FCB V3+ AND V4 TRAINING MANUAL

Transcription

1 FCB V3+ AND V4 TRAINING MANUAL Publication Number: TP00886 Revision Date: February 20, 2004 Revision: A

2 FCB V3+ and V4 TRAINING MANUAL The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met, in addition to the information contained in this manual. To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact: IMI Cornelius Inc. Corporate Headquarters One Cornelius Place Anoka, MN U.S.A. Internet: In the U.S.A.: phone: FAX: Outside the U.S.A.: phone: FAX: Trademarks and copyrights: Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, and Vista are registered trademarks of IMI Cornelius. Optifill trademark is pending. This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius. Printed in U.S.A. Copyright , All Rights Reserved, IMI Cornelius Inc.

3 NOTES: , IMI Cornelius Inc

4 TABLE OF CONTENTS SAFETY... 1 Safety Instructions... 1 Read and follow all safety instructions... 1 Recognize safety alerts... 1 Different types of alerts... 1 Safety Tips... 1 Authorized Service Personnel... 2 CO2 (Carbon Dioxide) Warning... 2 Shipping And Storage... 2 INTRODUCTION... 3 Preview Questions... 3 Key Things To Know / Do... 4 Overview... 5 Product Description... 5 Theory of machine operation... 5 Key components and features... 5 Dimensions & Weight... 7 FCB V4, 2 Flavor:... 7 FCB V4, 2 Flavor Over Counter:... 7 FCB V4, 4 Flavor Over Counter:... 7 FCB V4, 4 Flavor Remote:... 7 FCB V3 Plus, 4 Flavor:... 7 SYSTEM DETAILS... 8 Carbon Dioxide... 8 Water... 8 Syrup BRIX Procedure Mechanical Blender Freeze Cylinder Defrost System FCB V3+ and V4 - Hot Gas Defrost - Programmed FCB Manual Defrost Refrigeration System Controls and Electrical Sensors FCB V4 Control Panel FCB V3+ Control Panel APPENDIX Appendix A Installation Checklist Appendix B Recommended FCB Settings Appendix C Startup Procedures Appendix D Product Overrun Appendix E Water Supply Test Procedure Appendix F Water Flow Control Test Procedure Appendix G Zeroing-Out Error Totals Appendix H Plumbing Diagrams Appendix I Logic Flow Diagrams Appendix J Wiring Schematics , IMI Cornelius Inc.

5 Appendix K Wire Color Legend & Terminations Appendix L FCB V4 / V3+ Board Layout Appendix M Ribbon Connector / Control Panel Pinouts Appendix O V4 / V3+ Electrical Components Operating Characteristics Appendix P Chip Change Procedure Appendix Q Message Trouble Shooting Appendix R System Errors & Messages Displayed Error Conditions Appendix S Leveling Routine Appendix T Preventative Maintenance Checklist Appendix U Syrup Pressure Switch Test & Adjustment Procedure Appendix V Water Flow Appendix W Maintaining Product Quality Cornelius FCB Equipment - Operator Instructions Dispensed Product Throughput Dispensed product throughput matrix Programmed Defrost Scheduling Viscosity Setting NOTES: , IMI Cornelius Inc

6 SAFETY 1. SAFETY INSTRUCTIONS 1.1 Read and follow all safety instructions Read and follow all safety instructions in this manual and on the machine (decals, labels, and laminated cards). Read and understand all applicable OSHA (Occupation Safety and Health Administration) safety regulations before operating the machine. 1.2 Recognize safety alerts This is the safety alert symbol. When you see it in this manual or on the machine be alert to the potential of personal injury, or damage to the machine. 1.3 Different types of alerts There are three types of safety alerts: DANGER Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death, or equipment damage. WARNING Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or equipment damage. CAUTION Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or equipment damage. 2. SAFETY TIPS Carefully read all safety messages in this manual and safety signs on the machine. Keep safety signs in good condition and replace missing or damaged safety signs. Learn how to operate the machine and how to use the controls properly. Do not let anyone operate the machine without proper training , IMI Cornelius Inc.

7 Keep your machine in proper working condition and do not allow unauthorized modifications to the machine. 3. AUTHORIZED SERVICE PERSONNEL CAUTION Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. 4. CO 2 (CARBON DIOXIDE) WARNING WARNING CO 2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO 2 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. Personnel exposed to high concentration of CO 2 gas will experience tremors which are followed rapidly by loss of consciousness and death. 5. SHIPPING AND STORAGE CAUTION Before shipping, storing, or relocating the unit, syrup systems must be sanitized and all sanitizing solution must be purged from the syrup systems. All water must also be purged from the plain and carbonated water systems. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the unit to freeze resulting in damage to the internal components , IMI Cornelius Inc

8 INTRODUCTION 1. PREVIEW QUESTIONS Check your current knowledge by taking a few minutes to answer the following questions: 1. Can FCB units be either defrost or refrigeration priority? 2. List the voltage of the water solenoid, syrup solenoid, pulse valve, and hot gas valve. 3. Explain three reasons why defrosting is necessary: 4. What is the beater motor current setting? 5. Why is the water inlet regulator necessary? 6. List three things that contribute to drink quality: , IMI Cornelius Inc.

9 2. KEY THINGS TO KNOW / DO Viscosity settings, carbonator pressure, and BRIX settings all have an effect on drink quality. Beater motor current should always be set at 150. There are two motor boards; they are not interchangeable. A two-flavor unit requires 100 GPH inlet water flow. A four-flavor requires 200 GPH inlet water flow. When replacing a master board you must program the motors and compressors/refrigerant before going through your start up procedure. Blender water inlet flow must be set at 1.3 oz per second. Always set the BRIX at the sample valves, not at the cylinder. Always use Dow Corning 111 when lubricating the O-rings on a FCB unit. If you reset the carbonator pressure, check the BRIX and adjust as necessary. Check the syrup sold-out switch and adjust as necessary after setup, PMs, and product related service calls (see Appendix for procedure) , IMI Cornelius Inc

10 3. OVERVIEW 3.1 Product Description The Cornelius V3+ and V4 Frozen Carbonated Beverage (FCB) electronic machines are simple in design and have built-in diagnostics to help the service technician quickly and effectively service the machine. The following is a description of the basics of machine operation, key components, features, and capacities. Theory of machine operation The post-mix V3+ and V4 FCB machine uses the same technology found in many of today s over-counter electric post-mix dispensers. Product flow through the system is as follows: Syrup from the tank or bag-in-box (BIB) enters the back of the machine and goes through a sold-out monitor, flow control system and into the blender. At the same time plain water enters the back of the machine and goes through a pressure switch, water regulator, carbonator, flow control, and into the blender. Carbon dioxide enters the back of the machine at the secondary regulators, then to the carbonator, and the blender. The blended product goes through a shut-off valve into the freeze cylinder. The product is frozen and continually mixed in the freeze cylinder until it is dispensed through the dispensing valve. Key components and features The brain of the FCB machine is a microprocessor located on the main control board. The microprocessor receives input signals from sensors on the machine and sends output signals to control various functions of the machine. The microprocessor also prevents the machine from running if product quality or safety standards are not being met. Inputs to the microprocessor: Beater motor current Syrup sold-out pressure switch Syrup sold-out float C0 2 -out pressure switch Water out pressure switch Sensors (3), two inlet and one outlet Keyboard (touch pad) Blender float switch Voltage reading , IMI Cornelius Inc.

11 Feature Microprocessor outputs: Carbonator pump on/off Compressor on/off Syrup and water solenoid activation Pulse valve refrigeration control Beater motor on/off Defrost solenoid on/off L.E.D. display NOTE: See Appendix I Logic Flow Diagrams on page 36 for inputs and outputs. Another input and output is the RS 232 port used for remote (modem) monitoring and diagnostics. The electronics package in the Cornelius FCB machines provides useful information to the operator and is easy to use with a little practice. Following are some of the design features and customer benefits of the electronic package: Customer Benefit Local programmable defrost Up to nine times a day allowing defrost to occur during slow business hours Diagnostics Checks components for proper function and cycle counts to greatly ease troubleshooting, service and data collection Totals Provides unit history Sleep/wake-up timer Allows for programmed sleep and wake-up times, providing electrical savings and component life extension Refrigeration program and viscosity control V4 sleep and walk-up times can be set differently for each day of the week, and it automatically adjusts for daylight savings time Both provide greater product consistency Provides additional control for the customer RS 232 port Enables remote connection for monitoring Digital display Displays messages (syrup out, CO 2 out, machine errors, etc.) , IMI Cornelius Inc

12 3.2 Dimensions & Weight FCB V4, 2 Flavor: Capacity oz./min. Electrical rating VAC, 60 cycle, single phase, 30 amp circuit Dimensions H, 19 1/4 W, 29 1/4 D Shipping weight lbs. FCB V4, 2 Flavor Over Counter: Capacity oz./min. Electrical rating VAC, 60 cycle, single phase, 30 amp circuit Dimensions /2 H, 19 1/4 W, 31 D Shipping weight lbs. FCB V4, 4 Flavor Over Counter: Capacity oz./min. Electrical rating VAC, 60 cycle, single phase, 15 amp circuit Dimensions /2 H, 19 1/8 W, 36 D Shipping weight lbs. FCB V4, 4 Flavor Remote: Capacity oz./min. Electrical rating VAC, 60 cycle, single phase, 30 amp circuit Dimensions /2 H, 32 1/2 W, 38 D Shipping weight lbs. FCB V3 Plus, 4 Flavor: Capacity oz./min. Electrical rating VAC, 60 cycle, single phase, 50 amp circuit Dimensions H, 33 W, 29 1/2 D Shipping weight lbs , IMI Cornelius Inc.

13 SYSTEM DETAILS 1. CARBON DIOXIDE A CO 2 primary regulator on a high pressure CO 2 tank (this would be a secondary regulator with bulk CO 2 ) feeds a wall-mount 160 psi secondary regulator, set at 80 psi. The secondary regulator feeds the BIB, and the FCB unit. This 80 psi CO 2 feeds secondary regulators inside the machine. These secondary regulators feed carbonator and blender tanks. The number of internal regulators is doubled in a 4 flavor machine. Bag-in-box pumps can be CO 2 driven or utilize a separate air pump/tank also regulated to 80 psi minimum. Note: There is a CO 2 pressure switch inside the machine set at 75 psi turn-on and 50 psi turn-off. This means that above a 75 psi reading, the machine operates but once below 50 psi the machine will shut down the blender tanks, the carbonator, and the unit will go into defrost. After defrost is complete, the refrigeration system will not start again until the CO 2 supply is replaced. CO 2 Supply Regulator Assembly BIB Pump Check Valve Pressure Switch Blend Tank Carbonator NOTE: CO 2 pressure must be 80 psi minimum at the unit. See CO2 Flow Diagram - Floor Model on page 28 for additional information. 2. WATER At the installation site, water will pass through a shut off valve and then through a water filter system (if installed), water pressure regulator, and then to the water pressure switch in the FCB machine. NOTE: 12 psi minimum, 100 gph, see Appendix E Water Supply Test Procedure on page , IMI Cornelius Inc

14 Pressure Switch Pump Carbonator Check Valve Syrup Freeze Cylinder Water Inlet Pressure Regulator psi Dual Check Valves Flow Regulator/ Solenoid Valve Blender From the water pressure switch, the water goes to the water pressure regulator which is factory set at psi. From the regulator, the water goes to the carbonator pump through a double check valve and then into the carbonator tank. From the carbonator the water flows through a flow regulator set at 1.3 oz./sec (see Appendix F Water Flow Control Test Procedure on page 24). The water then flows through another check valve and into a Y fitting where the syrup enters. The combined carbonated water and syrup enter the blender, and after being blended enters the freeze cylinder. NOTE: The water pressure switch closes at approximately 16 psi and notifies the microprocessor that all is well. The water pressure switch will turn off at approximately 10 psi and notify the microprocessor that there is a problem. This results in an H 2 0 Out message on the control panel. The syrup and water solenoids then shut off stopping flow to the blender. The compressor and carbonator pump(s) will continue to operate for 90 seconds if the water pressure remains below 10 psi then the microprocessor shuts down. NOTE: Water pressure regulator(s) and carbonator pump bypass(es) wear and need to be tested to make sure they are in their proper operating range (250 psi ± 12). NOTE: See Appendix H Plumbing Diagrams on page 26 for water and carbonated water flow diagrams , IMI Cornelius Inc.

15 3. SYRUP Syrup is delivered in bag-in-boxes or tanks. The syrup is pumped from the BIB at 80 psi minimum. It flows through a pressure switch used to monitor pressure in the syrup line. If the BIB is empty or the pump stops for any reason, the pressure switch detects the lost pressure and shuts down blender operation. Pump Flow Regulator Solenoid Valve Water Freeze Cylinder BIB Pressure Switch Check Valve Blender After leaving the syrup pressure switch, the syrup moves to the flow control/solenoid valve which regulates the syrup flow. The microprocessor tells the solenoid to open, allowing syrup to flow to the check valve. The check valve prevents blended product from backing up into the syrup solenoid. The syrup enters a Y fitting and blends with water before entering the blender tank. The blender tank acts as a freeze cylinder reservoir. 3.1 BRIX Procedure 1. Press the AUTOBLEND/BLEND ON button for the side to be BRIXed. Watch the blend tank fill and when the level reaches the first mounting bracket leg, press FILL/BLEND OFF to stop blender filling. 2. Open sample valve and purge at least 5 ounces before drawing test sample. 3. Draw test sample and measure its BRIX. 4. If necessary, adjust syrup flow control. Drain product from blender and repeat steps Perform this procedure on the other side. NOTE: Never adjust the water flow rate to set BRIX. NOTE: See Appendix H Plumbing Diagrams on page 26 for the syrup flow diagram , IMI Cornelius Inc

16 4. MECHANICAL 4.1 Blender The FCB blender has a volume capacity of 80 ounces, but typically holds 35 ounces of actual product during normal operation. The syrup and water solenoids are controlled by a float switch inside the blender. When the blender float switch drops the syrup and water solenoids open and mixed product begins to flow into the blender. When the float switch reaches the top, the syrup and water solenoids shut off. The product flow rate out of the blender is between 1.0 and 1.4 oz./sec. to the freeze cylinder. This is less than the flow into the blender, to prevent over drawing the blender. NOTE: The two most likely causes of blender tank overflow are: not enough programmed defrosts blender CO 2 regulator set too low. see Appendix H Plumbing Diagrams on page 26 for flow diagrams 4.2 Freeze Cylinder The freeze cylinder holds approximately 180 ounces of product. Product leaving the freeze cylinder is between 24 and 28 degrees Fahrenheit. Freezing of the product results in approximately a 10% expansion of the product, which can back up into the blender. This is not the same expansion known as overrun. Overrun is when freezing and CO 2 cause the product to expand as it leaves the freeze cylinder. NOTE: Desired expansion/overrun rate is between %. NOTE: See Appendix D Product Overrun on page 21. NOTE: Worn scraper blades affect drink quality and product expansion/overrun. 4.3 Defrost System The FCB units have manual and programmed hot gas defrost systems. FCB V3+ and V4 - Hot Gas Defrost - Programmed With V3+ and V4 electronics, defrost can be set to occur up to 9 times per day. An example: the first defrost of the day can be set at 9:00 a.m. on barrel number one. Now barrel number two will automatically follow at 10:00 a.m. (1 hour after barrel number one went into defrost). There must be at least two hours between defrost cycles. Again, barrel number two will follow at 12:00 a.m. Generally, you can expect a defrost time of 7 1/2 minutes plus a 30 second motor calibration with hot gas defrost machines, then the product refreezes. NOTE: Older units may have 30 minute defrost separation , IMI Cornelius Inc.

17 NOTE: Defrost every 3 hours or less depending on the customer needs. FCB Manual Defrost When the FCB unit is placed in manual defrost, the unit goes into a 10 second pump-down to clear the evaporator. Both cylinders are then defrosted, unless one of them is set to not defrost. 4.4 Refrigeration System 1. Viscosity Controls (starts and stops compressor): 4 (wet) - 12 (stiff) 2. Beater Motor Current: adjust to 150, which equals 0 viscosity. 3. Leveling Routine: Stabilize product consistency. See Leveling Routine Chart (in appendix section of this manual). 4. Sensors/Pulse Valves: Refrigeration metering using timed modulation. Modulation changes with temperature change. Thermistors on the Inlet and Outlet of the evaporator send information to the microprocessor which controls the modulation rate. 5. Two Minute Timer: To prevent short cycle of the compressor. Activated on compressor shut-down. Blender float zeros the timer. Extend compressor life. 6. To maintain consistency if no product has been dispensed, the refrigeration is cycled every 5 minutes. 7. Float activity will turn the blender on. 8. If the viscosity goes below the set point for 5 seconds, the refrigeration will turn on. 9. NOTE: See Appendix S Leveling Routine on page , IMI Cornelius Inc

18 5. CONTROLS AND ELECTRICAL 5.1 Sensors The following information will help you better understand FCB sensor operation. The three sensors; left input, right input, and common output are thermistors. These thermistors change resistance with temperature changes. The resistance increases as the temperature lowers and decreases with higher temperatures. After entering the programming select sensor, the two inlet and common outlet temperatures will be displayed. The first group is the cylinder 1 inlet temperature, the second is the cylinder 2 inlet temperature, and the last group (far right) is the common temperature. LO will be displayed in any group if there is an open sensor problem. The display on the FCB shows all three sensors (XX*XX*XX). Sensor operating range is from -9 to 89 F. If a sensor is open (greater than 5 mega ohms), the machine will stop and display SENSOR 1, 2 or 3 (3 is common outlet). By looking at the sensor display the bad sensor will be identified by LO on the display. The limits on the sensors that the microprocessor controller looks for are greater than 5 mega ohms for an open LO indication. A HI indication will be displayed if the sensor is above 89 F (less than 3667 ohms), but it does not stop machine operation. Therefore, with a shorted sensor the machine may continue to run without any error or sensor message on the display. If a sensor is suspected as being shorted together, check via trouble shooting mode and look for a HI indication or check with an ohmmeter for a short. Remember, if the actual room temperature is above 89 F, the message display will read HI. Typical sensor readings for troubleshooting are 32 = 16,300 ohms and are approximate values in ohms. NOTE: A sensor can read low because the temperature is out of the sensor s range (below -9 ), or because the sensor is open , IMI Cornelius Inc.

19 5.2 FCB V4 Control Panel Use During Programming To Leave Selected Menu Or Programming Mode And To Reset Errors ON 1 MOTOR 1 BLEND 1 ON / OFF SYRUP 1 PRIME OFF 1 ERROR RESET MESSAGE DISPLAY ON 2 MOTOR 2 BLEND 2 ON / OFF SYRUP 2 PRIME OFF 2 MANUAL DEFROST MENU SELECT CANCEL DEFROST???BACKWARD FORWARD? Stops Refrigeration & Beater Motor Primes Syrup Float to satisfy syrup message Starts/Stops Blender Filling Enters Programming Mode & Makes Selection During Programming Starts Motor No Refrigeration Starts Refrigeration & Motor Starts 1 Min. Manual Defrost Or Backs Up Programming Menu Cancels Defrost Or Advances Programming Menu 5.3 FCB V3+ Control Panel Enter Programming Hidden Touch Pad Lock Out Use During Programming To Leave Selected Menu Or Programming Mode And To Reset Errors AUTO 1 WASH 1 AUTO FILL 1 BLEND 1 ERROR RESET MESSAGE DISPLAY AUTO 2 WASH 2 AUTO BLEND 2 FILL 2 OFF 1 OFF 2 DEFROST (SELECT) CANCEL DEFROST (ADVANCE) Stops Refrigeration & Beater Motor Primes Syrup Float to satisfy syrup message and turns blender off Cancels Defrost Or Advances Programming Menu Starts Blender Filling Starts Motor No Refrigeration Starts Refrigeration & Motor Starts 1 Min. Manual Defrost Or Makes Selection During Programming , IMI Cornelius Inc

20 APPENDIX APPENDIX A INSTALLATION CHECKLIST Voltage: to 253 volts Circuit Amps: 2 flavor amp 4 flavor amp Water Inlet Size: /8 inch i.d. minimum Water Flow Rate: 2 flavor gallons per minute 4 flavor gallons per minute Air Flow: standard condenser inches on all sides of the unit top mounted condenser on the sides, 6 in back, 18 on top Unit Support: level counter or cart rated for 600 pounds CO 2 Pressures: To Unit psi at the unit To BIB Pumps psi at the unit To Carbonator adjust as needed (55 80 psi) To Blender psi Carbonated Water Flow Rate: ounces per second (13 ounces in 10 seconds) Brix: /- 1.0 Beater Motor Current Adjustment: (adjust with beater motors at operating temperatures and freeze cylinders filled with liquid product) , IMI Cornelius Inc.

21 V3+ Programming: 1. Set Clock Set Defrost 3. Set Sleep Set Wake 5. Set Viscosity Check Viscosity Read 7. Check Sensors Check Voltage 9. Check Diagnostics Check Total 11. Set Motors Set Refrigerant Type V3+ DIP Switches (with MOTORS selected on the Menu Selection): V4 Programming: 1. Set Clock Set Defrost 3. Set Sleep Set Wake Up 5. Set Viscosity Check Viscosity 7. Check Sensors Check Voltage 9. Check Diagnostics Check Totals 11. Set Motors Set Refrigerant 13. Check Options Set Calender 15. Set + D.S.T Set - D.S.T. NOTE: The V4 dip switches are set in the menu options , IMI Cornelius Inc

22 V4 Options Menu Selections: Off Point Of Sale 2. Off Point Of Sale 3. Off Expansion Valves 4. Off Beater Motor 5. Off Auto-Calibration 6. On Control Panel Security (if. desired) 7. Off Celsius Mode 8. On Daylight Saving time (if desired) 9. On Hot Gas Defrost 10. Off Service Use Only After Starting Unit: Check viscosity AND expansion/overrun after the compressor has cycled at least three times and the product has stabilized. NOTE: See Appendix C Startup Procedures on page 19 for startup procedures , IMI Cornelius Inc.

23 APPENDIX B RECOMMENDED FCB SETTINGS 1. VISCOSITY SETTING V4 & V to 12 Higher settings will result in colder (stiffer) product. Lower settings will result in warmer (softer) product. 2. CO 2 OPERATING PRESSURES Carbonator to 80 psi (see chart below) Blender psi NOTE: Always maintain a minimum of 25 psi differential between carbonator and blender. 3. CARBONATOR WATER TEMPERATURE / CO 2 PRESSURE SETTING CO 2 Pressure Setting Water Temperature 4. BRIX SETTING Always use a temperature compensated refractometer when testing the BRIX of the blended FCB product. Regular syrup should be set at 13. NOTE: Before testing BRIX, calibrate the refractometer with carbonated water from the FCB unit. 5. SYRUP PRESSURE The syrup pressure must be high enough to satisfy the internal sold out switches. Most installations would be psi. When setting the CO 2 regulator, allow for pressure drop for long tubing runs , IMI Cornelius Inc

24 APPENDIX C STARTUP PROCEDURES FCB V4 & V3+ START UP PROCEDURES NOTE: For 4-flavor units, complete start up procedures for the left side of the unit (cylinders 1 and 2). Repeat the procedures for the right side (cylinders 1-1 and 2-2). Both V3+ and V4 Complete installation of unit leaving everything turned OFF and the syrup disconnected. V3+ Set all DIP switches OFF except #9. V4 DIP switches will be set later in the procedure. Turn power to the unit ON. Voltage at L1 and L2 on contactor should be VAC (compressor not running). CO 2 message should be CO 2 OUT. Turn CO 2 source ON, set pressure to psig, CO 2 message should be CO 2 OFF. Set CO 2 pressure to psig for carbonators. Set CO 2 pressure to 30 psig for blenders. Purge air from the carbonators, blend tanks and freeze cylinders. Close product valves. H 2 O message should be H 2 O OUT. Turn water supply ON. Carbonator pump will not run while both SYRUP 1 and SYRUP 2 messages are displayed. H 2 O OUT message should be go off. Connect #1 and #2 syrup supplies. V3+ V4 Press FILL 1 and FILL 2. Carbonator pumps should run with no SYRUP 1 and SYRUP 2 messages. Press PRIME 1 and PRIME 2. Carbonator pumps should run with no SYRUP 1 and SYRUP 2 messages. Check total fill on carbonators (40 to 58 oz.). Check differential on carbonators (7 to 21 oz.). Check and adjust carbonated water flow rate on blender #1 and #2 to 13 oz. in 10 seconds. Fill both blenders. Check shutoff level and drain. Test both syrup pressure switches and adjust if necessary. NOTE: See Appendix U Syrup Pressure Switch Test & Adjustment Procedure on page 60 Adjust BRIX for #1 and #2 blenders to 13 ± 1.0 degrees , IMI Cornelius Inc.

25 Open both product valves. Slowly pull face plate relief valves to fill freeze cylinders. V3+ Set Clock. V4 Set Clock and the Day of The Week. Set automatic defrost times (no closer than 2 hours apart). Set sleep time(s). Set wake time(s). Set viscosity settings to Check sensors. V3+ Program motor selections: Emerson 60 and Klauber 60. V4 Program motor selections: Emerson 60. Program refrigerant type and compressor selections: 404A - 2HP or 404A - 3HP. V4 Set all dip switches OFF, except # 6 and # 9. Set # 8 ON when Daylight Savings Time option is used. Set Calendar. Set Daylight Savings Time plus or minus one hour. Set beater motor currents dip switch # 4 ON, then set to 150. V3+ Press Auto 1 and Auto 2. Voltage across T1 and T2 on contactor should be VAC. V4 Press ON 1 and ON 2. Voltage across T1 and T2 on contactor should be VAC. After 2nd freeze cycle, when the product has stabilized, test the 3rd drink. Make adjustments in viscosity and settings on CO 2 pressure, if necessary. V3+ Secure unit. V4 Record all necessary readings , IMI Cornelius Inc

26 APPENDIX D PRODUCT OVERRUN 1. PRODUCT OVERRUN BY VOLUME To determine product overrun by volume follow this procedure: 1. Fill cup with product. 2. Level the cup by scraping excess off of top. 3. Melt the product (use a microwave oven, if available). 4. Measure the ounces of liquid in the cup. 5. Check the chart below for overrun percentage. Product Overrun By Volume Melted Ounces Overrun Percentage Melted Ounces Overrun Percentage Melted Ounces Overrun Percentage Melted Ounces Overrun Percentage Melted Ounces Overrun Percentage 8.5 oz. Cup 14 oz. Cup 16 oz. Cup 24 oz. Cup 32 oz. Cup 3.0 oz. 183 % 5.0 oz. 180 % 5.0 oz. 220 % 8.0 oz. 200 % 11.0 oz. 191 % 3.5 oz. 143 % 5.5 oz. 155 % 5.5 oz. 191 % 8.5 oz. 182 % 11.5 oz. 178 % 4.0 oz. 113 % 6.0 oz. 133 % 6.0 oz. 167 % 9.0 oz. 167 % 12.0 oz. 167 % 4.5 oz. 89 % 6.5 oz. 115 % 6.5 oz. 146 % 9.5 oz. 153 % 12.5 oz. 156 % 5.0 oz. 70 % 7.0 oz. 100 % 7.0 oz. 129 % 10.0 oz. 140 % 13.0 oz. 146 % 5.5 oz. 55 % 7.5 oz. 87 % 7.5 oz. 113 % 10.5 oz. 129 % 13.5 oz. 137 % 6.0 oz. 42 % 8.0 oz. 75 % 8.0 oz. 100 % 11.0 oz. 118 % 14.0 oz. 129 % 6.5 oz. 31 % 8.5 oz. 65 % 8.5 oz. 88 % 11.5 oz. 109 % 14.5 oz. 121 % 7.0 oz. 21 % 9.0 oz. 56 % 9.0 oz. 78 % 12.0 oz. 100 % 15.0 oz. 113 % 7.5 oz. 13 % 9.5 oz. 47 % 9.5 oz. 68 % 12.5 oz. 92 % 15.5 oz. 106 % 10.0 oz. 40 % 10.0 oz. 60 % 13.0 oz. 85 % 16.0 oz. 100 % 10.5 oz. 33 % 10.5 oz. 52 % 13.5 oz. 78 % 16.5 oz. 94 % 11.0 oz. 27 % 11.0 oz. 45 % 14.0 oz. 71 % 17.0 oz. 88 % 11.5 oz. 22 % 11.5 oz. 39 % 14.5 oz. 66 % 17.5 oz. 83 % 12.0 oz. 17 % 12.0 oz. 33 % 15.0 oz. 60 % 18.0 oz. 78 % 12.5 oz. 28 % 15.5 oz. 55 % 18.5 oz. 73 % 13.0 oz. 23 % 16.0 oz. 50 % 19.0 oz. 68 % 13.5 oz. 19 % 16.5 oz. 45 % 19.5 oz. 64 % 17.0 oz. 41 % 20.0 oz. 60 % 17.5 oz. 37 % 20.5 oz. 56 % , IMI Cornelius Inc.

27 Product Overrun By Volume Melted Ounces Overrun Percentage Melted Ounces Overrun Percentage Melted Ounces Overrun Percentage Melted Ounces Overrun Percentage Melted Ounces Overrun Percentage 8.5 oz. Cup 14 oz. Cup 16 oz. Cup 24 oz. Cup 32 oz. Cup 18.0 oz. 33 % 21.0 oz. 52 % 18.5 oz. 30 % 21.5 oz. 49 % 19.0 oz. 26 % 22.0 oz. 45 % 19.5 oz. 23 % 22.5 oz. 42 % 20.0 oz. 20 % 23.0 oz. 39 % 23.5 oz. 36 % 24.0 oz. 33 % 24.5 oz. 31 % 25.0 oz. 28 % 25.5 oz. 25 % 26.0 oz. 23 % 26.5 oz. 21 % The formula for calculating overrun by volume is: ( Cup Size Melted Ounces ) * 100 Melted Ounces , IMI Cornelius Inc

28 APPENDIX E WATER SUPPLY TEST PROCEDURE The water supply should provide at least 12 psi and 100 gallons per hour at the unit. To check the water supply follow this procedure: 1. Connect 3/8 inch tube to the water supply. This tubing should be the same length as the tubing that will supply the FCB unit. 2. Turn the water supply on and measure how long it takes to fill a 5 gallon pail. It should fill the pail in 3 minutes or less. 3/8 tubing Water supply 5 gallons in 3 minutes = 100 gallons per hour 5 gallon pail , IMI Cornelius Inc.

29 APPENDIX F WATER FLOW CONTROL TEST PROCEDURE The procedure for checking the water flow control is as follows: 1. Close the blender outlet valve. 2. Drain the blender using the sample valve. 3. Manually open H 2 O solenoid for 10 seconds. 4. Observe H 2 O level per diagram. 5. Adjust H 2 O flow control as necessary (clockwise to increase flow). After 10 seconds of filling, the water level should be at the BOTTOM EDGE of the UPPER RIDGE of the lower support bracket. Blender Bracket s UPPER ridge Water Level Lower support bracket Water flow should be 13 ounces in 10 seconds , IMI Cornelius Inc

30 APPENDIX G ZEROING-OUT ERROR TOTALS 1. ZEROING-OUT V3+ / V3 ERROR TOTALS 1. Set dip switch 10 to the ON position. NOTE: Dip switches are located on the Main board on the V3+ and V3. 2. Go to the Totals Screen and to the total to be zeroed. NOTE: The total hours for PWR, SLEEP, ERR1 & 2 can not be zeroed. 3. Press AUTO 2, WASH 2, AUTO BLEND 2, FILL 2, and OFF 2. The total and will blink. 4. Press ERROR RESET to zero the total. 5. Set dip switch 10 to OFF for normal operation. 2. ZEROING-OUT V4 ERROR TOTALS 1. Go to the Options menu and set dip switch 10 to the ON position. 2. Press ERROR RESET. 3. Select Totals and to the total to be zeroed. 4. Press ON 2, MOTOR 2, BLEND 2, PRIME 2, and OFF 2. The total and will blink. 5. Press ERROR to zero the total. 6. Return to the Options menu and set dip switch 10 to the OFF position , IMI Cornelius Inc.

31 APPENDIX H PLUMBING DIAGRAMS FCB Flow Diagram - Floor Model , IMI Cornelius Inc

32 FCB Flow Diagram - Over Counter Model , IMI Cornelius Inc.

33 CO 2 Flow Diagram - Floor Model , IMI Cornelius Inc

34 CO 2 Flow Diagram - Over Counter Model , IMI Cornelius Inc.

35 Plain Water Flow Diagram - Floor Model , IMI Cornelius Inc

36 Plain Water Flow Diagram - Over Counter Model , IMI Cornelius Inc.

37 Carbonated Water Flow Diagram - Floor Model , IMI Cornelius Inc

38 Carbonated Water Flow Diagram - Over Counter Model , IMI Cornelius Inc.

39 Syrup Flow Diagram , IMI Cornelius Inc

40 Product Flow Diagram , IMI Cornelius Inc.

41 APPENDIX I LOGIC FLOW DIAGRAMS REFRIGERATION SOLENOID #1 SYRUP SOLENOID #1 H 2 0 SOLENOID #1 BEATER MOTOR #1 HOT GAS SOLENOID #1 ELECTRIC DEFROST * DEFROST & BEATER MOTOR SIGNAL #1 * OUTPUT BOARD #1 KEYPAD SWITCHES SOLDOUT SWITCHES CARB SWITCH CARB. 3 HP COMP. (floor model only) CARBONATOR SWITCH CARBONATOR MOTOR DIP SWITCHES COMPRESSOR MOTOR POWER SOURCE ASSEMBLY MOTHERBOARD MOTHERBOARD MICROPROCESSOR MICROPROCESSOR HIGH PRESSURE CUTOUT (water cooled unit only) CONTACTOR COMPRESSOR FAN MOTOR(S) BLENDER SWITCHES INLET TEST 1 & 2 DISPLAY BOARD OUTLET TEST 3 DEFROST & BEATER MOTOR SIGNAL #2 * OUTPUT BOARD #2 REFRIGERATION SOLENOID #2 SYRUP SOLENOID #2 H 2 0 SOLENOID #2 BEATER MOTOR #2 HOT GAS SOLENOID #2 ELECTRIC DEFROST * * Electric defrost on remote refrigeration only Logic Flow Diagram , IMI Cornelius Inc

42 , IMI Cornelius Inc. CO 2, Water & Syrup Flow Diagram CO2 REG. PRIM. CO2 REG SEC. CARB TANK DBL CHK VALVE CO2 CHECK VALVES ARE BRASS LIQUID CHECK VALVES ARE STAINLESS STEEL SYRUP SUPPLY 1 SYRUP SUPPLY 2 CARB. H20 PUMP SYRUP SOLD-OUT SWITCH 1 SYRUP SOLD- OUT SWITCH 2 H2O PRESS. REG. SYRUP SOLD-OUT FLOAT SW 1 SYRUP SOLD- OUT FLOAT SW 2 H2O PRESS. SWITCH SYRUP REG. 1 FREEZE CYLINDER 1 CARB. H2O FLOW REG.1 H2O FILTER CARB H2O FLOW REG. 2 FREEZE CYLINDER 2 SYRUP REG. 2 SYRUP SOLENOID VALVE 1 PRODUCT SHUT-OFF VALVE 1 H2O SOLENOID VALVE 1 VALVE SHUT OFF H2O SOLENOID VALVE 2 PRODUCT SHUT-OFF VALVE 2 SYRUP SOLENOID VALVE 2 LIQUID CHECK VALVE 1 BLENDER TANK 1 LIQUID CHECK VALVE 1 H2O SOURCE LIQUID CHECK VALVE 2 BLENDER TANK 2 LIQUID CHECK VALVE 2 FCB V4 & V3+ Training Manual

43 Refrigeration Flow Diagram , IMI Cornelius Inc

44 APPENDIX J WIRING SCHEMATICS NO.1 SYR NO.2 SYR H2O CO2 YELLOW ORN GRAY LBS BLACK RED BLUE WHITE RBS BLACK RED WHITE RED IN 1 YEL OUT SWITCHES THERMISTERS IN 2 OUT3 RIBBON BD NO. 1 NO.1 BLUE YELLOW 1A B YELLOW NO.1 REF SOL SYR SOL H2O SOL PURPLE ORANGE/PURPLE ORANGE/YELLOW CPU MASTER BOARD CLOCK RAM BD NO. 2 2B RIBBON SWITCH PAD DISPLAY BOARD RED GRAY A GRAY BLUE/PINK WHITE/ORN WHITE/BLUE REF SOL SYR SOL H2O SOL BLACK NO.2 WHITE NO.2 L1 BLACK V3+ AND V4 LOW VOLTAGE CIRCUIT FLOOR MODEL 3 H.P. AND OC2 MODELS PRIOR TO SERIAL NO. 56D. (OC2 WITH 56D AND AFTER HAS SOME WIRE COLORS DIFFERENT, ALTHOUGH WIRING IS THE SAME) WIRING SCHEMATIC 1A 1B 2A 2B L2 WHITE ALL PLUGS VIEWED FROM OUTSIDE OF ELECTRONIC BOX AND PLUGGED IN. 2. SOLID DOTS INDICATE BLANK SPACES (NO WIRES). 3. ALL PLUGS HAVE VISABLE RIB ON OUTSIDE OF PLUG FOR ORIENTATION. Wiring Schematic Low Voltage , IMI Cornelius Inc.

45 1 1 FCB V4 & V3+ Training Manual BLACK NO.1 WHITE SEE LOW VOLTAGE SCHEMATIC FAN BLACK WHITE NO.2 BLACK SEE LOW VOLTAGE SCHEMATIC BLACK MASTER BOARD CLOCK RAM CPU CARB RELAY L1 BLACK L2 WHITE GD GREEN PLUG GRAY COMP WHITE CARB DISPLAY B W G G W COMPRESSOR RELAY BD NO. 1 BD NO. 2 1A B 2B A BLUE DEF SOL RED WHITE GREEN- WHITE BROWN WHITE NO. 1 BEATER MOTOR NO. 1 WHITE NO.2 ORANGE BLACK-YELLOW WHITE-RED BEATER MOTOR NO. 2 SW WHITE BLACK BROWN 110 V POS OUTLET HIGH PRESSURE CUT ON ON H2O COOLED BLUE CONTACTOR COIL CARB PUMP(S) WHITE 3/4 AMP POS TRANSFORMER 5 WHITE C COMPRESSOR CONTACTOR 1 RELAY 2 RED S R COMPRESSOR CONTACTOR BLACK START RUN FAN IF AIR COOLED L1 BLACK V3+ AND V4 HIGH VOLTAGE CIRCUIT 1. FLOOR MODEL 3 H.P. AND OC2 MODELS PRIOR TO SERIAL NO. 56D OC2 NO. WITH 56D AND AFTER HAS SOME WIRE COLORS DIFFERENT, ALTHOUGH WIRING IS THE SAME L2 WHITE WIRING SCHEMATIC 1A 1B 2A 2B ALL PLUGS VIEWED FROM OUTSIDE OF ELECTRONIC BOX AND PLUGGED IN. 2. SOLID DOTS INDICATE BLANK SPACES (NO WIRES). 3. ALL PLUGS HAVE VISABLE RIB ON OUTSIDE OF PLUG FOR ORIENTATION. Wiring Schematic High Voltage , IMI Cornelius Inc

46 APPENDIX K WIRE COLOR LEGEND & TERMINATIONS WIRE COLOR LEGEND FOR CORNELIUS FL 3 HP & OC2 PIN Voltage To/From OLD NEW PLUG 1A 1 Black Brown 220AC L1 2 White Blue 220AC L2 3 Brown Brown/Red 220AC Left Beater Motor 4 Blue Brown/White 24AC #1 Transformer 5 Purple Purple 24DC #1 Refrigeration Solenoid 6 Orange/Purple Orange/Purple 24AC #1 Syrup Solenoid 7 Orange/Yellow Orange/Yellow 24AC #1 H2O Solenoid 8 Green Green/Yellow Gound Panel Ground 9 Blank Blank Blank Blank 10 White Blue 220AC Board #2. Pin Yellow Red/Yellow 24AC #1 Transformer 12 Blank Blank Blank Blank 13 Blank Blank Blank Blank 14 Blank Blank Blank Blank 15 Blank Blank Blank Blank PLUG 1B 1 Blue Brown/White 220AC #1 Defrost Solenoid 2 Blank Blank Blank Blank 3 Blue Brown/White 220AC #1 Defrost Solenoid 4 Blank Blank Blank Blank PLUG 2A 1 Blank Blank Blank Blank 2 Black/Yellow Black/Yellow 220AC Carbonator Pump(s) 3 Orange Orange 220AC Right Beater Motor 4 Red Red 24AC #2 Transformer 5 Blue/Pink Blue/Pink 24DC #2 Refrigeration Solenoid 6 White/Orange White/Orange 24AC #2 Syrup Solenoid 7 White/Blue White/Blue 24AC #2 H2O Solenoid 8 White/Red White/Red 220AC Compressor Contactor 9 Black Brown 220AC L1 10 White Blue 220AC L2 11 Gray Gray 24AC #2 Transformer 12 Blank Blank Blank Blank PLUG 2B 1 Red Red 220AC #2 Defrost Solenoid 2 Blank Blank Blank Blank 3 Red Red 220AC #2 Defrost Solenoid 4 Blank Blank Blank Blank PLUG 3 1 Yellow Red/Yellow 16VDC CO2 Switch 2 Red Red 16VDC CO2 Switch 3 Blue Brown/White 16VDC H2O Switch 4 Gray Gray 16VDC #2OutofSyrupSwitch 5 Orange Orange 16VDC #1OutofSyrupSwitch 6 Yellow Red/Yellow 16VDC H2O,#1,#2,OutofSyrupSwitch PLUG 4 1 White Blue 16VDC #1 Blender Switch 2 Black Brown N/A Capped Off at Blender Switch 3 Red Red 16VDC #1 Blender Switch PLUG 5 1 White Blue 16VDC #2 Blender Switch 2 Black Brown N/A Capped Off at Blender Switch 3 Red Red 16VDC #2 Blender Switch 1A 1B 2A 2B ALL PLUGS VIEWED FROM OUTSIDE OF ELECTRONIC BOX AND PLUGGED IN. 2. SOLID DOTS INDICATE BLANK SPACES (NO WIRES). 3. ALL PLUGS HAVE VISABLE RIB ON OUTSIDE OF PLUG FOR ORIENTATION. Wire Color Legend - FL 3 hp and OC , IMI Cornelius Inc.

47 APPENDIX L FCB V4 / V3+ BOARD LAYOUT , IMI Cornelius Inc

48 APPENDIX M RIBBON CONNECTOR / CONTROL PANEL PINOUTS 1. V4 RIBBON CONNECTOR / CONTROL PANEL PINOUTS , IMI Cornelius Inc.

49 2. V3+, V3, V2 RIBBON CONNECTOR/CONTROL PANEL PINOUTS , IMI Cornelius Inc

50 3. V4 RIBBON CONNECTOR / CONTROL PANEL PINOUTS ALL BUTTONS Pin Syrup Prime 1 Pin not used Pin Blend 1 ON/OFF Pin Menu Select Pin Motor 1 Pin Manual Defrost Pin ON 1 Pin OFF 2 Pin to all buttons Pin not used Pin OFF 1 Pin ON 2 Pin Error Reset Pin Motor 2 Pin Cancel Defrost Pin Blend 2 ON/OFF Pin not used Pin Syrup Prime 2 Pin not used 4. V3+ RIBBON CONNECTOR / CONTROL PANEL PINOUTS ALL BUTTONS Pin Fill 1 Pin not used Pin Auto Blend 1 Pin Defrost Pin Wash 1 Pin OFF 2 Pin Auto 1 Pin OFF 1 Pin Security Pin to all buttons Pin Security Pin Auto 2 Pin Error Reset Pin Wash 2 Pin Cancel Defrost Pin Auto Blend 2 Pin not used Pin Fill 2 Pin not used , IMI Cornelius Inc.

51 APPENDIX N WIRING SCHEMATIC - WATER COOLED Wiring Schematic Water Cooled (only 2-flavor w/o condenser fans) , IMI Cornelius Inc

52 APPENDIX O V4 / V3+ ELECTRICAL COMPONENTS OPERATING CHARACTERISTICS The following chart lists part numbers, vendors, and data for electrical components use in the V4 and V3+ FCB units. Description H.P. Part Number Vendor Refrigeration System Electrical Data (Ohms measured disconnected) (Run/Start) Compressor - 60 Hz R Bristol.80 / 2.73 Ohms Compressor - 50 Hz R Bristol.94 / 4.08 Ohms Compressor - 60 Hz R-404a Copeland 1.08 / 2.66 Ohms Compressor - 50 Hz R-404a Copeland 1.14 / 2.98 Ohms Compressor - 60 Hz R-404a Copeland Start Relay for Bristol 60Hz GE 8350 Ohms Coil Start Capacitor for Bristol 60Hz GE, York 25 MFD 440V Run Capacitor for Bristol 60Hz GE, York 161 / 193 MFD Run Capacitor for Bristol 50Hz 2 GE, York Start Relay for Copeland 50 / 60Hz GE IN V OUT V Start Capacitor for Copeland 50 / 60Hz GE, York 145 MFD Start Capacitor for Copeland 60Hz Copeland MFD 330V Start Relay for Copeland 60Hz GE Run Capacitor for Copeland 50Hz GE, York 45 MFD 370V Run Capacitor for Copeland 60Hz GE, York 40 MFD 370V Run Capacitor for Copeland 60Hz Copeland 40 MFD 330V Contactor for all Compressors Pulse Valves White Rogers, Square D Parker (Jakes Evans) 70 Ohms Defrost Valve Parker (Jakes Evans) 410 Ohms Cond. Fan EM & S 48 Ohms Blending / Carb. System Carb Motor Emerson , IMI Cornelius Inc.

53 Float Switch (Blender) Madison Closed when Down Float Switch (Sold Out) Madison Closed when Out B.N.B. Switch Shur-flo Closed when Out Water Pres Cut-out SW Ranco, will be Shur-flo Open, No Pressure CO2 Pressure Cut-out Ranco Open, No Pressure V3 and Older Solenoid Water / Syrup Honeywell Water Valve / Regulator Cornelius 6.4 Ohms Syrup Valve / Regulator Cornelius 6.4 Ohms Drive System Drive Motor 60Hz Klauber 10 / 21 Drive Motor 50 Hz Klauber 11 / 29 Relay for the Klauber Motor MRC Drive Motor 60 Hz Von Weise Drive Motor 50 Hz Von Weise Drive Motor 50/60 Hz Emerson 8.4 Ohms Electronics Description H.P. Part Number Vendor Electrical Data (Ohms measured disconnected) (Run/Start) Main Board Electro-pro N/A Relay Board # Electro-pro N/A Relay Board # Electro-pro N/A Display Board Electro-pro N/A V3+ Touch pad Switches V4 Touch Switches Panel-tec Panel-tec see Appendix M Ribbon Connector / Control Panel Pinouts on page 43 Sensor Electro-pro 16,300 Ohms at 32 Degrees Fan Control Box Globe 1400 Ohms NOTE: There is no ohm value for surflow pump because it is DC inter/rectified , IMI Cornelius Inc

54 APPENDIX P CHIP CHANGE PROCEDURE The purpose of this notice is to describe the proper method for changing a chip on the master board of a Cornelius machine should it become necessary. CAUTION: Static electricity can destroy sensitive electronic circuits. Always wear static straps or keep yourself grounded to the machine while working in the electronic boards. Tools needed: 32 pin dip extractor (chip puller) Wrist ground strap Procedure: 1. Unplug machine. 2. Remove top panel on floor models. Open door to access the control box on the OC2 machine. 3. Remove lid to control box on. 4. Place the chip puller and new chip on the machine (chip still in the container). 5. Attach ground strap to the bare metal control box. 6. Carefully remove the new chip from shipping container. Save shipping container to pack old chip in. 7. Place chip puller on chip and gently squeeze until tool grips the chip. 8. Pull the chip puller straight up with a gentle end to end rocking motion to remove the chip. Place old chip in the original container. 9. Carefully place new chip in the socket and make sure all pins are started in their holes. Press firmly straight down on the chip until it is fully engaged in the socket. Note: Proper placement of the chip can be confirmed by aligning the small indent on one end of the chip with the indent on the outline that is drawn on the board. 10. Remove ground strap. 11. Replace control box lid , IMI Cornelius Inc.

55 12. Replace top machine panel or close access door. 13. Plug in machine. 14. Defrost both barrels. 15. Check Viscosity read. If both sides read 0 go to If either side reads other than 0, beater motor currents needs to be reset. 17. Turn machine on auto and check for normal operation. 18. Secure machine , IMI Cornelius Inc

56 APPENDIX Q MESSAGE TROUBLE SHOOTING MESSAGE NOTES POSSIBLE FAULT Motor 1 or Motor 2 Sensor 1 or Sensor 2 or Sensor 3 Syrup 1 or Syrup 2 Low voltage. High voltage. Poor electrical connection. Bad motor or motor board. Freeze up - defrost cycle not working or not defrosting often enough or wrong motor selection. Defective shaft bearing. Leaking H2O solenoid. Leaking refrigeration solenoid. Ice build up on beater bar. Pressure switch adjusted out of range. Poor sensor mounting or corrosion between sensor and pipe. Poor electrical connection. Defective sensor. Restriction in syrup line. Out of syrup. BIB pressure to low. Air in syrup line. Defective BIB pump. Syrup float stuck, or saturated. Bad pressure switch, or miss adjusted. Excessive pressure drop in tubing , IMI Cornelius Inc.

57 MESSAGE NOTES POSSIBLE FAULT CO 2 Out H 2 O Out Refrigeration When viscosity is 3 or more unit will defrost and sleep until CO 2 is restored. Blenders, carbonator refrigeration disabled. Compressor run time exceeds 25 mins. Less than 80 psi at switch. Bad pressure switch. On bulk system with primary regulator. Plugged pressure switch, try cleaning before replacing it. Restriction in CO 2 line. Low water pressure. Plugged water filters. Restricted supply lines. Bad pressure switch. Plugged condenser. Bad fan motor. Bad pulse valve (or electrical connection to either one). Low charge. Leaking defrost valve. High brix. Beater Motor running but not turning. Shaft (gear problem). Broken motor coupling. Broken or disconnected beater body. MESSAGE NOTES POSSIBLE FAULT Heater 1 or Heater 2 Error msg. will cancel defrost & calibration msg. Dip switch #9 not set correctly. C-FAIL Clock Failure Replace Dallas ( battery) chip. O-FAIL Opcode Failure Unplug unit, wait 1-1/2 minutes and replug unit in. If same message occurs replace master board , IMI Cornelius Inc

58 MESSAGE NOTES POSSIBLE FAULT E-Fail I-FAIL X-FAIL CO 2 Out H 2 O Out Refrig Defrost Current Sensor EPROM Failure Unplug unit, wait 1-1/2 minutes and replug unit in and check programming If error re-occurs replace EPROM chip. Unplug the unit, wait 1-1/2 minutes, plug it back in and check programming. If msg. re-occurs replace the master board. Unplug the unit, wait 1-1/2 minutes, plug it back in and check programming. If msg. re-occurs, replace the master board. Less than 80 psi CO 2 pressure. If the viscosity number is 3 or greater and the machine has run one complete refrigeration cycle, defrost cycle will occur and then the machine will go to sleep until CO 2 pressure is restored. When loss of water pressure occurs. The blenders are disabled, the refrigeration system and carbonator shall continue functioning for 1.5 minutes. If water pressure loss is detected beyond 1.5 minutes, the refrigeration system and carbonator shall be disabled. When the compressor run time exceeds 25 (hot gas), 30 (electric), plus or minus one minute. A current sensing device shall monitor the defrost controls to make sure the defrost system is operating properly , IMI Cornelius Inc.

59 APPENDIX R SYSTEM ERRORS & MESSAGES Displayed Error Conditions Message Displayed Error Items Affected By Error Beater Motor 1 Beater Motor 2 Refrig 1 Refrig 2 MOTOR 1 ERROR MOTOR 2 ERROR HEATER ERROR REFRIG ERROR SYRUP 1 ERROR SYRUP 2 ERROR High or Low Current OFF OFF High or Low Current OFF OFF ** Maximum Run Time on compressor exceeded Syrup Out Side One Syrup Out Side Two OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF CO 2 OUT CO 2 Out OFF OFF H 2 O H 2 O Out *OFF *OFF SENSOR 1 SENSOR 2 SENSOR 3 Open or Lo (see Sensors on page 13) Open or Lo (see Sensors on page 13) Open or Lo (see Sensors on page 13) OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF * The refrigeration system and carbonator shall continue to operate for 1.5 minutes after a water pressure loss has been detected. If water pressure loss continues beyond 1.5 minutes, the refrigeration system and carbonator will stop. ** 25-minutes on Standard System , IMI Cornelius Inc

60 Menu Commands Totals Menu Commands COMP HRS COMP CYC DFSTYC1 DFSTYC2 BLDRCYC1 BLDRCYC2 Description COMPRESSOR RUN HOURS COMPRESSOR CYCLES X100 DEFROST SIDE 1 CYCLES DEFROST SIDE 2 CYCLES BLENDER SIDE 1 CYCLES X100 BLENDER SIDE 2 CYCLES X100 SOLDOUT 1 SOLDOUT SYRUP SIDE 1 SOLDOUT 2 SOLDOUT SYRUP SIDE 2 BMTRHRS1 BEATER MOTOR 1 HOURS BMTRHRS2 BEATER MOTOR 2 HOURS PWR ON POWER ON HOURS AUTO ON 1 AUTO SIDE 1 HOURS AUTO ON 2 AUTO SIDE 2 HOURS ERR HRS 1 ERROR SIDE 1 HOURS ERR HRS 2 ERROR SIDE 2 HOURS SLEEP HRS SLEEP MODE HOURS SYR MIN 1 (see NOTE) SYRUP MINUTES (SIDE 1) SYR MIN 2 (see NOTE) SYRUP MINUTES (SIDE 2) NOTE: Displaying SYR MIN 1 or SYR MIN 2 on message display will indicate time in minutes syrup actually has been dispensed. Refer to table and formula below to calculate how much syrup has been dispensed. Brix A , IMI Cornelius Inc.

61 GALLONS = A x SYRUP MINUTES Note: A numbers are based upon a 4.4 to 1 water to syrup ratio. Using the table, choose the A number that corresponds to the BRIX setting. Multiply the A number by the syrup minutes reading to obtain the amount (gallons) of syrup used , IMI Cornelius Inc

62 APPENDIX S LEVELING ROUTINE VISCOSITY LIMITS/LEVELING ROUTINES (R-404a) New Leveling Routine (Code 94CD and newer Viscosity Set Point Lower Limit 1 Upper Limit 2 Current + Viscosity Beater Motor (approximate) * Equal to 150+ Viscosity 1 Lower limit must remain above for 5 seconds after leveling starts 2 Leveling starts Leveling Routine, R404A Refrigerant Compressor OFF timer is 2 minutes. Tops Off opposite cylinder before shutoff. Compressor ON timer is 5 minutes. Compressor will Top Off both cylinders. Pulse valve opens and equalization occurs for 5 seconds before the compressor starts. Any blender float activation will start compressor. Compressor will start if viscosity falls below the set point for 5 seconds. Pump down before defrost = 10 seconds. Compressor shuts off after 6 leveling routines even if viscosity is below lower limit. Motor current will adjust 1 count each time the unit completes a scheduled defrost. Any time the number 4 DIP switch is turned ON, it locks in that setting when it s turned OFF , IMI Cornelius Inc.

63 APPENDIX T PREVENTATIVE MAINTENANCE CHECKLIST Customer Name Store Address City, St., Zip Phone Model # And Serial # 1. Replace the O-Rings and bushing in each barrel. P.M. Kit P/N 3680 and 1040(V3) 2. Check the following and replace if necessary: Scraper Blades Face Plate O-Ring Sensor Beater Body Spinner. 3. Dispensing Valve (Motorman): Check Caged O-Ring and Replace If Necessary. Lube Caged O-Ring. Adjust Return Spring Tension. 4. Check for and repair CO 2, Water, Syrup leaks. 5. Water regulators wear out and need to be tested to make sure they are in their proper operating range. 6. Test function on Sold Out Switches: CO 2 Water pressure switch Syrup Sold Out systems. 7. Set all CO 2 pressure settings: Blender PSI Carbonator PSI , IMI Cornelius Inc

64 8. Brix all products: 13 ± 1.0 Brix Check Product Temperature Check Expansion/overrun (80-110%). 9. Check running water pressure (100 GPH at 15 PSI minimum). 10. Set beater motor current adjustment Check the following and reset if necessary: Time Clock Defrost Time Sleep Time Wake Time Viscosity Settings 4-12 Sensors Voltage (V3+ 198V - 253V) Beater Motor per manufacturer Refrigerant Type and Compressor All 10 Dip Switch Settings Calendar (V4 only) L. DST +/- Hr.(V4 only). 12. Clean unit as needed. 13. Clean condenser. 14. Sanitize unit. 15. Restart unit and check product expansion/overrun , IMI Cornelius Inc.

65 APPENDIX U SYRUP PRESSURE SWITCH TEST & ADJUSTMENT PROCEDURE The purpose of this procedure is to assure that the Syrup Sold Out System is functioning properly to prevent freeze-ups and motor errors. BIB Pressure Switch P/N 5081 or Kit P/N NOTE: Syrup pressure must be 80 psi at the unit. Test Procedure: 1. Shut off blend tanks. V3 - Press each Fill button. V4 - Press Blend OFF button. 2. Empty blend tank. Use sample tubes. 3. Disconnect B-I-B box at syrup supply. 4. Activate blend tanks. V3 - Press each Auto Blend button V4 - Press Blend ON button. If the pressure switch is operating correctly the FCB will go into the Syrup Out indication before each blend tank fills completely. Adjustment: If the unit does not go into Syrup Out, adjust the pressure switch until it shows Syrup Out. Always adjust slightly past the cut-off point. This is anywhere from plus 1/8 to 1/4 turn. NOTE: You will experience a four second delay between Switch Shut-Off and Blender Shut-Off. Test at Installation: 1. Complete installation and set up FCB machine. 2. Connect syrup BIB to system. 3. Adjust CO 2 regulators to provide 80 PSI to the BIB pumps. 4. Prime the syrup systems. V3+ press the Fill buttons V4 press Prime button If the syrup light is still ON after priming the syrup system, adjust the pressure switch until the light goes out. NOTE: After adjustment, thumb screw must be reglued to prevent movement , IMI Cornelius Inc

66 APPENDIX V WATER FLOW In operation the liquid flows through the knife edged orifice in the bottom of the piston and then out the orifices in the sleeve. The outlet orifice size in the sleeve is regulated by the position of the piston. In the illustration, the piston is restricting approximately 1/2 of the outlet orifices. Sleeves Pistons Orifices Lower Fluid Pressure BUT Larger Orifice Openings Higher Fluid Pressure BUT Smaller Orifice Openings Same Volume Of Syrup/ Water Flows From Orifices Knife edge Syrup/Water Flow Lower Fluid Pressure Pushing Against Piston & Spring Higher Fluid Pressure Pushing Against Piston & Spring The position of the piston inside the sleeve is determined by the upward pressure of the liquid against the base of the piston and the downward pressure of the spring inside the piston (not shown here). The pressure of the spring is regulated by the adjusting screw. If the pressure of the liquid increases, the flow rate through the knife edged orifice will increase. The piston is moved upward closing off more of the outlet orifices. The same flow rate is thereby maintained , IMI Cornelius Inc.