Cornelius FCB - 2 Flavor Page 1 Service Manual Download

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FCB PINNACLE

2 and 4 Flavor

Service Manual

FCB - 2 Flavor

FCB - 4 Flavor

Release Date: October 30, 2003

Publication Number: 560007298SER

Revision Date:

May 07

, 20

Revision:

Summary of Contents for FCB - 2 Flavor

Page 1: ...FCB PINNACLE 2 and 4 Flavor Service Manual FCB 2 Flavor FCB 4 Flavor Release Date October 30 2003 Publication Number 560007298SER Revision Date May 07 2014 Revision J...

Page 2: ...n the equipment have been trained and are skilled in working with electrical plumbing pneumatic and mechanical equipment Appropriate safety precautions should be followed and all local safety and cons...

Page 3: ...Mode Recommendations 7 4 Viscosity Setting 7 Service 8 Preventive Maintenance 8 Preventive Maintenance Summary 8 Cleaning Air Filter Integral Only 8 Sanitizing 8 Stainless Steel Double Check Valve Ins...

Page 4: ...Replacement Baldor 52 Condenser Fan Motor Replacement Integral Only 53 Condenser Filter Replacement Integral Only 53 Foam Pack Replacement 54 Compressor Replacement 55 Hot Gas Valve Rebuilding 55 Puls...

Page 5: ...properly Do not let anyone operate the machine without proper training This appliance is not intended for use by very young children or infirm persons without supervision Young children should be sup...

Page 6: ...the freeze cylinder be careful to avoid crushing fingers between the magnet and any ferrous metal Keep the magnet free from metallic debris and wipe clean prior to reinstallation WARNING Strong Magnet...

Page 7: ...n covered with panels The panels enclosing the components and frame are easily removable to facilitate installation service and maintenance Each barrel has a transparent faceplate with an integral rel...

Page 8: ...Overcounter Integral Remote 4 Flavor w Cornelius Cart Height 43 75 in 43 75 in 74 75 in 74 75 in Width 14 5 in 28 in 14 5 in 28 in Depth 31 in 36 in with drip tray 31 in 36 in with drip tray 32 in 37...

Page 9: ...one required for each two barrels 561441250 Refrigeration line sets with flexible end and 90 degree fittings one required for each two barrels 561441253 Cornelius cart stainless steel 2 Flavor 6202017...

Page 10: ...where the FCB machine is operational and the minimum throughput set forth in the matrix above is not met on a per barrel basis product should be dispensed and discarded to increase throughput and help...

Page 11: ...ting The control system in Cornelius FCB equipment includes a function to select the desired product viscosity This function is referred to as Viscosity Setting There is a selectable Viscosity range o...

Page 12: ...hould be sanitized every 6 months per the following procedure using a non scented liquid household bleach containing a 5 25 sodium hypochlorite concentration 1 Press OFF from the BARREL STATUS menu on...

Page 13: ...usehold liquid detergent per gallon of warm water Connect the sanitizing fitting p n cc 28688 to the bag in box connector Put the connector in the bucket of wash water Turn barrel 1 blendonator ON fro...

Page 14: ...barrel 1 dispensing valve Open the dispense valve and dispense all plain water from the freeze cylinder and the blendonator As the plain water level lowers in the freeze cylin der partially close the...

Page 15: ...until water flows from the valve then close the valve Place barrel 1 in MOTOR mode from ON OFF MOTOR menu to start barrel 1 beater Allow beater to operate for 2 minutes then place barrel 1 in OFF mod...

Page 16: ...repairing the machine The control system needs to be accessed in the following situations Installing the Pinnacle Checking performance Servicing repairing the machine Checking for error messages The...

Page 17: ...SLEEP TIME menu 6 SET DEFROST select time menu 7 SET DEFROST set time menu 7A VISC SET menu 8 VISC DISPLAY menu 9 EVAPORATOR TEMPERATURES menu 10 TOTALS menu 11 DIAGNOSTICS menu 12 BARREL DATA menu 1...

Page 18: ...happens if that button is pressed Pressing a button performs the action labeled just above the button For example from the BARREL STATUS menu pressing button 1 labeled MENU displays a menu with more o...

Page 19: ...on ACTIVE 3 OFF turn all freeze cylinders OFF beater bar OFF and refrigeration INACTIVE 5 ERR Pressing ERR displays the ERROR menu which lists all system errors NOTE If there are no errors the ERR mes...

Page 20: ...menu SET WAKE UP go to SET WAKE UP menu SET SLEEP go to SET SLEEP TIME menu SET DEFROSTS go to SET DEFROST menu VISCOSITY SET go to VISC SET Menu menu VISC DISPLAY go to VISC DISPLAY menu EVAPORATOR T...

Page 21: ...or a list of messages CHOOSE MODE Menu Button Descriptions 1 BACK go back to the previous menu 2 ON turn the selected cylinder ON beater bar TURNING and refrigeration ACTIVE 3 OFF turn the selected cy...

Page 22: ...S menu menu 15 To set the time and or date press NEXT to select 1 of 6 fields HOURS MINUTES AM PM if used DAY MONTH YEAR Press UP and DOWN to change the field Then press BACK to save the changes The c...

Page 23: ...that day The preset time format used by the system will be used by the SET WAKE UP menu A WAKE UP must be set for every SLEEP The wake up program will run a 2 minute defrost whether it follows a sleep...

Page 24: ...LEEP See 3 Sleep Mode Recommendations on page 7 The merchandiser will stay ON during the SLEEP and the Motors and Barrel Refrigeration will be OFF The function of the ice bank during the SLEEP will de...

Page 25: ...back to the previous menu 2 DAY cycle through the list of days 3 GO go to the second defrost menu SET DEFROST TIME 4 UP increase the defrost number for this day 1 9 5 DOWN decrease the defrost number...

Page 26: ...osting There are no defrosts programmed from the factory To set defrost times 1 Press DAY to select 1 of 8 options SUNDAY MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY ALL DAYS 2 Press GO to advan...

Page 27: ...between cylinder selection and viscosity setting 4 UP increase the selected field by 1 hour or 15 minute increment 5 DOWN decrease the selected field by 1 hour or 15 minute increment To change the vis...

Page 28: ...ttings For example with a viscosity setting of 2 the system calls for refrigeration when the viscosity drops below 43 Refrigeration continues until the viscosity reaches 60 when leveling begins NOTE T...

Page 29: ...temperature The temperature scale used F or C is based on your input in the OPTIONS menu menu 15 The maximum temperatures are 97 F for the barrels BRL 1 or 2 and 48 F for the ice bank IB 1 The minimu...

Page 30: ...en in SLEEP mode COMP n xxxxx HR number of hours compressor n has run COMP n xxxxx CYC number of run cycles compressor n has performed AGITAT n xxxxx HR number of hours agitator motor n has run BRL ON...

Page 31: ...up When that cylinder is done the next cylinder group will begin After the cylinders the ice banks information is displayed on an ice bank by ice bank basis DIAGNOSTICS Menu Button Descriptions 1 BACK...

Page 32: ...to the previous menu 4 UP scroll list up 5 DOWN scroll list down BARREL DATA menu information BARREL status of cylinder n ON OFF MOTOR DEFROST ERROR EVAPS IN evaporator temperature IN EVAPS OUT evapor...

Page 33: ...pointer to the desired cylinder number and press ON or OFF to turn the auto matic filling ON or OFF BLENDONATOR Menu Button Descriptions 1 BACK go back to the previous menu 2 ON turns blendonator aut...

Page 34: ...ecurity lockout is enabled lockout will engage 15 minutes after last button press Once lockout is engaged the display goes to BARREL STATUS menu and the MENU button 1 is disabled Security is disengage...

Page 35: ...ple Valve is located in a different position then FIGURE 25 see the schematics in Appendix A for the two alternate constructions section 1 and 2 and their respective Brixing instructions 5 Open the va...

Page 36: ...re than turn increments Repeat steps 4 through 6 for each adjustment until desired Brix setting is achieved 9 After finishing step 8 for first barrel repeat steps 1 through 8 for next barrel NOTE If B...

Page 37: ...based on the status of the selected cylinder When not in defrost button 2 will read DFRST When in defrost button 2 will read CANCL Pressing DFRST will begin a manual defrost on the selected cylinder...

Page 38: ...8 VOLT The VOLT menu displays line voltage at the contactor The voltage will be displayed in Volts RMS VOLT Menu Button Descriptions 1 BACK go back to the previous menu FIGURE 28 Voltage 2003 2014 Cor...

Page 39: ...History Log Information The error history log records errors to diagnose potential issues The error log will retain information on the 50 most recent sets of events All errors dated will have occurred...

Page 40: ...nction box is good high voltage may not be getting up to the main board Check this voltage at J10 on the main board If the voltage is good at the board and the low voltage error remains main board is...

Page 41: ...er OFF Motor OFF Last Known State of System SYRUP SYRUP X CO2 Sold Out 8 Auto OFF Motor OFF Last Known State of System CO2 CO2 OUT H2O Sold Out 9 Auto OFF Motor OFF Last Known State of System H2O H2O...

Page 42: ...ith the unit to remove the magnet NOTE Sufficient force must be used to break the mag net lose from the end of the cylinder CAUTION The magnet is very strong heavy and fragile Be careful not to pinch...

Page 43: ...ont of the cylinder Reinstall 4 washers and nuts finger tight Then approximately 1 4 turn with a wrench FIGURE 33 FIGURE 34 9 When all the hardware is securely in place turn the blendonator ON then tu...

Page 44: ...board and connect them to the new board Make sure that the thermistor harness is not removed with the old board 5 Connect the power 6 Re attach the panels 1 Disconnect the power to the unit 2 Open the...

Page 45: ...ip 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 Pull the chip p...

Page 46: ...board and connect them to the new board 5 Connect the power and check that the D33 light comes on 6 Re attach the panels 1 Disconnect the power to the unit 2 Open the merchandiser door then remove to...

Page 47: ...ibbon cable protruding through the top FIGURE 40 6 Reconnect the wires while installing the cover 7 Connect the power and check to see that the control panel works properly Secure the circuit board do...

Page 48: ...location noted in step 3 1 Disconnect the power to the unit 2 Remove side panel 3 Remove contactor starter cover 1 screw Disconnect contactor 2 nuts Do NOT detach the wires from the contactor yet 4 On...

Page 49: ...rews holding motor on angled brackets 6 Replace the bad pump in the reverse order of steps 3 through 6 7 Re connect the CO2 water and syrup Turn the bottom blendonator brix valve to blendonator positi...

Page 50: ...4 Disconnect quick disconnect from float assembly Unplug wires Unscrew float assembly Remove pins from wire connector 5 Unscrew float from assembly 6 Reverse the procedure to install new float switch...

Page 51: ...n Inverter Boards prior to Hy Pot test as indicated in FIGURE 48 FIGURE 48 Emerson Inverter Board with disconnected Ground Lead 2 Set Hy Pot tester to the following parameters see FIGURE 49 Test Volta...

Page 52: ...ts is present continue If not remove the connector from J2 and measure the same pins on the Inverter board If 5 volts is present the cabling to the Hall board or the Hall board itself is bad Replace i...

Page 53: ...all Board If the voltage is changing very erratically replace the Hall Board Voltage should switch from 5 V D C to 025 approx FIGURE 53 FIGURE 54 4 Repeat step 4 above between Pins 3 5 as well as Pins...

Page 54: ...tion from the inverter board Test stator and connecting wiring at the inverter board FIGURE 58 2 Check the resistance of all three of the terminals FIGURE 59 FIGURE 60 FIGURE 61 The correct reading sh...

Page 55: ...Remove foam insulation Remove thermostat in center of stator assembly Unbend the index tabs and remove end cap FIGURE 62 8 Remove stator assembly from cylinder 4 nuts 9 Apply silicon grease Dow Corni...

Page 56: ...more inches from the device The magnetic field can affect operation of these devices which may cause bodily injury or death If disruption of device occurs or operation is adversely effected immediate...

Page 57: ...is engaged with the magnet 13 Reinstall the faceplate by pressing until it contacts the front of the cylinder and then install the washers and nuts finger tight only 14 Re connect the power and go thr...

Page 58: ...eep the magnet at 6 or more inches from the device The magnetic field can affect operation of these devices which may cause bodily injury or death If disruption of device occurs or operation is advers...

Page 59: ...ne on top of the compressor be careful so the line can be spliced back together 4 Remove the compressor and unsweat the discharge line Reverse the procedure to install new compressor Replace the dryer...

Page 60: ...he dryer Evacuate and recharge the system 1 Disconnect the power to the unit Remove back lower and middle panel 4 screws each 2 Turn off water at source Bleed pressure from water feed line at the rear...

Page 61: ...76 2 Press lamp locks to unlock lamp pins FIGURE 77 3 Disengage lamp pins by pulling lamp in a direction forward away from reflector surface and remove lamp NOTE Pulling down on lamp to disengage pins...

Page 62: ...e lamp or the lock may result FIGURE 79 1 Slide lamp into spring clips at bottom of reflector FIGURE 80 2 Engage lamp pins by pushing lamp in a direction toward the reflector surface making certain pi...

Page 63: ...nstall lens and lens support Restore power to unit FIGURE 82 FIGURE 83 demonstrates lampholder with lock properly engaged lamp omitted for clarity WARNING For proper and effective lamp func tion locks...

Page 64: ...iagnostics turn to ON or MOTOR mode D Replace Low High voltage ERROR A Line Voltage out of SPEC spec is 198 253 VAC for 60 Hz and 196 265 VAC for 50 Hz B Error range 180 260 A 1 Check line voltage 2 C...

Page 65: ...ctive D Incorrect wiring E Poor connections A Emerson replace board Baldor replace fuse B Replace thermistor harness C Swap side 1 2 controls see if motor will run D Check wiring with Pinnacle sche ma...

Page 66: ...if necessary D Ensure proper spacing around unit Fan Motor A Bad connection B Bad motor C Cracked or bent fan blade A Check connect B Replace motor C Replace fan blade Pulse Valve A Miswired B Defecti...

Page 67: ...GO select cylinder to be BRIXed NOTE Pressing CANCLE will stop the process WATER PRESSURE SWITCH AND WATER REGULATOR FLOW REGULATOR AND SOLENOID VALVE SINGLE CHECK VALVE PRODUCT PUMP SYRUP AND WATER A...

Page 68: ...sated hand type refractometers P N 511004000 are available from 6 Adjust syrup regulator to get a BRIX reading of 13 1 To increase reading turn syrup regulator clock wise FIGURE 7 8 After BRIX is adju...

Page 69: ...s 10 and 11 for the other freeze cylinders 14 Press BACK twice to go to the Main menu 15 Press ON after 5 seconds the compressor will start and the beater bars will rotate counterclockwise Wait 10 15...

Page 70: ...rrel is complete 11 If the BRIX reading is NOT within specification adjust the syrup Flow Control to bring the product within specification clockwise to increase BRIX counter clockwise to decrease BRI...

Page 71: ...ay become detached from valve Valve will then be forced from face plate and contents of dispenser will spill out Follow torquing and staking procedures carefully using tools designated to retain shank...

Page 72: ...ed Tighten shank nut as shown with torque wrench and spanner socket Torque wrench setting is 10 lb ft or 120 lb in Socket part number is 620711709 NOTE Do not use any other tool or method to tighten t...

Page 73: ...m ing staking stainless steel valve threads only inspect the threads and shank nut to ensure proper thread engagement This is what the Delta shank nut clear ance should look like Shank nut surface flu...

Page 74: ...ank nut as shown with torque wrench and socket Torque wrench setting is 10 lb ft or 120 lb in Socket part number is 620711709 NOTE Do not use any other tool or method to tighten the shank nut 3 After...

Page 75: ......

Page 76: ...Cornelius Inc www cornelius com...

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