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IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234 Telephone (800) 238-3600 Facsimile (612) 422-3246 Installation/Service Manual CHALLENGER I PRE--MIX AND POST-MIX COOLING UNITS IMPORTANT: TO THE INSTALLER. It is the responsibility of the Installer to ensure that the water supply to the dispensing equipment is provided with protection against backflow by an air gap as defined in ANSI/ASME A112.1.2-1979; or an approved vacuum breaker or other such method as proved effective by test. Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed, and maintained according to Federal, State, and Local Codes. Part No. 314920000 October 31, 1972 Revised: January 30, 1996 Control Code A THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment Ó IMI CORNELIUS INC; 1972--96 PRINTED IN U.S.A TABLE OF CONTENTS Page SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 RECOGNIZE SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDERSTAND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 FOLLOW SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO2 (CARBON DIOXIDE) WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIPPING, STORING, OR RELOCATING UNIT . . . . . . . . . . . . . . . . . . . . . . . GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 3 UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRE-MIX COOLING UNIT WITH FIVE-FLAVOR BAR VALVE . . . . . . . . . . . PRE-MIX COOLING UNIT WITH AND WITHOUT SEVEN-FLAVOR BAR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POST-MIX SEVEN FLAVOR COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRE--MIX SYSTEM WITH FIVE--FLAVOR BAR VALVE . . . . . . . . . . . . . . . . . PRE--MIX SYSTEM WITH SEVEN--FLAVOR BAR VALVE . . . . . . . . . . . . . . PRE--MIX SEVEN--FLAVOR SYSTEM WITHOUT BAR VALVE . . . . . . . . . . 3 3 POST--MIX SEVEN--FLAVOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 7 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SELECTING COOLING UNIT INSTALLATION LOCATION . . . . . . . . . . . . . . . . . . SEALING COOLING UNIT TO THE FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILL WATER TANK AND START COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING COOLING UNIT INLET AND OUTLET LINES . . . . . . . . . . . . . . . 7 8 8 8 9 INLET LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTLET LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACTIVATING CO2 SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING CO2 REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACTIVATING SYRUP, CARBONATED WATER, AND PLAIN WATER SUPPLIES ACTIVATING SYRUP SUPPLIES TO THE COOLING UNIT . . . . . . . . . . . . . 9 10 10 10 10 11 11 3 3 3 5 5 5 5 ACTIVATING CARBONATED WATER SUPPLY SUPPLY TO THE COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACTIVATING PLAIN WATER SUPPLY TO THE COOLING UNIT . . . . . . . . . UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATORS INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 12 13 OPERATING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 13 DISPENSING STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DAILY PRE--OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING CO2 REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING WATER--TO--SYRUP ‘‘RATIO’’(POST--MIX SYSTEM) OF DISPENSED PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 13 13 13 i 13 314920000 TABLE OF CONTENTS (cont’d) Page CLEANING AND SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 13 SANITIZING PRODUCT (PRE-MIX) OR SYRUP (POST-MIX) SYSTEMS . COOLING UNIT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING ICE WATER BATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOTE CARBONATOR YEARLY MAINTENANCE OR AFTER WATER SYSTEM DISRUPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 14 14 14 PREPARING COOLING UNIT FOR SHIPPING, STORING, OR RELOCATING 14 15 15 PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CO2 REGULATORS ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ADJUSTING DISPENSER (POST-MIX SYSTEM) DISPENSING VALVES FOR WATER-TO-SYRUP “RATIO”OF DISPENSED PRODUCT . . . . . . . . . . . . . . 16 CLEANING COOLING UNIT CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CHECKING COOLING UNIT ICE WATER BATH . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING COOLING UNIT WATER TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DAILY CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DAILY CLEANING OF BAR VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DAILY CLEANING OF DISPENSING STATION. . . . . . . . . . . . . . . . . . . . . . . . PERIODIC CLEANING OF COOLING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING AND SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 17 18 18 18 18 18 DAILY CLEANING OF UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SANITIZING POST-MIX SYRUP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 19 23 TROUBLESHOOTING PRE--MIX SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NO PRODUCT DISPENSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE OR BAR VALVE CLEAR BUT FOAMS IN CUP OR GLASS. . . . . . . . . . . . . . . . . . . . . . 23 23 DISPENSED PRODUCT FOAMS AS IT LEAVES DISPENSING VALVE OR BAR VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING POST--MIX SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPENSED PRODUCT 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’’. . . . . . . . . . . 23 23 24 24 24 ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW CONTROL DOES NOT DECREASE TO DESIRED WATER--TO-- SYRUP ‘‘RATIO’’. . . . . . . . . 24 DISPENSED PRODUCT CARBONATION TOO LOW. . . . . . . . . . . . . . . . . . . 24 DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT FOAMS IN CUP OR GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 DISPENSED PRODUCT PRODUCES FOAM AS IT LEAVES DISPENSING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ONLY CARBONATED WATER DISPENSED. . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ONLY SYRUP DISPENSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 314920000 ii TABLE OF CONTENTS (cont’d) Page TROUBLESHOOTING REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSOR DOES NOT OPERATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSOR WILL NOT STOP AFTER SUFFICIENT ICE BANK IS PRODUCED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM SUFFICIENT ICE BANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONDENSER FAN MOTOR NOT OPERATING. . . . . . . . . . . . . . . . . . . . . . . . AGITATOR MOTOR NOT OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 26 26 27 27 27 28 LIST OF FIGURES FIGURE 1. CHALLENGER COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 2. FLOW DIAGRAM (PRE-MIX SYSTEM WITHFIVE-FLAVOR BAR VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 3. FLOW DIAGRAM (PRE-MIX SYSTEM WITH SEVEN-FLAVOR BAR VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 4. FLOW DIAGRAM (PRE-MIX SEVEN-FLAVOR SYSTEM WITHOUT BAR VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 5. FLOW DIAGRAM (POST-MIX SEVEN-FLAVOR SYSTEM) . . . . . . . FIGURE 6. PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 7. WATER TANK COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 8. WIRING DIAGARAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6 6 6 6 16 17 22 LIST OF TABLES TABLE 1. DESIGN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TABLE 2. LOOSE-SHIPPED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii 4 7 314920000 SAFETY INFORMATION Recognize Safety Information This is the safety-alert symbol. When you see this symbol on our machine or in this manual, be alert to the potentially of personal injury. Follow recommended precautions and safe operating practices. Understand Signal Words A signal word - DANGER, WARNING, OR CAUTION is used with the safety-alert symbol. DANGER identifies the most serious hazards. Safety signs with signal word DANGER or WARNING are typically near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. DANGER WARNING CAUTION Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Learn how to operate the machine and how to use the controls properly. Do not let anyone operate the machine without instructions. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair function and/or safety and affect the machine life. CO2 (Carbon Dioxide) 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. Shipping, Storing, Or Relocating Unit CAUTION: Before shipping, storing, or relocating this Unit, the applicable syrup or product systems must be sanitized and all sanitizing solution must be purged from the syrup or product systems. All water must also be purged from the plain and carbonated water systems. A freezing ambient temperature will cause residual water remaining inside the Unit to freeze resulting in damage to internal components of the Unit. 1 314920000 THIS PAGE LEFT BLANK INTENTIONALLY 314920000 2 GENERAL DESCRIPTION This manual is a guide for installing, operating, and maintaining this equipment. Refer to Table of Contents for page location of detailed information pertaining to questions that may arise during installation, operation, service and maintenance, or troubleshooting this equipment. This section gives the description, theory of operation, and design data for the Challenger I Pre-Mix Cooling Unit with or without Seven-Flavor Bar Valve, the Challenger I Pre-Mix Cooling Unit with Five-Flavor Bar Valve, and the Challenger I Post-Mix Seven-Flavor Cooling Unit. UNIT DESCRIPTION The Challenger I Cooling Units are equipped with a 1/5 H.P. refrigeration compressor. PRE-MIX COOLING UNIT WITH FIVE-FLAVOR BAR VALVE (See Figure 2) The Cooling Unit is equipped with a five-flavor bar valve. The only requirements for operation are placing the Cooling Unit in operating position, filling Cooling Unit water tank with water, connection of product tanks to the Cooling Unit, and plugging the Cooling Unit power cord into an electrical outlet. PRE-MIX COOLING UNIT WITH AND WITHOUT SEVEN-FLAVOR BAR VALVE (see Figures 3 and 4) This Cooling Unit may or may not be equipped with a seven-flavor bar valve. The Cooling Unit not equipped with a seven-flavor bar valve requires connection of a dispensing station to the Unit. The only requirements for operation are placing the Cooling Unit in operating position, connecting dispensing station to the Cooling Unit if applicable, filling Cooling Unit water tank with water, connection of product tanks and a carbonated water tank to the Cooling Unit, and plugging Cooling Unit power cord into an electrical outlet. POST-MIX SEVEN FLAVOR COOLING UNIT (see Figure 5) This Cooling Unit requires connection to a dispensing station. The only requirements for operation are placing the Cooling Unit in operating position, connection of dispensing station to the Cooling Unit, connection of syrup, plain water, and carbonated water sources to the Cooling Unit, and plugging Cooling Unit power cord into an electrical outlet. WARRANTY REFERENCE INFORMATION Warranty Registration Date (to be filled out by customer) Unit Part Number: Serial Number: Install Date: Local Authorized Service Center: 3 314920000 FIGURE 1. CHALLENGER COOLING UNIT Table 1. Design Data Part Numbers: Challenger I with Seven--Flavor Pre--Mix Bar Valve Challenger I w/o Seven--Flavor Pre--Mix Bar Valve Challenger I with Five--Flavor Pre--Mix Bar Valve Challenger I Seven Flavor Post--Mix 2844632000 2844642000 2844652000 4163430000 Overall Dimensions: Height Width Length 13--1/8 inches 14--3/8 inches 16--3/8 inches Weight: Dry With water tank full of water Shipping Weight (Approx.) 60 pounds 82 pounds 75 pounds Water Tank Capacity 9--1/2 quarts Ice Bank (approx.) 6 pounds Cooling Capacity (see NOTE) 50 six oz. drinks at 4/min. NOTE: Figures represent the number of 6 ounce drinks dispensed below 40° F with inlet product temperature of 75° F and 75° F ambient. The compressor has a recovery of one 6 ounce drink per minute. Refrigeration Requirement: Refrigerant Type and Amount See Unit Nameplate Ambient Operating Temperature 40° F to 100° F Electrical Requirements: Operating Voltage Current Draw 314920000 115VAC, 60Hz 4 amps 4 THEORY OF OPERATION PRE--MIX SYSTEM WITH FIVE-- FLAVOR BAR VALVE (see Figure 2) A CO2 cylinder delivers carbon dioxide (CO2) gas through adjustable CO2 regulators to the product tanks. When valve on the bar valve is opened, CO2 pressure exerted upon the product tank pushes product from the tank, through the Cooling Unit cooling coil, and on to the bar valve resulting in a dispensed drink. PRE--MIX SYSTEM WITH SEVEN--FLAVOR BAR VALVE (see Figure 3) A CO2 cylinder delivers carbon dioxide (CO2) gas through adjustable CO2 regulators to the product tanks and to the carbonated water tank. When applicable valve (pre-mix drink or carbonated water) on the bar valve is opened, CO2 pressure exerted upon the product tank or the carbonated water tank pushes product or carbonated water from the tank, through the Cooling Unit cooling coil, and on to the bar valve resulting in either product or carbonated water being dispensed. Opening the plain water valve on the bar valve allows plain water to pass through the Cooling Unit cooling coil and on to the bar valve resulting in cold plain water being dispensed. PRE--MIX SEVEN-- FLAVOR SYSTEM WITHOUT BAR VALVE (see Figure 4) A CO2 cylinder delivers carbon dioxide (CO2) gas through adjustable CO2 regulators to the product tanks and to the carbonated water tank. When applicable dispensing valve (pre-mix drink or carbonated water) on the dispensing station is opened, CO2 pressure exerted upon the product tank or the carbonated water tank pushes product or carbonated water from the tank, through the Cooling Unit cooling coil, and on to the dispensing station resulting in either product or carbonated water being dispensed. Opening the dispensing station plain water dispensing valve allows plain water to pass through the Cooling Unit cooling coil and on to the dispensing station resulting in cold plain water being dispensed. POST--MIX SEVEN-- FLAVOR SYSTEM (see Figure 5) A CO2 cylinder delivers carbon dioxide (CO2) gas through adjustable CO2 regulators to applicable syrup tanks or bag-in-box syrup pumps and also to the remote carbonator. Plain water entering the remote carbonator water tank is carbonated by regulated CO2 gas also entering the tank. When the dispensing station dispensing valve is opened, CO2 pressure exerted upon the applicable syrup tank or bag-in-box syrup pump pushes syrup from the syrup supply, through the Cooling Unit cooling coil, and on to the dispensing station. Carbonated water is pushed from the carbonator water tank by CO2 gas head pressure through the Cooling Unit cooling coil and on to the dispensing station. Syrup and carbonated water meet simultaneously at the dispensing valve resulting in a carbonated drink being dispensed. Opening the dispensing station plain water dispensing valve allows plain water to pass through the Cooling Unit cooling coil and on to the dispensing station resulting in cold plain water being dispensed. 5 314920000 WATER FILTER INSTALLATION FOR FILTERS WITHOUT BUILT-IN WATER SHUTOFF VALVE PLAIN WATER SOURCE COOLING UNIT PLAIN WATER INLET COOLING UNIT SHUTOFF VALVE FILTER PRODUCT INLET PRODUCT INLET 3 5 2 4 CARB WATER INLET 1 FIVE-FLAVOR BAR VALVE 4 SEVEN-FLAVOR BAR VALVE FILTER SHUTOFF VALVE 3 6 WATER FILTER INSTALLATION FOR FILTERS WITHOUT BUILT-IN WATER SHUTOFF VALVE COOLING UNIT PLAIN WATER SOURCE PRODUCT INLET 5 1 COOLING UNIT FILTER SHUTOFF VALVE PRODUCT TO DISPENSING INLET STATION TO DISPENSING STATION PLAIN WATER SOURCE CARB WATER INLET CARB WATER INLET FIGURE 4. FLOW DIAGRAM (PRE-MIX SEVEN-FLAVOR SYSTEM WITHOUT BAR VALVE) FIGURE 5. FLOW DIAGRAM (POST-MIX SEVEN-FLAVOR SYSTEM) LINE LEGEND PLAIN WATER PRODUCT CARB WATER 314920000 2 FIGURE 3. FLOW DIAGRAM (PRE-MIX SYSTEM WITH SEVEN-FLAVOR BAR VALVE) FIGURE 2. FLOW DIAGRAM (PRE-MIX SYSTEM WITH FIVE-FLAVOR BAR VALVE) WATER FILTER INSTALLATION FOR FILTERS WITHOUT BUILT-IN WATER SHUTOFF VALVE 7 6 INSTALLATION This section covers unpacking and inspection, selecting installation location, installing the Cooling Unit, preparing the Unit for operation, and Cooling Unit operation. UNPACKING AND INSPECTION NOTE: The Cooling Unit 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 date of delivery) and immediately reported to the delivering carrier. Request a written inspection report from the Claims Inspector to substantiate any necessary claim. File claim with the delivering carrier, not with IMI Cornelius Inc. 1. After Cooling Unit has been unpacked, remove shipping tape and other packing material. 2. Unpack LOOSE--SHIPPED PARTS. Make sure all items are present and in good condition. Table 2. Loose-Shipped Parts Quantity Item No. Part No. Name 1 178025100 Tapered Gasket, White 2 178025200 3 Post-Mix 7-fl w/Bar Valve 7-fl 5-fl w/o Bar Valve 14 -- -- -- Tapered Gasket, Red -- 7 5 14 312109000 Decal, Franchise (as ordered) -- 1 1 -- 4 200468012 Sheet Metal Screw, Phil Truss Hd, Type A, No. 8 by 3/4--in. -- 4 4 -- 5 151459001 Drip Receptacle, Bar Valve -- -- 1 -- 151715039 Drip Receptacle, Bar Valve -- 1 -- -- 151714039 Bracket, Bar Valve -- 1 -- -- 151458001 Bracket, Bar Valve -- -- 1 -- 7 150807200 Adapter Fitting, 1/2--16 male by 1/2--16 male -- 7 5 7 8 150807100 Adapter Fitting, 7/16--20 male by 1/2--16 male -- 7 5 7 9 311245000 Reducer Fitting, 7/16--20 female by 1/2--16 male -- 7 5 7 10 176193000 Adapter Fitting, 7/16--20 male by 7/16--20 male 14 -- -- -- 11 150920000 Flavor Clips (as ordered) -- 7 5 -- 12 314490000 Clamp, Drain Hose -- 1 1 -- 13 315865000 Drain Hose -- 1 1 -- 6 7 314920000 SELECTING COOLING UNIT INSTALLATION LOCATION IMPORTANT: Ambient temperature for the Cooling Unit must not exceed 100°F. Operating ambient in excess of 100° F will automatically void the factory warranty and will eventually result in Cooling Unit refrigeration system failure. Several means are available to achieve proper ambient temperature and air circulation around the Cooling Unit which are wall air intake grilles and ceiling exhaust fans, air conditioning, etc. Check local codes. Select Cooling Unit installation location that meets the following requirements: 1. Meets operating ambient (100°F maximum) as outlined in preceding IMPORTANT note. 1. Near a properly grounded electrical outlet with proper electrical requirements. The electrical circuit should be fused at 15-amps (slow blow) or circuit must be connected through an equivalent HACR circuit breaker. No other electrical appliance should be connected to this circuit. ALL ELECTRICAL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES. 2. Close to a plain water inlet supply line if Cooling Unit requires plain water or remote carbonator to be connected. 3. Easily accessible for service and maintenance. NOTE: Air required to cool the condenser coil, is drawn in through bottom half of the coil (see Figure 6) and is discharged out through top half of the coil. The condenser coil opening on front of the Cooling Unit must be open to the room at all times so as not to restrict air circulation in and out of the Unit. This open to the room clearance must be provided to allow for proper air flow in and out of the condenser coil to cool the refrigeration system. 4. Make sure when Cooling Unit is installed in operating position, the condenser coil on front of the Unit is not restricted and is open to the room. SEALING COOLING UNIT TO THE FLOOR In areas within the United States, the National Sanitation Foundation (NSF) requires that the Cooling Unit be sealed to the floor. Perform the following procedure to seal the Cooling Unit to the floor. 1. Place Cooling Unit in operating position meeting installation location requirements. 2. Tilt the Cooling Unit up (maximum of 45°) to expose the bottom of the Cooling Unit base. 3. Liberally apply silastic sealant such as Dow Corning RTV 731 or equivalent on the Cooling Unit base bottom edges. NOTE: Do not move the Cooling Unit after positioning or seal from the base to the floor will be broken. 4. Lower the Cooling Unit into operating position to complete the seal from base to floor. Apply additional sealant around bottom of the base. The seal must have a minimum radius of 1/2--inch to prevent cracks and crevices and to insure a complete seal. FILL WATER TANK AND START COOLING UNIT 1. Remove fill cap from the Cooling Unit top cover (see Figure 6) . 2. Fill the water tank with clean water to top of the stainless steel cooling coils inside the water tank. USE LOW--MINERAL--CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS. 3. Install fill cap in Cooling Unit top cover. NOTE: As ice bank forms in the water tank, water expansion will take place and the excess water will escape through the water tank overflow tube into bottom of the Cooling Unit where the water will evaporate. 314920000 8 4. Plug the Cooling Unit power cord into a properly grounded electrical outlet. The compressor, condenser fan motor, and the agitator motor will start and begin forming an ice bank. Approximately four to six hours will be required to freeze a full six-pound ice bank starting with 90° F water. When a full ice bank has been formed, the compressor and condenser fan motor will stop but the agitator motor will continue to operate circulating ice water bath in the water tank. CONNECTING COOLING UNIT INLET AND OUTLET LINES NOTE: The Cooling Units that do not have bar valves connected to them at the factory are equipped with both inlet and outlet lines. All internal line connections have been made at the factory and all lines are labeled. INLET LINES Pre-Mix System With Five-Flavor Bar Valve. (see Figure 2) The Cooling Unit product inlet lines may be connected directly to the product tanks quick disconnects (use REDUCER FITTINGS (item 9) if applicable). Seal (if metal--to--metal connections) connections with TAPERED GASKETS, RED (item 2). If lines must be extended, use applicable ADAPTER FITTINGS (item 7 or 8) and minimum of .265--inch I.D. tubing. Pre-Mix System With and Without Seven-Flavor Bar Valve. (see Figures 3 and 4) The Cooling Unit product and carbonated water inlet lines may be connected directly to the product and the carbonated water tanks quick disconnects (use REDUCER FITTING (item 9) if applicable).The plain water source line may be connected directly to the Cooling Unit plain water inlet line. Seal (if metal-to-metal connections) with TAPERED GASKETS (item 2). If lines will be extended, use applicable ADAPTER FITTINGS (item 7 or 8) and minimum of .265-inch tubing. Post-Mix Seven-Flavor System. (see Figure 5) If using a syrup tanks system, the Cooling Unit syrup inlet lines may be connected directly to the syrup tanks quick disconnects. If using a syrup bag-in-box system, the Cooling Unit syrup inlet lines may be connected directly to the bag-in-box syrup pumps syrup outlets. The remote carbonator carbonated water outlet line and the plain water source line may be connected directly to the Cooling Unit carbonated water and the plain water inlet lines. If metal-to-metal connections are to be made, use TAPERED GASKETS (item 1) to seal the connections. If syrup, carbonated water, and plain water lines must be extended, use ADAPTOR FITTINGS (item 10) and a minimum of .265-inch I.D. tubing. 9 314920000 OUTLET LINES Pre-Mix Systems With five and Seven-Flavor Bar Valves. (see Figures 2 and 3) The bar valves are installed on the Cooling Units at the factory. The BRACKET, BAR VALVE (item 6) and DRIP RECEPTACLE, BAR VALVE (item 5) must be installed on underside of the counter. Use SHEET METAL SCREWS (item 4) to mount the bar valve bracket to underside of the counter, then attach the drip receptacle to the pins on the bar valve bracket. Install DRAIN HOSE (item 13) on the bar valve drip receptacle. Secure the drain hose with CLAMP, DRAIN HOSE (item 12). Install FLAVOR CLIPS (item 11) and DECAL, FRANCHISE (item 3) on the bar valve. Pre-Mix System Without Seven-Flavor Bar Valve. (see Figure 4) The Cooling Unit outlet lines must be connected directly to inlet fittings on backs of the dispensing station dispensing valves. If the dispensing station is shipped with inlet lines connected to the dispensing valves, disconnect and remove inlet lines and connect Cooling Unit outlet lines directly to the dispensing valves. Make sure the product outlet lines from the Cooling Unit to the dispensing station are well insulated. Post-Mix Seven-Flavor System. (see Figure 5) The Cooling Unit insulated outlet lines must be connected to the dispensing station. PREPARATION FOR OPERATION ACTIVATING CO2 SUPPLY 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. 1. Turn on CO2 supply to the CO2 regulators 2. Check CO2 system connections for leaks and tighten any loose connections ADJUSTING CO2 REGULATORS Pre-Mix System With Five-Flavor Bar Valve. (see Figure 2) Adjust the product tanks CO2 regulator to the proper operating pressure using either the Cornelius PRE-MIX COMPUTER slide rule or the bottling room chart. 314920000 10 Pre-Mix System With and Without Seven-Flavor Bar Valve. (see Figures 3 and 4) Adjust the product tanks and the carbonated water tank CO2 regulator to the proper operating pressure using either the Cornelius PRE-MIX COMPUTER slide rule or bottling room chart. Post-Mix Seven-Flavor System. (see Figure 5) ADJUSTING SYRUP SUPPLIES CO2 REGULATOR: Sugar Syrup Tanks CO2 Regulator. Adjust syrup tanks CO2 regulator to a minimum of 45-psi. Syrup Pumps (Bag-In-Box System) CO2 Regulator. Adjust the syrup pumps CO2 regulator to 70-psi. DO NOT EXCEED MAXIMUM CO2 PRESSURE SPECIFIED ON THE SYRUP PUMPS. ADJUSTING CARBONATOR CO2 REGULATOR Adjust carbonator CO2 regulator for the remote carbonator as instructed in manual provided with the carbonator. ACTIVATING SYRUP, CARBONATED WATER, AND PLAIN WATER SUPPLIES ACTIVATING SYRUP SUPPLIES TO THE COOLING UNIT IMPORTANT: All systems should be sanitized as instructed before Cooling Unit is put into operation. 1. Sanitize all syrup systems as instructed in the SERVICE AND MAINTENANCE section of this manual. 2. Activate syrup supplies to the Cooling Unit. ACTIVATING CARBONATED WATER SUPPLY SUPPLY TO THE COOLING UNIT Pre-Mix Systems--Connect full tank of carbonated water into the Cooling Unit carbonated water system. Post-Mix System-- Activate remote carbonator to provide carbonated water supply to the Cooling Unit. ACTIVATING PLAIN WATER SUPPLY TO THE COOLING UNIT Activate plain water supply to the Cooling Unit. 11 314920000 UNIT OPERATION 1. Dispense from applicable bar valve or dispensing station dispensing valve until all air is purged from the dispensing systems. 2. Check entire system for CO2, syrup, carbonated water, and plain water leaks and repair if evident. 314920000 12 OPERATORS INSTRUCTIONS This section covers operators instructions for operating controls, daily pre-operation check, adjustments, cleaning and sanitizing, and Cooling Unit maintenance. WARNING: Disconnect electrical power from the Unit to prevent personnel injury before attemping any internal maintenance. Only qualified personnel should service the internal components or electrical wiring. OPERATING CONTROLS BAR VALVE Place cup or glass under the bar valve nozzle. Press applicable flavor dispense button until cup or glass is full, then release the button. DISPENSING STATION Place cup or glass under the dispensing valve nozzle, then operate dispensing valve as instructed in manual provided with the dispensing station. DAILY PRE--OPERATION CHECK 1. The CO2 supply should be checked daily to make sure there is an adequate supply of CO2. If necessary, replenish the CO2 supply. 2. Make sure there is a sufficient product (pre-mix) or syrup (post-mix) supply and replenish if necessary. 3. Pre-Mix system--Make sure the carbonated water supply is adequate. If not, replace the carbonated water tank with a full one. ADJUSTMENTS ADJUSTING CO2 REGULATORS The CO2 regulators should be checked periodically for proper pressure settings by a qualified Service Person and if necessary, adjusted as instructed in SERVICE AND MAINTENANCE section of this manual. ADJUSTING WATER-- TO-- SYRUP ‘‘RATIO’’(POST-- MIX SYSTEM) OF DISPENSED PRODUCT The Water-to-Syrup ‘‘Ratio’’of the dispensed drink should be periodically checked by a qualified Service Person and if necessary, adjusted as instructed in manual provided with the dispensing station. CLEANING AND SANITIZING CLEANING Daily Cleaning of Bar Valve (Pre-Mix System). The bar valve (pre-mix system) should be cleaned at end of daily operation as instructed in SERVICE AND MAINTENANCE section of this manual. 13 314920000 Daily Cleaning of Dispensing Station (Post-Mix System). The dispensing station (post-mix system) should be cleaned at end of the daily operation as instructed in manual provided with the dispensing station. Periodic Cleaning of Cooling Unit. The Cooling Unit should be periodically cleaned as instructed in SERVICE AND MAINTENANCE section of this manual. SANITIZING PRODUCT (PRE-MIX) OR SYRUP (POST-MIX) SYSTEMS Sanitizing product (pre-mix) or syrup (post-mix) systems should be performed every 90-days by a qualified Service Person as instructed in SERVICE AND MAINTENANCE section of this manual. COOLING UNIT MAINTENANCE CLEANING CONDENSER COIL NOTE: Air required to cool the condenser coil, is drawn in through bottom half of the coil (see Figure 6) and is discharged out through top half of the coil. The condenser coil opening on front of the Cooling Unit must be open to the room at all times so as not to restrict air circulation in and out of the Unit. This open to the room clearance must be provided to allow for proper air flow in and out of the condenser coil to cool the refrigeration system. The Cooling Unit condenser coil must be cleaned every 30-days as instructed in the SERVICE AND MAINTENANCE section of this manual to maintain proper cooling of the condenser coil. The condenser coil cleaning procedure should be performed by a qualified Service Person. CHECKING ICE WATER BATH A ‘‘gurgle’’heard from the Cooling Unit indicates water level in water tank is low and more water should be added for maximum product cooling as instructed in the SERVICE AND MAINTENANCE section of this manual. This procedure should be performed by a qualified Service Person. REMOTE CARBONATOR YEARLY MAINTENANCE OR AFTER WATER SYSTEM DISRUPTIONS The remote carbonator water pump water inlet screen and the liquid double check valve assembly must be inspected and cleaned by a qualified Service Person as instructed in the SERVICE AND MAINTENANCE section of this manual. 314920000 14 SERVICE AND MAINTENANCE This section describes service and maintenance procedures to be performed on the Cooling Unit. IMPORTANT: Only a qualified Service Person should service the Cooling Unit internal components or electrical wiring. PREPARING COOLING UNIT FOR SHIPPING, STORING, OR RELOCATING CAUTION: Before shipping, storing, or relocating this Unit, the applicable syrup or product systems must be sanitized and all sanitizing solution must be purged from the syrup or product systems. All water must also be purged from the plain and carbonated water systems. A freezing ambient temperature will cause residual water remaining inside the Unit to freeze resulting in damage to internal components of the Unit. PERIODIC INSPECTION 1. Check Cooling Unit condenser coil for obstructions and dirt. DO NOT place objects in front of condenser coil. Restricting circulating air in and out of Cooling Unit will decrease its cooling efficiency. 2. The CO2 supply should be checked to make sure there is an adequate supply of CO2. If necessary, replenish the CO2 supply. 3. Check applicable syrup (post-mix system) or product (pre-mix system) supply and replenish if necessary. 4. Check carbonated water supply (pre-mix system) and if necessary, replace carbonated water tank with a full one. 5. Check entire system for leaks and repair as necessary. ADJUSTMENTS CO2 REGULATORS ADJUSTMENTS 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. Pre-Mix System Product Tanks CO2 Regulator. Adjust the product tanks CO2 regulator to the proper operating pressure using either the Cornelius PRE-MIX COMPUTER slide rule or the bottling room chart. 15 314920000 BAR VALVE BRACKET (ITEM 6) BAR VALVES OUTLET LINES BAR VALVE DRIP RECEPTACLE (ITEM 5) INLET LINES CLAMP (ITEM 12) DRAIN HOSE (ITEM 13) TOP COVER WATER FILL PLUG CONDENSER COIL FIGURE 6. PARTS IDENTIFICATION Pre-Mix System Carbonated Water Tank CO2 Regulator. Adjust the carbonated water CO2 regulator to the proper operating pressure using either the Cornelius PRE-MIX COMPUTER slide rule or the bottling room chart. Post-Mix System SUGAR SYRUP TANKS CO2 REGULATOR Adjust syrup tanks CO2 regulator to a minimum of 45-psi. SYRUP PUMPS (BAG-IN-BOX SYSTEM) CO2 REGULATOR Adjust the syrup pumps CO2 regulator to 70-psi. DO NOT EXCEED MAXIMUM CO2 PRESSURE SPECIFIED ON THE SYRUP PUMPS. REMOTE CARBONATOR CO2 REGULATOR Adjust remote carbonator CO2 regulator as instructed in manual provided with the carbonator. ADJUSTING DISPENSER (POST-MIX SYSTEM) DISPENSING VALVES FOR WATER-TO-SYRUP “RATIO” OF DISPENSED PRODUCT Refer to manual provided with the dispensing station for instructions to adjust the dispensing valves for Water-To-Syrup “Ratio”of the dispensed product. 314920000 16 ICE BANK CONTROL ANODE AGITATOR MOTOR BRACKET (SEE NOTE) NOTE; AGITATOR MOTOR LOCATED BELOW BRACKET. FIGURE 7. WATER TANK COMPONENTS CLEANING COOLING UNIT CONDENSER COIL (see Figure 6) NOTE: Air required to cool the condenser coil, is drawn in through bottom half of the coil (see Figure 6) and is discharged out through top half of the coil. The condenser coil opening on front of the Cooling Unit must be open to the room at all times so as not to restrict air circulation in and out of the Unit. This open to the room clearance must be provided to allow for proper air flow in and out of the condenser coil to cool the refrigeration system. Vacuum or use soft brush to clean Cooling Unit condenser coil. If available, use low--pressure compressed air. CHECKING COOLING UNIT ICE WATER BATH A ‘‘gurgle’’heard from Cooling Unit indicates water level in water tank is low and more water should be added for maximum cooling. Before adding more water, ice water bath and ice bank should be checked for cleanliness and water tank components checked for excess mineral deposit build-up. 1. Remove screws securing the Cooling Unit top cover, then remove the cover. 2. Inspect the ice water bath and the ice bank for cleanliness. The ice water bath should be clear and the ice bank should be free of foreign particles. 3. Check the water tank components for mineral deposit build-up. If cleaning of the water tank is necessary, proceed to CLEANING COOLING UNIT WATER TANK. 4. Fill the water tank with clean water to top of the stainless steel coils. USE LOW-MINERAl-CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS. 5. Install the Cooling Unit top cover and secure with screws. CLEANING COOLING UNIT WATER TANK (see Figure 7) 1. Unplug Cooling Unit power cord from electrical outlet. 2. Remove screws securing the Cooling Unit top cover, then remove the cover. 3. Using a syphon hose, syphon water out of the water tank. NOTE: If ice bank is clear and contains no foreign particles, it does not have to be melted down. Skip steps 4 and 5 and proceed with 6. 17 314920000 4. If ice bank is dirty, allow ice to melt. Hot water may be used to speed up melting of the ice. CAUTION: Never use an ice pick or other instrument to remove ice from inside the water tank. Such practice can result in a punctured refrigerant circuit or damage to the corrosion protective coating on the water tank. 5. Wash inside of the water tank, then rinse tank with plain water. CAUTION: Function of the anode in the ice water bath is to draw corrosive agents to itself and away from the water tank. Make sure the ice bank sensing bulb and the anode, with its rubber insulator in place on the top end, are properly placed in their respective positions. The anode must be completely insulated from the other metal components and only an aluminum screw must be used to secure its connecting wire to the water tank. If the anode is allowed to contact other metal parts, its effectivity will be destroyed, allowing corrosive action to take place on the water tank. 6. Use a fiber brush and carefully clean mineral deposit build-up from the agitator motor shaft, ice bank sensing bulb, and the anode. If after cleaning the anode, and it is found to be badly corroded, replace the old anode with a new one. Make sure only an aluminum screw is used to secure the anode connecting wire to the water tank. 7. Rinse all water tank components, then flush the water tank with clean water. 8. Using a syphon hose, syphon flush water from the water tank. 9. Fill the water tank with clean water to top of the stainless steel coils. USE LOW-MINERAL-CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS. 10. Install the Cooling Unit top cover and secure with screws. NOTE: As ice bank forms in the water tank, water expansion will take place and excess water will escape through the water tank overflow hose to the bottom of the Cooling Unit where the water will evaporate. 11. Plug Cooling Unit power cord into electrical outlet. The compressor, condenser fan motor, and the agitator motor will start and begin forming an ice bank. When full ice bank has been formed, the compressor and condenser fan motor will stop, but the agitator motor will continue to operate circulating ice water bath in the water tank. DAILY CLEANING Daily Cleaning of Bar Valve. At end of daily dispensing, wash bar valve in mild soap solution, then rinse thoroughly with plain water. Wipe bar valve dry with clean soft cloth. DO NOT USE ABRASIVE TYPE CLEANERS. Daily Cleaning of Dispensing Station. Daily cleaning procedure for the Dispensing is outlined in DAILY CLEANING OF UNIT. PERIODIC CLEANING OF COOLING UNIT. Wash exterior of the Cooling Unit, rinse with clean water, then wipe the Cooling Unit dry with a soft cloth. DO NOT USE ABRASIVE TYPE CLEANERS. CLEANING AND SANITIZING DAILY CLEANING OF UNIT 1. Remove cup rest from the drip tray. 314920000 18 2. Wash drip tray in place on the Unit, then rinse drip tray with hot water allowing water to drain out through the drain hose. 3. Wash cup rest, then rinse the cup rest with clean water. Install cup rest in the drip tray. 4. Clean all external surfaces of the Unit with a sponge. Rinse out the sponge with clean water, then wring excess water out of the sponge and wipe off all external surfaces on the Unit. Wipe Unit dry with a clean soft cloth. DO NOT USE ABRASIVE CLEANERS. 5. Remove nozzle and syrup diffusers from the dispensing valves. Place nozzles and syrup diffusers in sanitizing solution. 6. Wash the nozzles and syrup diffusers in sanitizing solution, then rinse them with potable water. 7. Re-install nozzles and syrup diffusers back on the dispensing valves. SANITIZING POST-MIX SYRUP SYSTEMS IMPORTANT: Only qualified Service Personnel should perform sanitizing procedure on the post-mix syrup systems. The post-mix syrup systems should be sanitized every 90-days using a non-scented household liquid bleach containing a 5.25 % sodium hypochlorite concentration. Proceed as follows to sanitize the post-mix syrup systems. 1. Disconnect syrup supplies from syrup systems. 2. Rinse quick disconnects (syrup tanks systems) or bag-in-box connectors (syrup bag-in-box systems) in warm potable water. STEP 1. WASH SYRUP SYSTEMS 3. Using a clean syrup tank (syrup tank system) or a five-gallon container (bag-in-box system), prepare a full tank or container of liquid dishwasher detergent by using 70_F (21_C) to 100_F (38_C) potable water and 0.5 oz. (15 ml) of liquid dishwasher detergent to one gallon of potable water. Stir detergent solution to thoroughly mix the solution. 4. Syrup Tank Systems. A. Observe and note CO2 pressure setting on the syrup tanks CO2 regulator, then re-adjust CO2 regulator to 60 to 80-psi. Pressurize syrup tank containing detergent solution to 60 to 80-psi. B. Connect detergent solution tank, pressurized at 60 to 80-psi, into one of the syrup systems. Bag-in Box Syrup Systems. C. Install bag valves, cut from empty bag-in-box syrup containers, on ends of syrup containers syrup outlet tubes connectors. D. Place all syrup outlet tubes, with bag valves on their ends, in container containing detergent solution. 5. Flush the syrup system and dispensing valve as follows: A. Place waste container under applicable dispensing valve. B. Activate the dispensing valve for one minute to purge all syrup and flush out the syrup system. C. Continue to activate the dispensing valve in cycles (“ON”for 15-seconds, “OFF”, then “ON”for 15-seconds). Repeat “ON”and “OFF”cycles for 15-cycles. 6. Connect detergent solution to the remaining syrup systems and flush syrup out of the syrup systems as instructed in step NO TAG preceding. 7. Remove detergent solution source from the syrup system. 19 314920000 STEP 2. FLUSH SYRUP SYSTEMS 8. Syrup Tank Systems. Connect syrup tank containing potable water, pressurized at 60 to 80-psi, into one of the syrup systems. Bag-in-Box Syrup System. Fill five-gallon container with potable water, then place all bag-in-box syrup containers syrup outlet tubes in container containing potable water. 9. Flush detergent solution out of the syrup system and dispensing valve as follows: A. Place waste container under applicable dispensing valve. B. Activate the dispensing valve for one minute to purge all detergent solution and flush out the syrup system. C. Continue to activate the dispensing valve in cycles (“ON”for 15-seconds, “OFF”, then “ON”for 15-seconds). Repeat “ON”and “OFF”cycles for 15-cycles. 10. Connect potable water source to the remaining syrup systems and flush detergent solution out of the syrup systems as instructed in step NO TAG preceding. 11. Remove potable water source from the syrup system. STEP 3. SANITIZE SYRUP SYSTEMS 12. Using a clean syrup tank (syrup tanks system) or a five-gallon container (bag-in-box system), prepare sanitizing solution using 70_F (21_C) to100_F (38_C) potable water and 0.5 oz. (15 ml) of non-scented household liquid bleach that contains a 5.25 % sodium hypochlorite concentration to one gallon of potable water. This mixture must not exceed 200 PPM of chlorine. Stir sanitizing solution to thoroughly mix. 13. Syrup Tank Systems. Connect sanitizing solution tank, pressurized at 60 to 80-psi, into one of the syrup systems. Bag-in-Box Syrup System. Place all bag-in-box syrup containers syrup outlet tubes in container containing sanitizing solution. 14. Sanitize the syrup system and dispensing valve as follows: A. Place waste container under applicable dispensing valve. B. Activate the dispensing valve for one minute to purge all water from and install sanitizing solution in the syrup system and dispensing valve. C. Continue to activate the dispensing valve in cycles (“ON”for 15-seconds, “OFF”, then “ON”for 15-seconds). Repeat “ON”and “OFF”cycles for 15-cycles. 15. Repeat stepsNO TAG and NO TAG to flush water out of and install sanitizing solution in the remaining syrup systems and dispensing valves. 16. Remove sanitizing solution source from the syrup system. 17. Allow sanitizing solution to remain in the syrup systems for not less than 10 or no more than 15-minutes (max.) contact time. STEP 4. WATER FLUSH SYRUP SYSTEMS WARNING: Flush sanitizing solution from the syrup systems as instructed. Residual sanitizing solution left in the syrup systems could create a health hazard. 314920000 20 18. Fill syrup tank (syrup tank system) or a five-gallon container (bag-in-box system) with potable water. 19. Syrup Tank Systems. Connect syrup tank containing potable water, pressurized at 60 to 80-psi, into one of the syrup systems. Bag-in-Box Syrup System. Place all bag-in-box syrup containers syrup outlet tubes in container containing potable water. 20. Flush sanitizing solution from the syrup system and the dispensing valve as follows: A. Place waste container under applicable dispensing valve. B. Activate the dispensing valve for one minute to purge all sanitizing solution out of the syrup system and the dispensing valve. C. Continue to activate the dispensing valve in cycles (“ON”for 15-seconds, “OFF”, then “ON”for 15-seconds). Repeat “ON”and “OFF”cycles for 15-cycles. 21. Repeat steps NO TAG and NO TAG preceding to purge sanitizing solution out of the remaining syrup systems and dispensing valves. 22. Remove potable water source from the syrup system. STEP 5. PURGE WATER OUT OF SYRUP SYSTEMS (RESTORE OPERATION) 23. Syrup Tank Systems. A. Noting syrup tanks CO2 regulator pressure setting observed in step 4 preceding, readjust CO2 regulator to the observed pressure setting, B. Connect tanks containing syrup into syrup systems. Bag-in-Box Syrup System. C. Remove all bag valves from bag-in-box syrup containers outlet tubes connectors. D. Connect bag-in-box syrup containers into the syrup systems. 24. Place waste container under dispensing valves. Dispense from all dispensing valves to permit syrup to purge all potable water from the syrup systems and the dispensing valves. Continue to dispense from the dispensing valves until only syrup is dispensed from the syrup systems and valves. WARNING: To avoid possible personal injury or property damage, do not attempt to remove the syrup tank cover until CO2 pressure has been released from the tank. 25. Dispose of waste sanitizing solution in a sanitary sewer, not in a storm drain, then thoroughly rinse the inside and the outside of the container that was used for sanitizing solution to remove all sanitizing solution residue. 21 314920000 314920000 22 GREEN WHITE SERVOCE CORD BLACK CONTROL BOX BLACK FIGURE 8. WIRING DIAGARAM GROUND BLACK TERMINAL BLOCK BLACK ICE BANK CONTROL WHITE AGITATOR MOTOR COMPRESSOR OVERLOAD RELAY CONDENSER FAN MOTOR TROUBLESHOOTING IMPORTANT: Only qualified personnel should service internal components or electrical wiring. WARNING: If repairs are to be made to a product system, remove quick disconnects from the applicable product tank, then relieve the system pressure before proceeding. If repairs are to be made to the CO2 system, stop dispensing, shut off the CO2 supply, then relieve the system pressure before proceeding. If repairs are to be made to the refrigeration system, make sure electrical power is disconnected from the unit. TROUBLESHOOTING PRE--MIX SYSTEM Trouble NO PRODUCT DISPENSED. Probable Cause Remedy A. Product tank quick disconnects not securely connected. A. Secure product tank quick disconnects. B. No product supply (product tank empty). B. Replenish product supply. C. No CO2 supply. C. Replenish CO2 supply. D. Product frozen in Cooling Unit cooling coil. D. Call Service Person. Oil film or soap scum in cups or glasses. A. Use clean cups or glasses. Ice used for finished drink is sub-cooled. B. Do not use ice directly from freezer. Allow ice to become ‘‘wet’’ before using. (Refer to following NOTE) A. DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE OR BAR VALVE CLEAR BUT FOAMS IN CUP OR GLASS. B. NOTE: Crushed ice also causes dispensing problems. When finished drink hits sharp edges of the ice, carbonation is released from drink. DISPENSED PRODUCT FOAMS AS IT LEAVES DISPENSING VALVE OR BAR VALVE. A. Refrigeration recovery rate of Cooling Unit exceeded, ice bank depleted. A. Allow ice bank to recover, then resume dispensing. B. Improper product tanks CO2 operating pressure. B. Call Service Person to readjust product tanks CO2 regulator. C. Dispensing valve or bar valve restricted or dirty. C. Call Service Person to sanitize system. D. Tapered nylon washer inside tube swivel nut connector distorted from being overtightened. D. Call Service Person to replace nylon washer and make sure it seats properly. E. Oil, water, or dirt in CO2 supply. E. Call Service Person to remove contaminated CO2. Clean CO2 system (lines, regulators, etc.) using a mild detergent. Install clean CO2 supply. 23 314920000 Trouble Probable Cause Remedy TROUBLESHOOTING POST--MIX SYSTEM DISPENSED PRODUCT 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’’. A. Dispensing valve syrup flow control not properly adjusted. A. Call Service Person to adjust Water--to--Syrup ‘‘Ratio’’of dispensed product. B. CO2 gas pressure to syrup tanks insufficient to push syrup out of tanks. B. Call Service Person to adjust CO2 regulator for syrup tanks. A. No syrup supply. A. Replenish syrup supply. B. Syrup Tanks System. B. Call Service Person to adjust CO2 regulator for syrup tanks. Syrup tanks CO2 regulator out of adjustment. Call Service Person to adjust syrup pumps CO2 regulator. Syrup Bag-In-Box System. Syrup pumps CO2 regulator out of adjustment. C. Product tanks CO2 regulator out of adjustment. C. Call Service Person to adjust product tanks CO2 regulator. D. Dispensing valve syrup flow control or syrup line restricted. D. Call Service Person to sanitize system. E. Improper syrup Baume. E. Replace syrup supply. F. Dirty or inoperative dispensing valve syrup flow control. F. Call Service Person to disassemble and clean dispensing valve syrup flow control. ADJUSTMENT OF A. DISPENSING VALVE SYRUP FLOW CONTROL DOES NOT DECREASE TO DESIRED WATER--TO-- SYRUP ‘‘RATIO’’ Dirty dispensing valve syrup flow control. A. Call Service Person to disassemble and clean dispensing valve syrup flow control. B. Tapered nylon washer inside tube swivel nut connector distorted from being overtightened. B. Call Service Person to replace nylon washer and make sure it seats properly. A. Carbonator CO2 regulator out of adjustment for existing water conditions or temperature. A. Call Service Person to adjust carbonator CO2 regulator. B. Air in carbonator tank. B. Call Service Person to vent air out of carbonator tank through relief valve. Open dispensing valve to make carbonator pump cycle on. C. Water, oil, or dirt, in CO2 supply. C. Call Service Person to remove contaminated CO2. Clean CO2 system (lines, regulators, etc.) using a mild detergent. Install a clean CO2 supply. DISPENSED PRODUCT CARBONATION TOO LOW. 314920000 24 Trouble DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT FOAMS IN CUP OR GLASS. Probable Cause Remedy A. Oil film or soap scum in cup or glass. A. Use clean cups or glasses. B. Ice used for finished drink is sub--cooled. B. Do not use ice directly from freezer. Allow ice to become ‘‘wet’’ before using. (refer to following NOTE) NOTE: Crushed ice also causes dispensing problems. When finished drink hits sharp edges of ice, carbonation is released from drink. DISPENSED PRODUCT PRODUCES FOAM AS IT LEAVES DISPENSING VALVE. A. Recovery rate of Cooling Unit exceeded, ice bank depleted. A. Allow ice bank to recover. B. Carbonator CO2 regulator pressure too high for existing water conditions or temperature. B. Call Service Person to reduce carbonator CO2 regulator pressure setting. C. Syrup over-carbonated with CO2 as indicated by bubbles in inlet syrup lines leading to Cooling Unit. C. 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. D. Dispensing valve restricted or dirty. D. Call Service Person to sanitize syrup system. E. Tapered nylon washer inside tube swivel nut connector in carbonated water system distorted from being overtightened. E. Call Service person to replace nylon washer. Make sure it is properly seated. F. Dirty water supply. F. Check water filter. Replace cartridge. (see NOTE) NOTE: If water supply is dirty, Service Person must 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. ONLY CARBONATED WATER DISPENSED. A. Quick disconnects not secure on syrup tanks. A. Secure quick disconnects on syrup tanks. B. Out of syrup. B. Replenish syrup supply. C. Syrup Tanks System. C. Call Service Person to adjust syrup tanks CO2 regulator. Syrup Tanks tanks CO2 regulator not properly adjusted. Call Service Person to adjust syrup pumps CO2 regulator. Syrup Bag-In-Box System. Syrup pumps CO2 regulator not properly adjusted. D. Inoperable dispensing valve. 25 D. Call Service Person to repair dispensing valve. 314920000 Trouble ONLY CARBONATED WATER DISPENSED. (CONT’D) ONLY SYRUP DISPENSED. Probable Cause Remedy E. Dispensing valve syrup flow control not properly adjusted. E. Call Service Person to adjust Water--to--Syrup ‘‘Ratio’’of dispensed product. F. Syrup flow control or syrup system restricted. F. Call Service Person to sanitize syrup system. A. Carbonator water inlet supply line shutoff valve closed. A. Open 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. Call Service Person to adjust carbonator CO2 regulator. TROUBLESHOOTING REFRIGERATION SYSTEM COMPRESSOR DOES NOT OPERATE. COMPRESSOR WILL NOT STOP AFTER SUFFICIENT ICE BANK IS PRODUCED. (NOTE--ICE BANK SHOULD JUST COVER CONTROL BULB) 314920000 A. Ice bank sufficient. A. Refrigeration not called for. B. Cooling Unit power cord unplugged. B. Plug in Cooling Unit power cord. C. No power source (blown fuse or tripped circuit breaker). C. Replace or reset circuit breaker. (Note: Fuse is not part of Cooling Unit.) D. Low voltage. D. Voltage must be at least 103 volts at compressor terminals when compressor is trying to start. E. Loose, disconnected, or broken wiring. E. Tighten connections or replace broken wiring. F. Overload protector cut out; overheated compressor. Condenser fan motor not operating as required. F. Compressor will cool enough to restart. Do not overdraw Cooling Unit. Refer to ‘‘CONDENSER FAN MOTOR NOT OPERATING’’ in this section. G. Inoperative overload protector or start relay. G. Replace inoperative part. H. Inoperative ice bank control. H. Replace ice bank control. I. Inoperative compressor. I. Replace compressor. A. Ice bank control cap tube kinked or broken. A. Replace ice bank control. B. Ice bank control stuck in closed position. B. Replace ice bank control. 26 Trouble COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM SUFFICIENT ICE BANK. Probable Cause Remedy A. Cooling Unit capacity is exceeded by overdrawing. A. Reduce amount of drinks drawn per given time. B. Cooling Unit located in excessively hot area or air circulation through condenser coil is restricted. B. Relocate Cooling Unit or check and if necessary, clean condenser coil. NOTE: Ice bank freezes from bottom of evaporator upward. A refrigerant leak or insufficient charge might show an ice bank at bottom and not at top of evaporator. NOTE: If overload protector cuts out compressor, condenser fan motor will continue to operate; otherwise; troubleshooting condenser fan motor problems is same as for ‘‘COMPRESSOR DOES NOT OPERATE’’ paragraph plus the following: CONDENSER FAN MOTOR NOT OPERATING. AGITATOR MOTOR NOT OPERATING. A. Tighten connections or replace cord. A. Jumper cord loose or disconnected from condenser fan motor or compressor terminals. Broken wire in cord. B. Fan blade obstructed. C. Remove obstruction. C. Inoperative condenser fan motor. D. Replace condenser fan motor. A. Cooling Unit power cord unplugged. A. Plug in Cooling Unit power cord. B. No power source (blown fuse or tripped circuit breaker). B. Replace fuse or reset circuit breaker. (Note: Fuse is not part of cooling unit.) C. Agitator motor propeller obstructed. C. Remove obstruction. D. Low voltage. D. Voltage must be at least 103 volts at compressor terminals when compressor is trying to start. E. Loose, disconnected, or broken wiring. E. Tighten connections or replace broken wiring. F. Inoperative agitator motor. F. Replace agitator motor. 27 314920000 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, Remcor or Wilshire product, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number, serial 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, 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 LD004 4/21/98 314920000 28 THIS PAGE LEFT BLANK INTENTIONALLY 29 314920000 IMI CORNELIUS INC. CORPORATE HEADQUARTERS: One Cornelius Place Anoka, Minnesota 55303-6234 (612) 421-6120 (800) 238-3600