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Installation Instructions CONVERTIBLE

1. E DUAL CHECK VALVE pz 4 STRAINER WATER PUMP PLAIN WATER COIL PLAIN WATER KIT OPTIONAL _ PLAIN WATER Ix DISPENSING VALVE WATER TEN 5 SOURCE WATER WATER COIL PRESSURE REGULATOR b SYRUP COIL 4 o o CARBONATOR SYRUP TANK PRESSURE PRESSURE 1 REGULATOR REGULATOR DISPENSING 70 80 psig 40 psig NOZZLE SOLENOID VALVE FLOW CONTROL S gt REFRIGERATED WATER BATH CHECK VALVE gi OCA KALI CYLINDER 4 LINE LEGEND CO PLAIN WATER CARB WATER E E SYRUP FIGURE 3 UNIT WITH SYRUP TANKS FLOW DIAGRAM 5 0575 INSTALLATION This section provides instructions for receiving unpacking and inspection location selection installation and preparation for operation RECEIVING Each Unit is completely tested under operating conditions and thoroughly inspected before shipment At time of shipment the carrier accepts the Unit and any claim for damage in transit must be made with the carrier Upon receiving Unit from the delivering carrier carefully inspect the carton for visible indication of damage Any damage or irregularities should be noted at this time not later than 15 days from date of delivery and immediately reported to the delivering
2. 22 SANITIZE SYSTEM 22 CLEAN REFRIGERATION SYSTEM 23 DUAL LIQUID CHECK VALVE ASSEMBLY MAIN Sancta Dele cae 24 2 GAS CHECK VALVE ASSEMBLY MAINTE NANCE RSS 25 TROUBLESHOOTING 27 GENERAL INFORMATION 27 APPLICABLE WARNINGS AND NOTES 27 UNIT ELECTRICAL DIAGRAM 27 WATER TO SYRUP RATIO IS INCORRECT 30 CARBONATION TOO LOW IN DISPENSED PRODUC Ta 30 DISPENSED PRODUCT IS CLEAR BUT FOAMS IN CUP OR GLASS 30 DISPENSED PRODUCT FOAMS AS IT LEAVES NOZZLE 30 NO PRODUCT DISPENSED 31 ONLY CARBONATED WATER IS DISPENSED 31 CARBONATOR TANK NOT FILLING PROPERLY aaa e ey a 31 FREQUENT SHORT FILL CYCLES CARBO NATOR TANK 32 ONLY SYRUP IS DISPENSED 32 COMPRESSOR DOES NOT OPERATE 32 COMPRESSOR DOES NOT STOP AFTER ICE BANK IS FORMED 32 COMPRESSOR RUNS CONTINUOUSLY BUT DOES NOT FORM AN ICE BANK 32 CONDENSER FAN NOT OPERATING 33 AGITATOR MOTOR NOT OPERATING 33 0575 TABLE OF CONTENTS CONT D PAGE SODA ONLY OF PLAIN WATER ONLY SWITCH DOES NOT OPERATE 33 ADDENDUM A 41 SEALING UNIT BASE TO COUNTERTOP USA 41 ADDENDUMB 42 SANITIZING THE SYSTEM USA
3. CONNECT WATER CONNECT CO2 9 CONNECT SYRUP LINES 11 CONNECT SYRUP LINES TO SYRUP SOURCES 11 MAKE ELECTRICAL CONNECTIONS 11 PREPARATION FOR OPERATION 11 PLAIN WATER AND STILL DRINKS 11 PURGING THE CARBONATOR SYSTEM 14 PURGING THE SYRUP SYSTEMS 14 ADJUSTING WATER TO SYRUP RATIO OF DISPENSED PRODUCT 14 ADJUSTING CO2 PRESSURE 15 BAG IN BOX CO2 SUPPLY 15 SYRUP TANK CO2 SUPPLY 15 OPERATORS INSTRUCTIONS 18 PRODUCT DISPENSE SWITCH OPERATION 18 CARBONATED DRINK 18 SODA CARBONATED WATER 18 PLAIN WATER PLAIN WATER KIT INSTALLED 18 DAILY PRE OPERATION CHECK 18 CHANGE 2 CYLINDER 18 PAGE CHANGE SYRUP TANK 19 BAG IN BOX SYRUP CONTAINER 20 WASH NOZZLE 21 WASH CUP REST AND DRIP TRAY 21 CLEAN UNIT EXTERIOR 21 SERVICE AND MAINTENANCE 22 APPLICABLE CAUTIONS AND NOTES 22 MAINTENANCE SCHEDULE 22 RESPONSIBILITY KEY 22 DAILY cee es 22 WEEKLY atv a bate ates 22 MONTHEY 2 ec nte 22 SIX MONTHS 22 YEARLY oliv DOT 22 WHEN OCCURRING 22 CHECK SYRUP TO WATER
4. CHECK VALVE lt B Wi WATER PUMP PLAIN WATER COIL PLAIN WATER KIT OPTIONAL PLAIN WATER gt 24115 RA DISPENSING VALVE WATER eU X SOURCE V WATER WATER COIL PRESSURE JUN a REGULATOR NA Nd REGULATOR DISPENSING 70 80 PSI SOLENOID VALVE TEN FLOW CONTROL 57 4 REFRIGERATED CHECK VALVE WATER SYRUP PUMP 4 MANIFOLD SSSS7 CYLINDER BAG IN BOX 4 LINE LEGEND PLAIN WATER CARB WATER SYRUP FIGURE 2 UNIT WITH SYRUP SOURCE FLOW DIAGRAM 0575 4 USED ON UNITS 1275 AND 1276 CHECK VALVE
5. D 4018 LANGENFELD GERMANY 6 49 2173 7930 FAX 49 2173 77 438 GREECE 488 MESSOGION AVENUE PARASKEVI e 153 42 ATHENS GREECE 30 1 600 1073 FAX 30 1 601 2491 HONG KONG 1104 TAIKOTSUI CENTRE 11 15 CHEUNG ST TAIKOKTSUE HONG KONG 852 789 9882 FAX 852 391 6222 ITALY VIA PELLIZZARI 11 1 20059 e VIMARCATE ITALY 39 39 608 0817 FAX 39 39 608 0814 NEW ZEALAND 20 LANSFORD CRES BOX 19 044 AVONDALE AUCKLAND 7 NEW ZEALAND e 64 9 8200 357 FAX 64 9 8200 361 SINGAPORE e 16 TUAS STREET SINGAPORE 2263 65 862 5542 FAX 65 862 5604 SPAIN POLIGONO INDUSTRAIL RIERA DEL FONOLLAR E 08830 SANT BOI DE LLOBREGAT BARCELONA SPAIN e 34 3 640 2839 FAX 34 3 654 3379 USA ONE CORNELIUS PLACE MINNESOTA 6 612 421 6120 FAX 612 422 3255 LD004 4 21 98 3 23 98 IMI CORNELIUS INC 1998 46 Rev P N Here
6. x 5 WATER PUMP ES 2 a 5 1 5x 2 23456789 101112 a GRN WH f MOTOR BLK 2 1 WHT E 24 VAC BLU AGIT 4 3 SEC PRI BLU MOTOR TRANSFORMER BLK WATER SODA AI gel BLK DOTTED WIRING IS FOR OPTIONAL STARTING CAPACITOR TOUCH SWITCH 9290 0564 D FIGURE 19 UNIT ELECTRICAL DIAGRAM TROUBLESHOOTING IMPORTANT Only qualified personnel should service internal components or electrical wiring power to Cooling Unit shut off plain water and CO supplies and relieve the carbonated WARNING If repairs to be made to carbonated water system disconnect electrical water system pressure before proceeding If repairs are to be made to syrup system remove quick disconnects from applicable syrup tank then relieve the system pressure before proceeding If repairs are to be made to CO system stop dispensing shut off supply then relieve the system pressure before proceeding If repairs are to be made to an existing Remote Condensing unit disconnect the power to the condensing unit before proceeding Trouble WATER TO SYRUP RATIO IS INCORRECT CARBONATION TOO LOW IN DISPENSED PRODUCT DISPENSED PRODUCT IS CLEAR BUT FOAMS IN CUP OR GLASS DISPENSED PRODUCT FOAMS AS IT LEAVES NOZZLE Probable Cause A Syrup regulator not properly adjusted B Tank system CO pressure to tank low C No syrup supply D
7. 0575 DISPENSING VALVES ALTN POSN BYPASS JUMPERS 2 COKE 4 AQUARIUS w Soya ee 27 POSN BYPASS JUMPERS SYR SYR SYR SYR 1 2 3 4 COKE OPT PLN SODA WTR WTR SYR SYR UP UP PUMP PUMP 53 52 SYRUP LINES SYR SYR UP UP Pume AQU COKE PUSH BUTTON LAYOUT TO PLAIN WAT CO INLET FITTING FOR UNITS WITH BAG IN BOX 0575 N B ALL FLAVORS CAN BE CONVERTED ER INSERT PLUG P N 2143 IN LINES IF SYRUP PUMP NO 2 OR NO 3 ARE NOT TO BE USED SYRUP COOLING COILS LINE ENDS 10 PIN RT ANGLE HEADER 1 640453 0 FIGURE 9 COVER DECAL PRODUCT SELECTION PANEL DETAIL EXAMPLE SYRUP PUMP NO 2 CONNECTS TO DISPENSING VALVE NO 2 THROUGH SYRUP COOLING COIL NO 2 SYRUP PUMP SYRUP PUMP FRONT VIEW BAG IN BOK SYRUP PUMP CORRESPONDENCE TO DISPENSING VALVE MANIFOLD SUPPLIES GAS 4 AND TO CARBONATOR BAG IN BOK PUMP DETAIL 16 FIGURE 10 DETAIL END FITTING Ady COLLAR 2 O RING SYRUP LINE gt E HOLD DOWN SCREW SYRUP INLET
8. 42 SANITIZING THE BAG IN BOX SYRUP SYS TEMS EE atin ea Tired 42 SANITIZING THE SYRUP TANK SYSTEMS 43 LIST OF FIGURES FIGURE 1 CONVERTIBLE POST MIX DISPENSER 1 FIGURE 2 UNIT WITH SYRUP SOURCE FLOW DIAGRAM 4 FIGURE 3 UNIT WITH SYRUP TANKS FLOW 5 FIGURE 4 NARROW AND SHALLOW DEPTH CONFIGURATIONS 8 FIGURE 5 CONVERSION DETAIL 8 FIGURE 6 COUNTERTOP HOLE LOCATION 10 FIGURE 7 BAG IN BOX CO2 SUPPLY 12 FIGURE 8 SYRUP TANK CO2 SUPPLY 13 FIGURE 9 COVER DECAL PRODUCT SELEC TION PANEL DETAIL 16 FIGURE 10 BAG IN BOX PUMP DETAIL 16 FIGURE 11 SYRUP LINE CONNECTION TO SYR UP PUMP 55 ean ee Ee 17 0575 PAGE FIGURE 12 RATIO MEASUREMENT DETAIL 17 FIGURE 13 SYRUP TANK 19 FIGURE 14 LINE END FITTING FOR SYRUP TANK CONNECTION 20 FIGURE 15 24 FIGURE 16 DUAL LIQUID CHECK VALVE ASSEM BEY ge 24 FIGURE 17 CO2 CHECK VALVE ASSEMBLY 26 FIGURE 18 INSTRUCTIONS FOR CRIMPING TUBE CLAMPS 28 FIGURE 19 UNIT ELECTRICAL DIAGRAM 29 FIGURE 20 CONVERTIBLE PARTS BREAKDOWN 34 FIGURE 21 WATER INLET LINE ASSY 36 FIGURE 22 SOLENOID VALVE ASSEMBLY 37 FIGURE 23 DUAL CHECK VALVE ASSEMBLY 37 FIGURE 24 CARBON
9. Dispose of unused detergent in a sanitary sewer not in a storm drain Fill the syrup tank with potable drinking water Place a cover on the syrup tank Apply CO pressure to the syrup tank Purge the detergent from the syrup systems as follows A Connect one of the syrup line end connectors to the syrup tank B Manually Open the corresponding syrup system dispensing valve by pressing the armature of the solenoid forward to cause detergent and water to flow from the nozzle C Hold the dispensing valve open until only water is dispensed 0575 44 20 21 22 23 24 D Dispense a sample of water from the nozzle Test the sample using a drop of phenolphthalein indicator This indicator becomes pink colored in the presence of even small amounts of detergent Thus when the indicator remains clear all detergent has been removed E Disconnect the syrup line end connector from the syrup tank F Repeat steps a through e for the remaining syrup systems Remove pressure from the tank Fill the syrup tank with 4 gallons 15 1 liters of water at a temperature between 70 degrees F to a maximum of 100 degrees F Add 1 0 02 29 57 ml of H B Fuller Monarch C S or equivalent sanitizer to provide a 200 ppm 200 mg liter active quaternary sanitizing solution to the container Mix thoroughly Apply pressure to the syrup tank Introduce sanitizer into syru
10. SUPPLY 0575 12 CORNELIUS INC SYRUP TANK PRESSURE GAGE 40 PSI CARBONATOR PRESSURE GAGE 70 80 PSI CARBONATOR PRESSURE REGULATOR COUPLING NUT CYLINDER PRESSURE GAGE 1800 1 H SYRUP TANK PRESSURE REGULATOR REGULATED CO5 TO SYRUP TANKS REGULATED CO TO CARBONATOR CYLINDER FIGURE 8 SYRUP TANK SUPPLY 13 0575 NOTE selection switch to disable the soda only and plain water only button work the same as the selectors for buttons 1 thru 4 The selection switch can be located one of two places the upper left corner or the lower left corner see Figure 9 Units are shipped with the switch in the on position which will enable the soda only S or plain water only W button to operate When requested they are set in the off position which will disable the soda only and plain water only buttons making them inoperative 4 Install dispense switch module in the Unit and secure it with two cross head screws PURGING THE CARBONATOR SYSTEM 1 Disconnect electrical power from the Unit 2 Turn on water to the Unit 3 Flood the system with water to drive out air as follows A Liftthe relief valve on the carbonator until water flows out of the valve B Manually open the S soda dispensing valve until water f
11. Secure top of logo panel with two screws COUNTERTOP HOLE LOCATION This procedure is used when water syrup CO and electrical connections are to be run through the countertop to the Unit To locate and make a cutout in the countertop proceed as follows 1 Place the Unit in operating position on the countertop 2 Using a pencil or masking tape mark three corners of the tower as shown in Figure 6 0575 2 4 26 ys e 4 7 e F IG U R W E 4 N A R R 5 7 Pur T zd T H IG U R A IO N S F IG U R E 5 V ERS IO N D E T A IL 3 Move the Unit to one side 4 Using the three marks as a guide mark the center of a three inch 7 5 cm diameter hole on the countertop 5 Cuta hole in the countertop at the location marked in previous step 6 Move the Unit into position over the hole SEALING UNIT BASE TO COUNTERTOP Refer to Addendum A for procedure required by the NSF International NSF for Units installed in the USA only NOTE connections must be made before the Unit is sealed to the countertop MAKING WATER SYRUP AND ELECTRICAL CONNECTIONS CONNECT WATER Make water connections as follows CAUTION If water source exceeds 40 psig 2 8 KG Cm2 a water pressure regulator kit must
12. Syrup tank or BIB syrup connections not tight E Dispensing valve flow regulator tank or BIB connections restricted F Dirty or inoperative syrup flow regulator A Cylinder CO pressure regulator out of adjustment B cylinder is low or empty Air in carbonator tank D Water oil or dirt in CO2 supply A Oil film or soap residue in cup or glass A Capacity of refrigeration System is exceeded B CO regulator pressure too high 30 Remedy Adjust ratio Refer to Installation Section Adjust pressure Refer to Operators Section Replenish syrup supply Check connections at syrup supply Sanitize system Refer to Addendum B Disassemble and clean Do not intermix parts Adjust cylinder pressure regulator Replace cylinder At Unit carbonator lift relief valve to vent air Remove contaminated cylinder Flush lines Install new cylinder and blow contaminants out of regulator s Rinse cups and glasses well after washing Allow time for ice bank to re form Ice bank depleted At cylinder reduce regulator pressure If diet product install diet secondary regulator Trouble NO PRODUCT DISPENSED ONLY CARBONATED WATER IS DISPENSED TANK NOT FILLING PROPERLY Probable Cause In syrup tank Unit syrup is over carbonated as indicated by bubbles Dispensing valve is
13. circuit board Open water supply valve Check that carbonator motor is receiving power Unplug electrical power to Unit momentarily Disconnect electrical power cord and allow Unit to thaw Refrigeration not called for Check power into Unit and into compressor Check condenser for cleanliness Compressor should start after two minutes Measure line voltage Line voltage must be at least 90 percent of rated voltage 103 VAC or 198 for compressor to start Replace ice bank control board Replace compressor Plug in connector on board Check ice bank probe for proper operation Reduce number of drinks served until ice bank forms Relocate Unit or provide additional Check condenser for condenser is restricted cleanliness check condenser fan Remove obstructions from top of Unit Ice bank at bottom of evaporator may indicate a refrigeration leak or insufficient charge repair recharge Clean condenser coil Check fan blade and motor Trouble CONDENSER FAN NOT OPERATING AGITATOR MOTOR NOT OPERATING SODA ONLY OF PLAIN WATER ONLY SWITCH DOES NOT OPERATE gt Probable Cause Agitator motor not running Fan blade obstructed Loosen set screw Faulty electrical connection Motor inoperative Agitator propeller obstructed Loose set screw Faulty electrical connection Motor inoperative Jumper on back of touch switch panel is in OFF posit
14. good operating condition 0575 22 RESPONSIBILITY KEY Operator Maintenance Technician DAILY Empty drip tray wash drip tray cup rest and nozzle O Clean exterior of Unit O Change oylinder if required Change syrup tank or bag in box syrup container if required WEEKLY O Taste each product for off taste MONTHLY M Check syrup to water ratio SIX MONTHS M Sanitize system YEARLY M Lift out refrigeration system and clean condenser and coils M Clean and fill water tank M Inspect liquid and check valves and replace ball seats WHEN OCCURRING Adjust CO pressure M Sanitize for flavor change M Add water to water tank if gurgle is heard Relocate or ship Unit to new location M Inspect liquid check valve after any water disruption plumbing work earthquake etc CHECK SYRUP TO WATER The syrup to water ratio should be checked monthly The procedure is given in Installation section SANITIZE SYSTEM The system must be sanitized at six month intervals when changing flavors or if Units is to be relocated The procedure is given in Addendum B Detergent solution must be introduced into the carbonator CAUTION Do Notuse any sharp object to ice from cooling coils A puncture will permanently CLEAN REFRIGERATION SYSTEM disable the refrigeration assembly The refrige
15. pressure gage pointer is outside the CHANGE CO CYLINDER zone adjust the line pressure as follows 15 1 Atthe pressure regulator use a small wrench to loosen locking nut on the pressure adjusting screw by turning it in a counterclockwise direction 2 Using a screwdriver slowly turn the line pressure adjusting screw clockwise to increase line pressure Counterclockwise rotation will lower line pressure 3 Tighten locking nut by turning it clockwise SYRUP TANK CO SUPPLY WARNING Wear protective eyewear to avoid injury from gas driven particles If line pressure to the syrup tanks shown on the syrup tank pressure gage see Figure 8 falls below 40 PSIG 2 8 Kg Cm2 2 85 BAR and the cylinder pressure gage pointer is outside the CHANGE CYLINDER zone adjust the syrup tank pressure regulator If line pressure to the carbonator shown on the carbonator gage see Figure 8 falls below 70 PSIG 4 9 Kg cm2 4 8 BAR and the cylinder pressure gage pointer is outside the CHANGE CYLINDER zone adjust the carbonator pressure regulator as follows 1 Atthe pressure regulator use a small wrench to loosen the locking nut on the pressure adjusting screw by turning it in a counterclockwise direction 2 Using a screwdriver slowly turn the line pressure adjusting screw clockwise to increase line pressure Counterclockwise rotation will lower line pressure 3 Tighten locking nut by turning it clockwise
16. the Unit turn on the water C 18 AT the carbonator pull up on the CO relief B valve ring to purge air from the carbonator TO SEE SPRING 2 19 electrical power to the Unit RETAINER 20 Place a cup under the nozzle then cycle the carbonator by pressing the soda selector posu BODY 21 Check product for carbonation check connections for water or gas leaks FIGURE 17 CHECK VALVE ASSEMBLY 0575 26 TROUBLESHOOTING GENERAL INFORMATION General information consists of applicable warnings and notes of direct concern to the repair person followed by the Unit electrical diagram and instructions for crimping tube clamps APPLICABLE WARNINGS AND NOTES WARNING Disconnect electrical N power from the Unit before removing the large cover to prevent personal injury WARNING Wear protective eyewear to avoid injury from gas driven particles WARNING Internal components of the Unit are to serviced only by trained personnel NOTE If repairs are to be made to the carbonated water system perform the following steps 1 Disconnect electrical power from the Unit 2 Atthe CO cylinder turn the shut off valve fully clockwise to turn off gas 3 At Unit remove screw and remove large cover 4 Atthe carbonator tank lift ring to open valve and bleed off NOTE If repairs are to be made to the syrup system of a bag in box Unit perform the following steps 1 Dis
17. 0087 317691 317015 0065 178025 100 0099 690945 0124 0651 320289 320240 180025 DESCRIPTION Cover Terminal Overload Compressor Relay Capacitor Start Compressors Hitch Pin Bushing Split Grommet Compressor 115V 60Hz Condenser Fan Motor 115V 60Hz 3 1 Watt Shroud Condenser Coil Fan 4 Blade 6 5 inch Dia Condenser Coil Fan 4 Blade 2 25 inch Dia Agitator Motor 115V 8 Watt Plate Agitator Motor Blade Agitator Motor Transformer 120 24 Fitting 1 4 by 6 16 20 Pump 115V 19 Bracket Water Pump Thread Rolling Screw Phil Pan Hd No 10 24 by 3 8 long Cover Control Box P C Board Control Box Assembly See Page 6 7 Thread Rolling Screw Phil Pan Hd 10 14 by 5 8 long Platform Carb Insulation Platform Carb Carb Tank Assembly See Page 6 5 Platform Refrigeration Insulation Platform Refrigeration Rod Support Evaporator Spacer Coil Push on Nut Ice Bank Probe Ass y Evaporator Coil Assembly See Page 6 5 Heat Exchange Assembly Dryer Dual Plug 3 4 Panel Bulkhead Fitting Plug 1 4 O Ring 239 1 0 by 070 5 Switch Touch Tapered Gasket White Wire Harness 24V Tie Cable Handle Tube Syrup Thread Rolling Screw Phil Pan Hd No 6 32 by 1 4 long Thread Rolling Screw Phil Pan Hd No 8 32 by 1 2 long O Ring 364 1 0 by 070 C S 0575 84 85 86 87 88 89 90 91 92
18. 117 Mexico 0118 Philippines 0119 Taiwan 0120 United Kingdom 0795 Spain 0796 Korea 0797 Holland 0798 Argentina Design Note All Units delivered from the manufacturer are configured to dispense carbonated drinks and carbonated water Any Unit may have an optional installation plain water kit field installed which allows dispensing of plain water or dispensing of still non carbonated drinks Refer to list of kits for part numbers Units with Bag in Box Syrup Supply see Figure 2 Regulated gas from a cylinder provides pressurization through a manifold to the syrup pumps and to a carbonator both within the Unit Plain water pumped under pressure by the carbonator pump into the carbonator tank absorbs the gas and is thereby carbonated When a drink dispense switch or soda carbonated water only switch is pressed the carbonated water solenoid valve is opened and pressure within the carbonator drives carbonated water from the carbonator through carbonated water cooling coils in the water tank then through a carbonated water flow control to the dispensing nozzle When a drink dispense switch is pressed a related syrup solenoid valve is also opened allowing the syrup pump to start forcing syrup through the syrup cooling coil in the water tank the adjustable syrup flow control the solenoid valve and on to the dispensing nozzle Syrup and carbonated water meet simultaneousl
19. 20 CORNELIUS INC One Cornelius Place Anoka MN 55303 6234 Telephone 800 238 3600 Facsimile 612 422 3232 Installation Instructions CONVERTIBLE Post Mix Dispenser INSTALLATION AND SERVICE MANUAL WITH ILLUSTRATED PARTS BREAKDOWN PREPARED EXPRESSLY FOR 0404 Company e Manual Part No 0575 January 1991 Revised October 6 1992 THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Installation Manual must be read and understood before starting to install or operate this equipment IMI CORNELIUS INC 1992 Printed in U S A TABLE CONTENTS GENERAL DESCRIPTION 1 READ THIS SECTION FIRST 1 GENERAL DESCRIPTION 1 UNIT DESCRIPTION 1 INSTALLATION KITS 2 PLAIN WATER CONVERSION KIT PINOT OG eR En 2 ICE TEA KIT P N 1347 2 LEG KIT P N 1294 2 THEORY OF OPERATION 3 6 6 6 6 7 RECEIVING UNPACKING AND LOCATION SELECTION INSTALLATION FILLING WATER TANK AND STARTING RE FRIGERATION SYSTEM 7 CONVERSION OPTION 7 COUNTERTOP HOLE LOCATION 7 SEALING UNIT BASE TO COUNTERTOP 9 MAKING WATER CO2 SYRUP AND ELECTRI CAL CONNECTIONS
20. 83296 Ball 187 Dia 14 183297 Spring 15 183298 Retainer FIGURE 24 CARBONATOR TANK ASSEMBLY ITEM PART NO NO DESCRIPTION 1174 Evaporator Coil Assembly 1 1177 Evaporator Coil 2 040132 Accumulator FIGURE 25 EVAPORATOR COIL ASSEMBLY ITEM PART NO NO DESCRIPTION 0051 Water Tank Assembly 1 0052 Tube 0710 Overflow Elbow FIGURE 26 WATER TANK ASSEMBLY 0575 38 t NO NO DESCRIPTION 0551 Valve Housing Assembly 2 1 0062 Bottom Housing 2 2 2 0042 Wrap Housing FIGURE 27 VALVE HOUSING ASSEMBLY ITEM PART 9 6 8 NO NO DESCRIPTION 0548 Manifold Assembly 4 8 7 4 4 1 0070 Manifold Pe 9 4 2 311527 Clamp For 312 O D Tube i mi 3 174004 Tube 156 1 0 by 31 1 2 long i NO 4 176004 Ferrule 31 for 312 O D Tube S 2 5 176017 Swivel Nut 7 16 20 6 770106 for 156 1 0 Tube 222 g 7 0075 Fitting Barb Elbow 8 317015 O Ring 239 1 0 by 070 C S SS de gt FIGURE 28 MANIFOLD ASSEMBLY 4 93 5 UN 62 4 3 PART ITEM PART NO NO DESCRIPTION NO NO DESCRIPTION 0026 Coil Assembly Syrup with Pumps 0027 Coil Assembly Carb Water Valve 1 1 1560 Tube 265 1 0 by 26 long Syrup 0765 Coil Assembly Syrup without Pumps 2 176000 Ferrule 47 4 for 500 O D Tube Valve 1 3 0074 Fitting Outlet S
21. 93 94 95 0575 183061 0520 0581 0570 1077 011117 1280 1331 186618 393149 770605 1446 DESCRIPTION Fitting 1 4 by 7 16 20 Retainer Water Line Foot Not Shown Fitting CO Inlet Manifold with Pump Coil Retainer Wire Clip Tube Ass y USA Not Shown Tube Ass y USA Not Shown Machine Screw Phil RD HD Stainless Steel No 6 32 3 4 Long Slinger Fitting Tee 7 16 20 Capacitor 36 ITEM NO 96 97 98 99 100 101 102 103 104 105 ITEM NO o m d PART NO 197164 197383 1448 1488 151460 318036 140117 1734 843304 822967 PART NO 1280 176017 770104 1560 176000 300200 0569 DESCRIPTION End Cap Capacitor Clip Mounting Bracket Thread Rolling Screw Fil Phil Hd No 10 24 By 3 8 Long Thread Rolling Screw Phil Pan Hd Stainless Steel No 6 32 1 2 Long Push on Nut 125 Stud Drain Tube 375 1 0 By 24 Long Clamp Cable Washer No 10 Washer No 6 DESCRIPTION Tube Ass y Water Inlet Swivel Nut 7 16 20 Nipple for 265 1 0 tube Tube 265 1 0 by 25 Long Ferrule for 500 O D Tube Clamp for 500 O D Tube Regulator Water Pressure FIGURE 22 SOLENOID VALVE ASSEMBLY ITEM PART ITEM PART NO NO DESCRIPTION NO NO DESCRIPTION 0537 Solenoid Valve Assembly Carb Water 8 310632 001 Adj
22. ATOR TANK ASSEMBLY 38 FIGURE 25 EVAPORATOR COIL ASSEMBLY 38 FIGURE 26 WATER TANK ASSEMBLY 38 FIGURE 27 VALVE HOUSING ASSEMBLY 39 FIGURE 28 MANIFOLD ASSEMBLY 39 FIGURE 29 COIL ASSEMBLY 39 FIGURE 30 CONTROL BOX ASSEMBLY 40 FIGURE 31 MANUAL OPERATION OF DISPENS ING VALVES Goud 42 LIST OF TABLES TABLE 1 DESIGN DATA 1 GENERAL DESCRIPTION READ THIS SECTION FIRST IMPORTANT This manual is a guide for installing operating and maintaining the Convertible Post Mix Dispenser Refer to the table of contents for page location of detailed information on questions that arise during installation operation service and maintenance or troubleshooting of this dispenser GENERAL DESCRIPTION This section gives the description theory of operation and design data for the Four Flavor Convertible Post Mix Dispenser with built in cold carbonator hereinafter referred to as the Unit UNIT DESCRIPTION see Figure 1 The Unit is compact and may be island mounted or installed on a front or rear counter Further it is designed so that it can be readily adapted to available counter space narrow front or shallow depth A full description of installation options is given in the Installation Section The refrigeration Unit is a lift out type which is easily removed for service and maintenance Syrup to water ratios in the dispensed product are readily adj
23. ERPENDICULAR CRIMPING LIFT AND SQUEEZE PINCER FOR PARALLEL OR SIDE SADDLE CRIMPING SLIDE CLAMPS ON TUBING BEFORE INSTALLING TUBING ON FITTING DON T IMPROPER KY CRIMPING PROPER CRIMPING ONE SIDED TWISTED OVER CRIMPED 1 5 _ POSITION CLAMP BEHIND FIRST BARB FITTING FOR CRIMPING FIGURE 18 INSTRUCTIONS FOR CRIMPING TUBE CLAMPS 0575 28 STANDARD ONS sp 75 5 5 5 GRN WHT 4 MODELS 1275 1276 ONLY WHT 6c BLU POWER SUPPLY k 4521 SOLENOID VALVES MAIN BOARD START 5 WHT 277 CAPACITOR BLK RED COMPRESSOR RELAY BR nS e i poe OVERLOAD WH i F y PLN SODA WIR WIR LL
24. Kg CM 5 5 BAR Tighten the locking nut PURGING THE SYRUP SYSTEMS 1 Place a cup under the nozzle 2 Manually open each syrup valve in turn and observe syrup flow Purging is completed when all air is removed from the system If syrup continues to show air bubbles check tightness of line connections See Figure 31 for manual operation of dispensing valves ADJUSTING WATER TO SYRUP RATIO OF DISPENSED PRODUCT The water to syrup ratio is measured by use of a ratio cup see Figure 12 having two chambers into which the soda and a selected syrup are dispensed The ratio if incorrect is adjusted by turning the related syrup flow regulator adjusting screw located on top of each syrup dispense solenoid valve NOTE Allow the refrigeration Unit to operate for at least an hour before making this adjustment The drink temperature should be no higher than 40 degrees F 4 4 degrees C 1 Remove the small cover over the dispensing nozzle and solenoids 2 Atthe top of the dispensing nozzle grasp the upright plastic extension on the water tube and pull the water tube from the center of the nozzle position A in Figure 12 then insert the water tube into the molded tube position B in front of the dispensing nozzle 3 Hold the ratio cup under the dispensing nozzle so that the large chamber of the ratio cup is under the molded tube and the smaller chamber is under the dispensing nozzle 4 Starting with the most viscous syrup
25. N CARBONATED DRINK To dispense a carbonated drink place a cup under the dispensing nozzle and press the desired dispense switch holding it pressed until cup is filled SODA CARBONATED WATER To dispense soda carbonated water place a cup under the dispensing nozzle and press S soda dispense switch holding it pressed until cup is filled PLAIN WATER PLAIN WATER KIT INSTALLED To dispense plain water place a cup under the dispensing nozzle and press W water dispense switch holding it pressed until cup is filled 0575 DAILY PRE OPERATION CHECK Each day before dispensing products the operator should check the pressure in the connected cylinder check that there is sufficient syrup wash the Unit nozzle the cup rest and the drip tray Instructions to accomplish each task follow CHANGE CYLINDER When the CO cylinder pressure drops causing the cylinder pressure gage pointer to indicate in the change CO cylinder area the cylinder must be changed see Figures 7 and 8 To change the cylinder proceed as follows 1 Turn oylinder shut off valve clockwise until it seats firmly 2 Using a wrench slowly loosen the coupling nut allow trapped gas to escape CAUTION When the coupling is separated be sure that the gasket remains inside the coupling nut 18 3 Support the regulator and gages and continue to turn the coupling nut until regulator and nut separ
26. OK FIGURE 11 LINE SYRUP a LIFT HERE CAP 2 p POSITION A WATER TUBE POSITION B MIXING HEAD 7 VALNE HOUSING ASSEMBLY NY RATIO CUP 2 2 WATER 77 17 ng FIGURE 12 RATIO MEASUREMENT DETAIL 17 0575 OPERATORS INSTRUCTIONS This section describes the Unit s operating controls and daily checks and maintenance procedures to be performed on the Unit and system by the operator WARNING Disconnect electrical N power to Unit to prevent personal injury before attempting any internal maintenance Only qualified personnel should service internal components of this Unit CAUTION Protect the Unit from N freezing conditions Water freezing in the system will cause serious damage Maintenance personnel can drain the system if freezing conditions are expected WARNING Displaces Oxygen N Strict Attention must be observed in the prevention of carbon dioxide gas leaks in the entire CO and soft drink system If a 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 CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation PRODUCT DISPENSE SWITCH OPERATIO
27. ank to melt from the cooling coils 26 Connect the Unit to electrical power Hot water may be used to hasten this operation Compressor condenser fan motor and agitator motor will start and an ice bank will form in the 11 Clean the condenser coil using a hand vacuum water tank As the ice bank forms excess water cleaner and a soft brush Low pressure air may runs out through the overflow tube into the drip be used Be careful of the cooling fins tray 23 0575 DUAL LIQUID CHECK VALVE ASSEMBLY MAINTENANCE WARNING The dual liquid check valve assembly must be inspected and serviced at least once a year under normal circumstances and after any water service disruption as may be caused by plumbing work or earthquake which might cause erratic flow of water through the system A defective valve could allow gas to back flow into the water system and create a health hazard WARNING Wear protective eye wear to avoid injury from gas driven particles The dual liquid check valve assembly requires yearly maintenance and an internal inspection following disruption of water service Perform servicing as follows 1 Disconnect electrical power from the Unit 2 At CO oylinder close the cylinder shut off valve 3 Atthe plain water inlet to the Unit shut off the water 4 Remove one screw from the large cover and remove the cover from the Unit 5 Atthe carbonator pull up on the relief valve ring to rele
28. ase 6 Atthe top of the dual check valve see Figure 15 use two wrenches to disconnect the inlet water line from the assembly 7 Remove foam insulating tube from the dual check valve 8 Using a wrench on the retainer see Figure 16 closest to the carbonator tank loosen and remove the dual check valve assembly from the welded in carbonator fitting 0575 24 DUAL CHECK VALVE ASS Y GAS CHECK VALVE ASS Y RELIEF VALVE RING CARBONATOR TANK FIGURE 15 CARBONATOR HOUSING O RING LU uer SLEEVE E aM Q BALL 25 SPRING O RING des SLEEVE vehe BALL O RING RETAINER SPRING FIGURE 16 DUAL LIQUID CHECK VALVE ASSEMBLY 9 Disassemble each check valve as shown in Figure 16 10 Wipe each part with clean lint free cloth 11 Using a hand lens inspect each part for burrs nicks corrosion or other indications of deterioration IMPORTANT NOTE Replace ball seat at each servicing 12 Replace damaged parts and ball seat 13 Reassemble each check valve 14 CAUTION In joining the two check valves together and in making installation on the carbonator do not overtighten use torque wrench to avoid damage to plastic seals 15 Assemble check valves together Tighten to 35 Ib in 3 95 newton mtr Do not overtighten 16 Install the dual check valve on the carbonator tank tightening to 35 Ib in 17 Install foam insulating t
29. ate from the tank fitting 4 Look inside the coupling nut to be sure that the gasket remains inside WARNING Always secure the cylinder with a safety chain to prevent it from falling over A broken valve may allow the cylinder to act as a projectile causing serious injury or property damage 5 Install cover on empty cylinder 6 Unchain the empty CO cylinder and carefully set it aside 7 Secure the full cylinder with the chain and remove cover from cylinder 8 Install regulator on a full cylinder using the coupling nut Be sure that the gasket remains inside Tighten using a wrench 9 Open cylinder shutoff valve Listen for leakage and observe both gages If a leak is heard close cylinder shutoff valve tighten the coupling nut then open the cylinder valve SYRUP A syrup tank should be changed when gas is dispensed through the nozzle and no syrup is dispensed Fittings on the tanks and mating fittings on the ends of the and syrup lines are of the quick disconnect type which close off gas and liquid flow when disconnected see Figures 13 and 14 To change a syrup tank proceed as follows 1 Atthe tank press down on the collar of the syrup line end fitting while turning it counterclockwise to release it 2 Press down on the collar of the CO line end fitting while turning it counterclockwise to Move the empty tank aside and place a full tank in
30. be used to ensure correct Unit operation Refer to Installation Kits paragraph for part number CAUTION Do not use a saw to cut N tubing use a tubing cutter or knife to avoid contamination of tubing with particles of material CAUTION Water pipe connections and fixtures directly connected to a potable water supply shall be sized installed and maintained according to federal state and local laws 1 Connect tubing to water source but do not connect to Unit at this time Allow three feet 92 cm extra tubing length below the countertop for servicing the Unit 2 Check water pressure If water pressure is greater than 40 psig 2 8 Kg Cm2 install water pressure regulator 3 Flush water supply line thoroughly by running four gallons 15 liters of water to drain 4 Remove one screw and remove large cover from the Unit 5 Remove small cover from the Unit 6 Remove two screws at the top left rear of the bulkhead panel and lift the pump wrap from the Unit 7 Route water supply tubing through hole in countertop and through hole in bulkhead panel and connect to carbonator pump inlet using a flare seal washer Use a back up wrench to avoid damaging the carbonator pump 8 Route the water tank drain line NSF requirement for USA installations down through the countertop hole Note that the end is plugged 9 Turn on the water supply and check for leaks 10 Ifa pressure regulator other than one sup
31. c Provides the necessary parts to connect syrup and water to a Unit having internal syrup pumps 0575 Syrup Tank Installation Kit P N 0103 US Provides necessary parts to connect syrup CO and water to a Unit without internal syrup pumps Syrup Tank Installation Kit P N 0105 metric Provides necessary parts to connect syrup CO and water to Unit without internal syrup pumps Water Pressure Regulator Kit P N 0107 Regulates water pressure on water inlet supply line Pressure is factory preset to 30 PSIG NOTE The water pressure regulator is required in locations where the water pressure exceeds 40 PSIG 2 8 Kg cm2 2 8 BAR Ideal water pressure ranges from 25 to 40 PSIG PLAIN WATER CONVERSION KIT P N 0106 The plain water conversion kit when installed allows plain water only to be dispensed and the Unit may be set up to also dispense a combination of carbonated and still non carbonated drinks ICE TEA KIT P N 1347 The ice tea kit contains the parts required to convert syrup system No 4 to provide an ice tea drink LEG KIT P N 1294 The leg kit when installed raises the Unit four inches above the countertop Such an installation relieves U S users from the NSF requirement to seal the Unit to the countertop DECAL KITS The following decal kits are available Kit Part Number Applicable To 0110 United States of America 0111 Australia 0112 China 0113 France 0114 Germany 0115 Italy 0116 Japan 0
32. carrier Request a written inspection from the carrier s claims inspector to substantiate claim File claim with the delivering carrier not with IMI Cornelius Inc UNPACKING AND INSPECTION UNPACK A UNIT AS FOLLOWS 1 Cuttwo bands 2 Lift carton wrap off Unit 3 Remove top foam packaging Retain installation manual decal kit and electric plug if applicable CAUTION Unit must be lifted by its base To avoid damage do not lift using valve housing or pump wrap 4 Lift Unit off base foam packaging 5 Carefully inspect Unit for evidence of damage If evidence of damage is found notify delivering carrier and file a claim against the carrier 6 Remove loose shipped parts from carton Check contents per Table 2 1 TABLE 1 LOOSE SHIPPED PARTS Part Part Description Model No Qty No 0080 0088 1275 1276 2175 Drip Tray 1 1 1 1 0071 Cup Rest 1 1 1 1 XXXX Decal Kit as 1 1 1 1 ordered by customer 0110 Flavor Kit 1 1 0575 0581 Legs 6 6 6 6 0582 Screws 6 6 6 6 0639 Abbreviated 1 1 1 1 Installation Manual 0566 Syrup Inlet Tube 4 Ass y 1062 Bag Seal 9x12 1 1 1 1 W Backing 1331 Tube Cut 500 Vin 1 1 72 2143 Plug 1 1 180025 000 O Ring 4 310461 000 Thread Rolling 2 2 2 2 Screw LOCATION SELECTION The Unit may be island mounted or installed on a front or rear counter provided that the following requirements are satisfied WARNING electrical wiring must conf
33. connect electrical power from the Unit 2 Atthe CO cylinder turn the shut off valve fully clockwise to turn off gas 27 3 Atthe Unit draw soda from the dispenser Check the line pressure gage for zero pressure indication 4 Draw syrup from the dispenser to bleed off syrup pressure NOTE If repairs are to be made to the syrup system of a syrup tank system perform the following steps 1 Disconnect electrical power from the Unit 2 Atthe CO cylinder turn the shut off valve clockwise to turn off gas 3 Atthe regulator use two wrenches to crack the outlet fitting of the regulator to relieve gas pressure Check the regulator pressure gage for zero pressure indication An alternate method is as follows A Disconnect syrup lines from the syrup tank B Atthe Unit draw syrup from the dispenser to bleed off syrup pressure UNIT ELECTRICAL DIAGRAM see Figure 19 NOTE The printed circuit board can be removed from the control box as follows 1 Release and remove the cover 2 Insert a small screwdriver into the oval hole in the top of the printed circuit board and rest the screwdriver shank on the top inside edge of the control box and gently lever the board upward from its contacts Instructions for Crimping Tube Clamps see Figure 18 Troubleshooting Table Table 5 1 lists the most common problems possible causes and remedies 0575 PULL SOUEEZE FOR P
34. drinking water 6 Place the line end connectors with installed bag valves into the water 7 Place a waste container under the dispensing nozzle 0575 42 ARMATURE PRESS HERE SOLENOID 10 11 12 13 14 15 FIGURE 31 MANUAL OPERATION OF DISPENSING VALVES Remove the small cover from the top of the Unit Manually open each syrup dispensing valve by pressing the armature of the solenoid forward to cause syrup and water to flow from the nozzle see Figure 31 Hold each syrup solenoid dispensing valve open until only water is dispensed Remove the syrup line end connectors from the water Fill the 5 gallon container with potable drinking water at room temperature 70 degrees to 100 degrees F and add 3 4 ounce per gallon of water 6 ml Per liter of Diversify DIVOFLOW 185 or equivalent detergent to provide a sodium hydroxide solution Mix the contents of the container thoroughly Place the syrup line end connectors with bag valves installed into the detergent Hold each dispensing valve open until the water is displaced by the detergent CAUTION To avoid damage to metallic parts of the system do not allow the detergent solution to remain in a syrup system longer than 15 minutes 16 Allow the detergent to remain the syrup systems for at least 10 minutes but no longer than 15 minutes 17 Remove the line end connectors from the detergent 18 Dispose
35. e line end connectors Save the bag valve 29 Connect each syrup line end connector to the pre selected syrup source 30 Hold each dispensing valve open until the syrup purges the sanitizer from the lines and only syrup is dispensed 31 Replace the small cover on top of the Unit 32 Connect electrical power to the Unit 33 Dispense and taste each product for off flavor 34 Dispose of the waste sanitizing solution in the sanitary sewer not in storm drain Rinse both containers SANITIZING THE SYRUP TANK SYSTEMS This is a procedure for sanitizing syrup systems of the Convertible Post Mix Dispensers which have syrup tanks P N 0088 0097 and 1276 Sanitize the syrup systems as follows 1 Atthe Unit disconnect electrical power 2 Remove the small cover from the top of the Unit 3 Place a waste container under the dispensing nozzle 4 Disconnect the syrup line end connectors from the syrup tanks 5 Wash each line end fitting in warm water to remove syrup accumulation 6 Fill a clean syrup tank with potable drinking water Place a cover on the tank 7 Apply CO pressure to the tank 8 Flush syrup from the lines as follows A Connect one of the syrup line end connectors to the syrup tank B Manually open the corresponding syrup System dispensing valve by pressing the armature of the solenoid forward to cause syrup and water to flow from the nozzle see Figure 31 C Hold the dis
36. e one screw from the large cover and remove the cover from the Unit 5 Atthe carbonator pull up on the relief valve to release CO 6 Using two wrenches disconnect the CO inlet line from the top of the gas check valve assembly NOTE Ball seat will remain in the body when the housing is removed 7 Carefully remove the housing from the top of the welded in body 8 Using a pencil point remove the the ball seat quad ring from the body 9 Remove the ball spring and retainer from the body 10 Wipe each part with clean lint free cloth 11 Using a hand lens inspect each part for burrs nicks corrosion or other indications of deterioration IMPORTANT NOTE Replace ball seat quad ring Part Number 183294 at each servicing 12 Replace damaged parts and ball seat quad ring 13 Reassemble CO gas check valve as follows A Place the spring over the retainer and drop the two into the valve body Balance the ball atop the spring C Using a new ball seat quad ring Part No 183294 assemble the spring ball and the ball seat into the body 0575 14 Screw the Housing over the body and tighten to 22 Replace large cover and secure it with one 35 Ib in 3 95 newton mtr Screw 15 Using two wrenches connect the CO line to lt gt the top of the gas check valve assembly ma HOUSING 16 Atthe cylinder open the cylinder shut off valve QUAD RING 17 Atthe plain water inlet to
37. e screw in large top cover and remove the large cover CAUTION The carbonator water pump motor must be electrically disconnected to avoid damage to the pump by running dry 2 Disconnect water pump electrical connector at the control box located in the refrigeration compartment Plastic locks both top and bottom must be released before connector can be unplugged 3 Remove plastic plug from the water tank fill hole centered in front of the condenser coil 4 Install drip tray first followed by the cup rest which is placed on the drip tray 5 Place funnel in water fill hole NOTE The water tank must be completely filled before applying electrical power to the Unit to ensure correct operation of the refrigeration Unit The refrigeration system will not operate without water in the water tank The presence of water must be detected by electronic ice bank control probes within the water tank 6 Fill water tank with approximately 4 1 2 gallons 17 liters of water until water flows out of the tank overflow tube into the drip tray 7 Remove funnel and replace plastic plug in the water fill hole CAUTION Unit must be electrically N grounded to avoid possible fatal electrical shock or serious injury to the operator The power cord is provided with a three prong grounded plug If a three hole grounded electrical outlet is not available use an approved method to ground the Unit 8 Remove any shipping ma
38. er See Page 6 4 Solenoid Valve Syrup See Page 6 4 Housing Valve See Page 6 6 O Ring 176 I D by 070 C S Thread Rolling Screw Phil Pan Hd 8 32 by 3 long with Pumps Manifold Ass y with Pumps See Page 6 6 Screw with Pumps Pump Syrup 80 psi with Pumps Service Cord Thread Cutting Screw Phil Truss Hd Stainless Steel 8 18 by 1 2 long Cap Nut Stainless Steel 7 16 20 Dual Check Valve Assembly See Page 6 4 Coil Syrup Valve No 1 with Pumps See Page 6 6 Coil Syrup Valve No 1 without Pumps See Page 6 6 Retainer Coil Coil Assembly Syrup Without Pumps Valves 2 3 amp 4 see Page 6 6 Coil Assembly Syrup With Pumps Valves 2 3 amp 4 see Page 6 6 Coil Plain Water See Page 6 6 Coil Carb Water see Page 6 6 Wrap Water Bath Wrap Water Bath USA Tank Water See Page 6 5 Fastener Compressor Cover 35 ITEM NO 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 NO 309742 0049 1447 398034 400 317781 189723 0006 1314 0005 0013 0001 0066 0016 0081 0227 314129 009 187485 0008 0039 312251 0041 0077 0879 0010 0033 0034 0521 1176 1175 0031 0037 317665 1468 1174 1315 1346 172128
39. es for sharp kinks Sanitize syrup system Refer to Addendum B Check water supply to Unit Reset water pump safety cutout by momentarily unplugging electrical power from the Unit Check probe plug on electrical control box Replace pump and motor Trouble FREQUENT SHORT FILL CYCLES OF CARBONATOR TANK ONLY SYRUP IS DISPENSED COMPRESSOR DOES NOT OPERATE COMPRESSOR DOES NOT STOP AFTER ICE BANK IS FORMED COMPRESSOR RUNS CONTINUOUSLY BUT DOES NOT FORM AN ICE BANK 0 Probable Cause Probe terminal disconnected or loose Probe incorrectly wired Faulty probe Faulty logic circuit board Water supply is turned off At Unit carbonator motor is disconnected Water pump safety system has removed power to the pump Unit is frozen Ice bank is sufficient No power to Unit Compressor overloaded Line voltage too low Inoperative ice bank control board Inoperative compressor Ice bank connector loose or not plugged in Ice bank probe or connections may be faulty Cooling capacity is exceeded by load Unit is located in an excessively hot area or air circulation through cooling Check for ice bank at bottom of evaporator in water tank Dirty condenser coil Condenser fan not functioning 32 gt Remedy Check and tighten all electrical connections to probe Verify correct wiring using wiring diagram Replace probe Replace logic
40. f syrup connections see Figure 9 4 Apply product decals from the kit to dispense switches to correspond to the product dispensed NOTE Lubricate O rings before installation using food grade non petroleum base lubricant e g Dow Corning 111 or equivalent 11 5 On bag in box Units refer to Figures 10 and 11 Lubricate O rings and connect each syrup line to that syrup pump corresponding to the dispense switch to be used by inserting line end fittings into inlet on top of the pump and securing there to the pump by tightening a modified notched phillips hold down screw against the collar on the line end fitting 6 On tank Units connect each line to a numbered syrup cooling coil line end within the pump wrap using stepless clamps CONNECT SYRUP LINES TO SYRUP SOURCES Connect syrup lines to syrup sources for bag in box or tank Units as described in Operator s Instructions CAUTION Do not plug into power outlet at this time MAKE ELECTRICAL CONNECTIONS Route Unit power cord down through the pump wrap area and countertop hole and bring it out near the power outlet but do not plug it in at this time power cord plug is loose shipped with Unit install it on power cord end in compliance with applicable codes and regulations PREPARATION FOR OPERATION This subsection provides information needed to set up the product selection panel purge the carbonator system start up the Unit and adjus
41. in sodium hydroxide be non perfumed and have low sudsing and easily rinsible characteristics The sodium hydroxide should be between 2 percent and 10 percent in the concentrated detergent WARNING Phenolphthalein must be kept away from children it is a powerful laxative and may cause serious illness if taken internally 0575 WARRANTY IMI Cornelius Inc warrants that all equipment and parts are free from defects in material and workman ship 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 210 RIVERWOOD NSW 2210 AUSTRALIA 61 2 533 3122 FAX 61 2 534 2166 AUSTRIA AM LANGEN FELDE 32 A 1222 VIENNA AUSTRIA e 43 1 233 520 FAX 43 1 2335 2930 BELGIUM BOSKAPELLEI 122 2930 BRAASCHAAT BELGIUM 32 3 664 0552 FAX 32 3 665 2307 BRAZIL RUA ITAOCARA 97 TOMAS COELHO RIO DE JANEIRO BRAZIL 55 21 591 7150 FAX 55 21 593 1829 ENGLAND TYTHING ROAD ALCESTER WARWICKSHIRE 49 6 EU ENGLAND 44 789 763 101 FAX 44 789 763 644 FRANCE e 71 ROUTE DE ST DENIS F 95170 DEUIL LA BARRE PARIS FRANCE 33 1 34 28 6200 FAX 33 1 34 28 6201 GERMANY CARL LEVERKUS STRASSE 15
42. ion 33 Oo 0 Remedy Check agitator motor replace if necessary Remove obstruction clean motor Tighten set screw Repair connections Replace motor Clear obstruction Tighten set screw Repair connections Replace motor Move jumper to on position FIGURE 20 CONVERTIBLE PARTS BREAKDOWN 34 0575 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 NO 0080 0088 1275 1276 0019 0025 0086 1180 0071 0069 188652 0064 310461 0044 150065 0007 0893 0878 0011 1178 0537 0538 0551 110677 0012 0548 0550 0073 0050 317784 770452 774005 020 0026 0765 0067 1671 1672 0014 0027 0596 1181 0051 309741 DESCRIPTION Convertible 115V 60HZ with Pump Convertible 115V 60HZ without Pump Convertible 115V 60HZ with Pump USA Convertible 115V 60HZ without Pump USA Cover Larger Top Cover Small Top Wrap Pump Wrap Pump USA Rest Cup Drip Tray Thread Rolling Screw SL Truss Hd Stainless Steel No 8 32 by 3 8 long Panel Splash Thread Rolling Screw Phil Pan Hd No 8 32 by 3 8 long Latch Wrap O Ring 1 051 1 0 by 070 C S Nozzle Wire Harness Panel and Decal Ass y Fitting Carb Water Body Valve Mixing Head Solenoid Valve Carb Wat
43. lows freely from the nozzle with no indication of air 4 Atthe COs cylinder pressure regulator loosen the locking nut on the pressure adjusting screw and turn the pressure adjusting screw fully CCW 5 Open cylinder valve slowly 6 Turn the pressure regulator pressure adjusting screw slowly CW to provide a pressure of 50 psig 3 5 Kg Cm2 3 44 BAR priming pressure 7 Tighten the locking nut 8 Open the S soda dispensing valve manually to drive all water from the carbonator and water coil 9 Connect the water pump electrical connector to the control box connector 10 Apply electrical power to the Unit NOTE The electronic control incorporates a time delay for compressor start On initial start up or whenever power is interrupted compressor may not start for 5 minutes 0575 14 NOTE The water pump is equipped with a timer which will allow it to run continuously a maximum of five minutes after which the motor will stop The timer can be reset by momentarily removing electrical power to the Unit The pump motor will then operate as needed 11 Atthe Unit press the soda or S selector intermittently until the carbonator has cycles at least three times Soda water should be clear and well carbonated 12 Atthe pressure regulator loosen the locking nut on the pressure adjusting screw and turn the screw clockwise to provide a pressure between 70 PSIG 4 9 Kg Cm 4 8 BAR and 80 PSIG 5 6
44. of unused detergent in a sanitary sewer not in a storm drain Wash the container thoroughly 19 Fill the 5 gallon container with potable drinking water Place the line end connectors in the water 20 Hold each dispensing valve open until the detergent is displaced by the water 21 Dispense a sample of water from the nozzle Test the sample using a drop of phenolphthalein indicator This indicator becomes pink colored in the presence of even small amounts of detergent When the indicator remains clear all detergent has been removed 22 Remove the line end connectors from the water 23 Fill the 5 gallon container with 4 gallons 15 1 liters of water at a temperature between 70 degrees F to a maximum of 100 degrees F 24 Add 1 0 oz 29 57 ml of H B Fuller Monarch 6 or equivalent sanitizer to provide a 200 ppm 200 mg liter active quaternary sanitizing solution to the container Mix thoroughly 25 Place the syrup line end connectors in the sanitizing solution 26 Hold each dispensing valve open until only the sanitizing solution is dispensed 27 Allow the sanitizing solution to remain in the syrup systems from eight to ten minutes CAUTION To avoid damage to metallic parts of the system do not allow the sanitizing solution to remain in the syrup systems longer than 15 minutes 28 Remove syrup line end connectors from the sanitizing solution and remove the bag valves from th
45. orange press the selection switch to draw a drink into the two parts of the ratio cup until the ratio cup is at least two thirds full 5 Place the ratio on a level surface and observe that the soda and syrup levels are at the same level If not use a screwdriver to adjust the syrup flow regulator adjusting screw by 1 4 turn at a time Clockwise rotation of the screw will increase the syrup flow and counterclockwise rotation of the screw will decrease the syrup flow Check the adjustment by drawing a drink Repeat steps 4 and 5 NOTE If the most viscous syrup cannot be set by adjusting the syrup flow regulator increase the CO pressure by 5 PSIG 0 35 Kg Cm2 0 34 BAR and repeat the adjustment After the most viscous syrup ratio is set do not change the pressure For bag in box installations do not adjust regulator higher than 80 PSIG 5 6 Kg Cm2 5 5 BAR 6 Adjust the ratios for the remaining selections following the same procedure 7 At the top of the dispensing nozzle grasp the upright plastic extension on the water tube and lift the water tube from the molded tube and insert it into the center of the nozzle 8 Replace the small cover ADJUSTING PRESSURE SUPPLY WARNING Wear protective eyewear to avoid injury from gas driven particles If line pressure shown on the line pressure gage see Figure 7 falls below 70 PSIG 4 9 Kg Cm2 4 8 BAR and the cylinder
46. orm to national and local electrical codes 1 Locate Unit near a grounded electrical outlet having a dedicated circuit fused at 15 amps slow blow for 115VAC units Alternate protection using an equivalent HACR US circuit breaker may be used CAUTION Condenser coil cooling N air is drawn into and discharged from the top of the Unit Failure to provide sufficient clearance over the top of the Unit may cause the compressor to overheat and fail A minimum of 14 in 35 cm clearance is required over the top of the Unit 2 Locate Unit so that a minimum of 14 inches 35 cm clearance exists over the top of the Unit IMPORTANT Bag in Box Units are provided with 8 ft 2 4 M syrup lines The difference in height between the Unit and the bag in box syrup containers must not exceed 8 2 4 M 3 Locate Unit close to a water inlet supply line with pressure and flow as given in the listing of Physical Characteristics and Requirements INSTALLATION NOTE The following text gives the steps to fill the water tank and start the refrigeration system Note cool down may require two or more hours However if a countertop installation is to be made which requires locating a hole in the countertop or if the base of the Unit is to be sealed to the countertop USA procedures per Addendum A should be completed before the Unit is filled with water FILLING WATER TANK AND STARTING REFRIGERATION SYSTEM 1 Remov
47. p system as follows A Connect one of the syrup end line connectors to the syrup tank B Manually open the corresponding syrup system dispensing valve by pressing the armature of the solenoid forward to cause water and sanitizer to flow from the nozzle C the syrup system dispensing valve open until only sanitizer is dispensed D Disconnect the syrup line end connector from the syrup tank E Repeat steps a through d for the remaining syrup systems CAUTION To avoid damage to metallic parts of the system do not allow the sanitizing solution to remain in the syrup system longer than 15 minutes 25 26 27 Allow the sanitizing solution to remain in contact with the syrup systems from eight to ten minutes Connect each syrup line end connector to a syrup tank of the pre assigned flavor Manually open each syrup system dispensing valve to allow syrup to purge sanitizer from the syrup lines 28 29 30 31 32 Hold each syrup sysiem dispensing valve open until only syrup is dispensed Connect electrical power to the Unit Taste each dispensed product for ofi flavor Remove CO pressure from the syrup tank containing the sanitizer Rinse the sanitizer from the syrup tank and from the waster container Dispose of the waste sanitizing solution in the sanitary sewer not in the storm drain 45 33 Replace the small cover on top of the Unit Detergent to conta
48. pensing valve open until only water is dispensed D Disconnect the syrup line end connector from the syrup tank E Repeat steps a through d for the remaining syrup systems 9 Remove pressure from the tank 10 Fill the syrup tank with water at room temperature 70 degrees to 100 degrees F and add 3 4 ounce per gallon of water 6 ml per liter of Diversify DIVOFLOW 185 or equivalent detergent to provide a sodium hydroxide solution 0575 Mix the contents of the syrup tank thoroughly Place a cover on the tank Apply CO pressure to the tank Fill the syrup systems with detergent solution as follows CAUTION To avoid damage to metallic parts of the system do not allow the detergent solution to remain in syrup systems longer than 15 minutes 14 15 16 17 18 A Connect one of the syrup line end connectors to the syrup tank B Manually open the corresponding syrup system dispensing valve by pressing the armature of the solenoid forward to cause water and detergent to flow from the nozzle C Hold the dispensing valve open until only detergent is dispensed D Disconnect the syrup line end connector from the syrup tank E Repeat steps a through d for the remaining syrup systems Allow the detergent to remain in the system for at least ten minutes but no longer than 15 minutes Remove CO pressure from the syrup tank Rinse the syrup tank thoroughly with water
49. plied with the Unit is installed set it to 30 PSIG 2 112 2 Connect supply as follows WARNING Always secure the cylinder with a safety chain to prevent it from falling over A broken valve may allow the cylinder to act as a projectile causing serious injury or property damage 1 Place CO cylinder in service location and secure it with a safety chain 2 Connect CO pressure regulator assembly to cylinder Use a new coupling washer if the regulator coupling does not have a built in C ring seal see Figures 7 and 8 CAUTION Do not apply pressure to the line at this time 3 Using approved 0 265 1 0 tubing and fittings from the installation kit connect the tubing assembly to the regulator using a flare seal washer Use a back up wrench to prevent damage to the regulator assembly 4 Route CO tubing up through the hole in the countertop leaving three feet 92 cm of extra tubing below the countertop for servicing the Unit 5 Route the tubing through the tower pump wrap and the Unit bulkhead panel 0575 CROSS HEAD SCREW 2 PUMP WRAP HOLE LOCATION COUNTER TOP MARK COUNTER AT CORNERS OF PUMP WRAP FIGURE 6 COUNTERTOP HOLE LOCATION 0575 10 6 In the bag in box Unit connect the line to the manifold located below the syrup pumps see Figure 9 amp 10 In Units with syr
50. position Remove protective caps from the syrup 3 pin and the CO 2 pin connectors on the syrup tank Dip tank connectors in warm water to clean them Place collar of syrup line 0 over the 3 pin connector on the syrup tank press down on the collar and turn it clockwise to lock Place collar of CO line end fitting over the 2 pin connector on the syrup tank press down on release it the collar and turn it clockwise to lock HANDLE A A A A A A A SYRUP CONNECTION 3 PIN TOP VIEW CONNECTION 2 1111 SYRUP SIDE VIEW FIGURE 13 SYRUP TANK 19 0575 COLLAR FIGURE 14 LINE END FITTING FOR SYRUP TANK CONNECTION BAG IN BOX SYRUP CONTAINER Change a Bag in Box syrup container when no syrup is dispensed The amount of syrup remaining in a bag in box container can be estimated by lifting the container A full 5 gallon 19 liters container weighs approximately 1 2 Ib 0 23 Kg To change a container proceed as follows WARNING Use operated pumps only in a well ventilated area 1 At the bag in box container unscrew the red line end connector from the bag connector of the empty box The line end connector is of the quick disconnect type which eliminates syrup flow from the line CAUTION Do not puncture box or internal bag 2 Open
51. ransformer connector from standing connector on the transformer 19 Connect carbonator water pump power connector to the standing connector on the 7 Disconnect dispensing switch module 24 control box power connector from standing connector on the transformer 20 Connect carbonator tank level control probe electrical connector to the standing connector 8 Using a magnetic screwdriver remove three on the control box screws from the refrigeration Unit platform Two screws are along the left side and a third is 21 Within the Unit connect refrigeration assembly centered along the right side of the platform electrical power cord to connector of main power cord NOTE When removed the lift out refrigeration system should be rested its cooling 22 Place small cover on Unit 23 Install plug in the end of the water tank drain NOTE If refrigeration system does not easily lift line out wait 15 20 minutes for ice to melt Do not torea 24 Using a funnel fill the water tank with approximately 4 1 2 gallons of water 17 liters until water flows out of the tank overflow tube into the drip tray 9 Using the plastic refrigeration deck handle lift the refrigeration assembly from the Unit and place it on a flat surface in a basin resting it on its bottom coils Note that a partial ice bank will 25 Place large cover on the Unit and secure it with remain on coils the removed screw 10 Allow ice b
52. ration system and the water tank should be cleaned each year Effort involves disconnecting 12 Use a fiber brush and water to carefully clean electrical connections removing screws and lifting mineral deposits from cooling coils and agitator the refrigeration system clear of the Unit exposing motor shaft the condenser and the water tank 13 Place a 5 gallon 19 liter container under the To clean proceed as follows plugged water tank drain line 1 Disconnect electrical power from the Unit and 14 he plug f h k drain line allow ice bank to partially melt emove the plug from the water tank drain line and drain water into the container 2 Remove small tower cover from Unit 15 Wash inside of water tank with plain water and wipe dry with a lint less cloth 3 Remove one screw from large cover and remove cover 16 Using the plastic refrigeration deck handle carefully lower the lift out refrigeration system 4 Within Unit disconnect refrigeration power cord into place in the Unit from main power cord by separating connector 17 Using a magnetic screwdriver install three screws in the platform to fasten the system to 5 Disconnect carbonator tank level control probe the Unit electrical connector from standing connector on the control box in right f Unit A E 18 Connect dispensing switch module 24VAC power connector to standing connector on the 6 Disconnect carbonator water pump power t
53. restricted or dirty Dirty water supply No electrical power to Unit Disconnected wire at dispensing valve Unit is frozen Selector circuit board not connected to power Transformer is burned out Connections to syrup tanks or BIB loose No syrup Syrup tank CO regulator out of adjustment Inoperable dispensing valve Syrup flow regulator out of adjustment Lines restricted to syrup flow regulator No water supply Water pump on safety cutout Faulty carbonator probe Pump is worn out 31 Remedy At syrup tanks remove CO and syrup connections Depress tank gas valve in syrup line to Unit to relieve pressure Shake tank vigorously and depress tank gas valve Repeat as required to remove excess carbonation 4A Clean nozzle 4B Sanitize System Refer to Addendum B Flush Unit water lines and Unit carbonator It may be necessary to disconnect lines to carbonator tank remove invert and flush tank Install water filter or replace cartridge in existing filter Apply electrical power Turn off electrical power and repair Disconnect electrical power cord and allow Unit to thaw Connect circuit board to 24V transformer Check transformer and replace if necessary Check connections to syrup supply Replenish syrup supply Adjust syrup tank CO regulator Repair or replace dispensing valve Adjust water to syrup ratio Refer to installation Section Check lin
54. s C with syrup and water inlet temperature at 90 degrees F 32 2 degrees C Refrigeration Compressor Horsepower with evaporator coil at 20 degrees F 1 8 HP 1120 BTU 0575 Refrigerant R12 5 5 07 Ambient Operating Temperature 40 degrees F 4 4 degrees C to 90 degrees F 32 degrees C Electrical Requirements 115VAC 60HZ 5 6 Amps Inlet Water Requirements Minimum Flow Pressure 1 8 Kg cm2 1 7 BAR Maximum Static Pressure 2 8 Kg cm2 2 8 BAR CAUTION If water source exceeds 40 PSIG 2 81 Kg cm2 a water regulator kit must be used to avoid improper Unit performance or damage Refer to kit list for part number 25 PSIG 40 PSIG NOTE Water pressure must be less than the CO pressure and must be within the maximum and minimum limits CO Requirements Bag in Box Units Maximum Pressure 80 PSIG 5 6 Kg cm2 5 5 BAR Minimum Pressure 70 PSIG 4 9 Kg cm2 4 8 BAR Syrup Tank Units Carbonator Maximum Pressure 80 PSIG 5 6 Kg cm2 5 5 BAR Minimum Pressure 70 PSIG 5 2 Kg cm2 4 8 BAR Syrup Tanks Recommended Pressure Sugar 40 PSIG 2 8 kg cm2 2 8 Bar Diet 6 12 PSIG 0 42 0 85 Kg cm2 0 4 0 83 BAR INSTALLATION KITS The following kits are separately available for the Convertible Post Mix Dispenser Bag in Box Installation Kit P N 0102 USA Provides the necessary parts to connect syrup CO and water to a Unit having internal syrup pumps Bag in Box Installation Kit P N 0104 metri
55. t the water to syrup ratio PLAIN WATER AND STILL DRINKS All Units as shipped will dispense only carbonated drinks Units that are equipped with the plain water kit can dispense plain water and may also be set to dispense from zero to four still non carbonated drinks by use of drink selection switches 1 through 4 as described in the following procedure 1 Remove two cross head screws from the top of the dispense switch module see Figure 5 2 Lift dispense module carefully up and out for access to circuit board NOTE On the rear of the dispense panel circuit board are four plug in selectors labelled with numbers and flavors corresponding to the numbering on the front of the dispense panel Each selector has two positions soda and water as shown in Figure 9 3 convert flavors 1 2 3 or 4 to dispense plain water pull the applicable plug in selector from its circuit board pins and shift it to the left one pin and reinstall it on these pins 0575 LINE PRESSURE GAGE 70 80 PSI COUPLING NUT CORNELIUS INC CYLINDER SHUT OFF VALVE REGULATOR CYLINDER PRESSURE GAGE 1800 PSI PERL 12000 600 51 CHANGE CYLINDER LINE PRESSURE ADJUSTING SCREW LOCK NUT REGULATED CO TO UNIT SYRUP PUMPS AND CARBONATOR CYLINDER d cM FIGURE 7 BAG IN BOX
56. t through a hole in the countertop seal the lines and plug the 4 Apply a silastic sealant eg Dow Corning RTV remaining opening with mastic material such as 731 or equivalent on all base edges Permagum or equivalent 41 0575 ADDENDUM B SANITIZING THE SYSTEM USA IMPORTANT Only trained personnel should perform sanitizing procedures WARNING Wear protective eyewear to avoid injury The syrup systems must be sanitized once every six months whenever there is a flavor change or an flavor is noted in the product This is the ambient sanitizing procedure whereby syrup is first flushed from the system with water then a detergent is introduced followed by a second water flush A sanitizer is next placed in the system and it is finally purged with syrup NOTE Detergent solution must not be introduced into the carbontor SANITIZING THE BAG IN BOX SYRUP SYSTEMS This is a procedure for sanitizing syrup systems of the Convertible Post Mix Dispensers which have syrup pumps P N 0080 0096 and 1275 SANITIZE THE BAG IN BOX SYSTEM AS FOLLOWS 1 Atthe Unit disconnect electrical power 2 Disconnect the syrup line end connectors from the bag in box containers 3 Wash each fitting in warm water to remove syrup accumulation 4 Install a bag valve cut from an empty bag in box container on each syrup line end connector 5 Fill a clean plastic 5 container with potable
57. terials from refrigeration compartment 9 Connect the Unit power plug to a grounded electrical outlet having correct voltage and amperage rating Compressor condenser fan motor and agitator motor will start When a full ice bank is formed compressor and condenser fan motor will stop but agitator motor will continue to run As the ice bank forms excess water will run out through the overflow tube into the drip tray CONVERSION OPTION The Unit is readily configured from the standard narrow front configuration to a shallow depth configuration as shown in Figure 4 If this option is required proceed as follows referring to Figure 5 This option consists simply of interchanging the positions of the logo panel and the dispense switch module no additional parts are required 1 Remove small tower by lifting cover up and off Unit 2 Remove two screws securing top of logo panel to the tower 3 logo panel out of the tower 4 Remove two screws securing top of dispense switch module to the tower CAUTION Use care in handling the dispense switch module and its attaching electrical conductors 5 Carefully separate dispense switch module from its position in the tower 6 Install dispense switch module in the tower opening from which the logo panel was removed 7 Secure top of the switch module with two Screws 8 Install logo panel in the tower opening from which the dispense switch was removed 9
58. the flap on a new box by rapping sharply with palm of hand Do not use a sharp instrument to open 0575 3 Pull the bag connector from the box unscrew and remove the dust cap 4 Dip the red syrup line end connector warm water to clean it 5 While holding the bag connector screw the red syrup line end connector onto the bag connector Turn the end connector clockwise until it is fully seated about 4 1 2 turns NOTE The bag in box container once connected can be placed in any convenient position 20 6 Atthe dispenser draw product until a good flow of syrup is obtained WASH NOZZLE NOTE Do not use detergent as it may cause foaming and give the product an off flavor 1 Remove the nozzle from the Unit by turning it 1 8 turn counterclockwise 21 2 Wash the nozzle in warm water no detergent and dry it 3 Reinstall the nozzle on the Unit with a clockwise turn WASH CUP REST AND DRIP TRAY 1 Lift the cup rest and drip tray from the Unit 2 Empty drip tray 3 Wash both cup rest and drip tray using a mild detergent 4 Dry both items and reinstall on Unit CLEAN UNIT EXTERIOR Clean the Unit exterior using a cloth with mild detergent Rinse with cloth moistened in plain water Do not use harsh abrasives 0575 SERVICE AND MAINTENANCE APPLICABLE CAUTIONS AND NOTES WARNING Wear protective eye wear to a
59. ube over the check valve assembly 18 Using two wrenches connect the inlet water line to the top of the check valve assembly 19 Atthe CO cylinder open the cylinder shut off valve 20 Atthe plain water inlet to the Unit turn on the water 21 Atthe carbonator pull up on the CO relief valve ring to purge air from the carbonator 22 Apply electrical power to the Unit 23 Place a cup under the nozzle then cycle the carbonator by pressing the soda selector 24 Check product for carbonation check connections for water or gas leaks 25 Place large cover on the Unit and secure it with a screw GAS CHECK VALVE ASSEMBLY MAINTENANCE WARNING The gas check valve assembly must be internally inspected and serviced at least once each year under normal conditions WARNING Wear protective eye wear to avoid injury from gas driven particles The check valve located on the top of the carbonator see Figure 15 must be internally inspected at least once a year and any defective parts replaced The ball seat quad ring must be replaced at each servicing Note that the valve body see Figure 15 is welded to the carbonator tank To service the CO gas check valve assembly proceed as follows 1 Disconnect electrical power from the Unit 2 At CO oylinder close the cylinder shut off valve 3 Atthe plain water inlet to the Unit shut off the water 4 Remov
60. up tanks route the CO line through the bulkhead panel and connect the line end connector to the inlet on the carbonator tank check valve using a flare seal washer 7 In Units with syrup tanks connect secondary regulator pressure lines to each syrup tank WARNING Displaces Oxygen N Strict Attention must be observed in the prevention of carbon dioxide gas leaks in the entire CO and soft drink system If a 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 CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation CONNECT SYRUP LINES Connect syrup lines within the Unit as follows IMPORTANT All syrup systems must be sanitized before Unit is put into operation 1 Sanitize all syrup systems after connecting syrup lines following instructions below Refer to Addendum B for sanitizing procedure NOTE Refer to Figure 9 for location and identification of the dispense switches NOTE Coca Cola should always be in position No 1 on the switch panel as this position has a longer cooling coil than the other three positions 2 Route one syrup line for each product up through the hole in the countertop 3 Refer to the decal on inside of the large top cover for location of product decals and identification o
61. ustable The Unit is configured for use with either bag in box BIB syrup containers or for use with pressurized syrup tanks Units configured for use with bag in box syrup containers have internal syrup pumps and require one applied CO pressure Units using pressurized syrup tanks do not have internal syrup pumps and require two separate applied pressures Legs and hardware are provided for those Units to be installed outside of the USA Table 1 Design Data Identification Part No Volts HZ Pumps 0080 115 60 Yes 0088 115 60 No 1275 115 60 Yes 1276 115 60 No NOTE U S A only FIGURE 1 CONVERTIBLE POST MIX DISPENSER Coca Cola and Coke are registered trademarks of the coca Cola Company Physical Characteristics and Requirements Overall dimensions Width 12 1 2 in 81 75 cm Height 17 7 8 in 45 4 cm Depth 23 4 4 In 59 cm weights Shipping one carton 77 lb 35 Kg Dry Weight approx 72 lb 32 5 Kg Bank Weight approx 8 Ib 3 6 Kg Refrigeration Assembly 36 Ib 16 3 Kg Water Tank Capacity without ice 4 6 gallons 17 bank liters Countertop Dispensing Capacity 75 degree ambient 23 9 degrees C fifty 12 oz drinks dispensed at or below 40 degrees F 4 4 degrees C with syrup and water inlet temperatures at 75 degrees F 23 9 degrees C 90 degree ambient 32 2 degrees C twenty five 12 02 drinks dispensed at or below 40 degrees F 4 4 degree
62. usting Screw 0538 Solenoid Valve Assembly Syrup 9 1318 Flow Control top Syrup 1 1320 Block Valve 10 180025 O Ring 364 I D by 070 C S 1319 Bod CAN 14 1545 Retainer Housing 12 1081 Thread Cutting Screw SL Hex Hd 0837 22 Phil Pan Stainless Steel No 8 18 by 1 2 long 13 0024 Solenoid 24V du Piston Syrup Syrup 14 187188 Screw Phil Pan Hd No 8 32 by 1 4 310754 011 Piston Water long 5 317431 Cylinder Flow Control Syrup 15 317579 Arm Solenoid 317431 011 Cylinder Flow Control Water 16 0854 Spring Conical 310482 Spring 17 311355 Valve Inlet 317816 O Ring 676 1 0 by 070 C S 1 2 8 4 5 6 7 2 8 4 5 6 8 ITEM PART NO NO DESCRIPTION 774005 020 Dual Check Ass y 1 774014 Body JODO z 3 774003 Sleeve 4 302 Ball 312 Dia 5 990139 355 Spring 6 011 O Ring FIGURE 23 DUAL CHECK VALVE ASSEMBLY 7 774002 Body 8 774013 Retainer 37 0575 DESCRIPTION NO NO 0521 Carb Tank Assembly 1 0035 Carb Tank 2 312926 Clamp For 500 O D Tube 3 1559 Tube 265 I D by 2 long 4 1305 Probe Level Control 5 180024 O Ring 424 1 0 by 103 C S 6 1658 Wire Harness Liquid Level 7 1116 Stem Assembly 8 0522 Insulation Carb 9 343457 Hex Nut Stainless Steel 8 32 10 398031 001 Washer Stainless Steel No 8 11 183309 Adapter 12 183294 Quad Ring 145 1 0 by 070 5 13 1
63. void injury from gas driven particles CAUTION Before shipping storing N 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 Refer to Addendum B for sanitizing instructions US CAUTION In cold weather Unit must be protected from freezing Water freezing in the system will expand causing damage to internal components NOTE The water pump is equipped with a timer which will allow it to run continuously a maximum of five minutes after which the motor will stop The timer can be reset by momentarily removing electrical power to the Unit NOTE If a gurgle is heard from the Unit it indicates a low water level in the water tank To add water proceed as follows 1 Disconnect electrical power from the Unit 2 Remove screw in top of large cover and remove 3 Add water as described in Section Il under the heading Filling Tank and Starting Refrigeration System 4 Replace large cover and screw 5 Apply electrical power to the Unit MAINTENANCE SCHEDULE The following maintenance schedule lists items to be performed by either an operator or a qualified maintenance technician in order to keep the system in
64. y at the dispensing nozzle to produce a carbonated drink flowing from the nozzle Units with a plain water kit can also dispense only plain water Units may also be configured to dispensed up to four still non carbonated drinks Units with Syrup Tanks see Figure 3 Regulated provides pressurization for the syrup tanks and gas to the carbonator within the Unit Plain water pumped under pressure by the carbonator pump into the carbonator tank absorbs the gas and is thereby carbonated When a drink dispense switch or soda carbonated water only switch is pressed the carbonated water solenoid valve is opened and pressure within the carbonator drives carbonated water from the carbonator through carbonated water cooling coils in the water tank then through a carbonated water flow control to the dispensing nozzle When a drink dispense switch is pressed pressure exerted on the syrup tank contents drives syrup from the syrup tank through an individual syrup cooling coil in the water tank then through an adjustable syrup flow control to the dispensing nozzle Syrup and carbonated water meet simultaneously at the dispensing nozzle to create a carbonated drink flowing from the nozzle Units equipped with a plain water kit can also dispense plain water Units also may be converted to dispense up to four still non carbonated drink types 0575 USED ON UNITS 1275 AND 1276 DUAL CHECK VALVE
65. yrup 1671 Coil Assembly Syrup without Pumps 770104 Nipple for 395 O D Tube Plain Wa Valves 2 3 amp 4 ter 1672 Coil Assembly Syrup with Pumps 4 176017 Swivel Nut 7 16 20 Plain Water Valves 2 3 amp 4 5 770401 Fitting Elbow Plain Water 0014 Coil Assembly Plain Water 6 180025 O Ring 364 1 0 Syrup with Pumps FIGURE 29 COIL ASSEMBLY 39 0575 3 N ITEM PART ITEM PART NO NO DESCRIPTION NO NO DESCRIPTION 0879 Control Box Ass y 4 0068 Service Cord 0072 Control Bok 5 1487 Wire Harness 2 0706 Retainer Board 222 187254 Screw Phil Truss Hd 6 3 8 3 186564 Strain Relief Long FIGURE 30 CONTROL BOX ASSEMBLY 0575 40 ADDENDUM A SEALING UNIT BASE TO COUNTERTOP USA To comply with the requirements of the NSF NOTE When Unit is lowered into place do not International NSF the base of a Unit must be move it or seal will be broken sealed to the countertop and all access holes to the inside of the Unit must be closed off with a mastic 5 Lower Unit into exact operating position on the material To seal a Unit to the countertop proceed as countertop follows 6 Apply additional sealant around the Unit so that h lant h ini i f 1 2 Inch 3 Carefully tilt the connected Unit up to expose Te Sea an RAS S Ol IG the base 7 If lines are connected to the Uni

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