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Cornelius pbd175 User Manual

Cornelius pbd175
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PBD175 (SPIRE 3.0)
Service Manual
Release Date: September 01, 2015
Publication Number: 620062609SER
Revision Date: September 06, 2016
Revision: D
Visit the Cornelius web site at www.cornelius.com
for all your Literature needs.

Table of Contents

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Cornelius pbd175 Specifications

General IconGeneral
ModelPBD175
BrandCornelius
Voltage115V
MaterialStainless Steel
TypePost-Mix Beverage Dispenser

Summary

Safety Instructions and Guidelines

Safety Overview, Alerts, and Recognition

Covers general safety instructions, alert symbols, and how to recognize them.

Safety Tips and Qualified Personnel

Provides safety tips for operation and defines requirements for qualified service personnel.

Safety Precautions and Handling Procedures

General Safety, Shipping, Storage, and CO2 Warnings

Details precautions for servicing, shipping, storage, CO2, and product usage.

Decommissioning and Unit Transport

Provides procedures for unit decommissioning and safe transportation.

Manual Introduction and System Overview

Manual Structure and System Description

Outlines the manual's organization and describes the dispenser's system.

Critical Component Storage Temperatures

Lists specific storage temperature ranges for critical dispenser components.

Counter Preparation for Installation

Marking and Cutting the Counter

Details the process for marking and cutting the counter for unit installation.

Control Panel and Interface

Control System and Interface Details

Explains the control system, its interface, and diagnostic capabilities.

Service Screen Functions and Operations

Describes the service screen for performing maintenance and troubleshooting.

Spire Subsystems

Computer and Power Supplies

Details the unit's computer and its 30V and 12V/24V power supplies.

Control Boards and Hub

Covers Valve Control Board, ADA Console, LX3 Board, and Powered USB Hub.

Spire Subsystems - Valve Assemblies

Valve Function and Types

Explains the function and types of valves (water, syrup, flavor shots) in the dispenser.

Spire Subsystems - Boards

LX3 Board and Valve Control Board

Details the LX3 Board and Valve Control Board, including their location and power.

Spire Subsystems - Control Boards

Agitator/Carbonator Control Board

Explains the function and power input of the Agitator/Carbonator Control Board.

ADA Console Details

Provides further details on the ADA console's function and location.

Operation

Starting the Unit

Provides steps for powering on the dispenser and its initial startup sequence.

Icemaker Capability

Details the dispenser's icemaker adapter specifications and installation notes.

Preventative Maintenance Procedures

General Procedures and Warnings

Covers shutdown procedures, cleaning warnings, and required cleaning solutions.

Daily Cleaning Steps

Provides instructions for daily cleaning of the cup pedestal, exterior, and nozzles.

Preventative Maintenance - Daily & Monthly

Daily Maintenance Checks

Lists daily checks for product temperature, ice level, pressure, carbonation, and CO2 supply.

Monthly Cleaning Procedures

Outlines monthly cleaning requirements, in addition to daily procedures.

Sanitizing Syrup Lines and BIB System

Details the step-by-step process for sanitizing syrup lines and the BIB system.

Sanitization and Priming Functions

Sanitization Cycle Steps

Guides the technician through the sanitization cycle, including pre-rinse, sanitize, soak, and post-rinse.

Entering Service Mode and Priming

Service Screen Access and PIN Entry

Explains how to access the service menu via PIN entry and its functions.

Priming Functionality

Explains how to open a valve for an unlimited time to purge lines.

NUC Power Button Operations

Shutting Down and Rebooting the Computer

Provides instructions for shutting down and rebooting the computer using the NUC power button.

Sold Out Syrups and Valve Mapping

Sold Out Syrups Feature Usage

Explains how to lock a brand or flavor from dispensing, e.g., for a leaking valve.

Mapping the Valves Process

Allows changing the brand/flavor displayed on the UI, mapping brands to valves.

Valve Mapping and Assignment

Valve Assignment Process Steps

Details the steps to map valves, including picking new assignments and confirming changes.

Reference Valve Layout

Explains how to view the valve layout and assignment on the screen.

Valve Assignment Options and Calibration

Valve Assignment Option Details

Describes the options available after selecting a brand or flavor for assignment.

4 Second BRIX Calibration

Explains how to dispense a 4-second pour for checking syrup volumes or dispensing accuracy.

Sanitization and Priming Functions

Sanitization Cycle Steps

Guides the technician through the sanitization cycle with graphical prompts.

View Layout Selection

Shows the mapped valves and how they appear on the user screen.

Actions Options and BRIX Calibration

Actions Options Overview

Lists selections for navigating different options available to the service technician.

Adjust Water to Syrup Ratio (BRIX)

Provides detailed steps for adjusting the water to syrup ratio (BRIX) of the dispenser.

Input Flow Rates and System Status

Define Input Flow Rates

Allows inputting flow rates for water, carbonated water, and flavor shots.

Systems Options and Equipment Status

Accesses diagnostics screens to check component and system status (Green/Red indicators).

System Monitoring and Maintenance

Controller Status Monitoring

Monitors computer temps and validates communication for controllers and display.

Preventative Maintenance Reminders

Acts as a reminder for scheduled maintenance tasks like filter and fan cleaning.

Component Replacement - Cladding

Removing the Cladding

Provides step-by-step instructions for removing the unit's cladding.

Component Replacement - Display

Replacing the Touch Screen Display

Details the procedure for shutting down, unplugging, and replacing the touch screen display.

Display Replacement Steps

Disconnecting and Removing Display

Covers loosening mounting screws, removing cable connections, and lifting the display.

Display Reassembly and Connections

Reconnecting Cables and Reassembly

Details tightening screws, reconnecting cables, and replacing the rear door panel.

Component Replacement - Valves

Replacing Individual Valves

Provides instructions for shutting down, depressurizing, and replacing a unit valve.

Valve Replacement - Priming and BRIX

Priming and Balancing After Valve Replacement

Guides on priming new valves, sanitizing, and Brixing after replacement.

Replacing the Backblock

Details procedures for disconnecting CO2, bleeding pressure, and replacing the backblock.

Component Replacement - Computer

Computer Diagnostics

Explains how to diagnose computer malfunctions by checking cables, power, and LEDs.

Replacing the Computer

Provides step-by-step instructions for removing and replacing the unit's computer.

Computer Replacement Procedure

Disconnecting and Removing Computer

Covers removing the E-box cover, disconnecting connections, and removing the computer.

Installing and Reconnecting Computer

Details installing a new computer, reconnecting connectors, and closing the unit.

Valve Control Board Information

Valve Control Board Diagnostics

Explains how to diagnose issues with the Valve Control board by checking LEDs and connections.

Replacing the Valve Control Board

Provides instructions for removing and replacing the Valve Control board.

Valve Control Board Replacement

Disconnecting and Removing Board

Covers removing the E-box cover and disconnecting cables from the board.

Installing New Board

Details installing the new Valve Control board and reconnecting connectors.

ADA Control Board Information

ADA Control Board Diagnostics

Explains how to determine if the ADA board is faulty by testing its functionality.

Replacing the ADA Control Board

Provides step-by-step instructions for removing and replacing the ADA control board.

ADA Control Board Replacement Steps

Removing and Installing ADA Board

Covers removing the service cover, unplugging harness, and installing the new board.

Testing and Finalizing ADA Board Replacement

Details testing all buttons and functions, then reinstalling the service cover.

LED Spot Light Assembly Replacement

Replacing the LED Spot Lights

Provides instructions for shutting down, unplugging, and replacing the LED spot light assembly.

Enclave Re-Install Work Instructions

Enclave Removal Preparation

Details opening the door, removing ice slide/splash panel, and marking enclave screws.

Enclave Removal Steps

Covers loosening screws and carefully removing the enclave.

Enclave Installation - Connections and Drains

Stowing Lines and Installing Drip Tray

Details routing lines and installing the drip tray drain tube on the enclave.

Enclave Installation Considerations

Emphasizes proper line routing and drain tube installation for correct fit.

Enclave Installation - Securing and Testing

Securing the Enclave

Provides instructions for pushing, tightening, and securing the enclave.

Door Closure Check

Details checking door closure to ensure it doesn't grab or rub the gasket on the enclave.

Enclave Adjustment and Final Checks

Enclave Adjustment for Door Closure

Explains how to adjust enclave screws if the door has difficulty closing.

Splash Panel Reinstallation

Covers reinstallation of the splash panel and final verification of unit function.

Component Replacement - Carbonator Sensor

Carbonator Sensor Diagnostics

Explains how to diagnose issues with the carbonator sensor.

Replacing the Carbonator Sensor

Provides step-by-step instructions for removing and replacing the carbonator sensor.

Ice Bin Agitator Replacement

Ice Bin Agitator Replacement Procedure

Details the procedure for shutting down, removing, and replacing the ice bin agitator assembly.

Agitator Timer Board Replacement

Agitator Timer Board Replacement Procedure

Provides instructions for removing and replacing the agitator timer board.

Agitator Motor Replacement

Replacing the Agitator Motor

Details the procedure for unplugging, removing, and installing a new agitator motor.

Agitator Settings and Ice Chute Adjustment

Off-Cycle Agitator Settings

Explains the importance of setting ON/OFF times for ice agitation.

Ice Chute Restrictor Adjustment

Details how to adjust the ice chute opening for different ice types and flow rates.

Ice Maker Mounting

Ice Maker Mounting and Checks

Covers checks for proper ice maker and dispenser function and mounting the bracket.

Ice Maker Installation Steps

Securing the Ice Maker

Details placing the ice maker, centering it, and securing the bracket with screws.

Ice Maker Final Installation

Sealing and Connections

Covers sealing the ice maker, making connections, and installing the manual fill lid.

Filler Panel Installation

Filler Panel Securing and Check

Details installing the filler panel and checking for fit and function.

Troubleshooting - Valve Issues

Low Syrup Flow Diagnosis

Flowchart to diagnose and resolve low syrup flow problems.

Troubleshooting - Valve Activation

Some Valves Activating Troubleshooting

Flowchart for diagnosing issues when some valves activate unexpectedly.

Troubleshooting - Valve Activity

No Valve Activity Diagnosis

Flowchart to diagnose issues when there is no valve activity.

Troubleshooting - Valve Activity

One or Two Valves Activating Troubleshooting

Flowchart for diagnosing issues when one or two valves activate unexpectedly.

Troubleshooting - Display Issues

Screen Locked Up Diagnosis

Flowchart for diagnosing and resolving a locked-up display screen.

UI Screen Black Diagnosis

Flowchart for diagnosing why the UI screen is black.

Troubleshooting - UI Screen Black

UI Screen Black Continued

Continues the flowchart for diagnosing a black UI screen.

Troubleshooting - UI Display Messages

UI Screen Blue with "NO SIGNAL"

Flowchart for diagnosing 'NO SIGNAL' message on the UI screen.

Out of Service Message on UI

Flowchart for diagnosing 'Out of Service' messages on the UI.

Troubleshooting - Power Supply

No Power to Display Diagnosis

Flowchart for diagnosing power issues with the display.

Troubleshooting - Power and Drink Quality

No Power to Computer Diagnosis

Flowchart for diagnosing power issues with the computer.

Low or No Carbonation Diagnosis

Flowchart for diagnosing issues related to low or no carbonation.

Troubleshooting - Drink Quality and ADA

High Water Temperature Diagnosis

Flowchart for diagnosing issues with high water temperature.

Carbonation Water Flow Low Diagnosis

Flowchart for diagnosing low carbonation water flow.

ADA Buttons Not Functioning

Flowchart for diagnosing issues when ADA buttons do not function.

Wiring Diagrams

Internal and External EBOX Wiring

Diagrams showing wiring for the PEPSI SPIRE 3.0 INTERNAL and EXTERNAL EBOX.

Chilled Lines Diagram

Chilled Lines and Legend

Diagram illustrating chilled lines, including a legend for identification.

Valve Board Diagram

Valve Board Connector Layout

Diagram of the valve board showing connector layout for flavor, brand, and water banks.

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