Training Manual Wilshire Juice
Contents
1. WILSHIRE TRAINING MANUAL VY CARBON DIOXIDE WATER V SYRUP CONCENTRATE Vo MECHANICAL V REFRIGERATION VY CONTROLS amp ELECTRICAL gt C Greta D Wilshire Juice Training Manual Wilshire Juice Training Manual The products technical information and instructions contained in this manual are subject to change without notice These instructions are not intended to cover all details or varia tions of the equipment nor to provide for every possible contingency in the installation operation or maintenance of this equipment This manual assumes that the person s work ing on the equipment have been trained and are skilled in working with electrical plumb ing pneumatic and mechanical equipment It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met in addition to the information contained in this manual To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact IMI Cornelius Inc Internet Corporate Headquarters www cornelius com One Cornelius Place Anoka MN 55303 6234 U S A Email tech service 9 cornelius com In the U S A Outside the U S A phone 763 421 6120 phone 763 421 6120 800 238 3600 FAX 763 422 3297 FAX 800 535 4235 Trademarks and copyrights Aurora blendanator Cornelius Decade Hydro Boost Sitco Rancor Spirit UF 12. 4 Adjusting Flow Rates 4 Concentrate 4 Miscellaneous Concentrate Tips 5 SLJ Units 5 QLT Units 5 Setting Ratios 5 Mechanical 6 Concentrate Pump Disassembly 6 SLJ Rinse Flush Valve Rebuilding 7 SLJ Valve Mixing Block Rebuilding 9 Miscellaneous Mechanical 11 Refrigeration 12 Water Thermostat 12 Concentrate Thermostat 12 Control Relay 12 Refrigerant Solenoid Valve 12 Heat Exchanger Assembly 12 Compressor 13 Condenser 13 CondenserFan 13 gt gt m ps o Z m lus Z em U N 2 2 o m lt Wilshire Juice Training Manual
3. Dryer 13 Air Flow 13 Refrigerant Charging 13 Filter Dryer Replacement 14 Condenser Cleaning 14 Miscellaneous Refrigeration 15 Controls and Electrical 16 TROUBLE SHOOTING 17 ATTACHMENTS ee eee eee eee 19 cee 21 amp gt Wilshire Juice Training Manual INTRODUCTION 1 PREVIEW QUESTIONS Check your current knowledge by taking a few minutes to answer the following questions 1 Water and concentrate thermostats are interchangeable True False 2 The transformer does NOT control the cooling system True False 3 Condenser airflow passes over the compressor first True False 4 Ratio refers to the amount of water required to dilute one part of concentrate True False 5 O rings may be installed dry lubrication is not recommended True False Z 2 a Q Z 2 KEY THINGS TO Know Do v Work Safely Always unplug disconnect the power to the dispenser before servicing and get help lifting the unit if it must be removed from the counter v Make certain that the water line has adequate pressure at
4. Wilshire Juice Training Manual 2 Remove four screws on front holding electrical box and two screws on each side of the fan shroud Remove Two Screws On Each Side Of Fan Shroud Remove Four Screws In Front 3 Pullfan shroud forward Fan Shroud Condenser on lt 02 4 Clean with brush compressed air lt If necessary remove three screws gt each side of the fan and move e 5 it out of the way ESE gt N 5 5 Miscellaneous Refrigeration e The water inlet valve solenoid assem eina bly should be replaced as a unit Valve The water inlet valve solenoid assem bly has a Y strainer that may need periodic cleaning solenoid 1999 IMI Cornelius Inc 15 Wilshire Juice Training Manual 6 CONTROLS AND ELECTRICAL l Transformer blue leads are 26 VAC and go to the pumps red leads are 24 VAC and go to the merchandiser Blue leads go to pumps Red leads go to merchandiser ballast board e The unit s ON OFF switch may be on the underside of the unit or on the inside of the door There is also a switch on the bottom of the door that turns on and off as the door is opened and closed Both of these switches turn off the pumps but not the refrigeration N lt m A gt m Un gt Un 16 1999 IMI Cornelius Inc amp gt Wilshire Juice Training Manual TROUBLE SHOOTING TROUBLESHOOTI
5. CUSTOMER REACTION Pouch in holder wrong flow restriction Low False refill light Decrease water flow Might correct brix False refill light Poorly mixed drink Pulsing splashing dispense Unmixed concentrate at bottom of cup Pump slide not fully engaged Low brix False refill light Decrease water flow Can t achieve good brix False refill light Poorly mixed drink Sticky pump rollers Low brix Decrease water flow Can t achieve good brix False refill light Poorly mixed drink Ambient water to dispenser Drinks above 45 F during peak volume Exceeds drink capacity of 20 oz per minute Service call complaint NOTE Must supply 3 8 chilled water line to dispenser to generate unlimited drink capacity 1 4 water line to dispenser Poor flow rate High velocity dispense 18 Decrease water flow Might correct brix Poorly mixed drink High velocity dispense Pulsing splashing dispense Unmixed concentrate at bottom of cup 1999 IMI Cornelius Inc Wilshire Juice Training Manual ATTACHMENTS The following attachments should be included with this lesson Minute Maid Orange Juice 6L Pouch Helpful Hints guide SLJ1000 1 Voltage Regulator Board Installation Instructions QLT180 Voltage Regulator Board Installation Instructions 1999 IMI Cornelius Inc
6. 1999 IMI Cornelius Inc amp gt Wilshire Juice Training Manual 16 The SLJ and QLT circuit boards wire in the same way True False 17 The SLJ circuit board uses a continuity test to check for the sold out or refill condi tion True False 18 The function of the speed switch is to A help dispense drinks faster by increasing water velocity B slow down the dispense rate when ice is used C allow for low water pressure brixing of higher ratio concentrates D keep busy waitresses from overflowing drinks 19 The QLT circuit board differs from the SLJ primarily in the way they sense the sold out or refill condition gt True _ False ANHIAH I 1999 IMI Cornelius Inc 23 Wilshire Juice Training Manual NOTES 24 1999 IMI Cornelius Inc IMI Cornelius Inc One Cornelius Place Anoka MN 55303 1592 U S A Part No TP00908 TECHNICAL May 10 2002 SERVIGES
7. Van guard Venture Olympus and Vista are registered trademarks of IMI Cornelius Inc Optifill trademark is pending This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius Printed in U S A Copyright 1999 2002 Rights Reserved IMI Cornelius Inc Wilshire Juice Training Manual NOTES amp gt Wilshire Juice Training Manual TABLE OF CONTENTS INTRODUCTION 1 Preview Questions 1 Key Things Know Do 1 Overview 2 Product Description 2 Dimensions amp Capacities 3 All Quantum Dispensers 3 Quantum 1000 Single Flavor 3 Quantum 2000 Two Flavor 3 Quantum 3000 Three Flavor 3 Quantum 4000 Four Flavor 3 SYSTEM DETAILS 4 Water 4 Water Quality 4 Water Flow
8. n lt 2 um m lt gt gt Un 5 2 Refrigerant Charging Charging any capillary tube controlled system requires accurate charging equip ment and technique The Cornelius Wilshire dispenser is no exception The amount of refrigerant in the system actively determines the operating pressures and temperature of its evaporators It is because of this that it s necessary to utilize a refrigerant scale or graduated charging cylinder whenever charging a system Whenever investigating a suspect sealed system of this type it s important to remember that its operating pressures are to a great degree determined by load ambient temperature and condition If the unit appears to be under charged check first for a dirty condenser If the unit is constantly running but not cooling the 1999 IMI Cornelius Inc 13 Wilshire Juice Training Manual problem may be a low charge If a low charge is suspected it is recommended that the system be evaluated and leak tested by standard methods NOTE Hooking up a high side hose to a system with only 6 25oz of refrigerant causes a quarter or more of the charge to backup into the hose immediately resulting in an Incorrect reading It 15 for this reason that operating pres sures are not published Since the initial production of the SLJ Quantum dispenser the amount of the refrigerant charge has changed Earlier units specify a 5 Ooz charge while later units specify a 6 25o
9. all times v Learn to use a good quality volt ohm meter Proper electrical trouble shoot ing is impossible without it 1999 IMI Cornelius Inc 1 Z Q Q x a Z Wilshire Juice Training Manual 3 OVERVIEW Transformer amp Relay Concentrate Compartment Water Cooling Coil Compressor Fan Condenser Air intake through bottom 3 1 Product Description Dispensers manufactured under the Cornelius Wilshire name have a long and dis tinguished history of service in the frozen juice industry As with their previous names Alco and Reynolds they have set the standard for utility reliability and long service lives against which their competitors are judged These dispensers have undergone an evolutionary development over the years in order to take advantage of newer technologies and yet retained their original char acter and simplicity of design While pumping systems have undergone changes to better meet the needs of our customers and cabinet design has been given a new and more pleasing look the refrigeration system has remained true to its original design There are two models of post mix juice dispenser Slim Line Juice SLJ comes in 1 2 3 and 4 flavor 2 and 4 are the most pop ular It can use a refillable or disposable juice container e Quick Load Tube QLT is almost identical to the SLJ except for the pump and juice pouch tray The one two and three flavor dispensers use a
10. oy ioh 1O OR ANG sy ISSUES amp ANSWERS BIB vs 6 LITER POUCH 1 217 Finished oz vs 2 048 Finished oz f have to change often CG INSTALLATION INSTRUCTIONS WILSHIRE SLJ1000 1 VOLTAGE REGULATOR BOARD VRB NE m INSTALLATION INSTRUCTIONS WILSHIRE QLT180 VOLTAGE REGULATOR BOARD VRB 19 gt lt 2 N Z m a lt s lt Wilshire Juice Training Manual INSTALLATION INSTRUCTIONS WILSHIRE QLT JUICE DISPENSER WIRING QLT Juice Dispenser Wiring Installation Instructions IMI Cornelius QLT Training video tape 20 1999 IMI Cornelius Inc REVIEW DATE NAME LOCATION The following questions summarize important points in this training lesson What function does the refrigerant solenoid valve perform A Turns the compressor on off B Controls refrigerant pressure C Controls refrigerant flow to the water coll D Controls cabinet temperature The water and cabinet thermostats can be interchanged True False Power for the compressor flows through A The water thermostat B The concentrate thermostat C The control relay D All of the above The transformer output is direct current DC True False Air is sucked into the unit and exhausted through the condenser True False Ice buildup on the interior cabinet wall
11. vari able speeds Some juice dispensers have speed switches which change the motor voltage from 28 to 18 This slows the motor to accommodate very low water pressure This is especially useful when high concentrate ratios are used 2 lt 2 4 m lt z gt Un 1999 IMI Cornelius Inc 11 un L gt un gt un amp gt Wilshire Juice Training Manual 5 REFRIGERATION The two evaporators in our design are independently controlled so that they don t both cool at once This prevents the cabinet or water thermostats from over cooling one evapo rator while trying to satisfy the other This is accomplished by using two thermostats wired parallel a control relay to connect them to the compressor and a liquid line solenoid valve to isolate the water cooling evaporator during cabinet cooling cycles During a cabinet concentrate cooling cycle the water may require cooling When this occurs the water thermostat closes sending current to the control relay At this point the compressor is already running so the current is passed on via the red wire leading to the refrigerant sole noid valve Once this valve is opened refrigerant flow is diverted to the water coil for cooling The cooling cycle is relatively short for average incoming water temperatures If incoming water is warm it may become necessary to hook up to a chilled water line from a beverage system in order to keep up with
12. 1525064 N m m gt m Un gt N 8 1999 IMI Cornelius Inc amp gt Wilshire Juice Training Manual 4 3 SLJ Valve Mixing Block Rebuilding Valves should be rebuilt if they are leaking Cornelius supplies all the parts necessary for rebuilding Loosen cam lock washer 1 Loosen cam lock washer on both water lines cam lock washers 2 Remove two screws on the bottom of the plate n lt n um les lt z E Un 1999 IMI Cornelius Inc 9 Wilshire Juice Training Manual Solenoid Wires 3 Remove Solenoid wires 4 Remove nut and Solenoid coll Solenoid Coil Nut Screws On Front Of Plate 5 Remove all screws Screws N lt m A gt m Un gt Un Fr 6 Separate valve halves Flow Control Flow Sleeve Control Piston 10 1999 IMI Cornelius Inc Wilshire Juice Training Manual 7 If necessary remove and replace flow control and check valve components Check Valve 8 Rebuild the valve and reassemble Replace all O rings making sure they are not pinched or twisted Be sure the cam lock washers are in the grooves of the water lines NOTE O rings should be lubricated with sanitary lubricant 4 4 Miscellaneous Mechanical 51 15 can be converted to QLTs see IMI Cornelius QLT Training video There is one motor per concentrate pump DC motors are used to allow
13. NG QLT DRINK QUALITY PROBLEMS ACTUAL PROBLEM amp SYMPTOMS REACTION Concentrate too cold Low brix False refill light Poorly mixed drink Unmixed concentrate at bottom of cup Poor flow rate Decrease water flow Might correct brix False refill light Poorly mixed drink Pulsing splashing dispense Unmixed concentrate at bottom of cup NOTE After 2 4 hours the concentrate will match the cabinet temper ature becoming more viscous resulting in high brix Concentrate too warm High brix Increase water flow NOTE After 2 4 hours the concentrate will match the cabinet temper ature becoming less viscous resulting in low brix Piercing device created a when it pierced through the pouch Low brix False refill light Decrease water flow Might correct brix False refill light Poorly mixed drink Pulsing splashing dispense Unmixed concentrate at bottom of cup NOTE Correct by rotating piercing device 90 180 Warm Hydrometer Floats higher in the cup indicating high brix Increase water flow Might lower brix Drinks taste weak 1999 IMI Cornelius Inc 247s Zi tr 02 T Z Q Z gt a N m mm O x gt Wilshire Juice Training Manual TROUBLESHOOTING QLT DRINK QUALITY PROBLEMS ACTUAL PROBLEM amp SYMPTOMS
14. and replace nozzle Flushing daily and sanitizing weekly is recommended 1999 IMI Cornelius Inc amp gt Wilshire Juice Training Manual 2 1 Miscellaneous CONCENTRATE Tips SLJ Units If the concentrate causes a false refill light the refill circuit can be bypassed jumped Jumper the two probes just above the dispense flush lever QLT Units QLT s usually use 5 to 1 concentrate which can look thawed in the bag but still be semi frozen Concentrate that is too thick to flow properly may cause a false refill light because the syrup may not have filled the tube When there is no concentrate in the tube the pump motor runs with no drag The concentrate sensor measures current draw on the motor and assumes that since there is no concentrate in the tube that the concentrate supply is empty 3 SETTING RATIOS A refractometer or hydrometer must be used to measure the post mix ratio Ratios are sometimes set by taste but this is not recommended 2 lt 0 um m lt z gt Un 1999 IMI Cornelius Inc 5 Wilshire Juice Training Manual 4 MECHANICAL At least once a year the concentrate pumps should be checked cleaned and the pump tub ing replaced 4 1 Concentrate Pump Disassembly 1 See Installation And Service Manual for pump platform removal procedure Housing 2 Remove four thumb screws housing cover and impeller Rotor Assembly Thumb Screws 3 Remo
15. peak or high demand periods Setting the water thermostat to a colder temperature does not increase the efficiency of the water coil and may result in the freeze up of the water coil during off peak hours Once the water thermostat is satisfied the refrigerant solenoid will close and cooling will be restored to the cabinet Water Thermostat Controls the refrigerant solenoid valve and the cooling of the water evapo rator coil Connects to the normally closed relay terminal Concentrate Thermostat Controls cooling of the concentrate compartment and operation of the start relay Connects to the normally open relay terminal and the relay coil Note These thermostats are of different sensitivities and must not be sub stituted for one another The same two parts are used in all models all years Control Relay Allows thermostats to individually control compressor operation without short cycling This relay is also used in all models all years Refrigerant Solenoid Valve Cuts off the flow of refrigerant to the water cooling coil when the water thermostat is satisfied Heat Exchanger Assembly Consists of the capillary tubes for the concentrate compartment and the suction line and insulation The capillary tube is soldered to the suction line to prevent condensation and balance system pressure If replacement becomes necessary the entire assembly must be replaced as one 12 1999 IMI Cornelius Inc amp gt Wilshi
16. re Juice Training Manual Compressor Moves the refrigerant through the system Pressurizes the refrigerant for heat dissipation in the condenser Condenser Dissipates heat from the compressor and refrigeration action Condenser Fan Circulates air across the compressor and condenser to facilitate heat removal Dryer Cleans and removes moisture from refrigeration system A standard dryer was in use for the SLJ until recently The dryer currently in use is a Parker style dryer The Parker distinguishes itself by having two inlets and two outlets When ordering a new dryer it is important to specify which dryer is needed The dryer should be replaced any time the refrigeration system is opened 5 1 Air Flow Airflow in earlier units such as the first revision SLJ model was brought through louvered side panels and directed across the compressor and through the con denser The second generation SLJ with the smooth side panels gets its airflow from the bottom and directs it first through the condenser and then across the com pressor On all models the airflow passes from the fan blades into the condenser This increases the efficiency of the refrigeration system but allows dirt to build up where it is difficult to see or remove On the positive side the condenser is designed to maximize airflow and minimize dirt buildup Even so the condenser should be cleaned yearly and checked whenever routine maintenance 15 per formed
17. s is A anormal part of the dispenser operation B due to the thermostat being set too cold C an indication that the concentrate has not been correctly thawed D all of the above 1999 IMI Cornelius Inc Wilshire Juice Training Manual 21 REVIEW Wilshire Juice Training Manual amp gt 10 11 12 13 14 15 22 The voltage regulator board provides DC power pump motor True False Pump hoses should be replaced A monthly B whenever flavors are changed annually D when they wear out If the juice machine has been laid down on its side it should be allowed to stand upright for at least one hour before starting _ False Ratio 15 a measure of the amount of water verses concentrate in the finished Juice drink _ False Brix 15 a measurement of the dissolved solids in the finished drink True False The knob on the mixing valve adjusts concentrate flow True False On the SLJ Quantum series dispensers the pump motor and solenoid valves are wired parallel with one another _ False The pump motor will rotate in the wrong direction if wired incorrectly True False The QLT circuit board may be substituted for the SLJ circuit board A once the pump assembly has been updated B whenever the SLJ board malfunctions C only on dispensers that are being converted to QLT applications D Both amp
18. single frame and a separate pump assembly for each flavor The four flavor dispenser is two two flavor units merged together Everything is interchangeable except the frames 1999 IMI Cornelius Inc amp gt Wilshire Juice Training Manual Each dispenser has two cooling evaporators one for water and one for concentrate Each evaporator has its own thermostat The dispensers are not self defrosting A lighted merchandiser is an option 3 2 Dimensions amp Capacities All Quantum Dispensers Flow Rate 1 6 2 2 oz sec Electrical rating 115 VAC 60 cycle single phase 9 43 amps c 220 VAC 50 cycle single phase 5 amps Dimensions 34 1 2 H with 4 legs 27 1 4 D Clearance 4 back 12 top Water Connection 3 8 SAE male flare 100 psi max static 20 psi min dynamic Quantum 1000 Single Flavor Dimensions 10 3 4 W Shipping weight 125 Ibs Quantum 2000 Two Flavor Dimensions 10 3 4 W Shipping weight 130 Ibs Quantum 3000 Three Flavor Dimensions Shipping weight 145 Ibs Quantum 4000 Four Flavor Dimensions 19 W Shipping
19. ve and replace clamps and pump tubing with new ones pump tubing and clamps kit p n 4509 Clamps Pump Hose 4 Clean components and check that the rollers spin freely N lt ea A gt m Un gt Un Impeller Rollers 6 1999 IMI Cornelius Inc amp gt Wilshire Juice Training Manual 4 2 SLJ Rinse Flush Valve Rebuilding Valves should be rebuilt if they are leaking Cornelius supplies a kit which includes all the O rings p n 45026100 1 See Installation And Service Manual for pump platform removal procedure 2 Remove four screws and lift valve assembly up disconnect wires in the back of the valve Screws 3 Remove two screws holding the valve to the bracket on lt on v e 4 Loosen screw that holds cam lock lt washer and disconnect the syrup line Fastening Screw amp N Cam lock Washer 1999 IMI Cornelius Inc 7 Wilshire Juice Training Manual Bottom Of Valve 5 Remove four screws from bottom of valve Screws amp Plate Top Of Valve 4 Bottom 6 Pull off bottom of valve of Valve and center section Center Section gt Of Valve J 7 Rebuild the valve and reassemble Be sure cam lock washer is in groove of the syrup line NOTE O rings should be lubricated with sanitary lubricant NOTE Red O ring at bottom of valve plate must be a tear resistant teflon Use p n 3
20. weight 156 lbs 1999 IMI Cornelius Inc 3 Z 2 a Q Z N m m gt m Un gt Un Wilshire Juice Training Manual 1 2 amp gt SYSTEM DETAILS WATER 1 1 Water Quality Water quality has an affect on Juice dispensing systems odor taste clarity foaming Water filtration is recommended to assure the best beverage taste 1 2 Water Flow Inlet water pressure should be regulated to 45 psi max 3 1 bar to prevent damage to pump tubing 1 3 Adjusting Flow Rates Adequate water flow 15 necessary and should at least 3 0 ounces per second 89 ml at the inlet CONCENTRATE Concentrate should be stored frozen and put into a cooler 72 hours before use Rapid cooling such as in a sink of hot water adversely affects flavor and leads to service calls Proper loading of concentrate is important Improper loading is a major source of ser vice calls Concentrates vary in viscosity and mixing valves must be adjusted accordingly When changing concentrate be sure to check the concentrate container O ring for damage It should be clean and wet with concentrate or a food grade lubricant Shake or stir pulp based concentrates When changing flavors be sure to flush the system and reset the pump Nozzles should be cleaned daily Remove the nozzles and wash in warm soap solution Rinse with clean water lubricate the O ring
21. z charge The reason for this change was driven by field ser vice issues While 5oz charge produces the optimum cooling temperatures slight under charge from this critical point can cause a flash freeze in the water evaporator inlet By increasing the charge to 6 250z we have increased the buffer zone between the correct charge and an under charge without any significant per formance loss Changes to the refrigeration system were not necessary to make this adjustment Early units with a 507 charge on the nameplate may be recharged to 6 2507 if refrigeration service is called for 5 3 Filter Dryer Replacement The style of filter dryer utilized in the Cornelius Wilshire juice dispenser has recently changed The dryer previously in use was a standard configuration Alco dryer with one inlet and one outlet Our new dryer is of a different configuration Instead of the standard configuration this dryer has two inlets and two outlets The two inlets are for the refrigerant line from the condenser and a process tube The two outlets are for the refrigerant line leading to the liquid line solenoid valve and the capillary tube that controls the concentrate evaporator 5 4 Condenser Cleaning To clean the Condenser or change the fan motor follow this procedure 1 Disconnect the power cord then remove the drip tray splash panel top panel and both side panels N m m gt m Un gt Un 14 1999 IMI Cornelius Inc
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