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International Carbonic Big Fella - Soda

1. 2 5 CONNECTING WATER 1 esee nennen 2 5 ELECTRICAL REQUIREMENTS sese 2 5 CHAPTER PREPARATION bt 3 1 PREPARING SYSTEM FOR 3 1 PREPARING AND STARTING REFRIGERATION 3 1 PURGE DISPENSING VALVES eene 3 1 ACTIVATE HIGH PRESSURE CO2 3 1 ACTIVATE LOW PRESSURE CO2 GAS AND SYRUP SYSTEMS 3 2 ADJUST WATER FLOW eene 3 2 ADJUST WATER TO SYRUP RATIO emen 3 2 ADJUST SIZE OF DRINK DISPENSED eene 3 2 CHAPTER IV OPERATORS 5 4 1 DAILY PRE OPERATION CHECK Ne 4 1 REPLENISHING CO2 SUPPLY seen 4 1 REPLENISHING SYRUP SUPPLY seen 4 1 COOLING 4 1 CHECKING WATER BATH nennen 4 2 CHANGING WATER BATH esses 4 2 ADJUSTMENTS tci ertet a 4 2 ADJUSTING WATER FLOW esee emen 4 2 ADJUSTING WATER TO SYRUP RATIO OF DISPENSED PRODUCT 4 2 ADJUSTING SIZE OF DRINK 4 2 TESTING FOR LEAKS a quas ieri
2. 6 5 CARBONATION TROUBLESHOOTING FLOW CHART 1 6 6 CARBONATION TROUBLESHOOTING FLOW CHART 2 6 7 CARBONATION TROUBLESHOOTING FLOW CHART 3 6 8 NOTE SEGTIONA i iii i aa pa TAR Ka M 6 9 LIST OF FIGURES Figure Title 1 1 EXPLODED VIEW OF BIG FELLA J nee 1 3 1 2 ILLUSTRATED PARTS BREAKDOWN OF BIG FELLA J 1 4 1 3 EXPLODED VIEW OF BIG FELLA pp 1 5 1 4 ILLUSTRATED PARTS BREAKDOWN OF BIG FELLA 1 6 TABLE CONTENTS CONT D Figure Title PAGE 1 5 ELECTRICAL SCHEMATIC SC BF see 1 8 1 6 ELECTRICAL SCHEMATIC 86 1 9 1 7 ELECTRICAL SCHEMATIC 24V 1 10 2 1 SAMPLE OF A POSSIBLE INSTALLATION 2 2 2 2 HIGH PRESSURE CO2 REGULATOR S 101 2 9 2 3 LOW PRESSURE CO2 REGULATOR 5 121 2 3 2 4 SUGGESTED WATER FLOW INSTALLATION 2 4 5 1 WATER PUMP Y STRAINER 80 5 4 5 2 CHEGK VALVES itecto Reo etu tuns 5 5 5 3 COMPOSITE EXPLODED VIEW OF CHECK VALVES AND RELIER VALVE tnra feti S sies tet 5 6 LIST OF TABLE 1 1 DESIGN DATA iter iie a rade 1 1 2 1 LOOSE SHIPPED anna 2 1 INTERNATIONAL CARBONIC INC has enjoyed over
3. 6 1 WATER PUMP 6 1 WATER PUMP OPERATES BUT WATER PUMP DOES NOT PUMP e 6 1 FROZEN WATER BATH a 6 2 COOLING OR CONDENSING UNIT NOT OPERATIONAL 6 2 AGITATOR MOTOR NOT 6 2 COMPRESSOR DOES 6 2 COMPRESSOR WORKS CONTINUOUSLY BUT DOES NOT FORM SUFFICIENT ICE 6 2 COMPRESSOR WILL NOT STOP AFTER SUFFICIENT ICE BANK IS PRODUCED eene 6 3 CONDENSER FAN MOTOR NOT 6 3 DISPENSING VALVES it cttm ree e kb HORREA 6 3 WATER OR SYRUP LEAKING FROM NOZZLE AFTER ACTUA TION TEE 6 3 NO WATER NO SYRUP BEING DISPENSED FROM VALVE 6 3 NO SYRUP BEING 6 4 NO WATER BEING 6 4 DISPENSED PRODUCT CARBONATED TO LOW 6 4 DISPENSED PRODUCT MAKES FOAM AS IT LEAVES NOZZLE ga ute tg tee eia 6 4 DISPENSED PRODUCT COMES OUT CLEAR BUT FOAMS WHEN IT TOUCHES CUP OR 6 4 WATER TO SYRUP RATIO TOO LOW OR TOO HIGH 6 5 ADJUSTMENT OF SYRUP METERING PIN DOES NOT PRODUCE DESIRED WATER TO SYRUP
4. Note Ground Terminals Carbonator Tank Water Bath Must be Commonly Grounded NOTE IF USING EXTRA 120V ACCESSORIES SUCH AS RECIRCULATING MOTOR ILLUMINATION CONNECTIONS AT TERMINAL A4 A5 FOR POWER BLACK LEG TERMINALS B4 B5 FOR NEUTRALWHITE LEG AND GROUND AT BOX OR ANY GROUND TERMINAL NOT IN USE TERMINALSGROUND TERMINALS ARE G1 G2 G3 G4 FIGURE 1 5 1 8 MOTOR COMPRESSOR G GREEN GROUND TERMINAL SCREW IN CONTROL BOX 110VAC X ON OFF SWITCH ILLUMINATION OPTIONAL BLACK RIBBED CONDENSING UNIT ICE BANK CONTROL INTERNATIONAL CARBONIC INC og ELECTRICAL HEM DATE 1 29 99 DRN BY GLW ADELANTO CALIFORNIA FIGURE 1 6 1 9 VALVE SCHEMATIC WHITE 24 VOLT 24 VOLT SINGLE 24 VOLT VALVES OA KEY SWITCH f 24 VOLT TRANSFORMER ELECTRICAL SCHEMATIC 24 VOLT FIGURE 1 7 1 10 The BIG FELLA was designed to manufacture 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
5. 4 2 CHAPTER V SERVICE AND 5 1 PERIODIC INSPECTION AND 5 1 BIG FELLA CABINET 5 2 CLEANING CONDENSER COIL seen 5 2 CHECKING CHANGING WATER BATH seem 5 2 CARBONATOR 5 4 LUBRICATION i ee RE REO ME geh 5 4 SERVICING CHECK VALVES sse nnne 5 5 REPLENISHING CO2 SUPPLY sse 5 7 TABLE OF CONTENTS cont d PAGE SYRUP FLAVOR CHANGE L a nns 5 7 CHANGING WATER FILTER CARTRIDGE OPTIONAL 5 7 ADJUSTMENT Sirni eerie e e eere RAE e 5 7 HIGH PRESSURE CO2 REGULATOR 5 7 LOW PRESSURE CO2 REGULATOR pp 5 8 DIET SYRUP TANK CO2 5 8 BRIX INSTRUCTION essere nnns 5 9 CLEANING AND SANITIZING esee emen nnne 5 11 CHAPTER VI TROUBLE SHOOTING eene 6 1 WATER PUMP MOTOR WILL NOT OPERATE 6 1 WATER PUMP MOTOR WILL NOT SHUT OFF 6 1 WATER PUMP WILL NOT SHUT OFF AND PRESSURE RELIEF ENGAGED s ia aula Susa ect deters Tunapa ad 6 1 SHORT CYCLING OF WATER PUMP MOTOR
6. 44 1 1158 DRAIN W CUP REST FIGURE 1 2 1 4 TITLE SC B F BIG FELLA POST MIX IC ADELANTO CALIFORNIA FIGURE 1 3 1 5 SC BF PARTNO DESCRIPTION 1 1 0653 LID 2 8 S0588 B SYRUP COIL 3 1 S0262 LF CARBONATOR TANK ASSEMBLY 4 1 50073 48 PROBE ASSEMBLY 5 2 90660 SERVICE PANEL SIDE 6 1 S0678 SERVICE PANEL REAR 7 1 S0684 WATER COIL COPPER S0208 A WATER REGULATOR NOT SHOWN OPTIONAL 8 1 90669 WATER LINE COPPER 1 S0203 UNION CONNECTOR 10 5 S0661 EVAPORATOR COIL RETAINER 11 5 S1323 EVAPORATOR GUIDE WEDGE 12 5 S0662 EVAPORATOR SUPPORT BRACKET 13 1 S0509 ACCUMULATOR 14 1 S0663 EVAPORATOR COIL ASSEMBLY 15 1 Z0010 CAP TUBE 9 050 16 1 0513 A BANK CONTROL 17 1 S0657 STAND PIPE 7 3 4 WHITE 18 1 S0658 OVERFLOW 8 GRAY 19 1 G0016 TYE WRAP LARGE 20 9 A0020 SCREW 8 32 X 3 8 TH S S 21 1 S0835 AGITATOR PUMP 22 INSULATION LEFT amp RIGHT SIDE 23 Suet INSULATION REAR 24 To INSULATION FRONT 25 Y E INSULATION BOTTOM 26 MOISTURE BARRIER 27 1 S0656 BUCKET COMPLETE W INSULATION 28 1 S0664 ICE BANK BULB CLIP FIGURE 1 4 1 6 SYM QTY PART DESCRIPTION 29 1 S0655 FRAME COMPLETE 30 1 E0276 TRANSF
7. QTY PART NO DESCRIPTION 1 1 S0653 LID 2 2 0660 SERVICE PANEL SIDE 3 1 S0678 SERVICE PANEL REAR 4 1 S0684 J WATER COIL 5 1 0020 DOUBLE CHECK VALVE 3 8 3 8 6 5 0661 EVAPORATOR COIL RETAINER 7 5 S1323 EVAPORATOR GUIDE WEDGE 8 5 S0662 EVAPORATOR SUPPORT BRACKET 9 1 0663 EVAPORATOR COIL ASSEMBLY 10 1 20010 CAP TUBE 9 050 11 1 S0509 ACCUMULATOR 12 1 0657 STAND 7 3 4 WHITE 13 1 0658 OVERFLOW 8 GRAY 14 1 0513 ICE BANK CONTROL 15 1 S0664 ICE BANK CONTROL BRACKET 16 1 G0016 TYE WRAP LARGE 17 1 S0835 AGITATOR PUMP 18 26 1 INSULATION LEFT amp RIGHT SIDE 19 Tr __ ees INSULATION REAR 20 12 110 INSULATION FRONT 21 ld o phata INSULATION BOTTOM 22 Tur 000mm MOISTURE BARRIER 23 1 S0656 BUCKET COMPLETE W INSULATION 24 1 S0655 FRAME COMPLETE 25 1 E0276A TRANSFORMER 40 VA 26 1 51308 CONTROL BOX W COVER 27 4 S1335 TERMINAL BOARD SPACER NVLON 3 8 28 1 S1310 CONTROL BOX COVER 29 1 S1309 TERMINAL BOARD 30 8 A0020 SCREW 8 32 X 3 8 TH S S 31 1 E0664 STRAIN RELIEF 32 1 0654 33 1 SET 0765 LEGS 34 5 S0046 BUSHING 35 1 S 7 8 HOLE PLUG 36 1 E0141 12 CORD 37 1 S0783 UNIT ON OFF SWITCH 38 1 S0768 SWITCH LOCK W KEYS 39 1 AEA3440YXAXL CONDENSING UNIT 1 3 HP AEA3440YXA COMPRESSOR ONLY 40 2 A0046 5 16 18 FLANGE WHIZ LOCK SCREW 3 4 41 8 PFC Il QR DISPENSING VALVES 42 1 S1158 A CUP REST 43 1 50743 DRAIN HARDWARE SET
8. 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 shake 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 in 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 svrup ratio to low or too high Svrup flow regulator not properlv adjusted gas pressure in syrup tanks insufficient Svrup tubing I D insufficient Adjust water to svrup 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 w
9. 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 Trouble 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 thermal overload protector Allow motor time to cool 2 Electrode inside carbonator tank 2 Replace carbonator tank defective electrode 3 LLC assembly Inoperable 3 Replace LLC assembly 4 Loose electrical connection 4 Tighten connection and or repair and or open electrical circuit 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 LLC assembly inoperable 3 Replace LLC assembly 4 Loose electrical connection and 4 Tighten connection and or repair or open electrical circuit open ground circuit 5 Carbonated water leak 5 Find and repair leak Water Pump 1 Electrode inside carbonator does 1 Replace defective electrode or
10. 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 BIG 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 drinks 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 7 gallons of water A certain amount of this water will be transformed into ice approximately 35 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 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 cle
11. motor will not not sense ground check and tighten ground shut off and connection at control box pressure relief 2 LLC assembly inoperable 2 Replace LLC 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 defective electrode 3 Carbonated water leak in system Repair carbonated water leak LLC assembly inoperable Replace LLC control assembly Water pump 1 Inlet water volume supply to low 1 Increase diameter of supply line capacity to low install holding tank 2 Water motor pump worn out 2 Replace water pump 3 Kinked or restricted water supply 3 Clear or replace restricted water line supply line 4 Foreign object in water pump or 4 Clear restrictions and check pump restriction to water pump 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 lnoperative 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 Badice bank control 1 Replace bad ice bank control bath 2 Refrigerant leak causing 2 Repair leak evacuate and re undercharge charge 3 Defective agitator mo
12. 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 5 Assemble check valves together as shown in Figure 5 1 6 Connect water inlet line to double check valve assembly 7 Activate the system as outlined in CHAPTER 5 22 GAS CHECK VALVE S 20 WATER CHECK VALVE FIGURE 5 2 CHECK VALVES 5 5 HOUSING CHECK VALVE 1 4 M F sas ser O RING CHECK VALVE pala sar cneckvave _ s 3 so __ _ 1 sae JADAPTOR HOUSING DOUBLE CHECK VALVE Pali sas houso cnece varve serme s LEVER HANDLE LEVER PIN FIGURE 5 3 EXPLODED VIEW CHECK VALVES 5 6 REPLENISHING C02 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 II 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 QCD s from empty or syrup C02 quick disconnects from emp
13. nozzle in bleach water this will turn the nozzle yellow and cause deterioration lt 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 5 10 SANITIZING PROCEDURES Your local health department rules and general area cleanliness should determine the frequency at which the unit should 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 OQ 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 at 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 brus
14. 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 only 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 BIB racks or syrup tanks are full 3 Make sure all QCD s are in an operational position or gas 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 BIB and approx 30 psi for FIGAL NOTE These pressures will vary depending on baume of product type of pumps etc 5 If 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 v
15. 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 ice 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 1 cup of citric acid for 2 gallons of water Stainless steel cleans well with carbonated water Then rinse with clean water 7 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 Shutoff plain water supply to water pump by closing shutoff valves in water supply line 3 Shutoff CO2 supply to BIG FELLA by closing shutoff valve on CO2 cylinder 4 Remove lid from unit 5 Gain acc
16. 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 Il in Canfield Ohio as Carbonic Dispensers We enjoyed patents on the first Sodajet type carbonator This method of carbonation instantaneously carbonated the water to 100 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 post mix 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 in the future CHAPTER I GENERAL DESCRIPTION This chapter gives the description theory of operation and design data for the BIG FELLA SC BF BIG FELLA J SC BF J and related components SYSTEM DESCRIPTION The BIG FELLA is a complete is a complete self contained remote cooling carbonation unit which when combined with related componen
17. A 245 grams Ambient operating temperature 40 F to 100 F Electrical Requirements The cooling unit requires a 115 VAC single phase 60 Hertz power circuit SC BF SC BF J Circuit Ampacity 14 9 Amps 8 2 Amps Condensing Unit 6 9 Amps 6 9 Amps Water Pump Motor 6 7 Amps NA Transformer 5 Amps 5 Amps Agitator 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 75 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 l 18 19 18 20 21 22 T 33 GO ALEX 38 a2 23 24 39 INTERNATIONAL CARBONIC INC IC ADELANTO CALIFORNIA 16 TITLE SC B J BIG FELLA J UICE PATE 1 6 05 DRN BY GLW CHK BY APPR BY FIGURE 1 1 1 3 SC BF J SYM
18. BIG FELLA INSTALLATION AND SERVICE MANUAL INTERNATIONAL CARBONIC INC 16630 KOALA RD ADELANTO CA 92301 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 PAGE PREFACE 1 CHAPTER GENERAL DESCRIPTION 3 1 1 SYSTEM DESCRIPTION esee 1 1 THEORY OF rennen nennen nennen nnne 1 11 CHAPTER II INSTALLATION Nt 2 1 UNPACKING AND INSPECTION eene 2 1 SELEGCTING LOGATION Lu e etn te cnn naa 2 1 LOCATION RECOMMENDATIONS FOR BIG 2 2 INSTALEATION n 2 te n et A aha e Pre de 2 2 INSTALL COOLING UN eene eene rennen 2 3 INSTALL HIGH PRESSURE CO2 REGULATOR CO2 CYLINDER AND LINES a ss aa atau esce pleads 2 3 INSTALL LOW PRESSURE REGULATOR AND 2 3 INSTALL WATER FILTER ASSEMBLY 2 4 INSTALL WATER PRESSURE REGULATOR OPTIONAL 2 4 INSTALL WATER HOLDING TANK 2 4 INSTALL DRAIN LINE mnm 2 5 INSTALL BIB OR SYRUP TANKS AND
19. NOT COME ON Non carbonated water svrup being dispensed oniv j Check CO2 supply Check water pressure 5 Water pressure greater than or closeto CO2 pressure will C02 cylinder is empty stop the carbonation process 1 Change C02 cylinder Install or adjust water regulator Y Hi pressure regulator is set to low or malfunctioning 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 _ 1 Install holding tank increase water feed I D 1 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
20. ORMER 40 VA TWO REQUIRED W 8 VALVES 31 1 S1308 CONTROL BOX W COVER 32 4 1335 TERMINAL BOARD SPACER NVLON 3 8 33 1 S1310 CONTROL BOX COVER 34 1 500688 JLIQUID LEVEL CONTROL LLC 35 1 E0664 STRAIN RELIEF 36 5 S0046 BUSHING 37 1 S 7 8 HOLE PLUG 38 H1 SET 90765 LEGS 39 1 E0141 12 CORD 40 1 S0783 UNIT ON OFF SWITCH 41 1 0768 SWITCH LOCK W KEYS 42 1 S0654 VALVE PLATE 43 2 S0170 HALF UNION BRASS 3 8 MF X 3 8 MP 44 1 S0103 PUMP PROTECTOR 45 1 S0104 PUMP PROTECTOR BRACKET 46 2 A0045 5 16 X 18 FLANGE WHIZ LOCK SCREW 1 2 47 1 0650 STRAINER BRASS 4 1 S0175 90 DEGREE ELBOW 3 8 X 1 4 4 1 S0200 PUMP CARBONATOR 50 1 S0106 CLAMP V BAND 51 1 S0096 MOTOR CARBONATOR 52 1 J AEA3440YXAXL CONDENSING UNIT 1 3 HP AEA3440YXA COMPRESSOR ONLY 53 2 A0046 5 16 X 18 FLANGE WHIZ LOCK SCREW 3 4 54 8 PFC I QR DISPENSING VALVES 55 1 S1158 A CUP REST 56 1 S0743 DRAIN PAN HARDWARE SET 57 1 1158 W CUP FIGURE 1 4 continued 1 7 S 68 B ELECTRICAL SCHEMATIC 120 VOLT 5 CONVERT TO THIS IF A CARB UNIT ICE BANK CONTROL 3 COMPRESSOR TRANSFORMER WHITE 120 BLACK INTERNATIONAL CARBONIC ING G2 G3 G4 b ON OFF AAs 545 B3 B4 Bs MOTOR2 CONDENSING MOTOR1 Li UNIT AGITATOR PUMP SHORT LONG HITE BLACK ELECTRODE GROUND TERMINAL SCREW IN CARB CONTROL BOX MOTOR PUMP
21. S 22 or valve relief S 215 Service check valves as outlined in SERVICING CHECK VALVES Reassemble as necessary Replace lid Plug refrigeration unit power cord in electrical socket Turn on plain water supply to water pump by opening shutoff valves in water supply line Turn on C02 supply to refrigerating unit by opening shutoff valve on C02 cylinder Activate all systems as outlines in CHAPTER III LUBRICATION Water pump motors bearing must be oiled periodically Refer to oiling instruction on motors DO NO OVER OIL 5 4 SERVICING CHECK VALVES lt 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
22. alves 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 dispensed as instructed in chapter IV OPERATOR INSTRUCTIONS CHAPTER IV OPERATORS INSTRUCTIONS This chapter covers operators responsibilities for daily pre operation check adjustments replenishing C02 and syrup supplies cleaning and sanitizing DAILY PRE OPERATION CHECK 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 Syr
23. ank control 5 Replace ice bank control 6 Inoperative overload protector or 6 Replace defective part start relay 7 lnoperative compressor 7 Replace compressor 8 Fullice 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 higher 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 Note Ice bank freezes from bottom of evaporator upward 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 co
24. ar This 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 S 739 ADJUSTMENTS Periodically C02 regulators should be checked for proper pressure settings if necessary adjust as instructed These settings can be recorded in NOTE section of this manual ADJUSTING WATER FLOW RATE If adjustment of water flow rate should be necessary adjust as instructed ADJUSTING WATER TO SYRUP RATIO BRIX OF DISPENSED PRODUCT Water To Syrup of dispensed product should be checked and if necessary adjust as instructed ADJUSTING SIZE OF DRINK DISPENSED FOR PORTION CONTROL 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 All connections including cylinder valve should be coated with soap solution If 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 wou
25. arer 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 BIG 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 The 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 BIB 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 BIB 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 BIG 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 Pr
26. at 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 sufficient 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 WATER FILTER FIGURE 2 4 SUGGESTED WATER FLOW INSTALLATION 2 4 INSTALL DRAIN LINE 1 Connect drain line on BIG FELLA unit with drain using 3 8 I D 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 BIB OR SYRUP TANKS AND ACCESSORIES OPTIONAL 1 Place BIB or syrup tanks as close as possible to BIG 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 fo
27. ater 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 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 long amp short elect connection at LLC wires to ensure they are not Re connect reversed electrical 1 Re connect electrical Motor Pump should engage Motor pump Comes 1 Motor Pump does Motor Pump does not 1 come on Re install motor Possible bad spade to terminal Pump replace Motor 1 Go to electrode Bad LLC replace Return motor spade to terminal Motor 41 CARBONATION TROUBLE SHOOTING FLOW CHART 2 MOTOR PUMP DOES
28. avor LOCATION RECOMMENDATIONS FOR BIG 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 POSSIBLE INSTALLATION INSTALLATION 1 Make all connections C02 gas plain water and syrups 2 Place BIG 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 S 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
29. bonate 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 2 Adjust water flow to 6 ounces in 5 seconds 3 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 4 Actuate valve until syrup separator is full of syrup Hold brix cup close enough to valve outlet to form S on the flexible plastic tube so as to prevent any water following the flexible tube into syrup section This formed S will also hold syrup in tube for a more reliable brix reading 5 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 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
30. ess to water bath 6 Pull up on carbonator tank relief valve to relieve CO2 pressure from tank 7 Loosen screen retainer and then pull screen retainer and water strainer screen out of water pump port 8 Clean any sediment from screen retainer and water pump port 9 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 10 Check O ring on screen retainer Replace worn or damage ring S 650 AA S 650A N A lt ES 2208 FIGURE 5 1 WATER PUMP Y STRAINER amp SCREEN CARBONATOR MAINTENANCE 1 2 10 11 12 13 14 Unplug refrigeration unit power cord from electrical socket Remove lid from unit 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 Shut off plain water supply to water pump by closing shutoff valve in water supply line Shut off C02 supply to refrigerating unit by closing shutoff valve on 602 cylinder Pull up on carbonator tank relief to relieve C02 pressure from tank Eliminate leak tighten bad connections or replace defective Probe assembly water double check valve S 20 gas single check valve
31. h Clean exteriors of valve with a soft clothe and warm water Replace valve nozzle then go to step 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 standing 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 OND NOTE WHEN SANITIZING A TWO FLAVOR VALVE BOTH SYRUPS SHOULD BE FLUSHED SIMULTANEOUSLY BOTH SYRUPS SHOULD BE CLEANED DETERGENT SOLUTION SIMULTANEOUSLY BOTH SYRUPS SHOULD BE FLUSHED UNTIL FREE OF DETERGENT SIMULTANEOUSLY AND BOTH SYRUPS SHOULD BE SANITIZED SIMULTANEOUSLY TROUBLE SHOOTING IMPORTANT Only qualified personnel should service the BIG FELLA unit and components WARNING To avoid personal injurv and or propertv damage alwavs disconnect
32. ior 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 a carbonated valve The water source should be regulated this is normally performed by the use of an in line water regulator our part number S 208 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 the 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 control 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 fre
33. ise we will increase pressure supplied to our carbonator which will be indicated on this gauge To lower pressure to carbonation system it is recommended that the adjustment screw be turned counter clockwise several full turns and then the relief valve 53 215 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 PRESSURE 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 BIB 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 BIB 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 car
34. ld 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 5 minutes or longer 7 Next completely back off low pressure regulator adjusting screw and if gauge needle of low pressure regulator commence 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 CHAPTER V SERVICE AND MAINTENANCE This chapter describes service and maintenance procedures to be performed on BIG FELLA units and related components PERIODIC INSPECTION AND CLEANING Daily 1 Clean any syrup from storage tanks BIB racks connecting sockets QCD s and general syrup storage area with warm water 2 Check the C02 gas supply If cylinder pressure is below 500 PSI 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 PSI 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 sho
35. nd inspection selecting location installing BIG 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 BIG 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 not 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 Q 1 Installation Service Manual 1 2 S 101 High Pressure C02 Regulator 1 3 85 221 Low Pressure 02 Regulator 1 4 S 1158 Drain pan BIG FELLA 1 5 5 105 6 Gas Line Inner Braid 1 S Product Decals 1 7 S 208 Water Pressure Regulator 1 8 Water filter 1 9 S 208A Water Pressure Regulator 1 Optional SELECTING LOCATION IMPORTANT Ambient temperature for BIG FELLA should not exceed 100 degrees F 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 2 1 ty per fl
36. nlet connection with in ten feet of the BIG FELLA All water inlet connections are clearly tagged ELECTRICAL REQUIREMENTS The BIG 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 CHAPTER PREPARATION All steps in previous chapters should be understood and carried out before proceeding PREPARING SYSTEM FOR OPERATION Be sure that electrical power is unplugged valve on C02 cylinder is closed valve on water supply line is closed and release pressure of C02 gas and water from carbonator tank PREPARING AND STARTING REFRIGERATION UNIT 1 BIG 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 BIG 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 F 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
37. nnections 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 syrup 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 body 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 No electrical power 1 Plug power into electrical syrup being box Check line voltage dispensedfrom 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 Badtransformer 5 Replace defective transformer 6 Disconnected wire 6 Attach disconnected wire 6 3 syrup being 1 Syrup container em
38. of high pressure C02 regulator S 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 53 145 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 74 inner braid plastic tubing from outlet of tee at low pressure regulator S 221 optional furnished with unit to supplied line from unit marked gas INSTALL LOW PRESSURE REGULATOR AND LINES OPTIONAL 1 Install low pressure C02 regulator on the wall or another supporting structure in general vicinity of cooling unit C02 cylinder BIB Rack or syrup tanks 2 Connect 1 4 inner braided plastic tubing from outlets of low pressure C02 regulator S 221 to inlets of BIB pump or syrup tanks AY FIGURE 2 2 FIGURE 2 3 HIGH PRESSURE C02 REGULATOR LOW PRESSURE C02 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 D water line 3 Connect water filter assembly outlet to BIG FELLA plain water inlet fitting using minimum 3 8 1 D water line See CONNECTING WATER INLET When a water filter is used it is important th
39. 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 valve 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 PARTSWATER valve cover removed DECREASE SYRUP INCREASE SYRUP 1 c L i 7 WATER METERING PIN SYRUP METERING PIN SYRUP 2 18 to 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
40. pty 1 Replenish syrup supply dispensed 2 Syrup lines crimped 2 Straighten syrup lines 3 CO2 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 attached 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 CO2 cylinder 3 Water oil or dirt in C02 supply 3 Clean contaminated CO2 system lines regulator etc and sanitize as instructed 4
41. r BIB or transfer tank installations 4 Connect line from low pressure regulator to QCD for BIB or install quick disconnect for transfer tank type installations 5 Install incoming syrup line to unit on QCD for BIB 6 Install quick disconnect on incoming line to accommodate transfer tank installs 7 Activate QCD 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 TO POTABLE WATER SUPPLY SHALL BE SIZED INSTALLED AND MAINTAINED ACCORDING TO FEDERAL STATE AND LOCAL LAWS The water connection on the BIG 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 BIG 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 BIG FELLA It can be reduced to 3 8 O D copper tubing and connected to the water i
42. 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 BIG FELLA power cord in electrical socket CHECKING CHANGING WATER BATH Periodically 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
43. sh water enters the carbonator through the soda jet after passing through an inlet fitting water pump and related tubing The water pump has impellers which drives the water through 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 continuous recirculating manner This action causes a breakdown 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 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 at which time the relay on the liquid level control will close engaging the motor once again CHAPTER II INSTALLATION This chapter covers unpacking a
44. tor 3 Replace defective agitator 4 Dirty water bath 4 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 2 Defective ice bank control 2 Replace ice bank control operational 3 Dirty condenser unit 3 Clean condenser unit w vacuum cleaner 4 Improper voltage amperage 4 Check for proper voltage amperage 5 Loss of refrigerant 5 Repair leak and replenish refrigerant 6 Bad overload and relay 6 Replace overload and relay 7 Compressor bad 7 Replace compressor 8 Restriction pinched or crimped 8 Repair straighten or replace line defective 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 V at compressor terminals at start 4 Loose disconnected or broken 4 Tighten connection or replace wire broken wiring 5 Inoperative ice b
45. ts will produce a variety of cooled carbonated and non carbonated beverages The BIG FELLA consists of a condensing unit a water reservoir water cooling coil a carbonator tank and carbonated systems only an agitator pump and syrup cooling coil s and dispensing valve s For proper function the BIG FELLA must have a water supply and electrical supply and drainage The BIG 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 BIB 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 BIG FELLA into a freezing ambient environment empty plain and carbonated water Syrup systems should be flushed ice bank melted and water drained from 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 BIG FELLA J BIG FELLA Height 24 7 8 24 7 8 Width 27 27 Depth 16 7 8 16 7 8 Weights Shipping 160 LBS 195 LBS Dry weight 125 LBS 165 LBS Operational Weight 181 LBS 221 LBS Ice Bank 35 LBS 35 LBS Capacities Unit water bath no ice bank 7 gallons Refrigerant requirement R 134
46. ty syrup tank 2 Install full syrup container in position rinse QCD s or quick disconnects in warm water then connect QCD s or syrup amp C02 quick disconnects to tank 3 Activate valve until syrup flows from valve normally See CHAPTER II SYRUP FLAVOR CHANGE 1 Remove QCD s from applicable BIB or syrup quick disconnects from applicable syrup tank 2 Sanitize applicable syrup system in accordance with instructions See paragraph CLEANING AND SANITIZING in this chapter 3 Install full syrup container in position rinse QCD s or quick disconnects in warm water then connect QCD s or syrup amp C02 quick disconnects to container 4 Activate valve until syrup flows from valve normally See CHAPTER II 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 PSI 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 BIG 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 clockw
47. uld 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 Weekly 1 Order syrup to maintain proper inventory 2 Check all C02 gas connections for leaks 3 Measure the water to syrup ratio 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 BIG FELLA CABINET MAINTENANCE PERIODIC CLEANING Periodicallv wash all external surfaces of BIG FELLA cabinet rinse with clean water and then wipe drv with a clean soft cloth DO NOT USE ABRASIVE TVPE 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 capacitv NOTE Cleaning condenser coil should be done during non use periods 1 Unplug
48. up 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 condenser 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 1 CHECKING WATER 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 ye

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