Cornelius FlavorFusion Series, FlavorFusion Installation Manual

INSTALLATION MANUAL

FlavorFusion with cold carbonation

Publication Number: 621057601INS

Revision Date: August 3, 2010

Revision: D

Visit the IMI Cornelis web site at www.cornelius.com for all your Literature need.

The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumb

ing, pneumatic, and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met, in addition to the information contained in this man ual.

This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is subject to all of the restrictions and limitations contained in the Commercial Warranty.

Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident, (6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained persons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, operating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100% compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the product dispensed which are adversely impacted by changes in liquid scale or chemical composition.

Contact Information: To inquire about current revisions of this and other documentation or for assistance with any Cornelius product

contact:

www.cornelius.com

800-238-3600

Trademarks and Copyrights: This document contains proprietary information and it may not be reproduced in any way without permission from

Cornelius.

Printed in U.S.A.

TABLE OF CONTENTS

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Read and Follow all Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Recognize Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Qualified Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Shipping and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Adjust Carbonator CO2 Regulator and Turn Water Inlet Supply Line On . . . . . . . . . . . . . . . 5

Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Gate Restrictor Plate and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Programming mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Programming Mode Flashing Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Setting Water Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Adjusting Syrup/Water Ratio (Brix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Setting a Button to Dispense Non-carbonated water Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Setting a Button to Dispense Carbonated water Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Back Room Package Position (BRP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Mounting Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Drip Tray Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Flow Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wiring Diagram - 120V Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Dispenser Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Carbonator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Diagnostics Guide for the Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

FlavorFusion Installation Manual

DANGER:

WARNING:

CAUTION:

WARNING:

SAFETY INSTRUCTIONS

READ AND FOLLOW ALL SAFETY INSTRUCTIONS

Safety Overview

• Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or laminated cards).

• Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before operating this unit.

Recognition

Recognize Safety Alerts

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

DIFFERENT TYPES OF ALERTS

Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment damage.

Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or equipment damage.

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or equipment damage.

SAFETY TIPS

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

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

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

• Do not let anyone operate the unit 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 unit in proper working condition and do not allow unauthorized modifications to the unit.

QUALIFIED SERVICE PERSONNEL

Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.

FlavorFusion Installation Manual

WARNING:

CAUTION:

DANGER:

WARNING:

SAFETY PRECAUTIONS

This unit has been specifically designed to provide protection against personal injury. To ensure continued protection observe the following:

Disconnect power to the unit before servicing following all lock out/tag out procedures established by the user. Verify all of the power is off to the unit before any work is performed.

Failure to disconnect the power could result in serious injury, death or equipment damage.

Always be sure to keep area around the unit clean and free of clutter. Failure to keep this area clean may result in injury or equipment damage.

SHIPPING AND STORAGE

Before shipping, storing, or relocating the unit, the unit must be sanitized and all sanitizing solution must be drained from the system. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the unit to freeze resulting in damage to internal components.

CO2 (CARBON DIOXIDE) WARNING

CO2 displaces oxygen. Strict attention MUST be observed in the prevention of CO2 gas leaks in the entire CO2 and soft drink system. If a CO contaminated area before attempting to repair the leak. Personnel exposed to high concentrations of CO experience tremors which are followed rapidly by loss of consciousness and DEATH.

2 gas leak is suspected, particularly in a small area, IMMEDIATELY ventilate the

2 gas

MOUNTING IN OR ON A COUNTER

When installing the unit in or on a counter top, the counter must be able to support a weight in excess of 600 lbs. to insure adequate support for the unit. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR

EQUIPMENT DAMAGE.

NOTE: Many units incorporate the use of additional equipment such as icemakers. When any addition equipment is used you must check with the equipment manufacturer to determine the additional weight the counter will need to support to ensure a safe installation.

FlavorFusion Installation Manual

CAUTION:

INSTALLATION 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..

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

Model Descriptions:

Maximum Number of Faucets Available:

Built–in Cold Plate: Yes

CO2 Operating Pressure

B=Beverage C=Coldplate H=Internal Carb Z=No Drip Tray

Ice Storage: 255 Pounds

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

Electrical:

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

Dimensions:



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

75-psig (max) for carb tank and brand syrup pumps 25-psig (max) for bonus flavor pumps

120/1/60,

9.3 Amp

4.7 Amps of Total Unit Draw

s of Total Unit Draw

220/1/50,

FlavorFusion Installation Manual

WARNING:

INSTALLATION

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 and must comply with all federal state and local codes, failure to comply could result in serious injury, death or damage to the equipment.

Water pipe connections and fixtures directly 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 inst of the dispenser sufficiently to clean the area beneath it. The dispenser MUST be placed in a horizontal position.

B. COUNTER MOUNTING

The ice 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

Apply a continuous bead of NSF Inter 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.

2. The beverage tubes, drain tube and power cord are routed through the large opening in the bottom of the

See the MOUNTING TEMPLATE (Figure 6): for locating the required clearance opening in the coun-

unit. ter 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, fitting 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 shut 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 P 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 pressure can be no more than 65 psi, etc.). Water over pressure (higher CO 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.

aller must provide flexibility in the product and utility supply to permit shifting the position

outline dimensions on the counter using the template drawings. Cut openings in the counter.

national (NSF) silastic sealant (Dow 732 or equal) approximately 1/4-inch

connected to a potable water supply shall be sized, installed, and

s, clamps, and insulation provided with the

off valve and water filter be installed in the

ER HOUR. If flow rate is less

2 OPERATING

2 operating pressure is 75 psi and the maximum water

2 operating pressure)

4. Locate the carbonator pump assembly and connect to powe

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 in

work should be done by a qualified service person.

r cord from the Ice/Drink Unit to the pump. The

dicated in applicable Flow Diagram Figure 8 or . This

+ 16 hidden pages

Cornelius FlavorFusion Series, FlavorFusion Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual