Installation and Operation Guide

Transcription

1 FRLB2 and FRLB2-S Installation and Operation Guide Revision S-L All Rights Reserved

2 Table of Contents Limited Warranty... 3 Freezer Temperature Requirements... 4 User Safety Notices... 5 Blender Installation Blender Operation... 9 Daily Cleaning and Sanitizing Preventive Maintenance System Descriptions Electrical Schematic Troubleshooting Warranty Procedure

3 Limited Warranty This product is warranted to be free from defects in material and/or workmanship for a period of one year from date of installation, not to exceed fifteen months from date of shipment from our factory. Any part or component which proves to be faulty in material and/or workmanship within warranty period may be returned to f REAL! for warranty credit. All labor for in-market repairs will be furnished by qualified technicians provided by customer at customer expense, not f REAL! expense, unless otherwise agreed to in writing at time of blender purchase. Major repairs determined by f REAL! to require removal of product from market for repair by a factory authorized representative will be performed at no cost to customer. This warranty is subject to the following exceptions/ conditions: Any use of non-genuine f'real! spare parts may, at f REAL! s discretion, void this warranty. Damage caused by carelessness, neglect, improper cleaning or maintenance and/or abuse (e.g., dropping. tampering or altering parts, equipment damaged in shipment, by fire, flood or an act of God) is not covered under this warranty In no event shall f REAL! Foods, LLC be liable for any other damages or losses including, but not limited to, lost sales, lost profits, cost of down time, loss of use of equipment, cost of substitute equipment, claims of Buyer s customers, or any other special, incidental or consequential damages. 3

4 Check Freezer Temperature Before Blender Installation Check Freezer Temperature Before Beginning Blender Installation! A potential cause of difficulties with the f REAL! Blender is the display freezer for frozen cups not being within the required 0 ºF to +6 ºF temperature range. 0 to +6 ºF is the ideal temperature for frozen f REAL! cups at time of blending. If freezer is equipped with a digital thermometer, without opening the freezer door, check to see that temperature of freezer is near the ideal temperature of 0 to +6 ºF. (Note - If freezer is not equipped with a thermometer that can be seen with the door closed, it is best to check the freezer temperature by sticking a temperature probe directly into a frozen cup, with the heat sealed lid still on. The air temperature can change rapidly when the freezer door is opened but the product in the frozen cups will take a minute or more to change temperature.) If freezer is too cold or warm, adjust accordingly, ensuring that temperature stabilizes in desired range. It is best to make an adjustment, and then come back at least 1 hour later to see what the new, stabilized temperature of the freezer is. (Note - If freezer temperature is unexpectedly warm, freezer may be in defrost mode, which takes about one half hour to complete. Check again later to see if temperature comes back down to ideal range. If temperature is still unexpectedly warm, confirm proper installation of freezer baffles below freezer, as instructed by freezer instructions. Also be sure freezer dust filter is not clogged.) If temperature is not in correct range, continue on with installation, but be sure to get temperature corrected or the f REAL! frozen drinks will not be of optimum quality. If frozen cups are warmer than ideal temperature, the blender may not blend them. Extra cold cups will cause the blender to take longer to blend them and will eventually shorten blender life if left uncorrected. If freezer is by Silver King, the best setting to start with is nine o clock on the freezer temperature control located in the back upper-right corner of the freezer. If this does not result in the correct temperature after one hour, adjust accordingly. Counterclockwise makes freezer warmer. Note: The 0ºF to +6 ºF temperature range applies to the display/serving freezer, not the longer term storage freezer. It is best to store frozen cups at 0ºF or colder if they are going to be held for more than a few days. 4

5 User Safety Notice Carefully read and follow all notices in this manual and on the equipment. All labels on the equipment should be kept in good condition. Replace any unreadable or damaged labels. Care should be taken to read and fully understand this Installation and Operation Guide before installing the blender. Failure to comply risks equipment damage, injury, fire, or shock hazard. All installation and maintenance work performed on blender must be performed by a qualified technician. It is the sole responsibility of the Buyer and Installer to ensure that this blender is installed in accordance with the National Electric Code, Basic Plumbing Code of Building Officials, and/or any other local electrical and plumbing codes as they apply. WARNING Connect filtered water supply to blender before connecting to power source. Blender has an electric water heater that begins heating as soon as blender power is turned on. Use only a properly protected electrical circuit capable of the rated load of 15.0 amps at 120V. Follow all applicable national/local electrical and plumbing codes. Read the entire Installation and Blender Operation sections of this manual before using product. Moving components rotate inside blending chamber during blending cycle. Never touch moving components or cup lid when blender is operating. Only use f REAL! Foods approved sanitizers on blender. Do not use chlorine based sanitizers on blender. Use only iodine or quaternary based sanitizers to avoid corrosion of stainless steel blender components. Unapproved use of sanitizers will void blender warranty. 5

6 Blender Installation Prepare f'real! Blender for Installation: Plug-in display freezer 1 hour before putting frozen product in the display freezer. Hoses required to complete installation of blender: 1. 1/4 ID braided hose for water line from filtered water supply, with shutoff valve. (Not Included) 2. 5/8 ID hose able to reach desired drain location in accordance with local ordinances. (Included) Unpack blender from its packing carton. Blender can then be lifted off carton base and placed in convenient location. Lift blender by placing one hand underneath blender cup holder and your other arm around back of blender in a hugging position. 7 Items are packed with blender. They are: 1. Cup lid - A five pound round cup lid shaped like the liberty bell. 2. Blending assembly including three sided lower shaft section - To screw onto bottom of blending shaft. 3. Female quick-connect fitting with a 1/4 barbed end - For use in water line connection. 4. Plastic 1/2 male pipe thread x 5/8 barb fitting - For use in drain line connection of 5/8 ID anti-microbial hose - For use in drain line connection. 6. Sanitizer kit for daily sanitizing - Including 2 Sanitizer cups, 4 brushes, Iodophor sanitizer bottle, test strips and sanitizing instructions. 7. Large bottle of Ecolab Oasis 146 sanitizer - To be used to fill sanitizing rinse reservoir. Open front access door of blender by pulling forward on small metal tab located under lower right corner of front access door. This will open blending chamber for access to blending shaft. Slide cup lid up onto blending shaft, directing shaft down through hole in its center. When properly oriented, the cup lid looks like the liberty bell. (Note: See page 16 of this manual for visual reference.) While holding cup lid up on shaft, thread lower spindle and blending assembly into bottom of blending shaft and hand tighten it hard. Metal Slider should move freely side-to-side. Close front access door by pushing it closed on its right side until you hear/feel it fully close. Fill sanitizing rinse reservoir by pulling straight out on blue front of sanitizing rinse reservoir, located just to left and behind shiny silver cup holder. Pull until tether prevents further travel. Remove front cap of sanitizer reservoir and fill reservoir to nearly full with Ecolab Oasis 146 sanitizer, and then slide reservoir back into position behind cup holder. 6

7 Installation - continued Prepare Power, Water, and Drainage: Power requirement The f REAL! blender requires 15 Amps of 120 Volt power, in compliance with local electrical code. (Note: Extension cords are not acceptable and may void warranty due to improper power supply.) Water line connection The f REAL! blender requires 25psi from a filtered, non-carbonated water source. Ensure water connection complies with local code. The blender is equipped with a male quick-connect fitting at lower back of blender to attach water line to. Connect the included female quick-connect fitting to a braided, flexible 1/4 ID water line from filtered water source using barbed end of fitting. (Note: Purge air out of main water line before connecting female quick-connect to blender.) Drain line connection The f REAL! blender is equipped with a 1/2 female pipe-threaded fitting at lower back of blender to attach drain line to. Ensure drain connection complies with local code. Thread included barbed tubing adapter into drain fitting on blender. Use included 5/8 ID anti-microbial drain line to route rinse/waste water from blender fitting to drain taking care to slope drain line downward all the way to drain to provide for free flow of rinse water. This 5/8 ID line is important because it helps to prevent microbial activity, which keeps line free of buildup over time. When tightening barbed hose fitting into female pipe-threaded fitting, do not over tighten plastic fittings. Install and Connect Blender: Place blender in desired location. Attach included anti-microbial drain line and route drain line tubing for free flow of rinse water. Attach water line by pressing female quick-connect fitting, attached to 1/4 water line as previously described, onto male fitting on blender. Be sure not to damage o-ring on male fitting when connecting female quick-connect. Turn on water pressure to blender. Plug power cord into 120 Volt circuit capable of supplying at least 15 Amps of power. (Note: Do not plug blender and sales floor freezer in the same outlet or power supply.) 7

8 Installation - continued Turn On Blender: Open front access door of blender by pulling forward on small metal tab located under lower right corner of front access door. Turn on blender power using red switch in upper left corner of blender. Upon power up, the new blender will purge water from the top water supply orifice inside the blending chamber for 10 seconds for the first 20 blending cycles. This is used to purge all air out of water supply line and water heater. Close front access door. Blender will begin heating water in hot water heater. Display will show temperature set point of 135ºF and actual water temperature. Water takes about three minutes to heat to set point. When water temperature reaches set point, blender is ready for use. Confirm Normal Blender Operation: Blue LED lights will begin flashing through their cycle, one at a time, and blender display will begin cycling through instructions for operation of blender. Place empty f REAL! blender cup in cup holder. If no empty cup is available, use sanitizer cup provided with blender for this startup procedure. With empty cup in cup holder, confirm that cycling of blue lights has stopped and the three green push buttons (Less Thick, Regular Thickness, and More Thick) are all lighted up. (If this is not the case see troubleshooting section in the back of this guide). Then press and hold center Regular Thickness button for ten seconds. This will start blender running through a full blending cycle in the empty cup. (Note, if center button is released too soon while an empty cup is in the blender, blender will stop its cycle and send the cup back down to its home position, and display will read To Use Blender, Cup Must Contain Hard Frozen Product. This is a safety feature to prevent people from using the wrong cup in blender as well as to prevent people from sending their cups through a second time, as this is potentially unsanitary.) When cycle is complete, remove cup from blender. Check to see that there is 1 and 1/8 inches of warm water in bottom of cup, as measured by placing cup on a flat counter and measuring up from counter to water s surface as faintly seen through cup side wall. This is the amount of water that is added during a regular thickness blending cycle. It s time to make a delicious f REAL! Frozen Beverage! 8

9 Blender Operation f REAL! Blender Operation: Operation of the f REAL! Blender has been designed to be entirely self-serve, and therefore, instructions are provided in several forms on the blender as well as on the f REAL! frozen cups. The Simple Operating Instructions are: 1. Remove your favorite frozen cup from freezer. 2. Remove lid from cup. 3. Place cup in cup holder. 4. Press green button with your preferred thickness. 5. When blender is through, remove your frozen blended drink and enjoy! Potential Mistakes by Customer, and What Happens: If customer does not remove lid, blender will sense this when the blending disc hits the foil lid and blender will reverse itself and bring cup back down to the home position. If customer uses wrong cup, blender will not run (for most cups). The blender senses for the correct height of cup using an infra-red (IR) sensor. The blender will only run when it senses the correct height cup in cup holder. The green buttons will not light up and they will not activate blender if IR sensor does not sense correct height cup. If customer uses wrong cup, but it is right height to trigger IR sensor, green buttons will light up, and blender can be activated, raising cup up into blending chamber and beginning to spin blending disc. However, as soon as blender senses that there is not the expected resistance of frozen product cup, it will stop and reverse itself, bringing cup back down to the home position. A message on the display will appear To Use Blender, Cup Must Contain Hard Frozen Product. If customer places a previously blended cup back into blender, blender can also be activated, raising cup up into blending chamber and beginning to spin blending disc. However, as soon as blender senses that there is not the expected resistance of frozen product cup, it will stop and reverse itself, bringing cup back down to the home position. A message on the display will appear To Use Blender, Cup Must Contain Hard Frozen Product. 9

10 Daily Cleaning and Sanitizing f REAL! Blender must be cleaned and sanitized every 24 hours as follows: 1. Gather: f REAL! Sanitizing Cup, a clean f REAL! Brush in good condition*, dishwashing liquid, and BTF Iodophor Sanitizer bottle or equivalent quaternary sanitizer approved by f REAL!. 2. Thoroughly wash hands with soap and warm water. 3. Put 2 3 squirts of dishwashing liquid into f REAL! Sanitizing Cup and fill cup about half way with hot water. 4. Open blender front door to access blending chamber by pulling on metal tab located under right corner of door. (Do not turn blender power off. Power must remain on for blender to recognize cleaning has been done properly). 5. Using clean f REAL! Brush dipped frequently in Sanitizing Cup with prepared dishwashing solution, thoroughly clean in the following order: a. First, the top and underside of metal cup lid. (Lift lid up along shaft to thoroughly clean underside of lid. This is the most important step in the entire process, so be sure to do it thoroughly every time.); b. Then the top & bottom of blending disc and slider. (Lift lid to access blending disc. Beware of sharp edges.); c. Then the blending shaft; d. Then the gray plastic blending chamber walls and front door liner; e. Then the clear plastic flip-up doors top and bottom, taking care not to press them fully open without supporting them, as this can cause their return springs to break off; f. And last, the interior bottom area of the gray plastic blending chamber. (Do this step last to avoid possible spreading of drain area material onto other cleaned surfaces.) 6. Close front door firmly. Blender will automatically rinse off cleaned components. 7. Rinse out f'real! Blender Sanitizing Cup with room temperature water and fill with room temperature water to Fill Line on Sanitizing Cup. Then add 4-6 drops of BTF Iodophor Sanitizer to room temperature water in Sanitizing Cup. (Or substitute approved quaternary sanitizer diluted to 200 ppm in cup.) 4-6 drops from spout of BTF Iodophor Sanitizer bottle is all that is needed to reach proper concentration. Sanitizing solution is still nearly clear when properly prepared. ** 8. Run 2-minute sanitize cycle: Place Sanitizing Cup with properly prepared sanitizing solution in blender cup holder; Press and hold both Less Thick & More Thick buttons for 5 seconds to begin sanitize cycle. Note: Do not use chlorine based sanitizers on blender. Chlorine sanitizers can cause serious damage to f REAL! blender disc and shaft, and will void warranty. Quaternary sanitizers may be acceptable if approved by f REAL! Foods. Call our Customer Support Center at for more information. 9. While 2 minute sanitize cycle timer counts down, clean f REAL! Brush and hands again with dishwashing liquid to ensure they are as clean as possible for Step 11, and then thoroughly rinse with warm water. 10. When sanitize cycle ends, remove Sanitizing Cup from cup holder, and open front door of blender again. 11. Use cleaned f REAL! Brush dipped frequently in Iodophor sanitizer solution from Sanitizing Cup to thoroughly apply sanitizing solution to: a. First, the underside of metal cup lid. (Lift lid up along shaft to thoroughly apply sanitizer to underside of lid.); b. And then, the top of metal cup lid. Be sure to apply solution to area touched when lifting the cup lid in prior step. 12. Pour remaining sanitizing solution down blender s internal drain located in gray plastic blending chamber. 13. Close front door firmly. Blender will automatically rinse off sanitized components. 14. Rinse f REAL! Brush and Sanitizing Cup thoroughly with hot water. Allow to dry and save for next day s use. * Notice: To avoid compromising f REAL! Blender cleaning and sanitizing, do not use f REAL! Sanitizing Cup or f REAL! Brush on equipment other than f REAL! Blenders. Replace sanitizing brush every three (3) weeks with new f REAL! Brush provided in kit to be sure brush is in good condition. Order replacement sanitizing kit as necessary by calling f REAL! Customer Support at ** To confirm Iodophor sanitizing solution is properly prepared, test strips are provided in vial with all sanitizer kits available from f REAL!. To use test strips: Remove test strip from vial using dry fingers. Dip test strip into prepared Iodophor sanitizing solution for 60 seconds without agitating, and then remove. Compare color of test strip to color comparison chart provided in vial. Colors in range from 12.5 ppm to 25 ppm confirm proper sanitizer concentration. 10

11 Preventative Maintenance Preventative Maintenance Recommendations The f REAL! Blender is designed to be virtually maintenance free. We do recommend these simple maintenance steps be taken to ensure trouble-free operation. Blender Refill automatic sanitizer reservoir monthly. The f REAL! FRLB2-S Blender automatically performs a sanitizing rinse of its blending components after each blending cycle. A sanitizer reservoir in the blender provides concentrated sanitizer for this sanitizing rinse. Pull forward on blue plastic front of sanitizer reservoir, located just to left and behind the silver cup holder, until tether prevents further movement forward. Remove reservoir cap and refill with Ecolab Oasis 146 sanitizer. If reservoir is more than half full, refilling every other month or less frequently is acceptable. Sanitizer is available from Ecolab or from f REAL! Foods Customer Support Center at Check water shot quantity after first month and then semi-annually. The f REAL! Blender adds a shot of warm water to the frozen cup as it blends. It is important that the proper amount of water be added to get the right thickness of frozen beverage. The proper water shot for a regular thickness beverage is 75 milliliters. See page 13 step #3 for further instructions on setting and testing water shot. This should be done after the first month of operation of blender, and then semi-annually thereafter. Change fluorescent bulbs annually. The three fluorescent bulbs behind the backlit panel should be changed once each year even if they are still working. One year is their design life and they will go out soon afterward if they are not changed. Remove the plastic backlit panel and change out all three bulbs with F6T5 bulbs available from the f REAL! Customer Support Center Freezer Clean freezer filter monthly. Follow instructions provided with freezer to clean dust filter. For the f REAL! freezer by Silver King, filter is accessed from front bottom left of freezer. Remove filter monthly and clean by running water through it until all dust is washed off. Blow off freezer condenser coils annually. The condenser coils slowly collect dust. They should be blown off once each year with compressed air. Remove the panel on the back of the freezer to access the coils and blow them off once each year. Recommended Preventative Maintenance Schedule Summary Monthly Semi-Annually Annually Clean Freezer Filter Blow Off Condenser Coils Check Water Shot Change Fluorescent Bulbs Refill Sanitizer Reservoir At end of 1 st Month And 11

12 Preventative Maintenance - continued Programming Water Shot Setting This water shot calibration is to be performed semi-annually during regular preventative maintenance and when replacing the main control board on blender. Procedure to Check and Set Water Shot Quantity: 1. Open front door and turn off power to unit by switching off red power switch at upper left. 2. Press and hold all three green buttons on front door (Less Thick, Regular Thick, More Thick). 3. Turn power back on while still pressing and holding the three green buttons. 4. Continue to hold the three green buttons until you see the display reading Sec on top row, and LESS TEST MORE on the bottom row. Note: Front door must remain open while making water shot adjustments. 5. Press the middle TEST button and immediately catch the water coming from the water injecting hole located just to the right side of the top of the blending shaft using the f REAL! Water Measuring Cylinder - Part number ( ) from the f REAL! Customer Support Center. 6. Water shot quantity should be milliliters (grams). If a measuring cylinder is not available, it is possible to catch the water shot in an empty f REAL! cup. After capturing water in cup, place cup on a flat surface and measure 1 1/8 from flat surface to top of water, which is slightly visible through sidewall of cup. To improve visibility of top of water, shine light down into cup as you measure. Height should be exactly 1 1/8 to top of water from surface cup is resting on. A slight difference makes a significant difference in thickness of frozen beverages, so measure carefully. 7. Adjust Sec for water shot timing by pressing corresponding green button on the front door display for MORE or LESS water to be dispensed. Adjustment range is from seconds. The higher the number of seconds, the more water will be dispensed. Note: If you need to adjust water shot to more than 6.0 seconds there may be a water restriction/clog in the pressure regulator or water valve which needs to be cleared up. 8. Press TEST (Regular Thick Button) and immediately catch water shot to check your changes. 9. Make additional adjustments to water level as needed to obtain milliliters. When water shot is properly set, close front door and press green button (Less Thick) corresponding to SAVE your setting. If you do not press SAVE, blender will return to setting from before you initiated changes without saving your new setting. Note: There is a program timer that will exit this programming mode without saving your new setting if no green buttons are pressed for 25 seconds. 12

13 System Operation Descriptions f'real! Blender Systems - Overview: The f REAL! Blender begins with real ingredients, such as real ice cream and milk for milkshakes, which are pre-frozen in a patented blending/serving cup. The cup is placed in the blender s cup holder. Customer chooses a thickness by selecting one of green user buttons on the front panel. The blender raises the cup up to its shaving/whipping components in the blending chamber and shaves through the hard frozen product while adding hot water to the frozen shavings. The blending disc then accelerates to high-speed and makes multiple passes up and down through the product, blending and whipping the combined mixture into delicious frozen beverages like real ice cream milkshakes. When the blending cycle is complete, the serving cup returns back down to the home position where it may be removed and enjoyed. The blender then automatically rinses and sanitizes the blending components and blending chamber to be ready for the next customer. System Descriptions and Functions: Backlit Panel If not already in place, a backlit panel should be placed in blender by directing tabs on panel s edges into slots at edges of blender s opening for the backlit panel. Press panel fully into position. Water System The blender has a hot water system to add hot water to frozen beverages during blending and also to rinse blending components and blending chamber with sanitizing water after each blending cycle. A filtered water line is attached to the blender using a barbed female quick-connect fitting. This fitting is engaged with a male fitting on the utility panel at the bottom back of the blender. Following the flow of water inside the blender from the connection point there are: 1. A pressure switch to ensure there is adequate water pressure to the blender. If water pressure drops below 25 psi., the display reads Water Pressure Too Low and the blender will not operate until water pressure is restored. 2. A pressure regulator which reduces the water pressure to 25 psi. 3. A water heater to heat the water to 135ºF. The heater also has a manually re-settable high temperature cutoff attached as a safety feature. 4. A blending water valve to direct water flow into frozen beverages during blending via a hose leading to an orifice in top of blending chamber, just to the right of blending shaft. 5. A sanitizing water valve to direct rinse water flow via a hose leading to the sanitizer injector, where sanitizer fluid is mixed into rinse water, and then to two sanitizing rinse nozzles located in blending chamber s left side. 13

14 System Operation Descriptions - continued Motors and Motion System The blender has two motors with associated positioning and blending mechanisms: The position motor, mounted near the bottom of the blender, drives the cup holder up and down via a toothed belt and positioning screw. The spindle motor, mounted near the top of the blender, drives the main blending shaft via a toothed belt. System Controls - Control Board The blender has a custom logic and motor control board which controls all blender functions and provides safety and diagnostic functionality. Off-Board Safety Override Controls There are four safety controls that are off the control board so they function independently from the control board in case of a control board failure. Off-board safety override controls are: 1. Manually re-settable 180ºF thermal overload protection on the hot water heater. 2. Manual In-line fuse for thermal overload protection on the position motor. 3. Automatically resetting thermal overload protection on the blending motor. 4. Safety door circuit, which passes through four safety switches, all of which have to be closed to allow power to reach the main motor switching relay. If this safety door circuit is broken, power is cut off to motor switching relay which immediately cuts power to both motors, stopping the blender. The four switches in the circuit are as follows: 1. Door switch for front access door, just below door locking solenoid at top right of blender. 2. Switch on clip at back of left hand clear flip-up door 3. Switch on clip at back of right hand clear flip-up door 4. Actuator switch mounted next to blender position screw and linear slide, down near the bottom, which overrides flip-up door switches when flip-up doors are opened by cup holder moving up through them. 14

15 System Operation Descriptions - continued Items monitored, controlled and/or powered by the control board: 1. LCD display is used to display operating instructions to the self-serve user as well as to display alert and diagnostic messages for the operator. 2. Four blue LED lights light up in sequence during normal operation. They will also all flash simultaneously to provide an error alert when the LCD display displays specific error messages, such as when daily cleaning or sanitizing have not been done for 72 hours. 3. Three green buttons, each with internal LED light, start blender or allow for other operator input. 4. Infrared cup sensor senses presence of correct size cup. IR sensor and receiver are mounted on right hand side of blender at height of cup holder, behind dark red lens. 5. Hot water heater to heat water to 135ºF. When blender is first turned on, temperature set point and actual water temperature are displayed on display and blender will not function until water temperature reaches set point of 135ºF. Once set point is reached first time, water temperature is not displayed and blender function is not interrupted by water temperature again. 6. Two drive motors (position and spindle), including full time, closed loop monitoring of RPM and amperage for comparison to expected values. 7. Bottom and top IR limit switches monitor cup holder movement. Bottom limit switch acts as home for cup holder movement at end of each blending cycle. Upon power up of blender, blender will also attempt to move cup holder down until this switch is mated in order to prepare for start of next blending cycle. Top limit switch provides only a fault detection function, stopping blender and triggering an error message display if cup holder rises too high during its programmed travel. 8. Safety switches for front access door and clear plastic flip-up doors ensure these doors are properly closed during blender operation, protecting customers and employees from potential injury from rotating components. 9. Safety interrupt for unexpected resistance during cup holder move up or down. While cup holder is moving up from or down to its home position, blender monitors current draw of position motor, and if an unexpected load is detected, cup holder reverses direction immediately. If cup holder was on the way up, it comes back down to its home position. If cup holder was on the way down, it rises about 1/4 and stops. This safety feature protects against potential injury to customers or damage to blender if an obstruction is placed in path of cup holder motion. 10. Daily cleaning and sanitizing cycles are required. If the front access door is not opened for 72 hours to clean the blending chamber, a Service Required, Notify Attendant error message will appear on the front display and attendant will be directed to an additional message, Cleaning Inside Required Daily (which is not shown to the customer). Blender will lock out until front door is opened and cleaning is performed. If sanitize cycle is not performed for 72 hours, Service Required, Notify Attendant error message will appear and attendant will be directed to an additional message, Use Sanitize Cup, Run Sanitizing Cycle. Blender will lock out until full 2 minute sanitizing cycle is completed. 15

16 System Operation Descriptions - continued f'real! Blender Component Identification: Component Identification is shown with parts spatially oriented as they are found in the blender, with replacement part numbers indicated CONFORMAL SLIDER 16

17 Electrical Schematic 17

18 Electrical Schematic - continued Dip Switch Descriptions Four dip switches are located on the blender circuit board. The standard settings for the FRLB2-S blender are - Off, Off, Off, On. That is, - Down, Down, Down, Up. Their functions are as follows: Switch 1 - Automated Sanitizer Bypass. This switch is only set Up to On when the circuit board is used with an model FRLB2 blender, which does not have the automated sanitizer feature. All FRLB2-S blenders have the automated sanitizer feature, and this switch should be set Down to Off. Switch 2 - Infrared sensor monitoring. If switch 2 is set Up to On, display shows strength of signal being received by infrared cup size sensor. When a standard size milkshake cup is present, the first two sets of 000 s on top line should read 255 M 255, though they may read slightly lower values. If either of these signals registers below 150 when a milkshake cup is present in cup holder, sensor should be replaced. If this is happening, recalibration of infrared sensors may be needed. See Calibration section below. Switch 3 - Motor monitoring. If switch 3 is set Up to On, top display line monitors Position Motor and bottom line monitors Spindle Motor. Farthest right digits, measure motor Amps. Middle digits, 0000 measure motor RPMs. Farthest left digits, 0000 on top line measure counts of the rotating position screw as sensed by the Position Screw Sensor. Switch 4 - Self-Serve speed. Blenders used in self-serve operations are designed to move cup holder up and down from blending zone at slower speed by switching switch 4 Up to On. Switching to Off is only for operator-assisted settings where operator is fully knowledgeable about blender operations. Calibrate - Infrared Sensor Recalibration is required if control board or infrared cup size sensor are replaced. To recalibrate, place any f'real! cup in cup holder and switch red blender power switch off. Press and hold both Less Thick and More Thick green buttons while turning power back on with red blender power switch. LCD screen will say Cup IR Sensor Recalibrating and blender will automatically begin recalibrating. Release green buttons. When recalibrating is complete, blender will say IR Recalibrated SAVE or CANCEL. Press green SAVE button (less thick) to save recalibration. Recalibration is complete. If SAVE button (less thick) is not pressed to save recalibration, blender will not be recalibrated. 18

19 Error Message Troubleshooting - Alphabetic List f REAL! operates a Customer Support Center. Our hours are 6:00am to 9:00pm CST 7 days a week. We are here to help you at option 1 or questions to callsupport@freal.com. Note: If an error message displays on blender screen, first turn blender off and on and then try to run another frozen f REAL! product. This will either clear or validate the error message. If message continues, find message below, listed alphabetically, for more troubleshooting/repair instructions. Auto-Sanitizer Is Running Low. Refill Sanitizer Reservoir Located Behind Left Side of Cup Holder. Use Ecolab Oasis 146 Sanitizer. Blender Will Run XXX More Cycles Before Lock-out if Not Refilled. Push Less & More Again To Resume. When sensor recognizes sanitizer is low in sanitizer reservoir, the blender displays this warning message during 2-minute sanitize cycle. You are allowed up to 350 more cycles before blender locks out making blender inoperable. 1. Fill sanitizer reservoir with Oasis 146 Quaternary Sanitizer by pulling out sanitizer reservoir located to left side of cup holder. Once filled, slide reservoir back in place. Sensor will recognize sanitizer level in reservoir and reset blender. (Note: Use only Oasis 146 Quaternary Sanitizer in reservoir. Other sanitizers will damage blender and could cause food safety risk.) 2. If problem continues, when facing front of blender, remove four screws from left side panel. Next to sanitizer reservoir is a sensor mounted to a metal bracket. This sensor has a LED light that will illuminate orange when it senses liquid in the reservoir. If orange light is not on, then bend sensor bracket in towards reservoir until sensor is touching reservoir. If orange LED still does not light up on sensor, then replace sensor. 3. To temporarily by-pass the sanitizer sensor, locate the 4 dip switches on the control board at the back of the blender. Turn on dip switch #1. As soon as the sensor is replaced, turn #1 off. Auto Sanitizer Is Now Empty. Refill Sanitizer Reservoir Located Behind Left Side of Cup Holder. Use Ecolab Oasis 146 Sanitizer. Blender Lockout Now In Effect. Refill Sanitizer To Reset Lockout. When sensor recognizes that sanitizer reservoir is empty, the blender displays this message. The blender is now inoperable until sanitizer reservoir is filled up with Oasis 146 Quaternary Sanitizer. 1. Fill sanitizer reservoir with Oasis 146 Quaternary Sanitizer by pulling out sanitizer reservoir located to left side of cup holder. Once filled, slide reservoir back in place. Sensor will recognize sanitizer level in reservoir and reset blender. (Note: Use only Oasis 146 Quaternary Sanitizer in reservoir. Other sanitizers will damage blender and could cause food safety risk.) 19

20 Troubleshooting - continued 2. If problem continues, when facing front of blender, remove four screws from left side panel. Next to sanitizer reservoir is a sensor mounted to a metal bracket. This sensor has a LED light that will illuminate orange when it senses liquid in the reservoir. If orange light is not on, then bend sensor bracket in towards reservoir until sensor is touching reservoir. If orange LED still does not light up on sensor, then replace sensor. 3. To temporarily by-pass the sanitizer sensor, locate the 4 dip switches on the control board at the back of the blender. Turn on dip switch #1. As soon as the sensor is replaced, turn #1 off. Blade Failure Call for Service. During blending process this message will display and shut blender down if spindle motor sees lower resistance than expected. This may indicate a failed blending disc or frozen product that is too soft. Open front door of blender and cycle power on and off. This will return cup holder to the home position so blending disc can be inspected. Next, lift up cup lid to look at the round blending disc. 1. Inspect large (2 diameter) blending disc located inside the blending chamber. (See page 15) 2. Replace blending disc if cracked, broken or missing. (Note: If replacement is necessary, please call f REAL! Call Center immediately at to report the situation. This is a highly unusual failure and one we take very seriously if it happens.) 3. Check the temperature of the freezer unit. Product must be kept between 0-6 degrees. If temperature is not correct, adjust freezer unit. 4. In some instances this message will be displayed if frozen product in f REAL! cups has air pocket in it prior to blending. To check, cycle power to blender and run another frozen product to test blender. If blender operates correctly, then the incident is isolated and blender is working properly. If you encounter this issue and you still have the product that did not blend properly, please record that product s flavor and full date code located on side of cup and report this to f REAL! Call Center. Check Lower Limit Switch For Error Service Required. Notify Attendant. With a f REAL! cup placed in cup holder, press one of the green push buttons and message appears. Locate lower limit switch by removing blender right side panel when facing front of blender. Looking inside blender and towards the bottom you will see a 1-inch by 1-inch circuit board. 1. Wipe off two black posts (optical eyes) of the switch. 2. Verify the three-wire connector is securely fastened to circuit board. 3. Verify wire connection TB9 - Bottom Limit is securely fastened to main electronic control board. 4. Try lifting the cup holder up by hand. If you are able to then, the ZBX nut may be broken. 5. If problem persists, replace limit switch. 20

21 Troubleshooting - continued Check Top Limit Switch For Error Service Required. Notify Attendant. While frozen product is being blended this error message is displayed and blender stops in mid-cycle. Cup holder remains up inside blender. Locate top limit switch by removing blender right side panel when facing front of blender. Looking inside blender and towards the top you will see a 1-inch by 1-inch circuit board. 1. Wipe off two black posts (optical eyes) of the switch. 2. Verify the three-wire connector is securely fastened to circuit board. The white wire should be toward front of blender with black wire toward back of blender. 3. Verify wire connection TB9 - Bottom Limit is securely fastened to main electronic control board. 4. If problem persists, replace limit switch. Cup Obstruction During Move Down Service Required Notify Attendant. Symptom 1: Message Appears After Frozen Product Is Blended And Cup Holder Is Returning To Home Position If during the blending cycle, this message is displayed, an object or high resistance on the lead screw has interfered with the cup holder lowering. Cycle power to blender and close front door to bring cup holder to the home position. 1. Remove any object interfering with cup holder moving down. 2. If problem persist, apply Quinplex grease on the lead screw and rerun frozen product. 3. Check the position motor pulley to make sure it didn t slide down the position motor shaft. If so, move pulley up and re-tighten the set screws. 4. If problem still continues then realign the lower bearing. Call f REAL! Customer Support Center for instructions on completing this realignment. Symptom 2: Message Displays Immediately After Pressing One Of The Green Push Buttons 1. Verify that the cup holder is not resting against the aluminum block located underneath the cup holder. You should have at least a ¼ inch gap between cup holder and the aluminum block. If you do not have the ¼ inch gap then raise cup holder up by turning the lead screw located on the top of the blender. 2. If problem persists, then replace electronic control board. The directional relay for position motor has failed. 21

22 Troubleshooting - continued Cup Obstruction During Move Up. Symptom 1: Someone Grabs The Cup Holder While It Rises Up While the cup holder moves up this error message appears when the position motor is seeing high current when turning the lead screw. This error message can occur while the cup holder is rising up and someone grabs the cup holder trying to hold it in place or if an object is in the way of the cup holder and prevents the cup holder from raising. 1. Remove any obstruction from the path of the cup holder. 2. Open front door and cycle power to the blender by turning the power off and then back on. The power switch is located in the upper left hand corner of the blender. After closing the front door the blender will lower the cup holder to the home position. Symptom 2: If Blender Makes Noise While Moving Up and This Error is Displayed 1. Use only Quinplex grease to lube the lead screw. Place an empty f REAL! Sanitizer cup in the cup holder and hold the Regular Thickness button for 10 seconds or place frozen product in the cup holder and run the blender 2-3 times to work the lube in on the lead screw. Note: You may need to run the blender more times until error message disappears. 2. Check the position motor pulley to make sure it didn t slide down the position motor shaft. If so, move pulley up and re-tighten the set screws. Cycle Interrupted Notify Attendant Symptom #1: Cup Holder Travels Up and Just As It Gets to the Flip Up Doors It Stops. 1. The micro switch is sticking and will need replaced. Symptom #2: After the Cup Starts to Blend This Error Displays 1. Remove the backlit panel from the front door Marketing material displaying f REAL! frozen products. Locate the magnet in the upper right hand corner, inside the front door. Verify magnet is not broken and still visible. Replace magnet if broken or missing. 2. Verify that the two black wires from the black magnetic reed switch going into a white connector are securely connected. 3. The double door arms with springs are fastened to the backside of the flip-up doors, verify they are still connected to the right and left flip-up doors and are making contact with the micro lever switch when the flip-up doors are fully closed. 4. Replace flip-up door if double door arm does not fasten correctly to flip-up door. 22

23 Troubleshooting - continued Symptom #3: As the Cup Holder is Going Down This Error Displays 1. This happens because the flip up doors didn t close like they should. They could be hanging up on the blending chamber before they are closing. 2. Verify that the flip up doors operate without any binding or tightness. Cups Too Cold Notify Attendant Blender Is Working Fine More Directions Will Show Here When Attendant Opens Front Door. Front Door Open: Freezer Temp May Be Cold Run Cup That Is Frozen Less Hard To Return To Normal Operation. The blender measures the resistance of the frozen product in the cup. If the resistance of the frozen product is too hard in the first ½ inch of the product, this error message appears. On the third consecutive Too Cold (-10 or colder) frozen product that is attempted, this error message appears. The blender is working fine but gives a warning that the freezer thermostat may be set too cold or product was taken out of walk-in freezer (-20 degrees) and put to the front of the display freezer shelf. 1. Remove the attempted blended cup and this error message clears. 2. Verify display freezer temperature is 0 to +6 degrees. 3. Run frozen product that is less frozen to reset counter. Product temperature should be 0 to +6 degrees with thermometer in center of product. 4. Stores are to rotate product up from bottom shelving and fill bottom shelf with new frozen product to allow time to thaw to 0 to +6 degrees. Cups Too Warm Notify Attendant Blender Is Working Fine More Directions Will Show Here When Attendant Opens Front Door. Front Door Open: To Use Blender Cup Must Contain Hard Frozen Product. Freezer Temp May Be Too Warm Run Cup That Is Frozen Hard To Return To Normal Operation. On the third consecutive frozen product that is attempted to blend this error message appears. The blender is working fine but gives a warning that the freezer may not be working properly. 1. Remove attempted blended cup and this error message clears. 2. Verify display freezer temperature is 0 to +6 degrees. 3. Verify front door of freezer is closing fully and not being held open by frozen product. 4. Run frozen product that is hard frozen to reset counter. 23

24 Troubleshooting - continued Hi Mixer Current Check Blade/Cup Round Blade May Be Bent Down And Hitting Bottom If So- Replace It During the blending process this message will display if the round blending disc has hit the bottom of the cup holder and has bent or broken the blending disc. Open the front door to the blender and lift up the cup lid weight to look at the round blending disc. 1. Verify if the blending disc is bent or broken and replace if broken or bent. (See Page 16) 2. Check the amount of water being added to cup and adjust if necessary. The correct amount of water is ml. (See page 11) 3. Verify that the freezer temperature is between 0 and +6 degrees. Adjust as necessary. 4. Run another shake, if cycle completes with no issue then monitor blender. 5. If issue continues or error will not clear, then replace control board. Less Thick Button Is Stuck This error message appears if the green Less Thick push button is stuck in. The Less Thick push button light is stuck ON, or when a customer places frozen product cup in cup holder and the cup holder raises up automatically. 1. Massage the button left to right and up and down to work button free. This may take a few minutes. If you can t free up the button, replace. 2. If problem continues, see troubleshooting guide for Cup Obstructions on pages Mix Motor Cutout High Temperature Service Required Notify Attendant Mixer current is less than 0.1 amps for 5 seconds. When the cup holder raises up into the blending chamber, the blender stops and this error message is on the blenders display. Locate the spindle motor by removing the right side panel, then remove the back panel along with the top blue panel. The spindle motor is the motor turning the upper pulleys that mixes the frozen products and is located on the back and top portion of the blender. 1. Verify that the lead wires that come out the side of the spindle motor to a white connector is connected securely. Make sure wires are fully seated into white connector. Tape this connection with electrical tape. 2. Spin the spindle motor by hand. If motor makes noise or is hard to spin. Replace the spindle motor. 24

25 Troubleshooting - continued 3. Verify display freezer temperature is 0 to +6 degrees. 4. Bend the front door switch forward. 5. If problem persist, then replace spindle motor. Mix Motor Encoder Failure Service Required Notify Attendant The encoder doesn t detect any movement from the mix motor for a period of 6 seconds. With a frozen product cup in the cup holder and one of the green buttons is selected, the cup holder raises up into the blending chamber then this error message appears on the display. Locate the spindle motor by removing the right side panel when facing the front of the blender, then remove the back panel along with the top blue panel. The spindle motor is the motor turning the upper pulleys that mixes the frozen product and is located on the back and top portion of the blender. 1. Verify that the lead wires that come out the side of the spindle motor, to a white connector, are secure. 2. Verify that the wires for the encoder, connected to the bottom of the spindle motor, are connected securely to the square connector and to the electronic control board located at the back of the blender. Location TB12 Mix Motor Sensor. 3. Verify the operation of the mix motor by doing a rinse cycle. The spindle motor should spin during the rinse cycle. If not then check the resistance of resistor R115 this is the largest resistor located on the lower left of the electronic control board. The resistance should be less than 1ohm. Typically, if this resistor is blown, it will measure high resistance on your multi meter and the motor will not spin. 4. If R115 resistor is blown then replace electronic control board. 5. If green LED MM Safety does illuminate, then replace spindle motor. More Thick Button Is Stuck This error message appears if the More Thick push button is stuck in. The More Thick push button light is stuck ON, or when a customer places frozen product cup in cup holder and the cup holder raises up automatically. 1. Massage the button left to right and up and down to work button free. This may take a few minutes. If you can t free up the button, replace. 2. If problem continues, see troubleshooting guide for Cup Obstructions on pages