Cornelius FlavorFusion User Manual

FlavorFusion with Cold Carbonation

DESCRIPTION

The FlavorFusion series of dispensers solves your ice and beverage service needs in a sanitary, space saving, economical way. Designed to be manually filled with ice from any remote ice–making source, these dispensers will dispense cubes (up to 1–1/4 inch in size), cubelets, and compressed (not flaked) ice. In addition, the units include beverage faucets, a cold plate, an internal carbonator tank and an external pump for the carbonator, and are designed to be supplied direct from syrup tanks with no additional cooling required.

CAUTION: Dispenser cannot be used with crushed or flaked ice. Use of bagged ice which has frozen into large chunks can void warranty. The dispenser agitator is not designed to be an ice crusher. Use of large chunks of ice which “jam up” inside the hopper will cause failure of the agitator motor and damage to the hopper. If bagged ice is used, it must be carefully and completely broken into small, cube-sized pieces and left to “temper” or warm up for a minimum of 20 minutes in room temperature before loading into the dispenser hopper.

SPECIFICATION

FlavorFusion Installation Manual

INSTALLATION MANUAL

Model Descriptions: B=Beverage

C=Coldplate H=Internal Cold Carb Z=No Drip Tray

Ice Storage: 255 Pounds

Maximum Number of Faucets Available:

Built–in Cold Plate: Yes

Electrical: 120/1/60,

Dimensions: 30 inch

4 nozzles with 4 brands each = 16 brands 2 nozzles with 4 bonus flavors each = 8 bonus flavors

9.3 Amps of Total Unit Draw

220/1/50,

4.7 Amps of Total Unit Draw

30-11/16 inch 39 inch (to top of bin) 41-10/16 inch (to top of lid)

Z-Models 30 inch 23-1/16 inch 39 inch (to top of bin) 41-10/16 inch (to top of lid)

CO

Operating Pressure 75-psig (max) for carb tank and brand syrup pumps

2

25-psig (max) for bonus flavor pumps

Revision Date: February 6, 2006 Revision: B

FlavorFusion Installation Manual

SAFETY INSTRUCTIONS

Read and Follow all Safety Instructions

Read and follow all safety instructions in this manual and on the machine (decals, labels, and laminated cards).

Read and understand all applicable OSHA (Occupation Safety and Health Administration) safety regulations before operating the machine.

Recognize Safety Alerts

This is the safety alert symbol. When you see it in this manual or on the machine be alert to the potential of personal injury or damage to the machine.

Different Types of Alerts

There are 3 types of safety alerts:

DANGER — Indicates an immediate hazardous situation which if not avoided WILL result in seri-

ous injury, death, or equipment damage.

WARNING — Indicates a potentially hazardous situation which, if not avoided, COULD result in

serious injury, death, or equipment damage.

CAUTION — Indicates a potentially hazardous situation which, if not avoided, MAY result in

minor or moderate injury or equipment damage.

Safety Tips

• Carefully read all safety messages in this manual and safety signs on the machine.

• Keep safety signs in good condition and replace missing or damaged safety signs.

• Learn how to operate the machine and how to use the controls properly.

• Do not let anyone operate the machine without proper training. This appliance is not intended for use by very young children or infirm persons without supervision. Young children should be supervised to ensure that they do not play with the appliance.

• Keep your machine in proper working condition and do not allow unauthorized modifications to the machine.

Qualified Service Personnel

CAUTION — Only trained and certified electrical, plumbing and refrigeration technicians should

service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES.

CO2 (Carbon Dioxide) Warning

WARNING — CO

CO

gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is suspected, particularly

2

in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO

rapidly by loss of consciousness.

Displaces Oxygen. Strict Attention must be observed in the prevention of

2

gas will experience tremors which are followed

2

Shipping And Storage

CAUTION — Before shipping, storing, or relocating the Unit, syrup systems must be sanitized

and all sanitizing solution must be purged from the syrup systems. All liquids, after sanitizing, must be purged from the unit. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the Unit to freeze resulting in damage to the internal components.

INSTALLATION

IMPORTANT: TO THE INSTALLER. It is the responsibility of the Installer to ensure that the water supply to the dispensing equipment is provided with protection against backflow by an air gap as defined in ANSI/ASME A112. 1.2– 1979; or an approved vacuum breaker or other such method as proved effective by test.

Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed, and maintained according to Federal, State, and Local laws.

1. Locate the dispenser indoors on a level counter top. A. LEG OPTION

Unpack the four (4) legs and install them into the threaded holes provided in the bottom of the unit. The installer must provide flexibility in the product and utility supply to permit shifting the position of the dispenser sufficiently to clean the area beneath it.

B. COUNTER MOUNTING

The ice drink dispenser must be sealed to the counter. The template drawing (see FIGURE 6) indicates where openings can be cut in the counter. Locate the desired position for the dispenser, then mark the outline dimensions on the counter using the template drawings. Cut openings in counter.

Apply a continuous bead of 4-inch inside of the unit outline dimensions and around all openings. Then, position the unit on the counter within the outline dimensions. All excess sealant must be wiped away immediately.

NSF International

FlavorFusion Installation Manual

(NSF) silastic sealant (Dow 732 or equal) approximately 1/

2. The beverage tubes, drain tube and power cord are routed through the large opening in the bottom of the unit. See the MOUNTING TEMPLATE (FIGURE 6) for locating the required clearance opening in the counter for these utility lines.

3. DRIP TRAY DRAIN ASSEMBLY (see FIGURE 7): Route the drain tube to an open drain with the end of the tube above the “flood” level of the drain. Use the tubing, fittings, clamps, and insulation provided with the Dispenser to assemble the drain. The completed drain line

must

pitch

continuously downward and contain no “traps” or improper drainage will result.

NOTE: IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the plain water inlet supply line. A Cornelius Water Filter (P/N 313860000) and QUICK DISCONNECT SET (P/N 313867000) are recommended.

CAUTION: Check the minimum flow rate and the maximum pressure of the plain water inlet supply line. MINIMUM FLOW RATE MUST BE AT LEAST 125-GALLONS PER HOUR. If flow rate is less than 125-gallons per hour, starving off the carbonator water pump will occur. Starving will allow the carbonator water pump to overheat causing the safety thermostat on the pump outlet to stop the water pump motor. Overheating could occur if the plain water supply line flow rate drops below 125gallons per hour. INCOMING PLAIN WATER INLET SUPPLY LINE WATER TO PUMP PRESSURE MUST REMAIN A MINIMUM OF 10 psi BELOW THE CARBONATED CO

PRESSURE. (Example: Carbonator CO

operating pressure is 75 psi and the maximum water

2

pressure can be no more than 65 psi, etc.). Water over pressure (higher CO

OPERATING

2

operating pressure)

2

can cause carbonator flooding, malfunction, and leakage through the carbonator relief valve. If water is exceeding maximum pressure specifications, a Water Pressure Regulator Kit must be installed in the plain water inlet supply line. If fitting connector is not available, tap into the plain water supply line with a 3/8 flare saddle valve.

4. Locate the carbonator pump assembly and connect to power cord from the Ice/Drink Unit to the pump. The cord is connected to the unit’s electrical box and has an electrical connector on the end that plugs into a receptacle in the junction box at the carbonator pump assembly. Connect inlet water to pump and pump outlet to Ice/Drink Unit using 3/8-inch food-grade tubing. Disable the pump from operating by switching the switch in the carbonator pump assembly junction box to the OFF position.

5. Connect the beverage system product tubes as indicated in applicable Flow Diagram FIGURE 8. This work should be done by a qualified service person.

FlavorFusion Installation Manual

NOTE: See applicable Flow Diagram (see FIGURE 8) or Decal on the lower front of the unit for the location of syrup and water connections.

6. Clean the hopper interior (see CLEANING INSTRUCTIONS in Owner’s Manual).

7. Connect the unit power cord to a 120 volt, 60 cycle, 3–wire grounded receptacle. For 220-240 Volt International Units, a 3-wire power cord is provided. An adapter plug for the particular country will need to be provided by the Installer.

ADJUST CARBONATOR CO2 REGULATOR AND TURN WATER INLET SUPPLY

INE ON

L

CAUTION: Before connecting the CO2 regulator assembly to a CO2 cylinder, turn the regulator adjusting screw to the left (counterclockwise) until all tension is relieved from the adjusting screw

spring.

1. Open (counterclockwise) CO the valve fully to back-seat the valve. (Back-seating the valve prevents leakage around the valve

shaft).

2. The carbonator CO2 regulator is fixed at a nominal 75 psi.

3. Open one of the post-mix dispensing valves to exhaust trapped air inside the carbonator tank.

4. Open the water inlet supply line shutoff valve.

UNIT OPERATION

WARNING: The unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator. The unit power cord is equipped with a three-prong plug. If a three-hole (grounded) electrical outlet is not available, use an approved method to ground the unit.

CAUTION: Never operate the carbonator pump with the water inlet supply line shutoff valve closed. “Dry running” the water pump will burn out the pump. A pump damaged in this manner is not covered by warranty.

1. Connect electrical power to the Unit.

2. Locate the switch on the junction box of the carbonator pump, and turn it ON. The water pump will start and fill the carbonator tank with carbonated water. The water pump will stop when the carbonator tank is full.

3. Check for water and CO

4. Dispense several drinks until the carbonator pump cycles on. The refill time should be about 5-7 seconds.

5. If the carbonator pump appears to be short-cycling, meaning a refill time of 1-2 seconds, refer to the Troubleshooting section.

cylinder valve slightly to allow lines to slowly fill with gas, then open

2

leaks, and tighten any loose connections

2

GATE RESTRICTOR PLATE AND ADJUSTMENT

The rate at which ice is dispensed can be adjusted by varying the opening of the gate restrictor plate as illustrated in FIGURE 1. Reducing the dispense rate of ice is especially desirable when using glasses or other containers with small openings. To adjust the gate restrictor plate, loosen the (4) nuts that hold the ice chute assembly to the bin. The restrictor plate can now be moved up or down. When the restrictor plate is fully up, the ice gate opening is 2-1/2” in height, and the maximum rate of ice dispense is available (approximately 3 oz/sec). Retighten the (4) nuts to set the desired restrictor plate opening. DO NOT EXCEED 40 IN-LB of torque.

DISCONNECT POWER BEFORE INSTALLING,

!

REMOVING, OR ADJUSTING RESTRICTOR.

INSTALL PLATE

ON STUDS AS

SHOWN

FlavorFusion Installation Manual

RESTRICTOR PLATE

ADJUSTMENT

4X

MAX TORQUE

40 in.-lb.

FIGURE 1. Gate Restrictor Plate

NOTE: Tighten (4) nuts for fastening lower ice chute in place to 40 in-lbs (max). Draw all four nuts tight uniformly.

FlavorFusion Installation Manual

PROGRAMMING MODE

The programming mode is exactly the same for both brand and bonus keypads.

To enter the programming mode, press and hold the two program buttons (see FIGURE 4) at the top of the keypad for approximately 4 seconds. All keypad LEDs will flash off for approximately 1 second to indicate the start of the programming mode.

To exit programming mode, press and hold the two program buttons for approximately 4 seconds. All keypad LEDs will flash off for approximately 1 second, resuming normal operation mode.

Programming Mode Flashing Sequences

Once in programming mode, each dispense button LED flashes in a sequence cycle according to one (1) of six (6) dispense types. For Brand Keypads, only dispense types 1 and 2 are used. For Bonus Flavor Keypads, dispense types 3 through 6 are used. The six (6) dispense types are described below, and shown in a timing diagram in FIGURE 2:

• Dispense Type 1, Carbonated water dispense: Solid LED

• Dispense Type 2, Non-carbonated dispense: Flashing LED 1.5 seconds ON, 1.5 seconds OFF

• Dispense Type 3, 1-second flavor shot: LED flashes once for ¼ second, followed by 3 seconds

OFF

• Dispense Type 4, 2-second flavor shot: LED flashes twice for ¼ second ON, ½ second OFF,

followed by 3 seconds OFF

• Dispense Type 5, 3-second flavor shot: LED flashes three (3) times for ¼ second ON, ½ second

OFF, followed by 3 seconds OFF

• Dispense Type 6, 4-second flavor shot: LED flashes four (4) times for ¼ second ON, ½ second

OFF, followed by 3 seconds OFF

Start proramming mode

Exit programming mode

1. Carbonated water dispense

2. Non-carbonated dispense

3. 1-second flavor shot

4. 2-second flavor shot

5. 3-second flavor shot

6. 4-second flavor shot

012345

Time (seconds)

FIGURE 2

Setting Water Flow Rate

Setting the water flow rate will require a timed dispense. To accomplish this, the following procedure should be followed:

1. Enter programming mode for the valve block by simultaneously pressing and holding both programming buttons for 4 seconds (see FIGURE 4). The LED’s for flavors 1-4 should flash off and then back on. The drink icon should turn off.

2. Set the valve block to a 4 second pour mode by simultaneously pressing and holding Flavor 1 and Flavor 4 buttons until the flash pattern for all four buttons changes.

3. Place an empty ratio cup under the appropriate nozzle and press the left program button for a 4 second dispense of carbonated water. There should be approximately 10 oz. dispensed.

4. If necessary, adjust the water flow control (see FIGURE 3), empty ratio cup, and repeat step 3. Otherwise empty ratio cup and repeat step 3 using the right program button for plain water.

5. Exit 4 second pour mode by simultaneously pressing and holding Flavor 1 and Flavor 4 buttons until the flash pattern for all for buttons changes.

6. Exit programming mode by simultaneously pressing and holding both programming buttons for 4 seconds.

FlavorFusion Installation Manual

Flow Adjuster Detail

(Water)

FIGURE 3. Valve with Flow Adjusters

(see plumbing diagram for plumbing and valve

configuration)

Bonus Flavor

Programming Buttons

(Left

and Right)

Optional

Bonus Flavor Icon

Optional

Bonus Flavor Button 1

Optional

Bonus Flavor Button 2

Optional

Bonus Flavor Button 3

Optional

Bonus Flavor Button 4

Optional

Bonus Flavor Nozzle

Optional

Brand Flavor Programming Buttons (Left and Right)

Drink Icon

Brand Flavor Button 1

Brand Flavor Button 2

Brand Flavor Button 3

Brand Flavor Button 4

Brand Flavor Nozzle

FIGURE 4

FlavorFusion Installation Manual

Adjusting Syrup/Water Ratio (Brix)

Timed Dispense Procedure

1. Enter programming mode for the valve block by simultaneously pressing and holding both programming buttons for 4 seconds (see FIGURE 4). The LED’s for flavors 1-4 should flash off and then back on. The drink icon should turn off.

2. Set the valve block to a 4 second pour mode by simultaneously pressing and holding Flavor 1 and Flavor 4 buttons until the flash pattern for all for buttons changes.

3. Place the water end of the ratio cup under the appropriate nozzle and press the left program button for a 4 second dispense of carbonated water. (Push the right program button for still water pour.)

4. Place the syrup end of the ratio cup under the nozzle and press the appropriate flavor button for a 4 second dispense of syrup. The fill line should be the same for both water and the syrup. Adjust the syrup flow control if necessary, then empty cup and repeat steps 3 and 4.

5. Repeat for all syrups in valve bank.

6. Exit 4 second pour mode by simultaneously pressing and holding Flavor 1 and Flavor 4 buttons until the flash pattern for all for buttons changes.

7. Exit programming mode by simultaneously pressing and holding both programming buttons for 4 seconds.

Setting a Button to Dispense Non-carbonated Water Only

1. Program the designated button to dispense non-carbonated water (see Programming Mode.)

2. Do not connect a syrup source to the inlet circuit of the designated button (1-14 or A1-A2.) If circuit 1 through 14 is chosen leave the coldplate inlet circuit plugged with the red cap. If circuit A1 or A2 is chosen, plug the end of the inlet tube with a red cap from the coldplate, or with tape.

Setting a Button to Dispense Carbonated Water Only

1. Program the designated button to dispense carbonated water (see Programming Mode.)

2. Do not connect a syrup source to the inlet circuit of the designated button (1-14 or A1-A2.) If circuit 1 through 14 is chosen leave the coldplate inlet circuit plugged with the red cap. If circuit A1 or A2 is chosen, plug the end of the inlet tube with a red cap from the coldplate, or with tape.

NOTE: The ambient circuits A1 and A2 do not give up a cold plate circuit.

Back Room Package Position (BRP)

G

C

D

H

I

F

E

C

E

G

J

M

D

F

H

JI

K

O

L

Q

N

K

M

O

FIGURE 5

W

S

P R

L

N

P

RQ

T

Y

V

U

S

T

U

V

X

W

ZY

X Z

Pumps

BIB Racks

MOUNTING TEMPLATE

30

26 3/8113/16

15/16

18 5/8

12

9

3 1/2

9 1/2

11

23

21 1/4

30

311/2

REMOVAB LE SINK

RECOMMENDED COUNTER OPENING SIZE 9 X 12 FOR UTILITIES AND BEVERA GE TUBING. OPENING CAN BE LOCATED ANYWHERE WITHIN SHADED AREA.

7/16 DIA.

23 1/16

Z Style

FlavorFusion Installation Manual

FIGURE 6. FlavorFusion Mounting Template

FlavorFusion Installation Manual

DRIP TRAY DRAIN ASSEMBLY

HOSE CLAMP

DRAIN LINE 1" I.D. PLASTIC TUBING (6') WITH INSULATION

FIGURE 7. Drip Tray Drain Assembly

DIAGRAMS

Flow Diagram

SYRUPS 1-2 (NON-CHILLED)

SYRUPS 1-8 (NON-CHILLED) (OPTIONAL)

B# = AMBIENT BONUS

A# = AMBIENT BRAND

XX = OUTLET LINE

14

11 13

B8

B7

10

N4 N4 N5 N5 N6 N6 N6N4

89

CW PW CW PW

N# = NOZZLE #1-6

W3 W2

12

B5 B6

A2

W2

W3

PW = PLAIN WATER

CW =CARBONATED WATER

FlavorFusion Installation Manual

CITY WATER

WATER FILTER

PUMP & MOTOR ASY

REQUIRED

PRESSURE

REGULATOR

OR BOOSTER

PUMP MAY BE

60 PSIG

REGULATOR

SECONDARY

FOR BRAND SYRUP

OUT

IN

CARB

TANK

W2

14

13

12

N6

12

11

W3

B8

B6

B7

B5

W2

10

9

A2

8

W3

14

11

13

B5B6B7

N5

B8

9

A2

8

10

N4

W1

W3

PW

W2

CW

W3

13

11

9

REGULATOR

SECONDARY

14

12

10

8

B6

20-25 PSIG

FOR BONUS SYRUP

B5

B8

CO2

CYLINDER

110 PSIG

PRIMARY REGULATOR

B7

BONUS SYRUP

BIB'S 20-25 PSIG

N1 N1 N2 N2 N3 N3 N3N1

A1

B4

B3

23 57

N1 N1 N2 N2 N3 N3 N3N1

1

CW PW CW PW

8

9

10

11

12

13

14

ICE

CHUTE

W2

A1

7

6

N3

5

W3

6

B2

B4

B2

B1

6

A1

5

7

B1B2B3

B3

N2

4

2

W2

3

2

4

W3 W2 W3 W2

1

W3

NOZZLES

4

1

3

N1

KEYPAD

BUTTONS

1 2

COLDPLATE

3

SYRUP INLET

4

5

6

7

CW

W3

PW

W2

7

6

5

B4

4

3

2

1

W2

W1

13

14

1

2

B1

B2

11

12

3

4

B4

9

10

5

6

B3

BONUS SYRUP

BIB'S 20-25 PSIG

A2

8

7

A1

BIB'S 60 PSIG

BRAND SYRUP

FIGURE 8. Flow Diagram

FlavorFusion Installation Manual

Wiring Diagram

ELECTRIC SHOCK HAZARD.DISCONNECT POWER

BEFORE SERVICING UNIT.

WHT

ICE

HEATER

BLK

AGIT.

BLU

BRN

BLK

MOTOR

BLU

GRN/YLW

GRN

RED

WHT

CARB.

PUMP

MOTOR

WHT

ASY

POWER

CORD

STARTER

BLK

LIGHT

SOCKET

WHT

BLK

TANK

CARB.

RED

BALLAST

BRAND

BONUS

BRAND

SYRUP

BLU

W2

14

KEY PAD

PW

LT BLU

13

W3

GRN

CW

WHT

12

11

YEL

RED

B2

B4

LT BLU

GRN

YEL

RED

SOLENOID

VALVE BLOCK

B3

B1

OPTIONAL

NO BONUS

NOT USED WITH

10

A2

GRN

LT BLU

9

W2

PW

YEL

8

W3

CW

WHT

BLU

ICE

GATE

SWITCH

BLK

WHT

BLK

EARTH

CARBMTR

EARTH_IN

EARTH

L2_AGIT

AGIT

BLK

HEATR

L2

L1

HEATR

XFORMR

CARB MOTR

CARBMOTR L2

ON

OFF

TIME

J4

WHT

BRN

GRN

AGIT

WHT

BLK

XFORMR

L2_

RED

BLK

L2_IN

BALST

L2_

L1_IN

L1_BALST

J7

J3

BLK

WHT

BLK

WHT

OPTIONAL

NO BONUS

NOT USED WITH

CAPACITOR

LED.

ICE CUBE

GRAPHIC

BLK

WHT

BLK

TRANSFORMER

YEL

TRANSFORMER

WHT

YEL

WHT

OPTIONAL

NO BONUS

NOT USED WITH

WHT

BLK

WHT

BLK

RED

BLK

RED

KEY

SWITCH

LIGHT

SOCKET

SYRUP

BRAND

BONUS

BRAND

SYRUP

KEY PAD

W2

A1

PW

LT BLU

WHT

7

W3

BLU

CW

GRN

YEL

5

6

RED

LT BLU

B2

B4

YEL

GRN

B3

B1

OPTIONAL

VALVE BLOCK

NOT USED WITH

NO BONUS

SOLENOID

3

4

GRN

WHT

LT BLU

2

W2

PW

1

W3

CW

BLU

BLK

RED

YEL

FIGURE 9. Wiring Diagram - 120V Unit

Wiring Schematic

L1 L2

FlavorFusion Installation Manual

EARTH

L1_IN

L1_BALLAST

L1_HEATER

CARB MOTOR

CARB MOTR

CARB EARTH

AGITATOR MOTOR

AGITATOR AGITATOR_L2

AGITATOR EARTH

OPTIONAL LIGHTING

BALLAST

FLOURESCENT LIGHT

STARTER

HEATER

CARB MOTR_L2

BALLAST_L2

HEATER_L2

L2_IN

E-BOARD

XFORMER_L1 L2_XFORMER

INTERFACE BOARD

ICE CUBE

E-BOARD

VALVE (6)

INTERFACE BOARD

LED

VALVE (6)

J7

J3

J4

TOUCHPAD

ICE GATE SWITCH

120V Pri

XFRMR1

24V Sec

KEY LOCK

INTERFACE BOARD

VALVE (6)

120V Pri

XFRMR2

24V Sec

KEY LOCK

INTERFACE BOARD

VALVE (6)

HIGH LEVEL PROBE LOW LEVEL PROBE GROUND

80 VA

TOUCHPAD

80 VA

TOUCHPAD

CARB TANK

INTERFACE BOARD

VALVE (6)

INTERFACE BOARD

VALVE (6)

TOUCHPAD

E-BOARD

FIGURE 10. Wiring Schematic

FlavorFusion Installation Manual

TROUBLESHOOTING

IMPORTANT: Only qualified personnel should service internal components or electrical wiring.

WARNING: If repairs are to be made to a product system, remove quick disconnects from the applicable product tank, then relieve the system pressure before proceeding. If repairs are to be made to the CO

pressure before proceeding. If repairs are to be made to the refrigeration system, make sure electrical power is disconnected from the unit.

Should your unit fail to operate properly, check that there is power to the unit and that the hopper contains ice. If the unit does not dispense, check the following chart under the appropriate symptoms to aid in locating the defect.

Symptom Cause Remedy

2

system, stop dispensing, shut off the CO2 supply, then relieve the system

Dispenser Troubleshooting

Blown fuse or circuit breaker

Agitator does not turn

Short circuit in electrical wiring Repair Wiring

Inoperable agitator motor (shorted motor)

No power Restore power or plug in unit

Improperly installed upper ice chute assembly (Reed switch is not being activated)

Inoperable reed switch Replace reed switch

Electrical board driver circuit is defective

Gear motor has open circuit Replace gear motor

Reed switch is not activated Improper assembly of upper ice chute to lower chute.

Broken wire in the 2-wire harness leading to the reed switch

Replace gear motor

Check the upper ice chute assembly for proper assembly and operation

Replace main control board

Check to make sure tongue of upper chute engages into the back of the lower chute, ensure upper chute engages outside the lower chute, and snap front of chute into place.

Repair of replace 2-wire harness

Bad connection at main control board, J3, pins 2 &3

Ice dispenses continuously

Slushy ice or water in hopper

Ice gate mechanism is stuck in open position

Stuck or bent ice lever (does not allow gate to close and open reed switch)

Blocked drains in cold plate Remove access covers in cold plate

Poor ice quality due to water quality or ice maker problems

Repair connection or replace 2-wire harness

Inspect gasket for proper position. Examine gate plate to see if it slides freely behind the lower ice chute.

Examine ice dispense lever to see if it is bent.

cover & inspect/clean drains

Correct water quality or repair ice maker

FlavorFusion Installation Manual

Beverage does not dispense

Beverage is too sweet

Unit will not dispense carbonated drinks. Dispenses syrup only.

Unit will not dispense carbonated drinks. Spurts CO

and

2

syrup only.

No 24VAC to valves Restore 24 VAC to valves

No CO

pressure Restore CO2 pressure

2

Valve brix requires adjustment Adjust valve brix

Carbonator is not operating Repair carbonator

No CO

City water pressure supply low or inconsistent

CO high.

in carbonator Restore CO2 pressure in carbonator

2

Booster pump must be used if dynamic water pressure drops below 40 psig.

pressure in carbonator tank is too

2

Check CO2 pressure regulator setting. 75 psig recommended. Relieve

pressure from carbonator tank.

Water valve will not open Check electrical connection to water

valve. Check resistance of coil (should be 9 ohms). Check for voltage at coil when brand button is depressed.

Carbonator tank is empty, because tank was emptied while power was applied to unit. 5 minute time-out of carbonator pump/motor occurred, and carbonator

Unplug the unit and reconnect the unit. Main control board will reset, ice agitation will occur, and carbonator tank will refill to normal level.

pump is locked off.

Note that this can occur while the water filter system is serviced or water supply is shutoff. If drinks are drawn from the dispenser while water pressure is shutoff, the carbonator pump starts and runs continuously, then shuts off on the 5 minute timeout.

Carbonated drinks are flat (low on

is out Replace CO

CO

2

carbonation)

Carbonator tank is 100% filled because the city water pressure exceeds the carbonator tank CO2 pressure regulator

setting.

Low water pressure Could be caused by excessively long

runs (over 40 ft.) of 3/8” water supply line.

Low water pressure Add water pressure booster pump

Plugged water filter. Change water filter

Water booster bladder has burst Replace water booster tank/bladder

1) low water pressure switch deactivates carbonator pump, 2) after 5 minutes reset and retry carbonator pump. If water supply is restored, the 5 minute timeout will not occur. Repeat reset a second time, but on a third time, then lockout carbonator pump, which will generate a service call.

2

CO2 setting for the carbonator tank is 75 psig, max water pressure is 60 psig.

If necessary, install a water pressure regulating valve.

Increase line size to 1/2”

FlavorFusion Installation Manual

No Syrup or

Syrup supply is empty Replace BIB Watered down drink dispensed

BIB pump not working Replace BIB pump

No CO

or compressed air supply to

2

BIB pump, or not enough pressure

Check CO2 pressure regulator setting. 65 psig recommended. Replace CO tank or fix compressor.

Carbonator Troubleshooting

Symptom Cause Remedy

Carbonator pump does not start to fill tank

Power cord for the carbonator pump

motor is not connected.

Carbonator pump is powered off the main control board inside the electrical box of the unit. Check that the umbilical cord is connected from the unit to the pump motor terminal box.

Power cord is connected but carbonator pump

Carbonator pump motor is disabled. Check the enable/disable switch on the

carbonator pump terminal box and enable it, if necessary.

does not run.

Probes were dry, unit was powered up,

water was not turned on, and

carbonator did not fill.

This results in a 5 minute timeout. Unplugging the unit and plugging it in will reset the unit and start the carbonator pump.

2

Carbonator pump is short cycling with every drink drawn

Carbonator tank overfills, overflows through relief valve, and pump shuts off after 5 minutes.

Water service was interrupted for more

than 5 minutes.

Unplugging the unit and plugging it in will reset the unit and start the carbonator pump.

Lower liquid level probe reads “dry”

while upper probe reads “wet”

Check color of leads going to probes. Black should go to bottom probe and white to top probe. Reverse if incorrect.

A. Poor electrical connections between

carbonator tank and main control board

A. Check connections at carbonator tank and at connector J4 on the main control board.

B. Broken wires between carbonator

B. Replace wire harness

tank and main control board

C. Defective liquid level probes C. Replace both liquid level probes

DIAGNOSTICS GUIDE FOR THE MAIN CONTROL BOARD

FlavorFusion Installation Manual

State

0Flash rate 3

1Flash rate

2Flash rate

3Flash rate

4Flash rate 1

Observed State

of Red LED

seconds

1/2 second

second

Sensor Input Control Response Service Remedy

Both probes read “wet” Standby mode. Pump

= OFF

Pump is OFF and HIGH probe reads “dry” and LOW probe reads “wet”

Both HIGH and LOW probes read “dry”

Entered when HIGH probe does not detect liquid, and LOW probe does detect liquid, and pump is ON

Entered when HIGH probe reads “wet” and LOW probe reads “dry”

Waiting for level to drop below LOW probe. Pump = OFF

Normal mode. Pump = ON

THIS IS AN ERROR CONDITION.

No service required

- Check electrical connections at the carbonator tank, and at connector J4 on the main control board

- Black wire should be connected to the LOW probe and also to Pin 4 of Connector J4

- Reverse the connections if incorrect

- Replace harness if necessary

5ON

continuously, but “flickers” every 3 seconds

6ON

continuously

Poor signal connection to the carbonator tank. May result in short cycling of the carbonator pump.

Entered when pump has run continuously for 5 minutes

Able to continue to function but carbonator pump short-cycles. Pump will come on each time a drink is drawn. THIS

SITUATION SHOULD BE CORRECTED.

THIS IS AN ERROR CONDITION.

Check the harness connections of the red signal wire at both ends:

1) at the carbonator ring terminal and

2) at Pin 5 of the J4 connector at the main control board

Unplug the unit and plug it back in. This will reset the unit's main control board and restart the carbonator pump.

FlavorFusion Installation Manual

DIAGNOSTICS GUIDE FOR FLAVORFUSION KEYPAD LIGHTING

Observations of LED Lighting on Customer Interface Keypad

Symptom Cause Remedy

1 Bonus Flavor Icon and/

or Drink Icon LEDs (see FIGURE 4) are ON continuously with four quick flashes every 30 seconds.

2 Bonus Flavor Icon and/

or Drink Icon LEDs (see FIGURE 4) are not in sync with the lighting sequence,

3 Keypad LED lighting is

not working

A. This indicates a poor connection in the lighting synchronization harness that connects the interface boards together.

B. This may result over time as the lighting sequence between push button pads can become slightly out of synchronization.

A. Poor connection between interface board and keypad PCB

B. Keypad LED's are burnt out

C. Interface board is defective.

A. Turn the keyswitch to disconnect power to the interface boards. Check the electrical connections between the harnesses that interconnect the right side of all interface boards together. Turn back the keyswitch to reconnect power.

B. Unplugging the unit and performing a power up will re-synchronize the lighting sequence.

A. Turn the keyswitch to disconnect power at the interface boards. Check harness connections at each interface board.

B. Turn the keyswitch to disconnect power at the interface boards. Unplug the ribbon cable from one interface board and test it by plugging it into the neighboring interface board. If the keypad still doesn't light up replace the keypad PCB.

C. Turn the keyswitch to disconnect power at the interface boards. Unplug the ribbon cable from one interface board and test it by plugging it into the neighboring interface board. If the LED's light up the interface board is defective. Replace the interface board.

D. Corrosion at connector between keypad and ribbon cable.

E. Main control board is defective.

4 During standby mode,

the brand and bonus LED icons do not alternate back and forth

- instead they light together.

Contact your local syrup or beverage equipment distributor for additional information and troubleshooting of beverage system.

Bonus buttons are incorrectly programmed as brand buttons, or vice versa.

D. Replace keypad circuit board and ribbon cable.

E. Replace the main control board.

Check the programming of each keypad and set each button as CW, PW, or timed dispense based upon the flavor lineup.

Cornelius FlavorFusion User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual