Cornelius QLT 180 BEVERAGE DISPENSER Installation Manual
INSTALLATION
&
SERVICE
MANUAL
MODEL
QLT180/1000-1,
1002-1, & 1001-1
IMI
CORNELIUS INC.
One Cornelius Place
Anoka,
MN
55303
Tel:
1-800-238-3600 / 763-421 -61 20
Fax:
763-422-3226
Part
No.
8531 2001
Revision-
July
C
22,2002
Installation & Service Manual
SEMI-ANNUAL
CAUTION: The following procedures require removal of the dispenser side
panel
A
0
1.
2.
3.
4.
0
1.
2.
3.
4.
ing.
Clean Water Inlet Strainer:
Remove the left side side panel from the dispense.
Turn
off
the water supply to the dispenser.
Remove the access port from the
located on the water inlet in the lower rear portion
dispenser.
Clean and reinstall the stainless steel water strainer.
Clean Chassis Interior:
Clean the condenser cooling fins.
Clean the air inlet grille located at the base
Clean the interior base.
Wipe the fan blade clean.
"
(8).
Disconnect the power cord from the receptacle prior to proceed-
"Y"
shaped solenoid
of
the
of
the dispenser.
5.
Reinstall the left side panel, turn on the water supply, and plug the dispenser into the power
receptacle.
8531
2001
10
Installation & Service Manual
TROU
BLE-SHOOTING
GUIDE
The following pages contain trouble-shooting information intended to aid an experienced service
If
person in diagnosing any operational problems that may occur.
problem after several attempts, contact the IMI Cornelius
/
you are unable to resolve the
Wilshire Inc. Technical Services department at 1-800-238-3600 (763-421-6120 outside the United States) between the hours of
8:OO AM and
PM Central Standard Time. You must have the model and serial number
(lo-
300
cated on the right side of the dispenser) prior to calling.
PROBLEM PROBABLE CAUSE REMEDY
Totally Inoperative
No
power to dispenser
due to tripped circuit
breaker.
0
Reset circuit breaker.
Confirm that breaker is
correct size and no other
equipment si operating on
the same circuit.
Also
confirm that supply voltage is
f
10% of name-
plate specifications.
0
Loose or broken power
0
Repair connection.
supply connection inside
dispenser.
Yo
Cooling
Line voltage is not within
f
10%
of
nameplate
specifications causing
compressor overload to
trip.
Both thermostats in
OFF
position.
Defective compressor
overload or start capacitor.
Defective start relay
lo-
cated on upper rear shelf
inside dispenser.
Compressor starts but
hums and trips overload.
Compressor starts but
does not switch
off
of
start
winding.
0
Contact an electrician.
0
Turn
ON
thermostats and
recalibrate the temperatures to
0
Replace.
There should
0
40°F f 5
be
age on the black wire of
the relay when there is
line voltage present
OR
orange
Replace relay
yellow wire.
if
test.
0
Seized or shorted compressor, replace.
0
Relay or compressor is
defective. Test and replace faulty item.
(45°C).
line volt-
on
the
it fails this
Compressor short cycles
on overload.
11 8531 2001
0
Excessively high discharge pressure due to
restricted condenser or
operative condenser fan
motor.
in-
Installation & Service Manual
No Cooling (Cont'd)
Yo
water dispensed, concen-
trate only.
0
Refrigerant leak.
0
No
watertodispenser.
0
Water supply line inside
refrigerated cabinet disconnected from pump
platform.
Water solenoid located on
pump platform clogged or
defective.
Main water solenoid
strainer located at base of
dispenser is clogged,
binding or defective.
No
water dispensed, con-
centrate only.
0
Repair leak, evacuate and
recharge system.
0
Restore water.
0
Reconnect.
0
Disassemble and clean
solenoid. Replace
essary.
0
Remove and clean strainer. Confirm 28VDC is
present at solenoid during
dispense. Confirm solenoid coil is not open. Disassemble and clean solenoid.
0
Add external regulator
and lower pressure to
psi
(3.5
bar).
if
nec-
50
No
water and no concentrate,
refrigeration is working.
Water supply pressure is
greater than
100
bar)
0
Freeze-up of water coil or
concentrate chamber.
0
Service switch located under drip tray in OFF position.
0
Door switch open.
0
6.25 amp fuse inside front
box
electrical
blown.
psi
(7
0
Unplug dispenser and al-
low 2-4 hours to thaw.
Water or concentrate thermostat set too low, recali-
f
brate to 40" F
0
Defective water or con-
5
centrate thermostat, replace. Refrigerant solenoid
stuck open or not closing
fully. Evacuate system,
replace solenoid valve
and recharge.
0
Turn on switch.
0
Door switch must be
in
closed
order to operate
pump. Check switch operation and replace
essary.
0
Replace with 6.25 amp,
25OVAC
slow
blow fuse
and test.
(4.5"C).
if
nec-
8531 2001
0
No output from transform-
0
Confirm transformer out-
er located on rear upper put by measuring for
shelf. 26VAC at fuse. Replace
transformer
if
necessarv.
12
Installation & Service Manual
No water and no concentrate,
refrigeration is working
0
Defective voltage regula-
tor board (VRB) located
0
Measure across the blue
and black wire located in
(Cont'd). inside front electrical box. the upper left corner of
the board. There should
be 28VDC present when
the dispense button is
pressed. Replace VRB
necessary.
0
Defective portion control
board.
0
Disconnect wire harness
from rear of portion control, close door switch and
short the orange and
black wires together on
If
the harness.
unit dis-
penses portion control
board
is
defective.
If
does not dispense the
voltage regulator board is
defective.
No
concentrate dispensed,
water only.
0
Dispense tube not fully
engaged into receptacle
0
Refer to
Loading
Concentrate
section of this
on concentrate pouch. manual.
if
it
0
Dispense tube disconnected from mixing chamber. manual.
0
Slide block on pump in
open position.
'
Switch on pump platform
in FLUSH position. tion.
0
Concentrate too cold, no
properly thawed. 3540°F (1.74.5"C) prior
I
Excessive remnant left in
0
Defective pump motor.
0
Concentrate pouch im-
empty concentrate pouch. properly thawed.
0
Concentrate pouch and/or
dispense tube improperly
installed. manual.
0
Refer to Concentrate
Loading section of this
0
Close and lock the slide
block. Refer to Concentrate Loading section of
this manual.
0
Move switch to RUN posi-
0
Concentrate should be
to loading.
0
Replace pump motor.
0
Concentrate should be
3540°F (1.7-4.5"C) prior
to loading.
0
Refer to
Loading
Concentrate
section of this
Concentrate refill light comes
on prematurely.
0
Concentrate pouch im-
0
Concentrate should
properly thawed. 3540°F (1.7-4.5"C) prior
to loading.
0
Concentrate pouch andlor
dispense tube improperly
installed. manual.
_____
0
Refer to
Loading
Concentrate
section of this
13 8531 2001
be
Installation & Servicg Manual
Concentrate refill light comes
on prematurely (Cont'd).
I
Concentrate refill light does
not come on at all.
Warm Drink
I
0
Loose wiring.
0
Check wiring connections
between the pump motor
and the VRB board.
0
Bad VRB board.
0
Bad pump motor.
0
Pump improperly locked
0
Replace VRB board.
0
Replace pump motor.
0
Close and lock pump.
or pump is open.
0
Run/flush switch is in the
0
Move switch to the RUN
FLUSH position. position.
0
Improperly loaded tube.
0
Refer to concentrate loading section of this manual.
0
Bad VRB board.
0
Bad portion control.
0
Incoming water supply too
0
Replace VRB board.
0
Replace portion control.
0
Optimum performance is
warm. achieved when the dis-
penser utilizes water from
a pre-cooler.
0
Ambient air too warm.
0
Excessive demand on dis-
penser.
0
Relocate dispenser.
0
Add water pre-cooler or
second dispenser.
I
I
Water continuously drips from
nozzle when in OFF mode.
No
Flush Cycle
0
Dirty condenser coil.
0
Inoperative condenser
0
0
fan. motor.
0
Defective water thermo-
0
stat.
0
Loss of refrigerant charge
0
due to leak in system.
0
Main water solenoid at
0
base of unit or water solenoid on pump platform not
off
shutting
0
Run/Flush switch on
pump platform
tightly.
in
Run position.
0
mode.
0
Defective Run/Flush
0
switch on pump platform switch.
(concentrate continues to
dispense while in Flush
mode).
Clean condenser coil.
Replace condenser fan
Replace thermostat.
Repair leak and recharge
system.
Clean solenoid(s), replace
parts as necessary.
Move switch to Flush
Replace Run/Flush
Concentrate warm, water cold
0
Concentrate thermostat is
off
turned
or not calibrated
properly.
8531 2001 14
0
Calibrate to be 3540°F
(1 -7-4.5"C).
Installation & Service Manual
Concentrate warm, water cold
(Cont'd).
Brix Problem
0
Concentrate thermostat
0
Replace thermostat and
defective (stuck open). calibrate to 3540°F
(1.7-4.5"C).
0
Defective start relay
cated on upper rear shelf
inside dispenser.
lo-
0
There should be line voltage on the black wire of
the relay when there is
line voltage present on the
orange
OR yellow wire.
Replace relay
test.
0
Loss of refrigerant charge
0
Repair leak and recharge
system. due to leak in system.
0
Water supply pressure too
low, less than 40 psi (2.8
bar) flowing or water pressure fluctuates sharply.
0
Water flow control binding
or spring is defective.
0
Improperly thawed concentrate. Brix changes as
0
Correct water supply
problem to ensure a
constant
40
flowing to the dispenser.
0
Clean and/or replace
parts as necessary.
0
Concentrate should be
3540°F (1.74.5"C) prior
the concentrate tempera- to loading.
ture changes (concentrate
becomes thinner as tem-
perature rises).
if
it fails this
psi (2.8 bar)
Pump Inoperative
0
Pump motor defective. 28VDC should be present
at pump motor during dis-
pense.
If
voltage is present and motor does not
start, replace pump motor.
0
No power to transformer
or no 28VAC output from
transformer.
Confirm transformer has
line voltage present on
primary side. If no 28VAC
output from the secondary
replace transformer.
0
Defective voltage regula-
tor board (VRB) located
inside front electrical box.
Measure across the blue
and black wire located
the upper
left
corner of
the board. There should
be 28VDC present when
the dispense button is
pressed. Replace VRB
necessary.
in
if
15
8531 2001
Installation & Service Manual
Pump Inoperative (Cont’d).
Machine continues to dispense after dispense button is
released or dispenses without
operator input.
0
Defective portion control
board.
0
Portion control pad stuck
in on position.
0
Relay on voltage regulator
board (VRB) stuck on.
0
Disconnect wire harness
from rear of portion control, close door switch and
short the orange and
black wires together on
If
the harness.
unit dispenses portion control
board is defective.
does not dispense the
voltage regulator board is
defective.
0
Disconnect the wire harness from the rear of the
portion control and close
the door. If unit does not
dispense on its own the
portion control is bad
(stuck on).
0
Disconnect the &wire
harness from the lower
right corner of the VRB.
the unit continues to dis-
pense on its own the VRB
is defective (relay stuck
on).
If
it
If
8531
2001
16
Installation
&
Service
Manual
System
Wiring
Diagram
17
8531
2001
Installation & Service Manual
0
0
0
0
Main Electrical
Box
Wiring Diagram
0
0
0
0
0
8631 2001
18
Installation & Service Manual
I
Item Number
I
I
1
6
Part Number
45551
455381
455091
451 55001
451 29001
451 52
491 57
49155
49154
45087
45088
00
000
Final
Assembly
P/N
45100401. (115VAC)
P/N
451 00402 (23OVAC)
I
Description
Pouch Holder, Plastic
Shelf, Plastic
Platform
Grill, Drip Pan
I
Drip Pan
Bracket, Drip Pan
Bushing
I
I
Shoulder Bolt - 1/4-20 X 1 3/16 S.S.
I
I
Upper Hinge Plate
..
I
Hinge - Top Cover
I
Hinge - Bottom Cover
Assembly,
-
-
19 85312001
QLT
Upper Hinge
180
w/Sold
I
Out Feature
I
1
I
I
I
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