Drop in service manual
Contents
1. Ey Ex S 143 TEE 1 4 HOSE S S CO2 CAN BE REPLACED WITH MECHANICAL AIR PUMP TITLE N j INTERNATIONAL CARBONIC INC POSSIBLE BIB RACK 3 8ST SET UP 3 8 PLASTIC SYRUP TUBING 11 24 98 1 4IBT NOTE ADD 6 INCHES TO SIDE DIMENSION GZZEZZ La WHEN INSTALLING PUMPS TO ONE GLW 1 4 PLASTIC TUBING NER BRAID SIDE ADD 12 INCHES TO SIDE DIMENSION 3 8IBT WHEN INSTALLING B I B ON BOTH SIDES 3 8 PLASTIC SYRUP TUBING ADELANTO CALIFORNIA INNER BRAIDED FIGURE 2 1 SAMPLE OF POSSIBLE INSTALLATION BACK ROOM 6 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 h2. electrical connection 8 Frozen water bath 8 See Frozen Water Bath 10 No water being Plain water inlet supply shutoff Open plain water inlet supply line shut off dispensed closed 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 open volt 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 CO2 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 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 disconnects leaves Relieve pressure shake tank vigorously dispensing as necessary to remove over valve carbonation Clean contaminated nozzle and sanitize 3 Dirty nozzle and valve cavity 3 as instructed S
3. quick coupler for later connection to B l B pumps at outlet side of box or connected to outlet quick disconnect for use on transfer tank Installing Drain DROP IN S ARE EQUIPPED WITH THE FOLLOWING DRAINS 232321 1 PVC NPT 222021 3 4 PVC NPT 142015 1 2 PVC NPT 201415 1 2 PVC NPT PLEASE USE CAUTION WHEN TIGHTENING FITTING TO COLD PLATE NOTE Do not reduce drain connection from cabinet outlet Be sure all connections are watertight Electrical Connection All units must be wired in accordance with N E C or local city ordinance Drop In units have electrical wire s extending from the base of the cabinet which are marked 24 volt This wire s will be connected to 24 volt transformer s The transformer supplied for carbonated systems will be 24 volt 40 VA When two 24 volt wires are routed through the drop in the number of valves exceed the amount recommended for voltage draw on one transformer The transformer voltage used for Juice applications will be 24 volt 40 VA Illumination When drop in units are supplied with illumination Optional a lamp cord with plug will extend from the base of the drop in The S 980 illuminated merchandiser is 115 volt The drop in unit is equipped with a door interlock switch for the dispensing heads National Sanitation Foundation requires the door be closed during the dispensing of beverages TRB Transfer Receptacle Box see illustration This optional part can be supplied
4. trapped air is relieved Manually depress valve actuating arm until carbonator is activated and carbonated water is being dispensed 6 Permit carbonator to run until it automatically shuts off Pump is now fully primed and carbonator is ready for use 7 Ice down drop in cold plate do not use sub cooled ice 8 Drop in unit is now ready for adjustment on water flow Prior to connecting syrup to individual valves adjust all valves for standard or fast flow water adjustments see brixing instructions son e Testing for Leaks Completely back off adjusting screw on low pressure regulator Close valve on top of CO2 cylinder Wait for 5 minutes or more If pressure on high pressure gauge decreases excessively there is a leak in the carbonator circuit All connections including cylinder valve should be coated with soapsuds If bubbles appear a leak is apparent Always be sure that the low pressure adjusting screw is completely backed off before testing carbonator circuit for leaks Otherwise gas going into the 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 After it has been determined that there are no leaks in the carbonator circuit open CO2 cylinder valve and adjust low pressure regulator to 15 p s i Allow enough time for the syrup tanks to fill completely with gas 5 minutes or longer 4 Next comple
5. IN 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 foamv 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 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 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 12 596 SODIUM HYPOCHLORITE BLEACH Use STAR at 18 oz pe
6. S 086 S L L NOILdINOSAG LHVd LHVd LHVd ON LHVd ALO WAS T T LO LO m O q N N CN m CN t CN CN CN Nl dOUQ 14 142015 BACK VIEW 15 201415 SODA WATER 14 1 4 lt FRONT VIEW REAR VIEW CABINET BASE SODA WATER 16 222021 SODA WATER REAR VIEW CABINET BASE SODA WATER 17 N 232321 N 18 ARBONATED REAR VIEW CABINET BASE SODA WATER ODA WATER 2 10 99 NOTE SECTION Frequently Called Numbers CO2 SETTINGS High Pressure Low Pressure Product Setup 1 19 PSI PSI 2 11 05
7. 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 INSTALLATION PROCEDURES GENERAL DESCRIPTION Upon receiving unit immediately uncrate and inspect for shipping damage ALL DROP IN S ARE SHIPPED WITH 3 SHIPPING LEGS THESE MAY BE REMOVED AFTER INSTALLATION ALTHOUGH IT IS RECOMMENDED THAT THESE REMAIN IN PLACE IN CASE OF UNIT REMOVAL FROM INSTALLATION SIGHT THE DROP IN UNIT IS EQUIPPED WITH STAINLESS STEEL INLET LINES THAT ARE LOCATED ON THE BOTTOM OF THE DROP IN BE SURE NOT TO BEND THESE LINES DURING INSTALLATION IF BENT OR CRIMPED UNIT COULD BECOME INOPERABLE WARNING Before shipping or relocating a DROP IN into a freezing ambient environment empty plain and carbonated water Syrup systems should be flushed and water drained from ice bin A freezing ambient environment will cause existing water in unit to freeze possibly resulting in damage to syrup coils water coil ice bin valve s etc At this time make sure all parts are also included with shipment i e high pressure regulator low pressure regulator legs etc If shipping damage has occurred immediately notify transit agency that transported equipment If
8. parts are missing notify factory Location of Soda Fast and Ice Cooled Equipment Prior to locating drop in in its permanent position mark and cut hole position The following hole sizes should be cut to accommodate the following Model Hole size 232321 23 1 2 X 23 1 2 222021 22 3 4 X 20 3 4 142015 14 3 4 X 20 3 4 201415 20 3 4 x 14 3 4 After hole is cut and prior to installing drop in into hole use RTV as a sealant around perimeter of hole Ice bin must be sealed to counter Some or all of the following connections may be made prior to installing the drop in in the counter The five 5 connections to be made are as follows Drop in soda line s to carbonator still drink line s to water Optional syrup lines to syrup containers or pumps drain to drain outlet and electrical to proper source Carbonator and Connection Water Supply See SODA FAST CARBONATOR Instruction Installation Procedure Drop In Soda Lines to Carbonator Connect lines marked SODA to soda outlet on carbonator Drop In Still Drink Lines Marked WATER Optional should be connected to incoming water source Note If connected on pressure side of water pump a water regulator must be installed After WATER line is made but prior to connection line should be flushed to eliminate any debris Non Carb Marked NON CARB and is syrup line that is dedicated to line marked WATER Drop In Syrup Lines 1 2 3 etc must be connected to B l B
9. DROP IN 142015 201415 222021 232321 INSTALLATION AND SERVICE MANUAL _ INTERNATIONAL CARBONIC INC 16630 Koala Rd Adelanto California 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 PAGE PREFACE A 1 GENERAL DESCRIPTION eon rores 2 Location of Soda Fast and Ice Cooled Equipment 2 Carbonator and Connecting Water Supply 2 Drop In Soda Lines to Carbonator 2 Drop In Still Drink Lines 2 Not al Ea addenda ad 3 DropsIniyr p Tifias mu m ode eret ene ince ae 3 Installing ba k ee u A ace ere AL tatu 3 Electrical Connection 3 e 3 TEB Z o O a 3 Installing High Pressure Regulator 4 Installing Low Pressure Regulator 4 Carbonator and Connecting Water Supply 4 pA A lars uod 4 Testing for Leaks iue oe nodi eade 4 Loose Shipped 5 Possible Installation nn U 5 Possib
10. and can be Made as a TRB 2 or TRB 4 the numeral 2 or 4 indicating the number of outlets required Ice Bin Capacity Drop In Units 201415 40LBS 142015 40LBS 222021 80LBS 232321 100LBS Installing High Pressure Regulator Install CO2 high pressure regulator furnished with Soda Fast unit on carbon dioxide gas cylinder always making certain a good washer is used in the connection and tighten securely so there is no leakage at this connection Replace regulator anytime it should continue to creep above the desired pressure setting Connect 1 4 tubing from outlet of gas regulator on CO2 tank for later connection to low pressure gas regulator assembly Installing Low Pressure Regulator Install low pressure on bulkhead rack or location of choice Connect 1 4 tubing from high pressure regulator to incoming port on low pressure regulator Fabricate necessary lines to connect to syrup boxes or tanks Connect it and adjust low pressure regulator Normal settings for transfer tanks average 10 to 40 p s i Carbonator and Connecting Water Supply See SODA FAST CARBONATOR Instruction Installation Procedure This step must be accomplished prior to proceeding Priming Pump Turn on water supply Open valve on CO2 tank Turn on electrical power Turn high pressure regulator screw clockwise until the pressure is adjusted to 90 to 100 p s i Actuate each valve by depressing push lever push button etc until all
11. d clean syrup flow control Adjust water to syrup ratio see Brix instruction 12 3 138 INTERNATIONAL CARBONIC INC DROP IN DATE 12 15 98 BY ADELANTO CALIFORNIA 13 3A3371S ASSV NIVHG 888 S rr8 S 6 8 S 6 8 S L 6L 8 LNOYS T3NVd 3OIAH3S r98 S 698 5 888 5 758 5 8 t dO 13S SS 9 091 vS8 S vS8 S vS8 S vS8 S 13S L ZL HOLVNO amp SHVO 1SV4 VAOS 14M9VHA NMOG 688 S 688 S 688 S 688 S L 9L 3A331S 98 S SS8 S 1 8 S cv8 S L SL v dO 13S 991 449 5 449 5 449 5 449 5 13S L tl ASSV 3WVH4 AYNLOld 31v ld 1L3M9n8 H3ddVHM c88 S 998 5 048 5 618 5 L L JNVH1I AHNLOld 88 S 098 S 898 S 9 8 S L HOOQ 188 S 98 5 998 5 618 S L LL S S dVO 2 1 X OZ v L MIYOS 9c V 9c V OL S S dVO X3H 23 1 X 72 0 MIYOS 6S V 6S V 0L MO 14 ASSY OILSV ld Y9LL S Y9LL S LOLL S LOLL S L 6 S S SdITIIHd 8 X 8 MIYOS 0c V 0c V 0c V 03V 5 8 SLE LOZ M 318V TIVAV LON 3SV3134 MOIND M 3ATVA II 03d HO II O4d HO II O4d Il O3d HO Il 94d L 41V Id DNILNAOW 3ATVA S88 S 898 5 898 5 9248 5 L 9 ASSV HOLIMS HOOQ 6S8 S 698 S 698 S 698 S L S M9071 HOLIMS 89L S 89 S 89 S 89 S L r MOVE WO M ASSV H3SIH r88 S 468 5 298 S vL8 S L 5 19538 HSVIdS ILNV 988 S c98 S 698 S 448 5 414 IdWOO HHSIONVHOH4W GILVNINATII 086 S 086 S 086
12. dispenser 8 Taste the beverage to verify that there is no off taste NOTE WHEN SANITIZING A 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 Cold plate systems Keep the ice bin clean and the cold plate free of mineral build up The interval for cleaning will vary depending on your water conditions If cold plates are not allowed to drain freely the system will loose efficiency TROUBLE SHOOTING IMPORTANT Only qualified personnel should service the DROP IN 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 Trouble Probable Cause Remedy DISPENSING VALVES Water or syrup 1 Foreign debris under plunger seat 1 a Disconnect syrup or water from leaking from or bent creased stem affected valve nozzle after b Relieve pressure by activating valve actuation c Remove E 623 nut from
13. ee refrigeration machine specifications 4 Temperature above quality limits 4 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 2 not use ice directly from freezer foams in cup or subcooled Allow ice to become wet before using class Note crushed ice also causes foaming of beverage Carbonation is released on sharp edges of the ice Water to syrup 1 Syrup flow regulator not properly 1 Adjust water to syrup ratio see ratio to low or adjusted dispensing station installation too high instructions 2 CO2 gas pressure in syrup tanks 2 Adjust low pressure regulator as insufficient instructed 3 Syrup tubing 1 0 Insufficient 3 Increase syrup tubing 1 0 Note see Brix instructions 11 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 B I B 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 an
14. le Installation Back Room 6 7 Proper Brixing Procedures 8 Sanitizing Procedures 9 Trouble SHOOUNG asus rennen 10 12 Drop In Exploded View 13 Drop In Exploded View 14 142015 Dimensional and Plumbing Layout 15 201415 Dimensional and Plumbing Layout 16 222021 Dimensional and Plumbing Layout 17 232321 Dimensional and Plumbing Layout 18 Notes as totos LA AT 19 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 II 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
15. old 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 PFC II 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 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 PARTS WATER valve cover removed DECREASE SYRUP INCREASE SYRUP 1 w KZ L lt SZJ WATER METERINGPIN Z m
16. r 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 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 6 Reconnect syrup containers and ready Unit for operation 7 Draw drinks to refill syrup lines and flush the chloride solution from the
17. 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 cord into electrical box syrup being 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 Bad transformer 5 Replace defective transformer 6 Disconnected wire 6 Attach disconnected wire No syrup being 1 Syrup container empty 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 regulator or plugged 6 Syrup disconnect not attached 6 Lubricate and attach correctly 7 Loose electrical connection of 7 Tighten connection and or repair open syrup solenoid and or open circuit Check proper voltage
18. tely back off low pressure regulator adjusting screw and if gauge needle of low pressure regulator commences to move downward there is a leak in the low pressure circuit Check all connections with soapsuds paying particular attention to syrup tank covers syrup quick disconnects etc If low pressure gauge needle remains stationary there is no leak 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 Qty 1 Installation Service Manual 1 2 S 768 K Keys 2 d Gere I D Labels 1per flavor 4 SF Carbonator 1 5 S 101 High Pressure CO2 Regulator 1 6 S 221 Low Pressure CO2 Regulator 1 7 S 105 6 Gas Line Inner Braid 1 Optional 1 2 WATER LINE INDIVIDUAL GATE VALVE 1 2 RECOMMENDED WATER FILTER RECOMMENDED 120 VAC SYRUP LINES TO BACK ROOM FLOOR DRAIN FIGURE 2 1 SAMPLE OF POSSIBLE INSTALLATION 5 BIBPJ FJ S 1 21 BIB JUICE PUMP FLOJET REGULATOR L P SINGLE PORT PRODUCT OUT PRODUCT IN E P GAS OUT BIBR2 N GAS IN RACK FOR BIB PUMPS 2 WIDE RACK INCLINED X4 S 1086 STEPLESS CLAMP FOR 1 4 S 144 CROSS 1 4 HOSE S S 3 Mon lt TO DISPENSER S 1087 x m U AZ ul R STEPLESS CLAMP 27 in AS 3 8 S 101 HIGH PRESSURE REGULATOR ES 24 gt QCD BIB CONNECTOR LIQUIBOX N
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