International Carbonic Lil Fella - Soda
Contents
1. FIGURE 5 2 CHECK VALVES 5 5 sas RING CHECK VALVE sao serme ceckvarve 3 so easken check vatve i s forsere _1 sae ADAPTOR HousiNG DOUBLE CHECK VALVE i sas jousmecueckvavesm Me s 2 1 5 1 8 14 13 12 11 10 5 9 i 1 qvem n FIGURE 5 3 EXPLODED VIEW CHECK VALVES 5 6 REPLENISHING 02 SUPPLY 1 Close empty C02 cylinder shutoff valve 2 Disconnect high pressure C02 regulator then remove empty C02 cylinder 3 Install full C02 cylinder and connect high pressure C02 regulator See installation procedure in CHAPTER MAKE SURE C02 CYLINDER IS POSITIONED IN UPRIGHT POSITION AND FASTENED WITH SAFETY CHAIN ALWAYS OPEN C02 VALVE COMPLETELY OR UNTIL BACK SEATED DURING OPERATION WHEN BOTTLE IS EMPTY ALWAYS CLOSE VALVE ASSEMBLY COMPLETELY REPLENISHING SYRUP SUPPLY 1 Remove Q C D s from empty or syrup amp C02 quick disconnects from empty syrup tank 2 Install full syrup container in position rinse Q C D s or quick disconnects in warm water then connect Q C D s or syrup amp C02 quick disconnects to tank 3 Activate valve until syrup flows from valve normally See CHAPTER SYRUP FLAVOR CHANGE 1 Remove Q C D s from applicable or syrup quick disconnects from applicable syrup tank 2 Sanitize applicable syrup system in accordance with instructions S2. 1 8 LF 12 SYM QTY PART NO DESCRIPTION 1 1 50770 LID W INSULATION 2 2 50751 SERVICE PANEL SIDE 2 2 S0751 A SERVICE PANEL AWNING SIDE 3 1 50750 SERVICE PANEL REAR 3A 1 S0750 A SERVICE PANEL AWNING REAR 4 7 A0051 A RIVETS BLACK 5 1 S0513 A BANK CONTROL 6 3 A0020 8 32 X 3 8 T H SCREWS S S 7 1 S1304 U BANK CONTROL BRACKET 8 1 S0739 STAND 6 1 2 WHITE 9 1 S0738 OVERFLOW 6 3 4 GRAY 10 1 S0835 AGITATOR PUMP 11 1 S0073 48 ASSEMBLY 12 2 S0741 EVAPORATOR COIL RETAINER 18 1 S0733 EVAPORATOR COIL ASSEMBLY 14 1 S0509 ACCUMULATOR 4 VERTICAL 15 1 Z0009 CAP TUBE 12 042 16 6 S0588 A SYRUP COIL 17 1 SO262 LF CARBONATOR TANK ASSEMBLY 18 3 H0020 T CLIP 3 8 X 5 16 19 1 S0684 WATER COIL COPPER 20 1 S0208 A WATER REGULATOR OPTIONAL 21 1 E0476 A TRANSFORMER 22 1 51308 TERMINAL BOX WITH COVER 23 1 50068 LIQUID LEVEL CONTROL LLC 24 1 S1310 TERMINAL BOX COVER 25 4 51335 TERMINAL BOARD SPACER NYLON 3 8 26 7 S0046 BUSHING 27 1 E0664 STRAIN RELIEF 28 te i ees MOISTURE BARRIER 12 29 T ues INSULATION LEFT 1 INSULATION REAR FIGURE 1 2 LF 12 Cont 31 INSULATION FRONT 1 392 INSULATION RIGHT SIDE INSULATION BOTTOM 34 1 MOISTURE BARRIER 23 35 1 50667 WATER LINE COPPER 36 1 0203 UNION CONNECTOR
3. 1 PREFACE INTERNATIONAL CARBONIC INC has enjoyed over 53 years of manufacturing excellence in the field of carbonation and in the beverage related industry We have had a long and proud history with quality as our standard and innovation as our goal Originally started just after World War in Canfield Ohio as Carbonic Dispensers We enjoyed patents on the first Sodajet type carbonator This method of carbonation instantaneously carbonated the water to 10096 saturation We developed the first patented dispensing valve to dispense bulk beverage with carbonation equal to or in excess of bottled beverages A valve with three flavors and soda was another first We were the first to incorporate the total postmix package i e carbonation refrigeration and the ability to dispense from one self contained unit We have pioneered many such firsts and will continue to develop advanced systems for the future such as electronic interrogatable portion controls to electronic liquid level controls We hope you enjoy this piece of equipment that has been produced to give many years of trouble free service We thank you for your purchase and hope we may serve you the future 1 CHAPTER GENERAL DESCRIPTION This chapter gives the description theory of operation and design data for the LIL FELLA 12 or LIL FELLA 23 and related components The LIL FELLA 12 or LIL FELLA 23 utilizes one cabinet but can be manufactured in many c
4. O ring on screen retainer Replace worn or damaged O ring Z A gt e S 650A S IS NOS FIGURE 5 1 WATER PUMP Y STRAINER amp SCREEN CARBONATOR MAINTENANCE 1 Unplug refrigeration unit power cord from electrical socket 2 Remove lid from unit 3 Look down into water bath if necessary use flashlight and inspect carbonator tank for leak Air bubbles will arise from place of leak if leak is below surface of water If leak is above surface of water soap bubbles should be used to find any leak 4 Shut off plain water supply to water pump by closing shutoff valve in water supply line 5 Shut off C02 supply to refrigerating unit by closing shutoff valve on C02 cylinder 6 Pull up on carbonator tank relief to relieve C02 pressure from tank 7 Eliminate leak tighten bad connections or replace defective Probe assembly water double check valve S 20 gas single check valve S 22 or valve relief S 215 8 Service check valves as outlined in SERVICING CHECK VALVES 9 Reassemble as necessary 10 Replace lid 11 Plug refrigeration unit power cord in electrical socket 12 Turn on plain water supply to water pump by opening shutoff valves in water supply line 13 Turn on C02 supply to refrigerating unit by opening shutoff valve on C02 cylinder 14 Activate all systems as outlines in CHAPTER III LUBRICATION Water pump motors bearing must be oiled periodically Refer to oiling instruction on moto
5. OR SYRUP LEAKING FROM NOZZLE AFTER ACTUATION NO WATER NO SYRUP BEING DISPENSED FROM VALVE NO SYRUP BEING DISPENSED NO WATER BEING DISPENSED DISPENSED PRODUCT CARBONATED TO LOW DISPENSED PRODUCT MAKES FOAM AS IT LEAVES NOZZLE DISPENSED PRODUCT COMES OUT CLEAR BUT FOAMS WHEN IT TOUCHES CUP OR GLASS WATER TO SYRUP RATIO TOO LOW OR TOO HIGH ADJUSTMENT OF SYRUP METERING PIN DOES NOT PRODUCE DESIRED WATER TO SYRUP RATIO CARBONATION TROUBLESHOOTING FLOW CHART 1 CARBONATION TROUBLESHOOTING FLOW CHART 2 CARBONATION TROUBLESHOOTING FLOW CHART 3 NOTE SECTION LIST OF FIGURES Figure Title 1 1 EXPLODED VIEW OF LIL FELLA 12 1 2 ILLUSTRATED PARTS BREAKDOWN OF LIL FELLA 12 1 2 ILLUSTRATED PARTS BREAKDOWN OF LIL FELLA 12 Cont 1 3 EXPLODED VIEW OF LIL FELLA 23 1 4 ILLUSTRATED PARTS BREAKDOWN OF LIL FELLA 23 PAGE d N SN SN DPPP AAAIAAAAG umb Zc CE la TABLE OF CONTENTS CONT D Figure Title 1 4 ILLUSTRATED PARTS BREAKDOWN OF LIL FELLA 23 Cont 1 5 ELECTRICAL SCHEMATIC 110V 1 6 ELECTRICAL SCHEMATIC 24V 2 1 SAMPLE OF A POSSIBLE INSTALLATION 2 2 HIGH PRESSURE CO2 REGULATOR 5 101 2 3 LOW PRESSURE CO2 REGULATOR S 121 2 4 SUGGESTED WATER FLOW INSTALLATION 5 WATER PUMP Y STRAINER amp SCREEN 5 2 CHECK VALVES 5 3 COMPOSITE EXPLODED VIEW OF CHECK VALVES AND RELIEF VALVE LIST OF TABLE 1 1 2 1 DESIGN DATA LOOSE SHIPPED PARTS N
6. quick disconnects Adjust low pressure CO2 regulator as instructed Connect disconnect securely Clear restriction or replace restricted line Disassemble and clean syrup flow control Adjust water to syrup ratio see Brix instruction 6 5 CARBONATION TROUBLE SHOOTING FLOW CHART 1 MOTOR PUMP NOT OPERATIONAL Valves dispensing gas amp syrup only Electrode Disconnect Check ground electrical connection at Remove spades from board and box terminal Motor 1 on LLC amp install on any open A terminal Check electrode Remove spade from wires to ensure long amp short elect connection at LLC 1 they not Re connect reversed electrical Re connect electrical Motor Pump should engage Motor pump Comes on Motor Pump does not come on Re install motor Possible bad motor spade to terminal Pump replace Motor 1 Go to electrode Bad LLC replace Return motor spade to terminal Motor 1 CARBONATION TROUBLE SHOOTING FLOW CHART 2 MOTOR PUMP DOES NOT COME ON Non carbonated water amp syrup being dispensed only Check CO2 supply Check water pressure Water pressure greater than or close CO2 pressure will C02 cylinder is empty stop the process Change C02 cylinder Install or adjust water regulator Y Hi pressure regulator is set to low or malfuncti
7. water flow to 6 ounces in 5 seconds Remove nozzle twist and pull down then insert syrup separator through nozzle be it S type or plastic tube and on 1 2 plastic syrup outlet located inside hidden nozzle area Then press nozzle back in position Actuate valve until syrup separator is full of syrup Hold brix cup close enough to valve outlet to form 5 on the flexible plastic tube so as to prevent any water following the flexible tube into syrup section This formed 5 will also hold syrup in tube for a more reliable brix reading Actuate valve allowing the soda water to flow into large section of cup and syrup into smaller section Adjust the syrup metering pin flow control as necessary to secure a proper brix When proper brix syrup adjustments have been made the two sections of the cup should fill to the desired ration Ts 5 9 Brix Instructions Continued BRIXING VALVE The water and syrup flows are individually adjusted by their respective metering pin or flow controls Located under the valve cover on the top rear of the valve see illustration One recommended method utilizes the ratio brix cup The brix cup is divided into two sections one to hold up to 9 parts water and the smaller section to hold one or two parts of syrup When adjusting a flavor with a ratio of more than 9 to 1 syrup 2 line must be used When using syrup 2 line the waterside is doubled to 18 to 1 vs 9 to 1 When facing the val
8. 0 SWITCH LOCK W KEYS 42 1 50779 6 VALVE PLATE 43 20 A0048 SCREW 10 X 1 2 TH SS 44 5 DISPENSING VALVES 45 1 1150 A CUP REST 46 1 0743 DRAIN PAN HARDWARE SET 47 1 1150 DRAIN PAN W CUP REST 48 1 91161 PLASTIC DRAIN OUTLET 90 DEGREE 49 1 51162 FLANGE PLUG 50 1 0175 90 DEGREE ELBOW 3 8 MP X 1 4 MF 51 1 0103 PUMP PROTECTOR 52 1 90104 PUMP PROTECTOR BRACKET 53 2 A0045 5 16 X 18 FLANGE WHIZ LOCK SCREW 1 2 54 1 0170 HALF UNION BRASS 3 8 MF X 3 8 MP 55 1 50650 STRAINER BRASS 56 1 0200 PUMP CARBONATOR 57 1 90106 CLAMP BAND 58 1 90096 59 16 51325 SQUARE GROMMET NUT 60 1 E0141 12 CORD 61 3 A0046 5 16 X 18 FLANGE WHIZ LOCK SCREW 3 4 62 1 AEA1360YXAXA CONDENSING UNIT 1 5 63 1 AEA1360YXA COMPRESSOR ONLY FIGURE 1 4 Cont 1 8 S 68 B ELECTRICAL SCHEMATIC 120 VOLT or MOTOR ICE BANK CONTROL COMPRESSOR TRANSFORMER INTERNATIONAL CARBONIC INC WHITE 120VAC BLACK G2 G3 G4 D ON OFF Ais f B3 B4 B5 MOTOR2 WHITE CONDENSING BLACK UNIT AGITATOR PUMP SHORT LONG HITE BLACK ELECTRODE GROUND TERMINAL SCREW IN CARB CONTROL BOX MOTOR PUMP Note Ground Terminals Carbonator Tank i and Water Bath Must be Commonly Grounded NOTE IF USING EXTRA 120V ACCESSORIES SUCH AS RECIRCULATING MOTOR ILLUMINATION ETC MAKE CONNECTIONS AT TERMINAL A4 A5 FO
9. 37 1 50731 BUCKET COMPLETE W INSULATION 98 3 A0046 5 16 X 18 FLANGE WHIZ LOCK SCREW 3 4 39 1 AEA1360YXAXA CONDENSING UNIT 1 5 H P 40 1 AEA1360YXA COMPRESSOR ONLY 41 1 50732 FRAME COMPLETE 4211 50783 UNIT ON OFF SWITCH 43 1 50768 SWITCH LOCK W KEYS 44 1 50769 5 VALVE PLATE 45 11 A0014 SCREW 10 X 1 2 TH SS 46 5 PFC II QR DISPENSING VALVES 47 20 A0048 SCREW 10 X 1 2 TH SS 48 16 1325 SQUARE GROMMET NUT 49 1 90765 LEGS 4 SET OF 4 50 1 51149 CUP REST 51 1 1149 DRAIN PAN W CUP REST 5211 50743 DRAIN PAN HARDWARE SET 53 1 51161 PLASTIC DRAIN OUTLET 90 DEGREE 54 1 51162 FLANGE PLUG 55 1 0141 12 CORD 56 1 0175 90 DEGREE ELBOW 3 8 MP X 1 4 MF 57 1 0103 PUMP PROTECTOR 58 1 50170 HALF UNION BRASS 3 8 MF X 3 8 MP 59 1 50104 PUMP PROTECTOR BRACKET 6011 50650 STRAINER BRASS 61 2 A0045 5 16 X 18 FLANGE WHIZ LOCK SCREW 1 2 62 1 50200 PUMP CARBONATOR 63 1 50106 CLAMP V BAND 64 1 50096 MOTOR CARBONATOR FIGURE 1 2 Cont 1 5 INTERNATIONAL CARBONIC INC LF 23 LIL FELLA 23 POST MIX ADELANTO CALIFORNIA FIGURE 1 3 6 LF 2 SYM QTY PART NO DESCRIPTION 1 1 0780 LID W INSULATION 2 2 0750 SERVICE PANEL SIDE 2A 2 50750 SERVICE PANEL AWNING SIDE 3 1 0751 SERVICE PANEL REAR 3A 1 50751 SERVICE PANEL AWNING REA
10. F POSSIBLE INSTALLATION INSTALLATION INSTALL COOLING UNIT 1 Make all connections C02 gas plain water and syrups Place LIL FELLA in position Make sure sufficient space between bulkheads walls and overheads is available for proper air circulation around cooling unit 2 2 INSTALL HIGH PRESSURE C02 REGULATOR C02 CYLINDER AND LINES FOR CARBONATED UNITS ONLY 1 Install high pressure C02 regulator 5 101 on C02 cylinder using a new seal gasket MAKE SURE NEW WASHER IS INSIDE REGULATOR ASSEMBLIES COUPLING NUT BEFORE CONNECTING TO CYLINDER WARNING To avoid personal injury and or property damage always secure C02 cylinder with safety chain to prevent cylinder from falling It is recommended that the C02 cylinder be installed away from heavily traveled areas such as doors passageways corridors etc 2 Connect 1 4 inner braided plastic tubing from outlet of high pressure C02 regulator 5 101 on C02 cylinder to Tee connection at low pressure regulator S 221 using prefabricated gas charging line S 105 3 A line must be fabricated at this time Cut inner braid tubing to size and install nipple 95 145 and nut S 150 to each end of tubing making sure either oetiker or ferrule is previously installed on line Secure these connections by use of proper tool Connect 14 inner braid plastic tubing from outlet of tee at low pressure regulator S 221 optional furnished with unit to supplied line from unit mar
11. LIL FELLA INSTALLATION AND SERVICE MANUAL LF 12 INTERNATIONAL CARBONIC INC 16630 Koala Rd Adelanto CA 92301 800 854 1177 IMPORTANT This manual is a guide for installing operating servicing and maintaining this equipment Refer to Table of Contents for page location of detailed information to answer questions that arise during installation operating service and maintenance or installation of this equipment TABLE OF CONTENTS PREFACE CHAPTER GENERAL DESCRIPTION SYSTEM DESCRIPTION THEORY OF OPERATION CHAPTER INSTALLATION UNPACKING AND INSPECTION SELECTING LOCATION LOCATION RECOMMENDATIONS FOR LIL FELLA INSTALLATION INSTALL COOLING UNIT INSTALL HIGH PRESSURE CO2 REGULATOR CO2 CYLINDER AND LINES INSTALL LOW PRESSURE REGULATOR AND LINES INSTALL WATER FILTER ASSEMBLY OPTIONAL INSTALL WATER PRESSURE REGULATOR OPTIONAL INSTALL WATER HOLDING TANK OPTIONAL INSTALL DRAIN LINE INSTALL OR SYRUP TANKS AND ACCESSORIES CONNECTING WATER INLET ELECTRICAL REQUIREMENTS CHAPTER PREPARATION PREPARING SYSTEM FOR OPERATION PREPARING AND STARTING REFRIGERATION UNIT PURGE DISPENSING VALVES ACTIVATE HIGH PRESSURE CO2 SYSTEM ACTIVATE LOW PRESSURE CO2 GAS AND SYRUP SYSTEMS ADJUST WATER FLOW RATE ADJUST WATER TO SYRUP RATIO ADJUST SIZE OF DRINK DISPENSED CHAPTER IV OPERATORS INSTRUCTIONS DAILY PRE OPERATION CHECK REPLENISHING CO2 SU
12. PPLY REPLENISHING SYRUP SUPPLY COOLING UNIT MAINTENANCE CHECKING WATER BATH CHANGING WATER BATH ADJUSTMENTS ADJUSTING WATER FLOW RATE ADJUSTING WATER TO SYRUP RATIO OF DISPENSED PRODUCT ADJUSTING SIZE OF DRINK DISPENSED TESTING FOR LEAKS CHAPTER SERVICE AND MAINTENANCE PERIODIC INSPECTION AND CLEANING LIL FELLA CABINET MAINTENANCE CLEANING CONDENSER COIL CHECKING CHANGING WATER BATH WATER PUMP MAINTENANCE CARBONATOR MAINTENANCE LUBRICATION SERVICING CHECK VALVES REPLENISHING CO2 SUPPLY G G CO GQ GO Q1 QI Q1 Q1 QI QI CTI ON N N TABLE OF CONTENTS cont d SYRUP FLAVOR CHANGE CHANGING WATER FILTER CARTRIDGE OPTIONAL ADJUSTMENTS HIGH PRESSURE 2 REGULATOR LOW PRESSURE 2 REGULATOR DIET SYRUP TANK CO2 REGULATOR BRIX INSTRUCTION CLEANING AND SANITIZING CHAPTER VI TROULBESHOOTING COOLING UNIT WATER PUMP MOTOR WILL NOT OPERATE WATER PUMP MOTOR WILL NOT SHUT OFF WATER PUMP WILL NOT SHUT OFF AND PRESSURE RELIEF ENGAGED SHORT CYCLING OF WATER PUMP MOTOR WATER PUMP CAPACITY TOO LOW WATER PUMP OPERATES BUT WATER PUMP DOES NOT PUMP FROZEN WATER BATH COOLING OR CONDENSING UNIT NOT OPERATIONAL AGITATOR MOTOR NOT OPERATING COMPRESSOR DOES NOT OPERATE COMPRESSOR WORKS CONTINUOUSLY BUT DOES NOT FORM SUFFICIENT ICE BANK COMPRESSOR WILL NOT STOP AFTER SUFFICIENT ICE BANK IS PRODUCED CONDENSER FAN MOTOR NOT OPERATING DISPENSING VALVES WATER
13. R 4 7 A0051 A RIVETS BLACK 5 6 50588 SYRUP COIL 6 1 0262 LF CARBONATOR TANK ASSEMBLY 7 1 0073 48 PROBE ASSEMBLY 8 1 0835 AGITATOR PUMP 9 1 0513 A ICE BANK CONTROL 10 1 1304 U ICE BANK CONTROL BRACKET 11 3 A0020 8 32 X 3 8 T H SCREWS S S 12 1 0203 UNION CONNECTOR 13 1 50667 WATER LINE COPPER 14 1 50684 WATER COIL COPPER 1 50208 WATER REGULATOR NOT SHOWN OPTIONAL 15 2 0741 EVAPORATOR COIL RETAINER 16 3 H0020 T CLIP 3 8 X 5 16 17 1 0733 EVAPORATOR COIL ASSEMBLY 18 1 0509 ACCUMULATOR 4 VERTICAL 19 1 Z0009 CAP TUBE 12 042 20 MOISTURE BARRIER 12 21 Test Exe INSULATION LEFT 22 xiu INSULATION REAR 23 d INSULATION FRONT 24 1 ees INSULATION RIGHT SIDE 25 INSULATION BOTTOM 26 MOISTURE BARRIER 23 27 1 0739 STAND PIPE 6 1 2 WHITE 28 1 0738 OVERFLOW 6 3 4 GRAY 29 1 0731 BUCKET COMPLETE W INSULATION 30 1 0732 FRAME COMPLETE FIGURE 1 4 LF 23 Cont SYM QTY PART NO DESCRIPTION 31 1 E0476 A TRANSFORMER 55 VA 32 1 1308 TERMINAL BOX WITH COVER 33 1 50068 LIQUID LEVEL CONTROL LLC 34 1 1310 TERMINAL BOX COVER 35 4 5 1335 TERMINAL BOARD SPACER NYLON 3 8 36 7 0046 BUSHING 37 1 E0664 STRAIN RELIEF 38 11 A0014 SCREW 10 X 1 2 SS 39 1 90765 LEGS 4 SET OF 4 40 1 0783 UNIT ON OFF SWITCH 41 1 133
14. R POWER BLACK LEG TERMINALS B4 B5 FOR NEUTRAL WHITE LEG AND GROUND AT BOX OR ANY GROUND TERMINAL NOT IN USE TERMINALSGROUND TERMINALS ARE G2 G3 G4 FIGURE 1 5 1 9 VALVE SCHEMATIC 24 VOLT 24 VOLT SINGLE 24 VOLT VALVES KEY SWITCH Ue VB 77 24 VOLT TRANSFORMER ELECTRICAL SCHEMATIC 24 VOLT FIGURE 1 6 1 10 THEORY OF OPERATION The LIL FELLA was designed to manufacture and dispense carbonated or non carbonated beverages much like your local bottling plant that cans or bottles your favorite carbonated or non carbonated drink Initially water is chilled and then carbonated to dispense a quality drink To chill the water the water is routed through a water coil that is submerged in an ice cold water bath The temperature of the incoming water is at ambient temperature as it enters the water coil As the incoming water passes through the water coil the heat is removed from the water in the water coil and chilled to a temperature acceptable for a quality drink In both cases carbonated or juice drinks this procedure is performed If the LIL FELLA is a carbonated unit the water is now routed into a carbonator tank where this cold water is mixed with CO2 This water is now transformed into a carbonic acid soda water and then routed to a valve where it will be mixed with a syrup concentrate and dispensed In the case of the juice or non carbonated dri
15. SIZED INSTALLED AND MAINTAINED ACCORDING TO FEDERAL STATE AND LOCAL LAWS The water connection on the LIL FELLA is made to a flexible water line by means of a 3 8 male flare Due to the large capacity of the pump any restriction of the incoming fresh water supply would starve the water pump and create noise within the pump poor carbonation and extremely long running time After all primary water lines are made up but prior to connecting water supply to cabinet be sure to thoroughly flush all incoming water lines to remove all scale and any impurities that may be in the lines It is important to remember that the LIL FELLA has a carbonator capacity of a minimum of 100 gallons per hour Therefore it is imperative that the fresh water conduit has not less than 3 8 1 0 passageway for any distance greater than ten feet from the LIL FELLA It can be reduced to 3 8 O D copper tubing and connected to the water inlet connection with in ten feet of the LIL FELLA water inlet connections are clearly tagged ELECTRICAL REQUIREMENTS The LIL FELLA requires a 120 VAC single phase 60 Hertz power circuit and must be wired in accordance with N E C or local ordinance NOTE Check CHAPTER for running amperage and connect to appropriate electrical circuit 2 5 CHAPTER III PREPARATION All steps in previous chapters should be understood and carried out before proceeding PREPARING SYSTEM FOR OPERATION Be sure that electrical power is u
16. URE TO CARBONATION SYSTEM SHOULD NOT EXCEED 75 PSI LOW PRESSURE C02 REGULATOR The low pressure C02 regulator setting can and will vary dramatically from one installation to the next Variables such as distance from syrup containers to point of serving horizontal or vertical runs baume of product to whether or transfer tanks are used will influence where the low pressure regulator is adjusted A good starting point as an adjustment is 40 psi for B I B and 30 psi for transfer tanks NOTE After primary adjustment on low pressure regulator always go to farthest serving station from syrup storage area and adjust heaviest baume syrup normally ORANGE If adjustment can be made proceed with all other flavors DIET SYRUP TANK C02 REGULATOR S 121 The diet C02 regulator is normally used only on transfer tank installations and should be set from 6 to 10 psi depending on length of run In some cases where a vertical run is encountered pressure may be set as high as 15 psi Excessive C02 pressure may cause diet syrup to carbonate resulting in foam 5 8 BRIX INSTRUCTIONS 1 Make sure carbonator water flow is in an operating condition i e high pressure regulators set water and power on and refrigeration in a ready to go mode In the case of juice systems make sure water flow is un restricted It is also recommended that a water pressure regulator be utilized on all systems Water bath systems must have an ice bank formed Adjust
17. ater flow rate should be necessary adjust as instructed ADJUSTING WATER TO SYRUP RATIO BRIX OF DISPENSED PRODUCT Water To Syrup BRIX of dispensed product should be checked and if necessary adjust as instructed ADJUSTING SIZE OF DRINK DISPENSED FOR PORTION VALVES PCT ONLY Drink size of dispensed product should be checked and if necessary adjust as instructed TESTING FOR LEAKS 1 Completely back off adjusting screw on low pressure C02 regulator 2 Close valve on top C02 cylinder 3 Wait for 5 minutes or more If pressure on high pressure gauge decreases excessively there is leak in the carbonator circuit 4 2 4 All connections including cylinder valve should be coated with a soap solution bubbles appear a leak is apparent S Always be sure that the low pressure adjusting screw is completely backed off before testing carbonator circuit for leaks Otherwise gas going into syrup tanks would cause this high pressure gauge needle to balance with pressure in syrup tanks which would be a false indication of a leak in the carbonator circuit 6 After it has been determined that there are no leaks in the carbonator circuit open C02 cylinder valve and adjust low pressure regulator to 15 psi Allow enough time for the syrup tanks to fill completely with gas b minutes or longer 7 Next completely back off low pressure regulator adjusting screw and if gauge needle of low pressure regulator comme
18. atio on all beverages adjust ratio if necessary 4 Check condenser coil for obstructions or dirt Monthly 1 Clean condenser fins or filter to make sure the refrigeration unit has adequate air flow 2 Inspect components of cooling unit water bath for cleanliness 3 Check entire system for leaks or damaged components Repair as necessary 5 1 LIL FELLA CABINET MAINTENANCE PERIODIC CLEANING Periodically wash all external surfaces of LIL FELLA cabinet rinse with clean water and then wipe dry with a clean soft cloth DO NOT USE ABRASIVE TYPE CLEANERS CLEANING CONDENSER COIL IMPORTANT Air circulation through the condenser coil is required to cool the compressor Air is drawn in through grills on the top of the cooling unit through condenser coil and exhausted out grills on the top of unit Restricting air circulation through the cooling unit will decrease its cooling capacity NOTE Cleaning condenser coil should be done during non use periods 1 Unplug refrigeration unit power cord from electrical socket 2 Remove lid of unit 3 Vacuum or use a soft brush to clean fins of condenser coil Use low pressure compressed air or C02 gas to blow through condenser fins This should only be performed after normal business hours to prevent dust contamination A damp cloth on backside of condenser coil will prevent some dust contamination 4 Replace lid S Plug LIL FELLA power cord in electrical socket CHECKING CHANGING WATER BATH Period
19. ched 6 Lubricate and attach correctly 7 Loose electrical connection of 7 Tighten connection and or repair syrup solenoid and or open open circuit Check proper electrical connection voltage 8 Frozen water bath 8 See Frozen Water Bath No water being 1 Plain water inlet supply shutoff 1 Open plain water inlet supply line dispensed closed shut off valve 2 Water filter fouled clogged 2 Replace filter or cartridge 3 Pinched or crimped line 3 Repair defective line 4 Loose electrical connection 24 4 Tighten connection and or repair volt open circuit 5 Water pump motor worn out or 5 Replace motor damaged 6 Water pump worn out or 6 Replace water pump damaged 7 Frozen water bath 7 See Frozen water bath Volumes of 1 High pressure regulator out of 1 Adjust high pressure regulator as to low in adjustment instructed finished product 2 CO2 cylinder empty 2 Replace cylinder 3 Water oil or dirt in 602 supply 3 Clean contaminated CO2 system lines regulator etc and sanitize as instructed 4 Temperature above quality limits 4 See refrigeration machine specifications vs volume requirements Dispensed 1 Pressure of CO2 to high 1 Adjust high pressure regulator as product makes instructed foam as it 2 Syrup over carbonated with CO2 2 Remove syrup tank quick leaves disconnects Relieve pressure dispensing shak
20. continuous recirculating manner This action causes a breakdown of the surface tension of the water forming numerous minute gases filled water bubbles The micro thin walls of these water bubbles surrounded by gas both inside and out offer maximum water surface for the absorption of the gas The size opening through this jet permits large volumes of water to be carbonated As the incoming water is being carbonated the level within the tank rises to contact the upper probe tip which will de energize a relay on the liquid level control and stop the motor from turning the pump This motor will be inactive until water within the tank recedes below the long probe tip at which time the relay on the liquid level control will close engaging the motor once again 1 12 CHAPTER II INSTALLATION This chapter covers unpacking and inspection selecting location installing LIL FELLA and related components connecting water inlet and electrical requirements UNPACKING AND INSPECTION Upon receiving unit immediately remove unit from shipping carton and inspect for shipping damage NOTE Before leaving the factory all LIL FELLA units were carefully inspected and the carrier has accepted and signed for them Any damage or irregularities should be noted at the time of delivery and immediately reported to delivering carrier Request a written inspection report from claims inspector to substantiate any necessary claim File claim with delivering agency no
21. e Probable Cause Remedy Water pump 1 Inoperable water pump motor 1 Replace water pump motor motor will not Overheated motor cut off by Check for proper line voltage operate 2 thermal overload protector 2 Allow motor time to cool Electrode inside carbonator tank Replace carbonator tank defective electrode 3 L L C assembly Inoperable 3 Replace L L C assembly Loose electrical connection Tighten connection and or repair 4 and or open electrical circuit 4 open circuit Check line voltage 5 Defective pump protector S 103 5 Replace pump protector Water pump 1 Defective water pump 1 Replace water pump motor will not 2 Electrode inside carbonator tank 2 Replace carbonator tank shut off defective electrode 3 L L C assembly inoperable 3 Replace L L C assembly 4 Loose electrical connection and 4 Tighten connection and or repair or open electrical circuit open ground circuit 5 Carbonated water leak 5 and repair leak Water Pump 1 Electrode inside carbonator does 1 Replace defective electrode or motor will not not sense ground check and tighten ground shut off and connection at control box pressure relief 2 L L C assembly inoperable 2 Replace L L C assembly engaged Short cycling of 1 Ground connection loose or 1 Attach or tighten ground water pump disconnected connection motor 2 Electrode inside carbonator tank 2 Replace carbonator tank def
22. e second path of C02 is routed through low pressure regulator to be regulated at pressures suitable for the syrup concentrate being dispensed The low pressure regulator may be set at many different settings but primarily the settings are directed towards or transfer tank type installations The average settings may vary from 10 to 60 PSI this of course will be influenced by length of run ambient temperature and baume of product Typically installations are set at an average of 40 PSI and transfer tank installations are set at an average of 30 PSI As discussed earlier plain water enters the LIL FELLA through the incoming water line This water proceeds through the water coil where it is chilled prior to entering the carbonator tank or in the case of non carbonated drinks chilled prior to going directly to a valve Prior to entering the carbonator tank an optional regulator S 208A may be installed This assembly is utilized to maintain water pressure feeding a non carbonated valve when used in conjunction with carbonated valves 1 11 The water source should be regulated this is normally performed by the use of an in line water regulator If the water is not regulated and the water pressure is equal or greater than the incoming CO2 the act of carbonation will be greatly inhibited or completely eliminated At the proper settings the gas pressure will stop the water from entering the carbonator tank To force the water into t
23. e tank vigorously as valve necessary to remove over carbonation 3 Dirty nozzle and valve cavity 3 Clean contaminated nozzle and sanitize as instructed 4 Temperature above quality limits 4 See refrigeration machine specifications vs volume requirements Dispensed 1 Oil film or soap scum cup or 1 Use clean cups and glasses product comes glass out clear but 2 Ice used for finished drink is sub 2 Do not use ice directly from foams in cup or class cooled freezer Allow ice to become wet before using Note crushed ice also causes foaming of beverage Carbonation is released on sharp edges of the ice 6 4 Water to syrup ratio to low or too high Syrup flow regulator not properly adjusted gas pressure in syrup tanks insufficient Syrup tubing insufficient Adjust water to syrup ratio see dispensing station installation instructions Adjust low pressure regulator as instructed Increase syrup tubing 1 0 Note see Brix instructions Adjustment of syrup metering pin does not produce desired water to syrup ratio No syrup supply Syrup tank quick disconnects not secure Low pressure CO2 regulator out of adjustment QCD disconnected or improperly installed Syrup line restricted Dirty or inoperative metering pin or piston in syrup flow control Replenish syrup supply as instructed Secure
24. ective electrode 3 Carbonated water leak in system 3 Repair carbonated water leak L L C assembly inoperable Replace L L C control assembly Water pump 1 Inlet water volume supply to low 1 Increase diameter of supply line capacity to low install holding tank Water motor pump worn out Replace water pump 2 Kinked or restricted water supply 2 Clear or replace restricted water line 3 supply line 3 Foreign object in water pump or Clear restrictions and check pump 4 restriction to water pump 4 strainer for debris Water pump 1 Water supply to low or turned off 1 Inlet water supply must be a operates but minimum of 3 8 water pump 2 water pump 2 Replace water Pump does not pump 3 Water supply filter clogged 3 Replace filter 4 Water pump strainer clogged 4 Clean water pump strainer 6 1 Frozen water 1 Bad ice bank control 1 Replace bad ice bank control bath 2 Refrigerant leak causing 2 Repair leak evacuate and re undercharge charge 3 Defective agitator motor 3 Replace defective agitator 4 Dirty water bath 4 Melt ice empty amp clean bath Replenish w fresh water Cooling or 1 No electrical power 1 Plug power cord into electrical condensing unit box Check on off switch non Replace ice bank control operational 2 Defective ice bank control 2 Clean condenser unit w vacuum 3 Dirty c
25. ee paragraph CLEANING AND SANITIZING in this chapter 3 Install full syrup container in position rinse Q C D s or quick disconnects in warm water then connect Q C D s or syrup amp C02 quick disconnects to container 4 Activate valve until syrup flows from valve normally See CHAPTER CHANGING WATER FILTER CARTRIDGE Follow manufacturer s instructions for water filter ADJUSTMENTS HIGH PRESSURE C02 REGULATOR The high pressure C02 regulator will have two gauges that extend above and to the side of the bell housing screw area The P S I gauge will show graduated indications up to 3000 psi and be the gauge the farthest from the C02 cylinder connection This gauge will normally have a Red area indicating 500 psi to O psi This gauge will be used to check volume of liquid in the C02 cylinder The other gauge will show regulated pressure that will be delivered to the LIL FELLA carbonation system This gauge can be indicated from 0 160 psi up to 0 300 psi By turning the high pressure regulator adjustment screw clockwise we will increase pressure supplied to our carbonator that will be indicated on this gauge lower pressure to carbonation system it is recommended that the adjustment screw be turned counter clockwise several full turns and then the relief valve 8 215 be lifted lowering pressure in carbonating system now readjust When adjusting C02 high pressure regulator a setting of 70 75 psi is recommended 5 7 INLET C02 PRESS
26. ensed as instructed in chapter IV OPERATOR INSTRUCTIONS 3 2 CHAPTER IV OPERATORS INSTRUCTIONS This chapter covers operator s responsibilities for daily pre operation check adjustments replenishing C02 and syrup supplies cleaning and sanitizing DAILY PRE OPERATION GHECK 1 Make sure high pressure C02 regulator s pound per square inch indicator is not in shaded portion of dial If so C02 cylinder is almost empty and must be replaced NOTE This reading should be carried out at normal room temperature Make sure there is a sufficient syrup supply in all syrup containers If not replenish syrup supply REPLENISHING C02 SUPPLY NOTE If pound per square inch indicator of high pressure C02 regulator on C02 cylinder is in shaded portion of the dial C02 cylinder is almost empty and should be changed C02 supply must be checked daily and if necessary replenished as instructed see CHAPTER II REPLENISHING SYRUP SUPPLY Syrup supply must be checked daily and if necessary replenished as instructed see CHAPTER COOLING UNIT MAINTENANCE NOTE Air circulation through the condenser coil required to cool the condenser coil compressor is drawn in through grills on the cooling unit through condenser coil and is exhausted out grills on the sides of the unit Restricting air circulation through the cooling unit will decrease its cooling capacity To avoid needless and sometimes costly repairs it is imperative to keep co
27. he tank a liquid level control and motor pump will be used This combination will force the water into the tank mixing the water and CO2 together The carbonator utilizes a Soda Jet Recirculating Principle Our Company pioneered this principle in the early 1950 s This principle produces instantaneous carbonation at extremely large capacities of 100 gallons per hour minimum The level of the carbonated water within the stainless steel mixing tank is used to operate the motor driven pump The liquid level control in conjunction with a probe housed in the carbonator tank controls the pump motor The motor will come on when the carbonated water within the mixing tank recedes to a predetermined low level and stops the pump motor when the carbonated water reaches a predetermined high level During the cycle of operation fresh water enters the carbonator tank through the soda jet after passing through the water pump The water pump has impellers which drives the water through the water coil then a dual check valve and then through the soda jet and into the carbonator tank The position and angle of the soda jet is fixed to direct an extremely high velocity solid jet of fresh water so as to impinge upon the surface of the stored body of carbonator water within the stainless steel mixing tank The force created by this jet of fresh water entering the mixing tank causes all the water within to cascade and foamesce through the carbon dioxide gas area in a
28. ically check water level in water bath If it is low more water should be added for maximum product cooling Before adding more water water bath and ice bank should be checked for excessive mineral deposit build up NOTE The water in water bath should be changed and all components in water bath should be cleaned as often as necessary to keep it clean A convenient time to perform this operation is when the system is being sanitized 1 Unplug refrigeration unit power cord from electrical socket 2 Remove lid from unit 3 Look down into water bath if necessary use flashlight and inspect water bath ice bank and all components for cleanliness Water ice bank and all components should be clear and free of foreign particles If ice bank is clear of foreign particles it does not have to be melted down Proceed to step 10 if foreign particles are present in the ice bank proceed to step 4 4 Siphon out water with short hose or pull out over flow standpipe 5 Allow ice bank to melt Hot water may be used to speed melting CAUTION Never use an ice pick or other sharp instruments to remove from evaporator coil Such practice can result in puncture to the refrigeration circuit 5 2 6 Use fiber brush and carefully clean mineral deposit from all components 7 Wash evaporator coil with a mild soap solution Copper cleans well with mild solution of citric acid Stainless steel cleans well with carbonated water Then rinse with clean wa
29. ient orifice opening INSTALL WATER HOLDING TANK OPTIONAL When no water pressure is available or where the water supply system is inadequate a water holding tank may be installed above the pump level The pump will pump water from the holding tank to the carbonator WATER REGULATOR 1 2 GATE VALVE FIGURE 2 4 SUGGESTED WATER FLOW INSTALLATION 2 4 INSTALL DRAIN LINE 1 Connect drain line LIL FELLA unit with drain using 3 8 clear plastic pipe or 3 8 copper tubing to nearest outlet 2 Do not reduce drain connection from cabinet outlet 3 Be sure all connections are watertight INSTALL OR SYRUP TANKS AND ACCESSORIES OPTIONAL 1 Place or syrup tanks as close as possible to LIL FELLA unit preferably no farther than 5 feet 2 Lay out syrup lines from unit to syrup pumps or tanks 3 Connect lines from low pressure regulator for or transfer tank installations 4 Connect line from low pressure regulator to Q C D for or install quick disconnect for transfer tank type installations 5 Install incoming syrup line to unit on Q C D for 6 Install quick disconnect on incoming line to accommodate transfer tank installs 7 Activate Q C D or install quick disconnects to transfer tanks 8 Check all connections for leaks See Chapter IV CONNECTING WATER INLET WATER PIPE CONNECTIONS AND FIXTURES DIRECTLY CONNECTED POTABLE WATER SUPPLY SHALL BE
30. igher continuously volume unit but does not 2 Cooling unit located in 2 Relocate cooling unit form sufficient excessively hot area ice bank 3 Air circulation through condenser Check and if necessary clean coil is restricted condenser coil 4 Loss of refrigerant or in sufficient 4 Repair leak and or recharge with charge sufficient refrigerant 6 2 Note Ice bank freezes from bottom of evaporator upward A refrigerant leak or insufficient charge might show ice at bottom and not at top of evaporator Compressor will not stop after 1 Ice bank control capillary tube kinked or broken 1 Replace ice bank control sufficient ice 2 lce bank control stuck in closed 2 Replace ice bank control bank is position produced Note During overload protector shut off condenser fan motor will continue to work Otherwise troubleshooting condenser fan motor problems is the same as Compressor does not operate paragraph in addition to the following Condenser fan 1 Electrical cord loose or 1 Tighten connections or replace motor not disconnected from condenser fan cord operating motor or compressor terminals 2 blade obstructed 2 Remove obstruction 3 Inoperative condenser fan motor 3 Replace condenser fan motor DISPENSING VALVES Water or syrup 1 Foreign debris under plunger seat 1 a Disconnect sy
31. ing for at least 10 minutes 4 Flush the detergent solution from the syrup lines with clean water Continue rinsing until testing with phenolphthalein shows that the rinse water is free of residual detergent 5 Fill the syrup lines with a low PH 7 0 chloride solution containing maximum 200 PPM chlorine Make sure that lines are completely filled and allow standing for 30 minutes Reconnect syrup containers and ready Unit for operation Draw drinks to refill syrup lines and flush the chloride solution from the dispenser Taste the beverage to verify that there is no off taste NOTE WHEN SANITIZING TWO FLAVOR VALVE BOTH SYRUPS SHOULD BE FLUSHED SIMUTAINEOUSLY BOTH SYRUPS SHOULD BE CLEANED DETERGENT SOLUTION SIMUTAINEOUSLY BOTH SYRUPS SHOULD BE FLUSHED UNTIL FREE OF DETERGENT SIMUTAINEOUSLY AND BOTH SYRUPS SHOULD BE SANITIZED SIMUTAINEOUSLY 5 10 TROUBLE SHOOTING IMPORTANT Only qualified personnel should service the LIL FELLA unit and components WARNING To avoid personal injury and or property damage always disconnect electrical power shut off plain water and CO2 supplies before starting any repairs If repairs are to be made to the carbonated water system bleed carbonated water system pressure before proceeding If repairs are to be made to syrup system remove quick disconnects from syrup tanks or remove QCD from BIB then bleed system pressure before proceeding CARBONATOR Troubl
32. ked gas INSTALL LOW PRESSURE REGULATOR AND LINES OPTIONAL 1 Install low pressure 02 regulator on the wall or another supporting structure in general vicinity of cooling unit C02 cylinder rack or syrup tanks 2 Connect 1 4 inner braided plastic tubing from outlets of low pressure C02 regulator S 221 to inlets of pump or syrup tanks FIGURE 2 2 FIGURE 2 3 HIGH PRESSURE C02 REGULATOR LOW PRESSURE C02 REGULATOR REGULATOR S 101 S 221 2 3 INSTALL WATER FILTER ASSY OPTIONAL 1 Install water filter assembly on wall or other supporting structure 2 Connect water filter assembly to inlet of valve on water supply line using minimum 3 8 1 0 water line 3 Connect water filter assembly outlet to LIL FELLA plain water inlet fitting using minimum 3 8 D water line See CONNECTING WATER INLET When a water filter is used it is important that it has a minimum 100 gallons per hour capacity and should be thoroughly flushed before it is connected to the water inlet connection INSTALL WATER PRESSURE REGULATOR OPTIONAL If water pressure exceeds 40 psi a water pressure regulator or water pressure reducing valve should be installed in the water supply line and adjusted to maintain a pressure of 25 to 40 psi The water regulator must have an orifice of at least 3 16 so as not to restrict the water flow through the valve Valves that are built with 1 2 pipe thread connection usually have a suffic
33. ld be sanitized EQUIPMENT REQUIRED Stainless Steel containers product tanks or large volume container CO2 Supply if applicable Same as used with dispensing unit Cleaning Agent Sanitizing Solution Phenolphthalein Q N NOTE One recommended cleaning agent and sanitizing agent is manufactured by MT HOOD CHEMICAL CORP 4444 N W Yeon Avenue Portland Oregon 97210 Trade names are STAR CHLORINATED CLEANER CROWN 12 5 SODIUM HYPOCHLORITE BLEACH Use STAR 18 oz per 1 gallon of water yields 2 Sodium Hydroxide Solution Use Crown at 2 ounce per 9 gallons of water gives 200 PPM of available chlorine at a minimum contact time of 10 minutes 1 Disconnect syrup containers and remove product from tubing by purging with carbon dioxide or flushing with warm water 2 Visually inspect valve by removing nozzle and inspecting nozzle and valve cavity Clean nozzle with cleaning agent then sanitizing solution then with potable water Inspect valve cavity and if dirty clean with soft bristle brush Clean exteriors of valve with a soft clothe and warm water Replace valve nozzle then go to step 3 3 Fill syrup lines with a caustic based low sudsing non perfumed and rinsed detergent solution STAR The solution should be prepared in accordance with the manufacturers recommendations but should be at least 2 percent sodium hydroxide Make sure the syrup lines are completely filled and allow stand
34. nce to move downward there is leak in the low pressure circuit Check all connections with a soap solution paying particular attention to syrup tank covers If low pressure gauge needle remains stationary There is no leak 4 3 CHAPTER V SERVICE AND MAINTENANCE This chapter describes service and maintenance procedures to be performed on LIL FELLA units and related components PERIODIC INSPECTION AND CLEANING Daily 1 Clean any syrup from storage tanks B I B racks connecting sockets Q C D s and general syrup storage area with warm water 2 Check the C02 gas supply If cylinder pressure is below 500 P S I replace the cylinder NOTE Readings should be taken at normal room temperature approximately 70 degrees F and above If C02 cylinder is stored in a walk in refrigerator the P S I indicator will read below 500 psi even when cylinder is full 3 Check the C02 gas pressure supplying the carbonator and syrup tanks These pressures should not change If a change occurs repeatedly contact your local service agency It is suggested to make a comment about this occurrence in NOTE SECTION of manual 4 Clean the beverage dispensing area 5 Remove and clean nozzles and all exposed areas on valves 6 Wipe exterior of unit with moist towel Stainless cleans well with carbonated water 7 Weekly 1 Order syrup to maintain proper inventory 2 Check all 02 gas connections for leaks 3 Measure the water to syrup r
35. ndenser fins clean This may be accomplished by one of three methods One method is use of a condenser brush a longhaired soft bristle brush to gently sweep fins of condenser clean Second method is to use a strong vacuum The third method is to use C02 or an air hose to blow out condenser The latter method should only be attempted after normal business hours to avoid dust contamination 4 4 CHECKING WATER BATH Periodically check water level in water bath If it is low more water should be added as instructed for maximum product cooling This dehydration will normally not occur in normal temperate climate zones With normal humidity the opposite will occur therefore a condensate drain is installed Any extra water in the water bath will exit the unit via the drain outlet When unit is building it s first ice bank it is normal to have water overflow the into the drain hose CHANGING WATER BATH Drain water bath a minimum of twice a year This can be accomplished by siphoning water with short hose into bucket or removing over flow standpipe Once water is drained and ice bank is melted water bath water coils bath walls tank etc should be cleaned Fill water bath to the top of the standpipe 5 739 ADJUSTMENTS Periodically C02 regulators should be checked for proper pressure settings and if necessary adjust as instructed These settings can be recorded in NOTE section of this manual ADJUSTING WATER FLOW RATE If adjustment of w
36. nks the carbonator tank is not needed so the chilled water is directed straight to the valve Again it is mixed with a syrup concentrate and then dispensed The water bath holds approximately 4 gallons of water A certain amount of this water will be transformed into ice approximately 9 pounds This water reserve and ice bank will act as a reservoir for refrigeration This reserve is utilized during peak periods when the BTU output of the compressor is not sufficient to meet the demand of the draw It should be recognized that without refrigeration your carbonation system would not produce a drink that will hold carbonation There is a direct relationship between dispensed temperature and the volumes of C02 that can be held in liquid form The following will give a general overview of the flow of individual circuits and a clearer understanding of our mini bottling plant Carbon dioxide gas CO2 passes from a C02 cylinder through high pressure regulator S 101 The high pressure regulator regulates the CO2 feeding the LIL FELLA and should be set at 70 75 PSI The gas after leaving the high pressure regulator is routed through flexible tubing to a low pressure regulator The flow of CO2 is teed to go in two directions at the low pressure regulator One path takes the gas set at 70 to 75 PSI to the carbonator tank This gas must be at a pressure greater than the incoming water by at least 25 PSI to assure the proper function of the carbonator Th
37. nplugged valve on C02 cylinder is closed and valve on water supply line is closed and release pressure of C02 gas and water from carbonator tank PREPARING AND STARTING REFRIGERATION UNIT 1 LIL FELLA refrigeration is pre set at factory and ready to operate 2 Remove lid 3 Fill water bath with clean water until water runs out of condensate drain outlet S 739 above drain pan approximately 1 2 from top of water bath 4 Open water inlet supply line 5 Plug LIL FELLA power cord into electrical receptacle box turn power switch to the ON position Make sure compressor condenser fan motor agitator motor start The process of cooling the water bath will now commence With ambient and water temperature of 75 degree initial pull down or formation of complete ice bank will take approximately 3 hrs When full ice bank has been formed compressor and condenser fan motor will stop Agitator will continue to operate circulating water in water bath PURGE DISPENSING VALVES Dispense water from dispensing valves until all air is purged from soda water and non carbonated waterlines ACTIVATE HIGH PRESSURE C02 SYSTEM 1 Open valve on the C02 cylinder Be sure to open valve completely or until valve is back seated 2 Turn high pressure C02 regulator screw clockwise until the pressure is 70 to 75 psi Carbonated units only 3 1 3 Dispense water from dispensing valves until the carbonator activates Carbonated units onl
38. om water bath A freezing ambient environment will cause existing water in unit to freeze possibly resulting in damage to pump motor assembly syrup coils water coil water bath valve s etc TABLE DESIGN DATA COOLING UNIT Overall cabinet dimensions LF 12 LF 23 LF 12 J LF 23 J Height 24 1 2 24 1 2 24 1 2 121 4 133 822 40 12 19 9 8 24 3 8 23 3 16 24 3 8 23 3 16 Weights Shipping 140 LBS 140 LBS 113 LBS 113 LBS Dry weight 111 LBS 111 LBS 88 LBS 88 LBS Operational Weight 153 LBS 153 LBS 130 LBS 130 LBS Ice Bank 9 LBS 9 LBS 9 LBS 9 LBS 1 1 Capacities Unit water bath no ice bank 4 gallons Refrigerant requirement R 134 A 165 grams Ambient operating temperature enne 40 F to 100 F Electrical Requirements The cooling unit requires a 115 VAC single phase 60 Hertz power circuit Circuit Ampacity 9 6 Amps 9 6 Amps 3 4 Amps 3 4 Amps Conden
39. ondenser unit 3 cleaner Check for proper 4 Improper voltage amperage 4 voltage amperage Repair leak and replenish 5 Loss of refrigerant 5 refrigerant Replace overload and relay 6 Bad overload and relay 6 Replace compressor 7 Compressor bad 7 Repair straighten or replace 8 Restriction pinched or crimped 8 defective line line Agitator motor 1 Agitator propeller obstructed or 1 Remove obstruction or re not operating lost Attach propeller 2 Low voltage 2 Voltage must be at least 110 volt at terminals 3 Loose unplugged or broken 3 Tighten connection or replace wiring broken wiring 4 Bad agitator motor 4 Replace agitator motor Compressor 1 No power source 1 Plug power cord to electrical box does not Check line voltage operate 2 Electrical power to cooling unit 2 Turn on power switch to unit turned off 3 Low voltage 3 Voltage must be at least 110 at compressor terminals at start 4 Loose disconnected or broken 4 Tighten connection or replace wire broken wiring 5 Inoperative ice bank control 5 Replace ice bank control 6 Inoperative overload protector or 6 Replace defective part start relay 7 compressor 7 Replace compressor 8 Full ice bank 8 Refrigeration not called for Compressor 1 Cooling capacity is exceeded by 1 Reduce amount of drinks taken works over drawing per given time of install h
40. onfigurations The following data will refer to of the basic types of configuration The LIL FELLA 12 and the LIL FELLA 23 utilizes one cabinet The valves can be mounted on the narrow or long side of the cabinet If mounted on the narrow or 12 side the unit will be referred to as a LF 12 If the valves are mounted on the wide or 23 side the unit will be referred to as a LF 23 If data refers to both types we will refer to the unit as LIL FELLA SYSTEM DESCRIPTION The LIL FELLA is a complete beverage dispenser and when combined with related components will produce a variety of cooled carbonated and non carbonated beverages The LIL FELLA consists of a condensing unit a water reservoir water cooling coil a carbonator tank carbonated systems only an agitator pump and optional syrup cooling coil s and dispensing valve s For proper function the LIL FELLA must have a water supply and electrical supply and drainage The LIL FELLA is designed with a unique lift off drain pan that can be emptied at any convenient drain outlet Other items that will be required if used in B I B Bag in Box or transfer tank FIGAL installations will be High pressure regulator Low pressure regulator connecting lines quick couplers or disconnects and C02 WARNING Before shipping or relocating a LIL FELLA into a freezing ambient environment empty plain and carbonated water Syrup systems should be flushed ice bank melted and water drained fr
41. oning Adjust CO2 pressure at a minimum of 25 PSI above water pressure CARBONATION TROUBLE SHOOTING FLOW CHART 3 CARBONATOR NOT OPERATIONAL Water Pump Motor runs continuously NO EXCESSIVE PRESSURE AT EXCESSIVE PRESSURE AT VALVE VALVE OR PRESSURE RELIEF SYMPTONS SYMPTONS Valve will dispense syrup only and or Valve will dispense syrup and gas pressure relief may engage only Possible loud noise from water pump Y Little or no water volume No ground at LLC Repair _ Install holding tank increase water feed I D Electrode bad replace Restrictions at water pump Clear restrictions Defective LLC Replace Defective Motor Water Pump Replace NOTE SECTION Frequently Called Numbers CO2 SETTINGS High Pressure PSI Low Pressure PSI Product Setup 1 2 6 9
42. rs DO NO OVER OIL 5 4 SERVICING CHECK VALVES It is not recommended to disassemble the check valves unless it is absolutely necessary As stated before this necessity would be prompted by earthquakes disruption of water service etc The symptoms of a malfunctioning check valve would be Water check valve Carbonation through out water supply i e basins toilets etc or an activated vent valve Gas check valve Water in C02 cylinder water escaping from high pressure C02 regulator S 101 during cylinder change and possibly water in syrup containers If any of the above symptoms occur proceed with the following 1 Disconnect water line from double check valve outlet Remove double check from water pump outlet fitting 2 Remove one check valve from other then disassemble each check valve as shown in Figure 5 2 3 Wipe each part with clean lint free cloth Inspect each part especially the ball for burrs nicks corrosion deterioration and other damage Discard ball O ring S 13 and any damaged or suspicious parts and replace with new parts during re assembly 4 Reassemble each check valve as shown in Figure 5 2 ALWAYS INSTALL NEW O RING S 13 Assemble check valves together as shown in Figure 5 1 Connect water inlet line to double check valve assembly Activate the system as outlined in CHAPTER NOOO 5 20 WATER 5 22 GAS CHECK CHECK VALVE 1 VALVE
43. rup or water leaking from or bent creased stem from affected valve nozzle after b Relieve pressure by actuation activating valve c Remove E 623 nut from syrup or water solenoid d Remove e 525 coil assembly from e 527 stem e Remove E 527 stem from valve Note care should be taken not to dent smooth E 527 wall f Valve stem seat should be inspected for any foreign debris If debris is found remove at this time also check E 730 stem Movement should be unrestricted and free g Inspect E 730 plunger seat for damage replace if damaged h Reassemble by reversing above procedure No water no 1 Noelectrical power 1 Plug power cord into electrical syrup being box Check line voltage dispensed from 2 Frozen water bath 2 See Frozen water bath valve 3 Pinched or crimped lines 3 Repair defective line 4 Broken sub miniature switch 4 Replace defective switch 5 Bad transformer 5 Replace defective transformer 6 Disconnected wire 6 Attach disconnected wire 6 3 No syrup being 1 Syrup container empty 1 Replenish syrup supply dispensed 2 Syrup lines crimped 2 Straighten syrup lines 3 1602 cylinder empty 3 Change CO2 cylinder 4 QCD of syrup installed in 4 Re install QCD correctly correctly 5 Low pressure regulator defective 5 Repair or replace low pressure or plugged regulator 6 Syrup disconnect not atta
44. sing Unit 2 1 Amps 2 1 Amps 2 1 Amps 2 1 Amps Water Pump Motor 6 2 Amps 6 2 Amps NA NA Transformer 5 5 Amps 5 Amps 5 Amps Agitator 8 amps 8 amps 8 amps 8 amps Water Filter Recommended Optional See Manufacturer Specifications for Operating Conditions Pressure Incoming Water Pressure Regulator Optional 25 40 C02 High Pressure Regulator Carbonated units only PSI 70 175 C02 Low Pressure Regulator Carbonated Flavored units only BIB Approx 40 PSI C02 Low Pressure Regulator Carbonated Flavored units only FIGAL Approx 30 PSI C02 Low Pressure Regulator Optional FIGAL Approx 30 PSI C02 Diet Drink Pressure Regulator if required 6 10 PSI DISPENSING VALVES Ambient Operating Temperature 40 F to 100 F Electrical Requirements Operating Voltage 24VAC 6Ohz INTERNATIONAL CARBONIC INC LIL FELLA 12 POST MIX DATE 12 15 04 DRN BY GLW APPR BY ADELANTO CALIFORNIA FIGURE 1 1
45. t International Carbonic Inc Unpack LOOSE SHIPPED PARTS At this time make sure all parts listed are present and in good condition If any parts are missing notify factory TABLE 2 1 LOOSE SHIPPED PARTS Item Part No No Name 1 Installation Service Manual 23 5 101 High Pressure 02 Regulator 3 S 221 Low Pressure C02 Regulator 4 5 1149 Drain pan LF 12 5 S 1150 Drain Pan LF 23 6 5 105 6 Gas Line Inner Braid Product Decals 8 5 208 Water Pressure Regulator 9 Water filter 103 5 208 Water Pressure Regulator Optional SELECTING LOCATION IMPORTANT Ambient temperature for LIL FELLA should not exceed 100 degrees Operation of cooling unit in ambient above 100 degrees F can and will contribute to early failure of condensing unit and poor quality of finished product Q 1 1 1 1 1 1 1 1 1 1 ly per flavor 2 1 LOCATION RECOMMENDATIONS FOR LIL FELLA 1 Position unit as close as possible to proper electrical source 120V 60HZ 2 Position unit with a minimum of 2 space between bulkhead and cabinet for sufficient ventilation Allow enough space between ceiling and unit for lid removal 3 Position unit as close as possible to water source Half inch gate valve recommended for water connection 4 Enough space must be allowed to install C02 cylinder syrup containers racks pumps water filter etc 5 Position unit as close as possible to floor drain FIGURE 2 1 SAMPLE O
46. ter 8 Rinse out water bath with clean water until water running out of siphon hose is clean 9 Insert standpipe in drain hole 10 Fill water bath to top of standpipe 11 Replace lid 12 Plug refrigeration unit power cord in electrical socket WATER PUMP MAINTENANCE Warning The water pump inlet strainer screen must be inspected and serviced at least once a year under normal circumstances of after any disruptions plumbing work earthquake etc to the water supply systems that might cause clogged flow of water through system Water pump with no screen or a defective screen in the strainer would allow foreign particles into water system and create a health hazard 1 Unplug power cord from electrical socket 2 Shut off plain water supply to water pump by closing shutoff valves in water supply line 3 Shut off CO2 supply to LIL FELLA by closing shutoff valve on CO2 cylinder 4 Remove lid from unit to gain access to water bath 5 Remove right side service panel on LF 12 or lift up valve plate on LF 23 to gain access to water pump inlet strainer 6 Loosen screen retainer and then pull screen retainer and water strainer screen out of water pump port 7 Clean any sediment from screen retainer and water pump port 8 Inspect water strainer screen for holes restrictions corrosion and other damage A water strainer screen should always be used other wise particles could damage pump and foul the double check valve 9 Check
47. ve the syrup is always to the right and the water soda is to the left To decrease syrup or water flow turn metering pin clockwise To decrease syrup or water flow when using flow control valves turn counter clockwise To increase reverse rotation respectively The ultimate goal is to achieve a proper ratio of water vs syrup This ratio can and will vary with differing products TOP VIEW 18 PARTS WATER valve cover removed DECREASE SYRUP INCREASE SYRUP 1 c 2 7 WATER METERINGPIN SYRUP METERING PIN SYRUP 2 18 1 Brix Cup Maintenance Cleaning your valve is recommended to insure a constant quality drink If a valve is not sanitized on a regular basis nightly recommended the possibility of foamy and off tasting drinks is greatly increased 1 Turn off key switch normally located on valve plate or side of cabinet Or disconnect tower from electrical supply 2 Clean all exposed areas of valve with mild soap or sanitizing solution and warm water 3 Remove nozzle and place in warm water Do not soak nozzle in bleach water this will turn the nozzle yellow and cause deterioration It is recommended to use a soft bristle brush part No S 1064 to clean any hard to get areas of valve or nozzle Do not soak nozzle in extremely hot water nozzle will warp SANITIZING PROCEDURES Your local health department rules and general area cleanliness should determine the frequency at which the unit shou
48. y 4 Allow carbonator to run until it automatically shuts off Pump is fully primed and carbonator is now ready for use Carbonated units only 5 Check all connections on high pressure C02 system for leaks Repair any leaks that are found ACTIVATE LOW PRESSURE C02 GAS AND SYRUP SYSTEMS OPTIONAL 1 Make sure high pressure C02 regulator pressure is 70 to 75 psi 2 Make sure all racks or syrup tanks are full 3 Make sure all Q C D s are in an operational position or and syrup quick disconnects are connected tightly with syrup tanks 4 Turn low pressure C02 regulator screw clockwise until the pressure is approx 40 psi for and approx 30 psi for FIGAL NOTE These pressures will vary depending on baume of product type of pumps etc 5 f diet drink regulator is required turn C02 diet drink pressure regulator screw clockwise until the pressure is 6 to 10 psi 6 Dispense syrup from dispensing valves until all air is purged from syrup lines and syrup is dispensed 7 Check for syrup and gas leaks Repair any leaks that may be found ADJUST WATER FLOW RATE Adjust dispensing valves water flow rate as instructed in chapter IV OPERATORS INSTRUCTIONS ADJUST WATER TO SYRUP RATIO Adjust dispensing valves for Water to syrup Ratio of dispensed product as instructed in chapter IV OPERATOR INSTRUCTIONS ADJUST SIZE OF DRINK DISPENSED FOR PORTION CONTROL VALVES PCT ONLY Adjust size of drink disp
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