Installation Instructions Ice /soft Drink

Transcript

IMI CORNELIUS INC. One Cornelius Place Anoka, MN. 55303–1592 Telephone (800) 238–3600 Facsimile (612) 422–3232 Installation Instructions Ice /Soft Drink Post Mix Dispenser Model 2232 Part No. 91633 February 16, 1993 Revised: August 5, 1993 THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Installation Manual must be read and understood before starting to install or operate this equipment. IMI CORNELIUS INC; 1993 Printed in U.S.A. TABLE OF CONTENTS Page GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . 1 UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . 1 THEORY OF OPERATION . . . . . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 UNPACKING AND INSPECTION . . . . . . . . . . 3 IDENTIFICATION OF LOOSE–SHIPPED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SELECTING LOCATION . . . . . . . . . . . . . . . . . 3 INSTALLING UNIT . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLING UNIT ON COUNTERTOP . . 3 Page 10 Weekly cleaning of dispensing valves . . . . 10 Cleaning ice bin interior and sanitizing syrup SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CONNECTING DRIP TRAY DRAIN HOSE TO PERMANENT DRAIN . . . . . . . . . . . . . . . . . 4 CONNECTING SYRUP SOURCE LINES TO UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CONNECTING CARBONATED WATER LINES TO UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CONNECTING PLAIN WATER LINE TO UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily cleaning of unit exterior . . . . . . . . . . . CLEANING CO2 SYSTEM GAS CHECK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SERVICE AND MAINTENANCE . . . . . . . . . . . . 11 PREPARING UNIT FOR SHIPPING, RELOCATING, OR STORING . . . . . . . . . . . . 11 ICE BIN COVER, PANELS, AND CUP REST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ICE BIN COVER . . . . . . . . . . . . . . . . . . . . . . 11 PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DRIP TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PERIODIC INSPECTION . . . . . . . . . . . . . . . . 11 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 11 ADJUSTING CO2 REGULATORS . . . . . . . 11 4 ADJUSTING DISPENSING VALVES WATER FLOW RATE . . . . . . . . . . . . . . . . . . . . . . . . . 13 CONNECTING COMPRESSED AIR OR CO2 GAS LINE TO DISPENSER . . . . . . . . . . . . 4 ADJUSTING WATER–TO–SYRUP “RATIO” OF DISPENSED PRODUCT . . . . . . . . . . . . . . . 14 CONNECTING CHILLED PLAIN WATER OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PREPARATION FOR OPERATION . . . . . . . . . . 8 DISPENSED DRINK PORTION–CONTROL ADJUSTMENT (DOLE AND CC–1 DISPENSING VALVES) . . . . . . . . . . . . . . . . 15 OPERATORS INSTRUCTIONS . . . . . . . . . . . . . 9 OPERATING CONTROLS . . . . . . . . . . . . . . . . 9 OPERATING ICE PORTION–CONTROL DISPENSING SYSTEM . . . . . . . . . . . . . . . . 9 “CLEAN MODE” (FLASHING RED/AMBER L.E.D) . . . . . . . . . . . . . . . . . . 16 OPERATING PORTION–CONTROL DISPENSING VALVE . . . . . . . . . . . . . . . . . . 9 Unit power switch . . . . . . . . . . . . . . . . . . . . . 9 “NORMAL ICE PORTION–CONTROL ADJUSTMENT MODE” (SOLID AMBER L.E.D) . . . . . . . . . . . . . . . . 16 DAILY PRE–OPERATION CHECK . . . . . . . . 9 UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . 9 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 10 Adjusting CO2 regulators . . . . . . . . . . . . . . . 10 ICE PORTION CONTROL SYSTEM THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CLEANING AND ADJUSTING THE DISPENSER ICE PORTION–CONTROL SYSTEM . . . . . . 16 “EXTRA ICE ADJUSTMENT MODE” (SOLID RED L.E.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . 16 REPLENISHING CO2 SUPPLY . . . . . . . . . . . 19 REPLENISHING SYRUP SUPPLY . . . . . . . . 19 SYRUP FLAVOR CHANGE . . . . . . . . . . . . . . 19 Adjusting water–to–syrup “ratio” of dispensed product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REPLENISHING ICE BIN ICE SUPPLY . . . . 19 CLEANING AND SANITIZING . . . . . . . . . . . . 19 Adjusting portion–control sizes of dispensed drinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PERIODIC CLEANING OF ICE CHUTE . . 19 DAILY CLEANING OF UNIT EXTERIOR . 19 Adjusting ice portion–control system . . . . . 10 REPLENISHING CO2 SUPPLY . . . . . . . . . . . 10 WEEKLY CLEANING OF DISPENSING VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REPLENISHING SYRUP SUPPLY . . . . . . . . 10 REPLENISHING ICE BIN ICE SUPPLY . . . . 10 CLEANING ICE BIN INTERIOR AND SANITIZING SYRUP SYSTEM . . . . . . . . . 20 CLEANING AND SANITIZING . . . . . . . . . . . . 10 CLEANING CO2 GAS CHECK VALVES . . . . 21 Adjusting dispensing valves water flow rate 10 91633 i TABLE OF CONTENTS (cont’d) LIST OF FIGURES FIGURE 1. ICE/SOFT DRINK DISPENSER . . 1 FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION) . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FIGURE 3. COUNTERTOP CUTOUT . . . . . . . . 6 FIGURE 4. DISPENSER PLUMBING DIAGRAM 7 FIGURE 5. PARTS IDENTIFICATION . . . . . . . . 12 FIGURE 6. DOLE DISPENSING VALVE . . . . . . 13 FIGURE 7. CC–1 DISPENSING VALVE . . . . . . 13 FIGURE 8. DISPENSING VALVE PORTION–CONTROL COVER . . . . . . . . . . . . . 14 FIGURE 9. ICE PORTION–CONTROL SWITCH MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 FIGURE 10. CLEAN MODE (CLEAN ICE CHUTE) . . . . . . . . . . . . . . . . . . . . . 17 FIGURE 11. NORMAL ICE PORTION–CONTROL AND EXTRA ICE ADJUSTMENT MODE . . . . . 18 FIGURE 12. CO2 GAS CHECK VALVE . . . . . . 21 FIGURE 13. DISPENSER WIRING DIAGRAM 22 FIGURE 14. INSTRUCTIONS FOR CRIMPING TUBE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 LIST OF TABLES TABLE 1. DESIGN DATA . . . . . . . . . . . . . . . . . . . TABLE 2. LOOSE-SHIPPED PARTS . . . . . . . . . 91633 2 3 ii GENERAL DESCRIPTION IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, and maintaining this equipment. Refer to the Table of Contents for page location of detailed information or answers to questions that arise during the installation, operation, service and maintenance, or troubleshooting. This section provides a description, theory of operation, and design data for the six-flavor Model 2232 Ice/Soft-Drink Post-Mix dispenser (see FIGURE 1) hereinafter referred to as the Unit. UNIT DESCRIPTION The Unit is compact and may be installed on an island or on a front or rear counter. Carbonated water, plain water, and syrup are cooled as they flow through a sealed-in aluminum coldplate located in the bottom of the Unit ice bin. The Unit is equipped with six adjustable portion control dispensing valves that will dispense a “S” (small), “M” (medium), “L” (large), or an “XL” (extra-large) finished post-mix drink. The Unit is also equipped with an adjustable portion-control ice dispensing system that may be adjusted to dispense just the right amount of ice in a small, medium, large, or extra-large cup just prior to dispensing a soft drink into the cup. FIGURE 1. ICE/SOFT DRINK DISPENSER CAUTION: Before shipping, storing, or relocating this Unit, the 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 water in the Unit to freeze resulting in damage to internal components. Installation of LOOSE-SHIPPED PARTS, installation of Unit on the countertop, connecting carbonated water, plain water, syrup, and air or CO2 to the Unit, filling the ice bin with ice, plugging the Unit power cord into an electrical outlet, and performing the necessary adjustments is all that is required for Unit operation. 1 91633 remote carbonator, syrup tanks, and to the dispenser to operate the ice portion control system. Plain water enters the carbonator water tank and is carbonated by regulated CO2 gas also entering the tank. When dispensing valves are activated, CO2 gas pressure exerted upon contents of syrup tanks, pushes syrup from tanks, through dispenser coldplate coils, and on to the dispensing valves. Carbonated water is pushed from the carbonator water tank by CO2 gas head pressure and is pushed through the dispenser coldplate cooling coils to the dispensing valves. Syrup and carbonated water meet at the dispensing valves resulting in carbonated drinks being dispensed. No. 2 dispensing valve (second dispensing valve from the left facing the dispenser) is set up at the factory to dispense a “still” (non–carbonated) drink which requires plain water rather than carbonated water to be present at the dispensing valve. Table 1. Design Data Unit Part Number 115V, 60 HZ, Dispenser with Dole Dispensing valves 115V, 60 HZ Dispenser with CC-1 Dispensing Valves 220V, 50HZ, Dispenser with Dole Dispensing Valves 220, 50HZ, Dispenser with CC-1 Dispensing Valves Overall Dimensions: Width Height Depth Weight Ice Bin Storage Capacity Ambient Operating Temperature Electrical Requirements: 60 HZ UNIT: Operating Voltage and Current Dispensing Valves 50 HZ UNIT: Operating Voltage and Current Dispensing Valves 02632 02634 02633 02635 22 in. 36 5/16 in. 32 7/16 in. 248 Pounds 150 Pounds 40_ to 100_F If desired, No. 2 dispensing valve may be converted to also dispense a carbonated drink by disconnecting its plain water line from the chilled plain water circuit inside the Dispenser and connecting the water line to an available carbonated water outlet on the outlet side of the coldplate (see FIGURE 2) See Unit Nameplate 24V, 60HZ A Dispenser insulated plain water outlet line labeled “CHILLED WATER”, connected to the chilled plain water circuit inside the Dispenser, is available to provide chilled plain water to a remote plain water Dispenser or other equipment requiring chilled plain water. See Unit Nameplate 24V, 50HZ THEORY OF OPERATION (SEE FIGURE 2) A CO2 cylinder delivers CO2 (carbon dioxide) gas through adjustable secondary CO2 regulators to a 91633 2 INSTALLATION 1. A properly grounded electrical outlet with proper electrical requirements fused at 15 – Amps (“slow–blow”) or circuit connected through an equivalent HACR circuit breaker must be located close to the Unit. No other electrical equipment should be connected to this circuit. ALL ELECTRICAL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES. UNPACKING AND INSPECTION NOTE: The Ice/Drink dispenser was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it. Any damage or irregularities should be noted at the time of delivery (or not later than 15 days from the date of delivery) and immediately reported to the delivering carrier. Request a written inspection report from Claims Inspector to substantiate any necessary claim. File claim with the delivering carrier, not with IMI CORNELIUS INC. 2. Near a permanent drain to route and connect Unit drip tray drain hose. 3. Allow sufficient room above the Unit to remove Ice bin cover to replenish ice supply. 1. Unpack the Unit and remove all shipping tape and packing materials. INSTALLING UNIT 2. Unpack LOOSE–SHIPPED parts. Make sure all items are present and in good condition. INSTALLING UNIT ON COUNTERTOP 1. Locate exact location on countertop where Unit will be installed. Table 2. Loose-Shipped Parts Item No. Part No. Name Qty. 1 52077 Drain Hose, 5ft. 1 2 70750 Clamp, Drain Hose 1 3 70798 Tool, Dole Dispensing Valve 1 Cup Rest 1 4 70861 2. Refer to FIGURE 3 for instructions to cut indicated hole in countertop. 3. Remove Unit ice bin cover, then very carefully tip Unit over on its back. 4. Install DRAIN HOSE, 5–FT. (item 1) on drip tray drain fitting. Secure connection with CLAMP, DRAIN HOSE (item 2). IDENTIFICATION OF LOOSE–SHIPPED PARTS 5. Very carefully, restore Unit to its upright position. 6. Slide Unit into its operating position on countertop. 1. DRAIN HOSE (item 1) to be connected to drip tray and secured with CLAMP, DRAIN HOSE (item 2). NOTE: To comply with National Sanitation Foundation (NSF) requirements, Unit base must be sealed to countertop and all access holes to inside of Unit base must be sealed with permagum or equivalent sealant material. 7. To comply with National Sanitation Foundation (NSF) requirements, seal Unit base to countertop as follows: 2. TOOL, DOLE DISPENSING VALVE (item 3) used to turn water and syrup shutoff valves on dispensing valve mounting block to “ON or “OFF” position. 3. CUP REST (item 4) to be installed on drip tray. SELECTING LOCATION A. Tilt Unit up to expose bottom of base. This Unit may be Island–mounted or installed on a front or rear counter. Locate the Unit so the following requirements are satisfied. 3 91633 B. Liberally apply sealant such as Dow Corning RTV731 or equivalent on base bottom edges. C. Lower Unit into operating position on countertop. D. Apply additional sealant around bottom of Unit base. Seal must have a minimum radius of 1/2 inch to prevent crevices and to insure a complete seal. CONNECTING PLAIN WATER LINE TO UNIT (SEE FIGURE 2) Plain water connected to the Unit plain water inlet line labeled “PLAIN WTR” provides chilled water for the No. 2 dispensing valve, still (non–carbonated) drink and also provides chilled water out of the Unit plain water outlet line that may be used to provide chilled water to a plain water dispenser or other equipment requiring chilled water. No. 2 dispensing valve may also be converted to to dispense a carbonated drink by connecting its plain water inlet line to an available carbonated water outlet on the outlet side of the coldplate (see FIGURE 2). 8. Remove two screws securing dispenser back panel. Remove panel for access to drip tray drain hose, power cord, and inlet and outlet lines. 9. Route drip tray drain hose, power cord, and inlet and outlet lines down through hole cut in countertop. 10. Seal all access holes to inside of Unit base with permagum or equivalent sealant. 11. Install CUP REST (item 4) in drip tray. Proceed as follow to connect plain water to Unit plain water line labeled “PLAIN WTR”. 1. Route plain water line from plain water source up to Unit. 2. Connect plain water source line to Unit plain water inlet line labeled “PLAIN WTR”. CONNECTING DRIP TRAY DRAIN HOSE TO PERMANENT DRAIN CONNECTING COMPRESSED AIR OR CO2 GAS LINE TO DISPENSER NOTE: Drip tray drain hose routed to a waste container is not recommended due to sanitation and cleaning problems. Connection of drain hose to a permanent drain is recommended. (SEE FIGURE 2) IMPORTANT: A Compressed Air or CO2 Filter must be connected into the CO2 line connected to the Dispenser to operate the ice portion control system. Preferably, route lower end of drip tray drain hose to a permanent drain and connect. Regulated and filtered CO2 gas pressure or compressed air is required to operate the dispenser portion–control ice dispensing system. Proceed as follows to connect CO2 gas pressure source line to the Dispenser. CONNECTING SYRUP SOURCE LINES TO UNIT (SEE FIGURE 2) NOTE: Unit syrup inlet lines are labeled to identify the dispensing valves they serve. For example: line labeled “S1” must be connected to syrup source line that provides syrup to be dispensed from No. 1 dispensing valve (No. 1 dispensing valve is valve on left side when facing front of Unit). 1. Connect and route CO2 line from outlet side of the CO2 Regulator Assembly up to the Dispenser. 2. Connect CO2 source line to Dispenser CO2 inlet line labeled “AIR/CO2”. CONNECTING CHILLED PLAIN WATER OUTLET 1. Route syrup source lines from syrup tanks location up to Unit. (SEE FIGURE 2) 2. Connect syrup source lines to Unit syrup inlet lines labeled “S1” through “S6”. The Unit plain water outlet line labeled “CHILLED WATER” may be used to provide chilled water to a plain water dispenser or other equipment requiring chilled water. Proceed as follows to connect chilled water line to other equipment. CONNECTING CARBONATED WATER LINES TO UNIT (SEE FIGURE 2) 1. Connect and route insulated plain water line from equipment requiring chilled plain water up to Unit. 1. Route carbonated water source lines from carbonator location up to Unit. 2. Connect carbonated water source line to Unit carbonated water inlet lines labeled “CO2 WTR”. 91633 2. Connect insulated plain water line to Unit plain water outlet line labeled “CHILLED WTR”. 4 WATER PRESSURE REGULATOR LINE LEGEND CO2 PLAIN WATER CARB WATER SYRUP CARBONATED WATER MANIFOLD DISPENSER COLD PLATE PLAIN WATER SOURCE 6 WATER SHUTOFF VALVE WATER FILTER 5 S6 S5 REMOTE CARBONATOR 4 S4 S3 DISPENSER ICE PORTION–CONTROL SECONDARY CO2 REGULATOR 5 SUGAR SYRUP SECONDARY CO2 REGULATOR S2 DIET SYRUP SECONDARY CO2 REGULATOR STILL DRINK DIET DRINK S1 3 PW CW PRIMARY CO2 REGULATOR 2 CW GAS CHECK VALVE (7) CO2/AIR FILTER 1 CO2 DISPENSING VALVE (6) PORTION CONTROL ICE DISPENSING CHUTE ICE GATE SLIDE GATE CYLINDER GATE SOLENOID 91633 6 CO2 CYLINDER 5 4 3 2 1 CHILLED PLAIN WATER OUTLET LINE A PLAIN WATER DISPENSER OR OTHER EQUIPMENT REQUIRING CHILLED WATER MAY BE CONNECTED TO DISPENSER CHILLED PLAIN WATER OUTLET LINE. SYRUP TANKS (6) FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION) PLUGGED CARBONATED WATER OUTLET 22 3 15 16 1 4 1 2 OPENING AVAILABLE FOR HOSE OUTLETS 14 1 4 1 1 8 14 OPENING OPENING IN CABINET BOTTOM FOR DRAIN AND BEVERAGE HOSES 18 25 32 OPTIONAL LOCATION FOR COUNTER TOP CUTOUT 31 1 4 5 -18 THREADED HOLE LOCATIONS 16 FRONT OF UNIT 19 3 4 1 1 8 TOP VIEW (COUNTER CUT OUT/OPTIONS) ALL DIMENSIONS ARE IN INCHES FIGURE 3. COUNTERTOP CUTOUT 91633 6 STILL DRINK (NON–CARB) 1 2 DISPENSING VALVE(6) 3 4 5 6 POTION CONTROL ICE DISPENSING CHUTE ICE GATE SLIDE PLUG (SEE NOTE 2) GATE CYLINDER CARBONATED WATER MANIFOLD GATE SOLENOID COLD PLATE SYRUP INLET LINES POTABLE WATER AIR/CO2 (50–PSI MAX) CHILLED PLAIN WATER (SEE NOTE 1) SYRUP INLET LINE NOTE1: THE DISPENSER IS EQUIPPED WITH A COLD PLATE CHILLED PLAIN WATER OUTLET LINE THAT MAY BE USED TO PROVIDE CHILLED WATER TO A PLAIN WATER DISPENSER OR OTHER EQUIPMENT REQUIRING CHILLED WATER. CARB WATER LINE LEGEND AIR/CO2 PLAIN WATER CARB WATER SYRUP NOTE 2: NO. 2 DISPENSING VALVE MAY BE CONVERTED TO ALSO DISPENSE A CARBONATED DRINK BY CONNECTING ITS PLAIN WATER INLET LINE TO PLUGGED CARBONATED WATER OUTLET FITTING ON THE CARBONATED WATER MANIFOLD. FIGURE 4. DISPENSER PLUMBING DIAGRAM 7 91633 PREPARATION FOR OPERATION Dispenser Ice Portion–Control CO2 Regulator/filter assembly CAUTION: BEFORE OPENING CO2 CYLINDER SHUTOFF VALVE. Make sure primary and secondary CO2 regulators adjusting screws are turned to the left (COUNTERCLOCKWISE) until all tension is relieved from adjusting screws springs. Also, make sure the Dispenser Ice Portion Control CO2 Regulator/Filter Assembly adjustment knob is turned all the way to the left (counterclockwise). PULL UP ON ADJUSTMENT KNOB TO UNLOCK BEFORE ATTEMPTING TO TURN. Pull up on regulator adjustment knob to unlock. B. Turn regulator adjustment knob to the right (clockwise) until regulator gauge registers 50–PSI (Max), then push knob down to lock. 4. Check entire CO2 system connections for leaks. Tighten any loose connections. 5. Open plain water inlet supply line shutoff valve. Check for water leaks and tighten any loose connections. 6. Plug carbonator power cord into electrical outlet. Carbonator will start and continue to operate until carbonated water tank is full. 7. Place CUP REST (item 4) in drip tray. 8. Plug Unit power cord into electrical outlet. 9. Place Unit power switch on side of Unit in “ON” position. 10. Dispense from each dispensing valve until all air is purged from the plain and carbonated water systems. IMPORTANT: All syrup systems must be sanitized and Unit ice bin must be thoroughly cleaned before Unit is put into operation. 1. Open CO2 cylinder shutoff valve slightly to allow lines to slowly fill with gas, then open valve fully to back–seat valve. (Back–seating valve prevents leakage around valve shaft). 2. Check all CO2 connections for leaks. Tighten any loose connections. 3. Adjust primary CO2 regulator for carbonator and secondary CO2 regulator for syrup tanks and the CO2 Regulator/Filter Assembly for the dispenser ice portion–control system as follows Carbonator Primary CO2 Regulator. Refer to manual provided with carbonator and adjust primary CO2 regulator for carbonator operating pressure. 11. Sanitize all syrup systems and thoroughly clean ice bin interior as instructed. 12. Remove ice bin cover. IMPORTANT: Do not use hard–frozen (below 32_F) ice. After ice is removed from a freezer, allow the ice to sit at room temperature for approximately 1/2 hour before placing it in the bin. Ice to be used to fill ice bin must be in the form of small cubes, chunklets, or cracked ice (DO NOT USE FLAKE OR CRUSHED ICE). Sugar Syrup Tanks Secondary CO2 Regulator Adjust sugar syrup tanks secondary CO2 Regulator at 45–psig for syrup lines up to 10–feet in length plus one pound for each additional length of 10–feet, plus one pound for each 2–feet of vertical lift. For example: If syrup line total length is 30–feet and total vertical lift is 6–feet, then 45–psi + 2–psig (1–pound for every 2–feet of vertical lift which is 6–feet); total equals 45 + 2 + 3=50–psig CO2 regulator setting. Loosen lock nut on CO2 regulator adjusting screw, turn adjusting screw to the right (clockwise) until gage registers desired pressure, then tighten lock nut. 13. Observing preceding IMPORTANT note, fill ice bin with small cubes, chunklets, or cracked ice. 14. Install ice bin cover. ICE BIN COVER HAS TO BE IN INSTALLED POSITION ON UNIT BEFORE ICE AGITATOR WILL OPERATE. 15. Connect full syrup tanks into syrup systems. 16. Dispense from all dispensing valves to purge all air from syrup systems. 17. Adjust all dispensing valves for water flow rate as instructed. 18. Adjust all dispensing valves adjustable syrup flow controls for water–to–syrup “Ratio” of dispensed product as instructed. 19. Adjust all portion sizes of ice dispensed as instructed. Low–Calorie (diet) Syrup Tank Secondary CO2 Regulator. Adjust low–calorie (diet) soft drink tank secondary CO2 regulator at 10–psig for syrup lines up to 30–feet in length. Syrup lines longer than 30–feet in length may require a slightly higher CO2 regulator setting to 12–psig maximum. Excessive CO2 pressure may cause low–calorie syrup carbonation resulting in foam. 91633 A. 8 OPERATORS INSTRUCTIONS OPERATING CONTROLS DAILY PRE–OPERATION CHECK 1. Make sure CO2 cylinder primary CO2 regulator assembly 1800–psi gage indicator is not in shaded (“change CO2 cylinder”) portion of dial. If so, CO2 cylinder is almost empty and must be replaced as instructed. OPERATING ICE PORTION–CONTROL DISPENSING SYSTEM (SEE FIGURE 8) Normal portion–control ice dispensing may be performed by holding appropriate size cup under the ice chute, then press and release desired Small, Medium, Large, or Extra Large cup ice dispense switch. Desired ice portion will be dispensed into the cup. Extra ice may be dispensed into the cup by first pressing the “Y” (increase) ice dispense switch, then press the desired Small, Medium, Large, or Extra Large cup ice dispense switch. 2. Sufficient syrup supply in all syrup tanks. If not, replenish syrup supply as instructed. 3. Make sure ice supply in ice bin is adequate. If not, replenish ice supply as instructed. 4. Make sure drip tray is clean and clean cup rest is in place in drip tray. The ice portion–control system may be adjusted as instructed. UNIT OPERATION OPERATING PORTION–CONTROL DISPENSING VALVE 1. Make sure unit power switch is in the “ON” position. (SEE FIGURE 8) 2. Make sure ice supply in ice bin is adequate. If not replenish ice supply as instructed. Portion–control Drink Dispensing. A. B. Dispense appropriate portion size of ice in appropriate size cup. 3. Make sure ice bin cover is in place on top of ice bin. Hold cup containing ice under dispensing valve nozzle. 4. Hold appropriate size cup under ice chute. 5. Press and release desired Small, Medium, Large, or Extra Large ice dispense switch. Desired ice portion will be dispensed into cup. Note: Dispensing of a portion control drink may be stopped by pressing the “CANCEL/POUR” switch. Drinks may be manually dispensed (non–portion control) by pressing and holding the “CANCEL/ POUR” switch. C. Press appropriate ”S” (Small), “M” (Medium), “L” (Large), or “XL” (Extra Large) dispense switch to dispense product into cup. Extra ice may be dispensed into the cup by first pressing the “Y” (increase) ice dispense switch then press the desired Small, Medium, Large, or Extra Large cup ice dispense switch. 6. Hold cup containing ice under dispensing valve nozzle. Dispensing Plain or Carbonated Water Only. Note: Dispensing of a portion–control drink may be stopped by pressing the “CANCEL/POUR” switch. Drinks may be manually dispensed (non–portion control) by pressing and holding the “CANCEL/ POUR” switch. Dole Dispensing Valves – Hold cup under No. 2 dispensing valve nozzle, then press “WATER” switch to dispense plain water. To dispense carbonated water, hold cup under No. 5 dispensing valve and press “SODA” switch. 7. Press appropriate “S” (Small, “M” (Medium), “L” (Large), or “XL” (Extra Large) dispense switch to dispense product into cup containing ice. CC–1 Dispensing Valve – Hold cup under No. 2 dispensing valve nozzle then operate water lever on valve. To dispense carbonated water, hold cup under No. 5 dispensing valve and operate water lever. 8. Only plain or carbonated water may be dispensed as follows. UNIT POWER SWITCH Power switch is located on the left side of the Unit and must be in the “ON” position before dispensing valves will operate. Power switch in the “OFF” position does not interrupt power to the Ice Agitator Motor. 9 Dole Dispensing Valve. A. Place cup under dispensing valve with “WATER ” or “SODA” dispense switch on its front cover. 91633 B. Press applicable “WATER” or “SODA” switch to dispense plain water or carbonated water. REPLENISHING CO2 SUPPLY CO2 supply should be checked daily and if necessary, replenished as instructed. CC–1 Dispensing Valve. C. D. Place cup under carbonated drink dispensing valve or under non–carbonated (still drink) dispensing valve with water lever on valve. REPLENISHING SYRUP SUPPLY Syrup supply should be checked daily and if necessary, replenished as instructed. Operate dispensing valve water lever to dispense applicable plain or carbonated water only. REPLENISHING ICE BIN ICE SUPPLY ADJUSTMENTS Fill ice bin with ice as instructed. ADJUSTING CO2 REGULATORS CO2 regulators should be periodically checked for proper pressure settings and if necessary, adjusted as instructed. CLEANING AND SANITIZING ADJUSTING DISPENSING VALVES WATER FLOW RATE Daily cleaning of unit exterior should be performed at end of daily operation as instructed. Dispensing valves water flow regulators may be adjusted to vary amount of water dispensed as instructed. WEEKLY CLEANING OF DISPENSING VALVES DAILY CLEANING OF UNIT EXTERIOR ADJUSTING WATER–TO–SYRUP “RATIO” OF DISPENSED PRODUCT Dispensing valves should be cleaned as least once a week as instructed. Water–to–syrup “Ratio” of dispensed product should be checked periodically and if necessary, adjusted as instructed. CLEANING ICE BIN INTERIOR AND SANITIZING SYRUP SYSTEMS Ice bin interior should be cleaned and syrup systems should be sanitized as instructed every 30 days following Sanitizer Manufacturer’s recommendations. ADJUSTING PORTION–CONTROL SIZES OF DISPENSED DRINKS Portion–control sizes “S” (Small), “M” (Medium), “L” (Large), or “XL” (Extra Large) of dispensed drinks may be adjusted as instructed. CLEANING CO2 SYSTEM GAS CHECK VALVES (SEE FIGURE 2 AND FIGURE 12 ) The CO2 system gas check valves must be inspected and serviced at least once a year under normal conditions and after any CO2 system servicing or disruption as instructed. ADJUSTING ICE PORTION–CONTROL SYSTEM The ice portion–control system may be adjusted as instructed. 91633 10 SERVICE AND MAINTENANCE IMPORTANT: Only qualified personnel should service internal components or electrical wiring PREPARING UNIT FOR SHIPPING, RELOCATING, OR STORING PERIODIC INSPECTION 1. Check each dispensing valve for dripping that indicates valve is leaking and repair as necessary. CAUTION: Before shipping, storing, or relocating this Unit, the 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 water in the Unit to freeze resulting in damage to internal components. 2. Periodically check and make sure drip tray drain is not clogged. ADJUSTMENTS ADJUSTING CO2 REGULATORS (see FIGURE 2) Carbonator Primary CO2 Regulator. Refer to manual provided with carbonator and adjust primary CO2 regulator for carbonator operating pressure. ICE BIN COVER, PANELS, AND CUP REST REMOVAL Sugar Syrup Tanks Secondary CO2 Regulator. (see FIGURE 5) ICE BIN COVER Adjust sugar syrup tanks secondary CO2 regulator at 45–psig for syrup lines up to 10–feet in length plus one pound for each additional length of 10–feet,plus one pound for each 2–feet of vertical lift. For example; if syrup line total length is 30–feet and total vertical lift is 6–feet, then 45–psig + 2–psig (1–pound for every 2–feet of vertical lift which is 6–feet); total equal 45 + 2 + 3 = 50–psig CO2 regulator setting. Loosen lock nut on CO2 regulator adjusting screw, turn adjusting screw to the right (clockwise) until gage registers desired pressure, then tighten lock nut. Lift ice bin cover straight up off Unit to remove. ICE BIN COVER MUST BE IN PLACE ON UNIT BEFORE ICE AGITATOR WILL OPERATE. PANELS Cup Lid Holder Panel. Remove two screws securing cup lid holder panel, then remove panel. Ice Portion–Control Switch Module Panel. Remove two thumb screws securing ice portion–control switch module panel, then remove panel. Lower Access Panel. Remove two screws securing lower access panel , then remove panel. Cup Rest. Low–Calorie (diet) Syrup Tank Secondary CO2 Regulator. Adjust low–calorie (diet) soft drink tank secondary CO2 regulator at 10–psig for syrup lines up to 30–feet in length. Syrup lines longer than 30–feet in length may require a slightly higher CO2 regulator setting to 12–psig maximum. Excessive CO2 pressure may cause low–calorie syrup carbonation resulting in foam. Dispenser Ice Portion–Control CO2 Regulator/filter assembly Lift cup rest straight up off drip tray to remove. 1. Pull up on regulator adjustment knob to unlock. DRIP TRAY 1. Remove cup rest. 2. Turn regulator adjustment knob to the right (clockwise) to increase CO2 pressure (50–PSI Max) or turn knob to the left (counterclockwise) to decrease CO2 pressure. 2. Remove lower access panel as instructed. 3. Pull two retaining pins securing drip tray, then remove tray. 3. Push knob down to lock. 11 91633 ICE BIN COVER THUMBSCREW ICE AGITATOR DISC CUP LID HOLDER PANEL ICE AGITATOR ICE PORTION–CONTROL SWITCH MODULE PANEL ICE CHUTE LOWER ACCESS PANEL DISPENSING VALVE (6) RETAINING PIN(2) CUP REST DRIP TRAY FIGURE 5. PARTS IDENTIFICATION 91633 12 10. Turn syrup shutoff valve (right–side shutoff valve) to the OPEN (extreme CLOCKWISE) position. ADJUSTING DISPENSING VALVES WATER FLOW RATE SYRUP AND WATER SHUTOFF VALVES IN ”OPEN” POSITION 11. Install top cover on dispensing valve and secure with screw. 12. Install front cover on dispensing valve. 13. Connect syrup line quick disconnect to syrup tank outlet. ADJUSTABLE SYRUP AND WATER FLOW CONTROLS ADJUSTABLE WATER CONTROL ADJUSTABLE SYRUP CONTROL FIGURE 6. DOLE DISPENSING VALVE Dole Dispensing Valve. (see FIGURE 6) 1. Remove syrup line quick disconnect from syrup tank serving dispensing valve water flow rate check will be preformed on. 2. Remove front cover from dispensing valve by pulling out on bottom of cover. FIGURE 7. CC–1 DISPENSING VALVE 3. Remove top cover from dispensing valve by loosening screw on front of valve, then remove cover. CC–1 Dispensing Valve (see FIGURE 7) 1. Remove syrup line quick disconnect from syrup tank serving dispensing valve water flow rate check will be performed on. 4. Turn syrup shutoff valve (right–side shutoff valve) to the CLOSED (extreme COUNTERCLOCKWISE) position. 2. Remove applicable dispensing valve portion control cover by sliding cover up and off top cover. NOTE: Do not confuse syrup and water shutoff valves with dispensing valve flow controls adjusting screws. 3. Remove dispensing valve top cover by loosening screw securing cover, then lift cover up and off. 5. Position volume cup under dispensing valve nozzle. 4. Position volume cup under dispensing valve nozzle. 6. Press CANCEL/POUR switch and hold for 4 seconds. 5. Press CANCEL/POUR switch and hold for 4–seconds. NOTE: 10 fl ounces (296 ml) of water should be dispensed into cup for sugar based drinks and 7.6 fl ounces (225 ml) for sugar–free based drinks. NOTE: 10 fl ounces (296 ml) of water should be dispensed into cup for sugar based drinks and 7.6 fl ounces (225 ml) for sugar–free based drinks. 7. If the water volume is correct. proceed with Step 9 If the flow rate is not correct, proceed with Step 8 . 8. Turn dispensing valve water flow control adjusting screw to the right (CLOCKWISE) to increase or to the left (COUNTERCLOCKWISE) to decrease the flow of water. 6. If the water volume is correct, proceed with Step 10 If the flow rate is not correct, proceed with step 7. 7. Remove plastic cover from water flow regulator labeled “WATER”. 8. Turn dispensing valve water flow regulator adjusting screw to the right (CLOCKWISE) to increase or to the left (COUNTERCLOCKWISE) to decrease the flow of water. 9. Repeat Steps 2 through 7 for each dispensing valve until all valves are checked and/or calibrated (as required). Water flow rate check is complete. 13 91633 6. Press valve cover “CANCEL/POUR” switch and dispense approximately five ounces of water into ratio cup. Water and syrup levels should be even in ratio cup. NOTE: One (1) turn of the water flow regulator adjusting screw will change the water flow rate approximately 2 fl ounces (59 ml) per 4 second draw. 7. If water and syrup levels are not even in ratio cup, turn valve (see Figure 6) syrup flow regulator labeled “S4” (right–side regulator) adjusting screw to the left (counterclockwise) for less syrup or to the right (clockwise) for more syrup. 9. Install plastic cover on water flow regulator. 10. Install dispensing valve top cover and secure with screw. 11. Install portion control cover on top cover by sliding portion control cover down into place on top cover. 8. Repeat water–to–syrup “Ratio” test and adjust valve syrup flow regulator as many times as necessary until proper ratio of dispensed drink is achieved. 12. Connect syrup line quick disconnect to syrup tank outlet. L.E.D. INDICATOR LIGHT 9. Remove the syrup/water separator by turning and pulling down. CANCEL/POUR SWITCH 10. Install nozzle on valve by pushing up and turning until it is locked. 11. Install dispensing valve front cover. SODA OR WATER BUTTON CC–1 Dispensing Valve (see Figure 7) 1. Remove dispensing valve portion control cover by sliding cover up off top cover. 2. Remove dispensing valve top cover by loosening screw securing cover, then lift cover up and off. 3. Remove nozzle from dispensing valve by turning nozzle and pulling down. 4. Remove syrup diffuser from dispensing valve by pulling diffuser down and out of valve. 5. Place the syrup/water separator on the dispensing valve by pushing up and turning to tighten. FIGURE 8. DISPENSING VALVE PORTION–CONTROL COVER 6. Press portion control cover CANCEL/POUR switch (see FIGURE 8) momentarily to fill separator with syrup. ADJUSTING WATER–TO–SYRUP “RATIO” OF DISPENSED PRODUCT 7. Place the ratio cup under the separator, the large section of the cup under the large round body of the separator and the small section of the cup under the small tube, which is the syrup tube. Dole Dispensing Valve (see Figure 6) 1. Remove dispensing valve front cover (pull from bottom edge). 8. Press valve cover “CANCEL/POUR” switch and dispense approximately five ounces of water into ratio cup. Water and syrup levels should be even in the ratio cup. 2. Remove dispensing valve nozzle by turning and pulling down. 3. Install syrup/water separator on dispensing valve by pushing up and turning to tighten. 9. If water and syrup levels are not even in ratio cup, turn dispensing valve (see FIGURE 7) syrup flow regulator labeled “SYRUP” adjusting screw to the left (counterclockwise) no more than 1/4–turn at a time for less syrup or to the right (clockwise) no more than 1/4–turn at a time for more syrup. 4. Press valve cover “CANCEL/POUR” switch (see FIGURE 8) momentarily to fill separator with syrup. 5. Place the ratio cup under the separator, the large section of the cup under the large round body of the separator and the small section of the cup under the extended arm, which is the syrup tube. 91633 10. Repeat Water–to–Syrup “Ratio” test and adjust syrup flow regulator as many times as necessary until proper ratio of dispensed drink is achieved. 14 Dispensing of a portion control drink may be stopped by pressing the “CANCEL/POUR” switch. Drinks may be manually dispensed (non–portion control) by pressing the “CANCEL/POUR” switch. 11. Remove the syrup/water separator by turning and pulling down. 12. Install syrup diffuser on dispensing valve. 13. Install nozzle on valve by pushing up and turning until it is locked. 14. Install top cover on valve and secure with screw. S (SMALL) 15. Install portion–control cover on dispensing valve. M (MEDIUM) L.E.D. INDICATOR LIGHT DISPENSED DRINK PORTION–CONTROL ADJUSTMENT (DOLE AND CC–1 DISPENSING VALVES) L (LARGE) XL (EXTRA LARGE) DECREASE INCREASE SEE FIGURE 8. NOTE: In case of electrical power failure, dispensing valves portion controls have full memory function. B 1. At the same time press and hold “S” (small) and “XL” (extra large) dispense switches (see FIGURE 8) on dispensing valve front cover until L.E.D. indicator light on cover starts blinking. Blinking L.E.D. indicates portion control “set mode” has been activated. Y FIGURE 9. ICE PORTION–CONTROL SWITCH MODULE 2. Dispense small portion of ice in a small drink size cup, then place cup under dispensing valve nozzle. 3. Press and hold switch labeled “S” (small) on dispensing valve cover until cup is filled with product to desired level, then release switch. 4. With exception of using an appropriate size cup containing appropriate portion of ice, repeat steps 2 and 3 to adjust sizes of drinks dispensed when pressing “M” (medium), “L” (large), or “XL” (extra large) switches. 5. After all portion sizes of dispensed drinks have been adjusted, press and release “CANCEL/ POUR” switch to cancel portion control “set mode” and return to portion control operation. Any one of the dispensing valves portion sizes may be reprogrammed by at the same time pressing and holding the “S” (small) and “XL” (extra large) dispense switches (activate “set mode”), reprogram drink size, then press CANCEL/POUR SWITCH to return to portion control operation. 15 ICE PORTION CONTROL SYSTEM THEORY OF OPERATION A vertical plastic cylinder (ice chute) located on front of the dispenser is filled with ice by a revolving ice agitator located inside the ice bin. Ice is stored in the ice chute and is replenished after each ice dispensing operation. An ice gate, located in bottom of the ice chute, closes off bottom of the ice chute and supports the column of stored ice. The electronic selector/controller determines the duration of time the ice gate remains open when dispensing ice which controls the portion (amount) of ice that is dispensed. After ice has been dispensed, the controller starts the ice agitator which refills the ice chute. The controller also allows the next ice portion to be dispensed without waiting for the ice chute to be totally refilled. If there is not enough ice in the ice chute to dispense the next ice portion selection, the green L.E.D. (located on the ice dispense switch module) will flash until the ice chute has been refilled enough to allow an ice portion to be dispensed.The green L.E.D. will be turned on after the ice chute has been refilled which signals that an ice portion may be selected and dispensed. 91633 “NORMAL ICE PORTION–CONTROL ADJUSTMENT MODE” (SOLID AMBER L.E.D) CLEANING AND ADJUSTING THE DISPENSER ICE PORTION–CONTROL SYSTEM The “S” (small), “M” (medium), “L” (large), and the “XL” (extra large) sizes of dispensed ice may be increased or decreased as desired. Refer to FIGURES 9 and 11 for instructions to adjust ice portion sizes. There are three independent modes that may be entered into on the Ice Portion–Control System. They are the “Clean Mode”, “Normal Ice Portion–Control Adjustment Mode”, and the “Extra Ice Adjustment Mode”. To enter into each of these three modes, the person must start from the “Normal Operating Mode” (green L.E.D. indicator light on) and use the Y (increase) and the B (decrease) switches on the ice portion–control switch module (see FIGURES 9, 10, and 11 ) to step through to the desired mode. Proceed as follows. “EXTRA ICE ADJUSTMENT MODE” (SOLID RED L.E.D.) Extra ice may be dispensed into the cup by first pressing the “Y (increase) ice dispense switch, then dispense the desired normal ice portion size into the cup. Refer to FIGURES 9 and 11 for instructions to adjust sizes of dispensed extra ice portions. “CLEAN MODE” (FLASHING RED/AMBER L.E.D.) The dispenser ice chute must be periodically removed and cleaned and sanitized. Refer to FIGURES 9 and 10 for instructions to clean and sanitize the ice chute. 91633 16 FIGURE 10. CLEAN MODE (CLEAN ICE CHUTE) Thumb Screws (4) Ice Portion Control Program LED Y d Ice Chute Service Panel Removed Clean Mode (Clean Ice Chute) B Service Panel Thumb Screw Service Panel Ice Chute Strap Screws This Mode permits cleaning of the Ice chute. Normal Operating Mode (Solid Green LED) START HERE Press B & Y at the same time, then immediately release LED Flashing Red/Amber (Clean Mode) Press any Portion Switch This empties ice from the chute Remove Service Panel Thumbscrews, Then remove the panel Remove Ice Chute Strap Screws, Then Remove Strap Removal of the ice chute interrupts power to the Dispenser. (Flashing red LED will turn off) Remove the Four Thumbscrews securing the Ice Chute. Remove the Chute and gate cover. Wash ice chute, gate slide, and gate cover in detergent soap solution, then rinse thoroughly with plain water. Sanitize inside of ice chute, gate cover, and gate slide (refer to sanitizing syrup system for sanitizing solution mixture). Replace all Parts in Reverse Order of Removal Portion Control will automatically return to Normal Operating Mode. (Solid Green LED) 17 91633 This mode is used to adjust ice portion sizes Normal Ice PortionĆControl Adjust Mode IMPORTANT If no adjustments are made within 60 seconds, ice dispensing will return to normal operating mode. Adjustment Panel Increase L.E.D. Indicator Y B Light Normal Operating Mode (Solid Green LED) Press Y & B at the same time, then immediately release Decrease 1. Press and hold the desired ice portion selection button to be adjusted. 2. While holding the portion selection button, momentarily press the increase (Y) or decrease (B) to change the amount of ice dispensed. Each time the B or Y is pressed the ice portion will change. A slow flashing LED means the portion is set at minimum. A fast flashing LED means the portion is set at maximum. 3. After adjustment has been made, release the portion selection button. The green LED will flash for 5 seconds. Within this 5 sec., press cup size button being adjusted to take a sample. After 5 seconds the LED will return to solid amber (Normal adjustment mode). A solid red LED will be displayed briefly after dispensing a sample if the ice gate cylinder switch was shorted; a flashing red LED indicates an open in the ice gate cylinder switch wiring or an ice gate binding condition. 4. Repeat process until proper portion size is obtained. LED Flashing Red/Amber Press Y &B at the same time, then immediately release Normal Portion-Control Mode (Solid Amber LED is on) Extra Ice Adjustment Mode Normal Operating Mode (Solid Green LED) Start Here No Is the ice portion set as desired? Go to the next ice portion and repeat programming Press Y & B at the same time, then immediately release Momentarily press B and Y at the same time to go to “Extra Ice Adjust Mode”. Red LED will be turned on. LED Flashing Red/Amber Press Y & B at the same time then immediately release Yes Adjust No Adjustment Momentarily press B and Y at the same time to return to the normal operating mode. Green LED will be turned on. Solid Amber LED is "ON" Press Y &B at the same time, then immediately release Extra Ice Adjustment Mode (Solid red LED is "ON") Same adjustment procedure as normal ice portionĆcontrol adjust mode Note: To return ice portion control to factory settings, the ice portion control must be in the Normal Ice Adjustment Mode (Solid Amber LED). Then, at the same time, press and hold the small and extra large buttons for 1 second. The LED will go from amber to red and back to amber which signals that the portion sizes have been returned to the factory settings. FIGURE 11. NORMAL ICE PORTION–CONTROL AND EXTRA ICE ADJUSTMENT MODE 91633 18 REPLENISHING CO2 SUPPLY SYRUP FLAVOR CHANGE Sanitize applicable syrup system as instructed, then install full tank of new flavor syrup. WARNING: CO2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 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 CO2 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation. REPLENISHING ICE BIN ICE SUPPLY 1. Remove ice bin cover. IMPORTANT: IMPORTANT: Do not use hard–frozen (below 32_F) ice. After ice is removed from a freezer, allow the ice to sit at room temperature for approximately 1/2 hour before placing it in the bin. Ice to be used to fill ice bin must be in the form of small cubes, chunklets, or cracked ice (DO NOT USE FLAKE OR CRUSHED ICE). NOTE: When indicator on CO2 cylinder regulator assembly 1800–psi gage is in shaded (“change CO2 cylinder”) portion of dial, CO2 cylinder is almost empty and should be changed. 1. Fully close (clockwise) CO2 cylinder valve. 2. Slowly loosen CO2 regulator assembly coupling nut allowing CO2 pressure to escape, then remove regulator assembly from empty CO2 cylinder. 2. Observing preceding IMPORTANT note, fill ice bin with small cubes, chunklets, or cracked ice. 3. Install ice bin cover (ICE BIN COVER MUST BE IN INSTALLED POSITION FOR ICE AGITATOR TO OPERATE). CLEANING AND SANITIZING PERIODIC CLEANING OF ICE CHUTE The ice chute on front of dispenser must be periodically removed and cleaned. Refer to FIGURES 9 and 10 CLEAN MODE (CLEAN ICE CHUTE) for removal and cleaning procedure. 3. Unfasten safety chain and remove empty CO2 cylinder. WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder with safety chain to prevent it from falling over. Should the valve become accidentally damaged or broken off, CO2 cylinder can cause serious personal injury. DAILY CLEANING OF UNIT EXTERIOR 1. Remove cup rest from drip tray. 4. Position CO2 cylinder and secure with safety chain. 2. Wash out drip tray, then rinse tray with warm water allowing water to run down drain hose. MAKE SURE DRIP TRAY DRAIN HOLE AND DRAIN HOSE ARE NOT CLOGGED WHICH WOULD PREVENT WATER FROM EXITING DRIP TRAY THROUGH DRAIN HOSE. 5. Make sure gasket is in place inside CO2 regulator coupling nut,then install regulator on CO2 cylinder, 3. Wash cup rest, then rinse cup rest with clean water. Install cup rest in drip tray. 6. Open (counterclockwise) CO2 cylinder valve slightly to allow lines to slowly fill with gas, then open valve fully to back–seat valve. (Back–seating valve prevents leakage around valve shaft). 4. Clean all external surfaces of unit with sponge. Rinse out sponge with clean water, then wring excess water out of sponge and wipe off external surfaces. Wipe dry with clean soft cloth. DO NOT USE ABRASIVE TYPE CLEANERS. 7. Check CO2 connections for leaks, Tighten loose connections. WEEKLY CLEANING OF DISPENSING VALVES 1. Remove nozzle from dispensing valve by turning nozzle and pulling down. REPLENISHING SYRUP SUPPLY 1. Remove CO2 disconnect (grey) and syrup disconnect (black) from empty syrup tank, then remove tank. 2. Dole Dispensing Valve. 2. Place full syrup tank in position, then connect CO2 disconnect (grey) and syrup disconnect (black) to full syrup tank. 19 A. Remove diffuser/syrup tube from dispensing valve by pulling down. B. Place diffuser/syrup tube and nozzle in sanitizing solution. 91633 6. Using nylon brush (DO NOT USE WIRE BRUSH) and detergent soap solution, scrub entire interior surface of ice bin. 3. CC–1 Dispensing Valve. A. Remove syrup diffuser from dispensing valve by pulling down. B. Place syrup diffuser and nozzle in sanitizing solution. 7. Rinse entire inside area of bin with plain water. 8. Wash ice agitator disc, ice agitator, and ice bin cover in detergent soap solution. 4. Using a clean sanitized towel, wipe inside diffuser area. 9. Rinse ice agitator disc, ice agitator, and ice bin cover thoroughly with plain water. 5. Using a nylon pot brush, clean removed parts with sanitizing solution. 10. Install ice agitator and ice agitator disc on motor shaft and secure with thumbscrews. 6. Install removed parts on dispensing valve. 11. Using a clean container, prepare a sanitizing solution using 1/2 ounce of household bleach (Sodium Hypochlorite) to one gallon of cold (Ambient) potable water (200–PPM). CLEANING ICE BIN INTERIOR AND SANITIZING SYRUP SYSTEM The ice bin interior should be cleaned and syrup systems sanitized every 30–days 12. Using a plastic bristle brush (DO NOT USE A WIRE BRUSH), scrub ice bin cover, ice agitator, ice agitator disc, and entire inside area of ice bin with sanitizing solution. Cleaning Ice Bin Interior. 13. Slowly pour remaining sanitizing solution into ice bin which will allow sanitizing solution to run down over cold plate surface and out through drip tray to the permanent drain. WARNING: The ice bin contains hazardous moving parts. Do not attempt to clean ice bin until Unit power cord is disconnected from electrical outlet. Sanitizing Syrup System. CAUTION: Do not allow sanitizing solution to remain in syrup systems longer than recommended contact time. Exceeding contact time will result in damage to stainless steel components. CAUTION: DO NOT USE CHLORINE CLEANSING POWDERS FOR CLEANING. Use of chlorine cleaning powders will cause corrosive action on metal components. DO NOT USE SOLVENTS OR OTHER CLEANING AGENTS AS THEY MAY ATTACK THE PLASTIC MATERIAL. WARNING: Flush sanitizing solution from syrup systems as instructed. Residual sanitizing solution left in systems could create a health hazard. 1. Unplug Unit power cord from electrical outlet. 2. Remove ice bin cover. 1. Remove dispensing valves nozzles, wash in mild detergent, then reinstall nozzles on valves. 3. Using warm water, melt ice inside ice bin and on top of coldplate. BE CAREFUL NOT TO USE TOO MUCH WARM WATER AT A TIME AS FLOODING OF DRIP TRAY MAY OCCUR DUE TO WATER NOT EXITING DRIP TRAY INTO DRAIN HOSE FAST ENOUGH. 2. Disconnect electrical power to carbonator. 3. Shut off the main water supply, then close CO2 regulator to the carbonator. 4. Disconnect syrup tanks from the syrup systems. 4. Remove thumbscrew securing ice agitator disc and ice agitator on motor shaft. 5. Activate the dispensing valves to purge remaining carbonated water from the carbonated water system. 5. Remove ice agitator disc and ice agitator by pulling them straight up off motor shaft. 6. Use clean empty syrup tanks for each of the following: NOTE: Lime and scale deposits may be removed from metal components by using a cleaner such as Calgon Liquid Ice Machine Cleaner. 91633 A. 20 Cleaning tank – fill with hot (120° to 140 ° F) potable water. B. 8. Open CO2 regulator to carbonator, open main water supply, then connect electrical power to carbonator. Sanitizing tank – Fill with a chlorine sanitizing solution with a strength of one ounce of household bleach (sodium hypochlorite) to two gallons of cold (ambient) potable water (200–PPM). 9. Dispense from all dispensing valves until a proper drink is dispensed. MAKE SURE DISPENSED DRINK ARE FREE FROM OFF–TASTE. 7. Repeat the following procedure to clean and sanitize each of the syrup systems. A. Connect the cleaning tank containing potable water to one of the syrup systems, then connect CO2 to tank. B. Activate dispensing valve and dispense until syrup is purged from system and only water is dispensed. C. Disconnect cleaning tank containing potable water from syrup system. D. Connect tank containing sanitizing solution into the syrup system. E. Activate the dispensing valve until water is purged from the syrup system and until only sanitizing solution is dispensed. Allow sanitizing solution to remain in the syrup system for twenty minutes before proceeding to next step. F. Disconnect tank containing sanitizing solution from the syrup system. FIGURE 12. CO2 GAS CHECK VALVE G. Connect tank containing syrup into the syrup system. CLEANING CO2 GAS CHECK VALVES H. Dispense from dispensing valve until all sanitizing solution has been dispensed from syrup system and only syrup is dispensed. (see FIGURES 2 AND 12) I. Repeat preceding steps A through H to clean and sanitize remaining syrup systems. 21 The CO2 gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO2 system. ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED. 91633 FIGURE 13. DISPENSER WIRING DIAGRAM 91633 22 FIGURE 14. INSTRUCTIONS FOR CRIMPING TUBE CLAMPS 23 91633 THIS PAGE LEFT BLANK INTENTIONALLY 91633 24 TROUBLESHOOTING IMPORTANT: WARNING: Disconnect electrical power to unit to prevent personnel injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring. If repairs are to be made to CO2, syrup, or water systems, shut off CO2 and plain water supplies, discount carbonator power cord, disconnect syrup tanks, and bleed systems pressures before proceeding TROUBLESHOOTING POST–MIX SYSTEM Trouble WATER–TO–SYRUP “RATIO” TOO LOW OR TOO HIGH. ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW CONTROL DOES NOT INCREASE TO DESIRED WATER–TO–SYRUP “RATIO” . Probable Cause Remedy A. Dispensing valve syrup flow control not properly adjusted. A. Adjust Water–to–Syrup “Ratio” as instructed. B. CO2 gas pressure to syrup tanks insufficient to push syrup out of tanks. B. Adjust secondary CO2 regulator for syrup tanks as instructed. A. No syrup supply. A. Replenish syrup supply as instructed B. Syrup tank quick disconnects not secure. B. Secure quick disconnects. C. Syrup tanks secondary CO2 regulator out of adjustment. C. Adjust syrup tanks secondary CO2 regulator as instructed. D. Dispensing valve syrup flow control, syrup tank quick disconnect, or syrup line restricted. D. Sanitize syrup system as instructed. E. Improper Baume of syrup. E. Replace syrup supply. F. Dirty or inoperative dispensing valve syrup flow control. F. Disassemble and clean dispensing valve syrup flow control. G. Tapered nylon washer inside tube swivel nut connection distorted from being overtightened restricting syrup flow. G. Replace nylon washer. Make sure it seats properly. ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW CONTROL DOES NOT DECREASE TO DESIRED WATER–TO–SYRUP “RATIO”. A. Dirty or inoperative dispensing valve syrup flow control. A. Disassemble and clean dispensing valve syrup flow control. DISPENSED PRODUCT CARBONATION TO LOW. A. Carbonator primary CO2 regulator out of adjustment for existing water conditions or temperature. A. Adjust carbonator primary CO2 regulator (Reference manual provided with carbonator). B. Air in carbonator tank. B. Vent air out of carbonator tank through relief valve. Activate dispensing valve No. 1 to make carbonator pump cycle on. 25 91633 Trouble Probable Cause Remedy DISPENSED PRODUCT CARBONATION TO LOW. (con’t) C. Water, oil, or dirt, in CO2 supply. C. Remove contaminated CO2. Clean CO2 system (lines, regulator, etc) using a mild detergent. Install a clean CO2 supply. DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT FOAMS IN CUP. A. Ice used for finished drink is subcooled. A. If using purchased ice allow ice to melt slightly before using. B. Insufficient ice supply in dispenser ice bin. B. Replenish ice supply as instructed. C. Oil film or soap scum in cups C. Use clean cups. A. Carbonator primary CO2 regulator CO2 pressure set to high for existing water conditions or temperature. A. Reduce carbonator CO2 regulator setting. B. Syrup over carbonated with CO2 as indicated by bubbles in inlet syrup lines leading to dispenser. B. Remove syrup tanks quick disconnects. Relieve tank CO2 pressure, shake tank vigorously, then relieve tank CO2 pressure as many times as necessary to remove over–carbonation. C. Dispensing valve restricted or dirty. C. Sanitize syrup system as instructed. D. Tapered nylon washer inside carbonated water line swivel nut connector distorted restricting carbonated water flow. D. Replace nylon washer. Make sure it is properly seated. E. Dirty water supply. E. Check water filter. Replace cartridge. DISPENSED PRODUCT PRODUCES FOAM AS PRODUCT LEAVES DISPENSING VALVE. Note: If water supply is dirty, be sure to flush lines and carbonator completely. It may be necessary to remove lines to carbonator tank, invert tank and flush tank and all inlet lines to remove any foreign particles or dirt. NO PRODUCT DISPENSED FROM ALL DISPENSING VALVES. 91633 A. Dispenser rocker–type power switch in OFF position. A. place power switch in ON position. B. No electrical power to dispenser. B. Plug in dispenser power cord, or check fuse or circuit breaker. C. Disconnected or broken wiring to dispensing valves. C. Connect or replace wiring. D. Loose ground connection. D. Have ground connection repaired. E. Inoperative dispenser transformer E. Have transformer replaced. 26 Trouble NO PRODUCT DISPENSED FROM ONE DISPENSING VALVE. ONLY CARBONATED WATER DISPENSED. ONLY SYRUP DISPENSED. DISPENSING VALVE WILL NOT DISPENSE ANY PORTION CONTROL SIZE DRINK. NO RESPONSE FROM ONE OF THE PORTION CONTROL SWITCHES OR THE CANCEL/POUR SWITCH. Probable Cause Remedy A. Broken or disconnected wiring. A. Connect wiring or have repaired. B. Inoperative dispensing valve. Inoperative dispensing valve. B. Have dispensing valve repaired. C. Inoperative portion control. C. Replace portion control cover. A. Quick disconnects not secure on syrup tanks. A. Secure quick disconnects on syrup tanks. B. Out of syrup. B. Replenish syrup supply as instructed. C. CO2 regulator for syrup tanks not properly adjusted. C. Adjust syrup tank CO2 regulator as instructed. D. Inoperable dispensing valve. D. Have dispensing valve repaired. E. Dispensing valve syrup flow control not properly adjusted. E. Adjust dispensing valve syrup flow control (Water–to–Syrup “Ratio”) as instructed. F. Dispensing valve syrup flow control, syrup tank quick disconnect, or syrup lines restricted. F. Sanitize syrup system as instructed. A. Plain water inlet supply line shutoff valve closed. A. Open plain water inlet supply line shutoff valve. B. Carbonator power cord unplugged from electrical outlet. B. Plug carbonator power cord into electrical outlet. C. Carbonator CO2 regulator not properly adjusted. C. Adjust carbonator CO2 regulator (Reference manual provided with carbonator). A. Portion control not properly adjusted. A. Adjust all portion sizes on dispensing valve as instructed. B. Portion control cover electrical wiring disconnected. B. Connect portion control cover electrical wiring. C. Inoperable portion control. C. Replace portion control cover. A. Inoperable portion control. A. Replace portion control cover. 27 91633 TROUBLESHOOTING ICE DISPENSING SYSTEM Probable Cause Trouble NO ICE DISPENSED 91633 Remedy A. Ice bin cover not in place. A. Install ice bin cover. B. Insufficient ice supply in ice bin. B. Replenish ice supply as instructed. C. Ice in ice bin bridged (stuck together). C. Gently tap on ice to break it loose. D. No electrical power to dispenser. D. Plug in dispenser power cord, or check fuse or circuit breaker. E. Insufficient or no CO2 supply to dispenser. E. Restore CO2 supply to dispenser. F. Inoperative ice portion controller. F. Replace ice portion controller. G. Inoperative ice agitator motor. G. Replace ice agitator motor. H. Inoperative gate cylinder. H. Replace gate cylinder. I. Inoperative gate solenoid I. Replace gate solenoid. 28 IMI CORNELIUS INC. One Cornelius Place Anoka, MN. 55303–1592 Telephone (800) 238–3600 Facsimile (612) 422–3232 Installation Instructions WARRANTY IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius product, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number and the date of purchase. IMI Cornelius Offices AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166 AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930 BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307 BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829 ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644 FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201 GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, WEST GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438 GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491 HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222 ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814 NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361 SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604 SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379 USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (612) 421-6120 D FAX (612) 422-3255 29