on Motor One OFF OFF Motor 2 High C...
Page 33 - rate into the Dispenser electronics.; DISPLAYED ERROR CONDITIONS
26 312028000 1. Refer to PROGRAMMING MAIN MENU SELECTIONS ONTO MESSAGE DISPLAY and bring up “REF TYPE” (REFRIGERANT TYPE) on the message display. Press “DEFROST (SELECT) switch to lock in onthe selection. The sub menu of refrigerant types that may be brought up on the MESSAGE DISPLAY from“REF TYPE” ...
Page 34 - OPERATOR’S INSTRUCTIONS; supply, operators daily; CONTROL PANEL ASS’Y SWITCHES AND DISPLAYED MESSAGES; CONTROL PANEL ASS’Y SWITCHES; ‘‘FILL 1’’ and ‘‘FILL 2’’ Control Switches.
27 312028000 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 2 supply, operators daily cleaning of Unit, and sanitizing requiremen...
Page 35 - CONTROL PANEL ASSEMBLY DISPLAY MESSAGES
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 refrigerationsystem after cylinders h...
Page 36 - FREEZE CYLINDERS MANUAL OR AUTOMATIC DEFROST SYSTEMS
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 off 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...
Page 38 - ‘‘OVERRUN’’, AS APPLIED TO FROZEN CARBONATED BEVERAGES; gas; DRAWING 1
31 312028000 SYRUP FLOW REGULATORS 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 ...
Page 39 - IMPORTANT: The following CO
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 infrozen carbonated form of that drink. For example, drinks with 3.0 volume of carbonation will have more gasbreakout in ...
Page 40 - DAILY CLEANING
33 312028000 1. To 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 flowregulator, which may alter regulator adjustment. ...
Page 41 - ADJUSTMENTS
34 312028000 ADJUSTMENTS CARBONATED WATER FLOW RATE The carbonated water flow regulators (see Figure 2 and 12), which control carbonated water flow rate intoproduct blender tanks, are factory adjusted and normally do not require further adjustment. If adjustment shouldbecome necessary, adjust as ins...
Page 43 - gas could then back flow into the water system and create; CLEANING CO; The CO
36 312028000 PROGRAMMING FREEZE CYLINDERS BEATER “MOTORS” INTO UNIT ELECTRONICS Note in Table 6 “MOTOR SELECT” the number of freeze cylinders beater motors manufacturer ’s that are listed.Your Unit was manufactured and equipped with motors from one of these manufacturer ’s. A replacement freezecylin...
Page 44 - SERVICE AND MAINTENANCE; PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING; cylinder valve is fully opened and primary CO; TOP PANEL
37 312028000 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 attemptingany internal maintenance. Only qualified personnel should service internal components orelectrical...
Page 45 - FRONT ACCESS PANEL; OPENING AND CLOSING FRONT ACCESS DOOR; OPENING FRONT ACCESS DOOR; LUBRICATION; CARBONATOR WATER PUMP MOTOR; Servicing Dispensing Valves Caged O-Rings.
38 312028000 FRONT ACCESS PANEL Remove two screws securing front access panel, then remove panel and plastic spacers from the Unit. MAKESURE WHEN REINSTALLING THE FRONT ACCESS PANEL, TO REINSTALL THE PLASTIC SPACERS INBETWEEN THE PANEL AND THE UNIT FRAME. OPENING AND CLOSING FRONT ACCESS DOOR OPENIN...
Page 46 - FIGURE 5. OPERATING CONTROLS
39 312028000 CONTROL PANEL HIDDEN “SECURITY SWITCH” TOP PANEL TOP PANEL RETAININGSCREW (2) CONTROL PANEL FACEPLATE RELIEFVALVE (4) LOWER FRONTACCESS PANEL CUP REST DRIP TRAY SIDE PANEL (2) FAULT MESSAGE DISPLAY DISPENSING VALVE (2) FACEPLATE (2) BACK PANEL SIDE PANEL RETAINING SCREW VENTILATION LOUV...
Page 47 - FIGURE 6. UNIT INTERNAL COMPONENTS
40 312028000 RELIEF VALVE (2) PRODUCT BLENDER TANK (2) FREEZE CYLINDER (2) SECONDARY CO 2 REGULATOR (3) ACCUMULATOR CONDENSER COIL BEATER DRIVE MOTOR (2) REFRIGERATION COMPRESSOR FIGURE 6. UNIT INTERNAL COMPONENTS
Page 50 - tighten hold-down plates to secure spring housing.; CLEANING CONDENSER COIL; Periodically clean condenser coil as follows:; ADJUSTING PLAIN WATER PRESSURE REGULATOR; ounces per second and normally do not
43 312028000 15. Position SCRAPER BLADES (item 2) on BEATER (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). Turn beater to the right(clockwise) to lock in place. 16. Lubricate O-RING (item 5) with water to facili...
Page 51 - FIGURE 8. FREEZE CYLINDER CUTAWAY VIEW
44 312028000 1 Product Inlet Fitting 2 Scraper Blade (2) 3 Evaporator Coil 4 Relief Valve Port 5 O-Ring 6 Flatwasher (4) 7 Hex Nut (4) 8 Faceplate 9 Relief Valve 10 Valve Lever 11 Knob 12 Dispensing Valve 13 Beater 14 Allen Head Setscrew 15 Beater Shaft Coupling 16 Drive Pin 17 Bearing Housing Locki...
Page 52 - FIGURE 9. SERVICING BEATER MOTOR DRIVE SHAFT/SEAL ASSEMBLY
45 312028000 BEATER DRIVE MOTOR BEATER DRIVE MOTOR SHAFT ALLEN-HEAD SET SCREW COUPLING PLASTIC COUPLER COUPLING ALLEN-HEAD SET SCREW DRIVE SHAFT/SEAL ASS’Y BEATER DRIVE SHAFT LOCK RING BEARING ALLEN-HEAD SET SCREW (2) O-RING PLASTIC HOUSING O-RING SHAFT COUPLER DRIVE DRIVE COUPLER GAUGE, DRIVE/COUPL...
Page 53 - FIGURE 10. BEATERS AND SCRAPER BLADES INSTALLATION; from the product blender tank, then close the valve.
46 312028000 Key on Endof Post BEATER Key on End ofPost Key Slot on Blade Scraper blades must be mounted to the beater body asshown using the perforated edge as the leading edge.Line up key on end of posts with key slot in scraperblades. FIGURE 10. BEATERS AND SCRAPER BLADES INSTALLATION 1. Press ap...
Page 56 - PRODUCT CARBONATION ADJUSTMENT; IMPORTANT: Carbonator tank secondary CO; CLEANING AND SANITIZING; DAILY CLEANING OF UNIT
49 312028000 PRODUCT CARBONATION ADJUSTMENT (see Figures 2 and 6) Carbonation of dispensed product can also be varied to suit consumer preference by adjusting Unit carbonatorsecondary CO 2 regulator as follows: IMPORTANT: Carbonator tank secondary CO 2 regulator must be adjusted 25-psi higher or mor...
Page 59 - valve. This bleeds CO; YEARLY OR AFTER WATER SYSTEM DISRUPTION; gas could then back flow into the water system and create a health; SERVICING CARBONATOR WATER PUMP WATER STRAINER SCREEN; Disconnect electrical power from Unit.
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...
Page 60 - FIGURE 11. LIQUID CHECK VALVE ASSEMBLY; SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHECK VALVE; Disassemble each check valve as shown in Figure 11.
53 312028000 1 2 3 4 5 6 Index No Part No Name 1 317965000 Retainer 2 312196000 Spring 3 312419000 Ball 4 312415000 Washer, .300 I.D. 5 312418000 Quad Ring 6 317963000 Body *Install new ball seat each servicing. FIGURE 11. LIQUID CHECK VALVE ASSEMBLY SERVICING CARBONATOR WATER PUMP DOUBLE LIQUID CHE...
Page 61 - REPLENISHING SYRUP SUPPLY
54 312028000 10. Open CO 2 cylinder and water inlet supply lines shutoff valves. Check for water leaks and tighten any loose connections. 11. 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....
Page 63 - FIGURE 12. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK VALVE
56 312028000 SCREEN RETAINER O-RING (P/N 315349000) SCREEN (P/N 315348000) WATER PUMP MOTOR DOUBLE LIQUID CHECK VALVE ASS’Y WHITE TAPERED GASKET WATER PRESSURE SWITCH WATER PRESSURE REGULATOR WATER PUMP SYRUP SOLD-OUTFLOAT SWITCH (2) SYRUP SOLENOID VALVE (2) CARBONATED WATER FLOW REGULATOR (2) LIQUI...
Page 64 - GAS CHECK VALVE; REPLACING FREEZE CYLINDER BEATER DRIVE MOTOR
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 applicab...
Page 65 - ADJUSTING CARBONATOR TANK LIQUID LEVEL; adjustment is achieved.
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 ...
Page 66 - FIGURE 14. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT
59 312028000 RELIEF VALVE CARBONATED WATER TANK LEVEL CONTROL SWITCHES(2) SWITCHES ACTUATOR BRACKET ACTUATOR BRACKET ADJUSTMENT SCREW FIGURE 14. CARBONATOR LIQUID LEVEL CONTROL SWITCH ADJUSTMENT
Page 67 - FIGURE 15. REFRIGERATION FLOW DIAGRAM
60 312028000 HOT-GAS DEFROST SOLENOID VALVE ASS’Y (2) ELECTRONIC EXPANSION VALVE (2) FREEZE CYLINDER (2) EVAPORATOR STRAINER/DRYER ACCUMULATOR COMPRESSOR RECEIVER TANK CONDENSER COIL FAN ASS’Y FIGURE 15. REFRIGERATION FLOW DIAGRAM
Page 68 - FIGURE 16. WIRING DIAGRAM
Page 70 - TROUBLESHOOTING; Trouble
63 312028000 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 73 - TROUBLESHOOTING PRODUCT BLENDER TANKS AND CARBONATOR
66 312028000 Trouble Remedy Probable Cause MANUAL DEFROST CYCLEDOES NOT OPERATE WHEN‘‘DEFROST’’ SWITCH ISPRESSED. (cont’d) E. Master circuit board notoperating properly. E. Replace master circuit board. DEFROST CYCLE DOES NOTCANCEL AFTER PRESSING‘‘CANCEL DEFROST ’’SWITCH. A. Flat cable not properlyc...
Page 74 - TROUBLESHOOTING DISPENSED PRODUCT
67 312028000 Trouble Remedy Probable Cause CARBONATOR WATER PUMPWILL NOT SHUT OFF. A. Binding, damaged, or dirtycarbonated water tank balancemechanism. A. Clean, repair, or replace balancemechanism. ERRATIC CARBONATORWATER PUMP CYCLING. A. Insufficient water supplypressure. ‘‘H 2 O OUT’’ fault messa...
Page 76 - ILLUSTRATED PARTS BREAKDOWN
69 312028000 FCB OVERCOUNTER POST-MIX DISPENSERWITH V3+FEATURES(R-404A REFRIGERANT) 416136xxxx496136xxxx UNIT PART NUMBERS: ILLUSTRATED PARTS BREAKDOWN
Page 77 - FIGURE 17. OVERCOUNTER FCB POST-MIX DISPENSER
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 1...
Page 95 - WARRANTY; IMI Cornelius Offices
88 312028000 WARRANTY 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 orWilshire product, in your country, please write, fax or telephone the IMI ...
