Cornelius Quest 2000 Service Manual

QUEST 2000

®

Service Manual

Release Date: March 18, 2004

Publication Number: 720529901SER

Revision Date: April 25, 2014

Revision: D

Visit the Cornelius web site at www.cornelius.com

for all your Literature needs.

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, plumbing, 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 manual.

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 Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

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

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

Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Unit Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Concentrate Handling & Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Loading Concentrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Changing Concentrate Containers: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Brixing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Checking/Adjusting the Brix Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Planned Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 1 - Rinse With Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 2 - Sanitize Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 3 - Prepare Dispenser for Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Semi-Annual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Clean Water Inlet Strainer:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Clean Chassis Interior:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Trouble-Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Assembly Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

System Wiring Diagram QST 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Main Electrical Box Wiring Diagram QST 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

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DANGER:

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WARNING:

CAUTION:

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WARNING:

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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.

© 2002-2014, Cornelius Inc. - 1 - Publication Number: 85312001INS

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

!

WARNING:

CAUTION:

!

CAUTION:

!

!

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.

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 140 lbs.
(63.5 kg.) 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.

Publication Number: 85312001INS - 2 - © 2002-2014, Cornelius Inc.

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

UNIT SPECIFICATIONS

Nameplate Data: Model QST 2000, 115 VAC, 4.5 amps, 1 phase 60 hertz, 6.25 oz. (177g) R-

134a refrigerant. Test press: High side 400 psi (27.6 bar). Low side 100 psi (6.9
bar).

Model QST 2000, 230 VAC, 2.25 amps, 1 phase 50 hertz, 6.25 oz. (177g) R­134a refrigerant. Test press: High side 400 psi (27.6 bar). Low side 100 psi (6.9
bar).

Concentrate Storage: Two 0.8 gallon (3.0 liter) disposable bottles.

Clearance Recommended: 12” (30.48 cm) on top and 4” (10.16 cm) required in back for air circulation.

Electrical Connection: 6 ft. long (1.83 m) power cord with 3-prong plug attached to dispenser. Export

models have line cord less plug.

Power Supply: 15 amps at 120 volts dedicated power supply.

20 amps at 230 volts dedicated power supply.

Water Connection: 3/8 in. (0.95 cm) SAE male flare fitting on dispenser.

Water Supply Requirements: 60 psi (413.7 kilopascals) (4.1 bar) maximum static pressure. 30 psi (206.8

kilopascals) (2.1 bar) minimum dynamic pressure; i.e., flowing pressure
measured at dispenser water inlet with 3.0 (88.7 ml) per second water flow.
Optimum recommended pressure 50 psi (344.7 kilopascals) (3 .5 bar) dynamic
pressure.

Ice Bank/Pull Down: Weight 7-8 lbs. (4.1-4.5 kg.). Pull Down: 3 hours at 75°F (24°C)

© 2002-2014, Cornelius Inc. - 3 - Publication Number: 85312001INS

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

CONCENTRATE HANDLING & LOADING

It is recommended that the concentrate be thawed in a refrigerated 35°F-40°F (1.6°C-4.4°C) compartment for a
minimum of 48 hours prior to loading into the Quest Juice Dispenser.

WARNING: Concentrate must be completely thawed and within the temperature range of 35°F-40°F
(1.6°C-4.4°C) prior to loading. Failing to supply concentrate inside the recommended temperature
range, especially below 35°F (1.6°C), will cause an out of brix drink (refer to the Brixing Procedure
section for details).

LOADING CONCENTRATE

The Quest Juice Dispenser is designed to use either disposable juice concentrate containers
or the optional Cornelius generic refillable container sold separately.

1. Thoroughly shake concentrate prior to use.

2. Place concentrate containers on the dispensing platform shelf inside the refrigerated cabinet.

3. Engage the concentrate container by pressing it downward into the bottle adapter opening
on the dispensing platform.

NOTE: Be sure to lubricate the o-ring seal on the container nozzle. This will ensure a

good seal and allow the pumps to draw concentrated from the containers more easily. Failure
to create a good seal at this connection may result in weak drinks and/or seepage of concen­trate.

4. Prime each pump by closing the cabinet door and press each dispense button until concentrate flows from the
dispense nozzles.

CHANGING CONCENTRATE CONTAINERS:

1. Open the cabinet door and move the valve handle from “Dispense” to “Flush”

2. Close the door. Depress and hold the dispense button until clear water flows from the dispense nozzle.

3. Open the cabinet door and return the handle to “Dispense”.

4. Depress and hold the dispense button for 1-2 seconds. This will relieve water pressure from the concentrate
pump system.

5. Load concentrate container (see

Loading Concentrate

).

Publication Number: 85312001INS - 4 - © 2002-2014, Cornelius Inc.

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

BRIXING PROCEDURE

NOTE: If concentrate is not properly thawed, it will adversely affect the amount of concentrate dis-

pensed. Thawed product should be between 35°F/1.6°C to 40°F/4.4°C.

SUPPLIES

• 1-Small 12 oz. cup (354.8 ml)

• 1-Large 21 oz. cup (621.1 ml)

• 1-Straw

• Paper Toweling

• 1-Thermometer

• 1-Refractometer

Your will also need a flat blade screwdriver to turn a screw if brix adjustments are required.

NOTE: The refractometer shown above, P/N 511004000, is available through your local Cornelius Dis-

tributor.

CHECKING/ADJUSTING THE BRIX SETTING

The following instructions are for use with a refractometer.

1. Dispense approximately 8 oz. (236 ml) of drink and discard. Now draw a second 8 oz. drink.

2. Check drink temperature with a reliable thermometer (target is 35-45°F, or 1.6-7.2°C). Discard this drink after
checking temperature.

NOTE: If drink temperature is not within the target range, refer to the basic troubleshooting section.

3. Dispense a 12 oz (354.8 ml) drink sample into a clean, dry cup. Thoroughly stir the sample using a straw.

4. Using a straw, transfer a small sample of finished drink to the refractometer lens (refer to operating instructions
supplied with your refractometer). Check the brix reading against the brix chart below.

NOTE: The following brix chart is generic and intended for reference use only. Contact your frozen

concentrate supplier for specific brix readings.

Brix Reference Chart

Flavor Ratio Brix
Orange Juice 4+1 11.8
Grapefruit Juice 5+1 10.6
Cranberry Cocktail 4+1 13.5
Apple Juice 5+1 12.0
Grape 5+1 13.0
Lemonade 5+1 10.5
Tropical Punch 5+1 11.8
Sweetened Iced Tea 7+1 6.0
Pineapple Juice 4+1 12.8
Prune Juice 2+1 16.0

© 2002-2014, Cornelius Inc. - 5 - Publication Number: 85312001INS

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

Lowers Brix by increasing water

Raises Brix by reducing water

5. To change the brix setting, simply readjust the water flow rate. Located on each of
the valve assemblies inside the refrigerated compartment are the adjusting
screws for the water flow rate (one per valve).

If the brix reading is too high or low, rotate the appropriate water flow control
according to the diagram below. Repeat steps 1-5 until the brix setting is achieved.

IMPORTANT: When making changes to the water flow control, do not rotate more than 1/4 turn per

adjustment. Additionally, prior to taking your next brix reading, “tap” the
corresponding dispense button several times prior to drawing a sample. This will
clear remnant drink from the dispense nozzle AND help move the flow control to its
new setting.

Publication Number: 85312001INS - 6 - © 2002-2014, Cornelius Inc.

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

DISPENSE/FLUSH

LEVER

R

PLANNED MAINTENANCE SCHEDULE

DAILY

Flush System:

1. Move Dispense/Flush levers located on the platform assembly in the
refrigerated cabinet to the “Flush” position. Place an empty cup on the
drip tray below each dispense nozzle.

2. Close the door and depress each dispense button for 2-3 seconds or until
clear water flows from each dispense nozzle.

3. Return the Dispense/Flush levers to the “Dispense” position.

4. Press each dispense button for 1-2 seconds to release the water pressure
present in the concentrate pump system.

5. Clean Splash Zones & Dispense Nozzles:

6. On a daily basis, clean the external cabinet and splash areas
using a clean damp cloth. Remove and wash the cup rest and drip
tray using a mild dish soap.

7. Remove the dispense nozzles and static mixers by rotating each
90° and pulling down. Remove the mixing chambers by pulling
straight forward. Wash using a mild dish soap.

IMPORTANT: DO NOT wash nozzles, static mixers, or

mixing chambers in a dish washer. This will
distort the plastic and damage the o-rings.
Additionally, do not soak them in sanitizing
solution longer than 2 minutes.

WEEKLY

Check concentrate to water brix ratio (refer to the Brixing Procedure in this manual).

Sanitize the Juice Dispenser:

Step 1 - Rinse With Hot Water

1. Prepare two 2 oz. packets of Stera-Sheen Green Label sanitizing solution (or similar brand) by dissolving
each packet in 1 gallon (3.8L) of potable water to insure 200 ppm of available chlorine.

IMPORTANT: Use potable water at 80°F-100°F (26.7°C-37.8°C). Water above this range will

breakdown the chlorine count and minimize sanitation.

2. Remove the juice concentrate containers and place them in separate refrigerated compartment.

3. “Flush” the system by following the instructions in the Daily Section.

4. Fill a clean empty concentrate container with one quart of extremely hot tap water, approximately 140°F (60°C)
and place into unit. Dispense all of the hot water into a large container. Repeat for the remaining dispense valves.

5. Remove the mixing chambers, nozzles, and static mixers. Rinse in hot water to remove excess pulp and concen­trate.

6. Place the mixing chambers, nozzles, and static mixers in a separate container of sanitizing solution and agitate
vigorously. Allow the parts to soak for two minutes. Rinse thoroughly with fresh tap water.

7. Reinstall the static mixer, nozzles, and mixing chambers.

Step 2 - Sanitize Pump System

1. Fill a clean concentrate container with 2 quarts (1.9L) of fresh sanitizing solution.

© 2002-2014, Cornelius Inc. - 7 - Publication Number: 85312001INS

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

CAUTION:

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2. Place handles in the “dispense” position and close the door.

3. Press and hold the dispense button for 90 seconds then stop. Allow sanitizing solution to remain in the lines for 5
minutes.

4. After 5 minutes, dispense the remaining sanitizing solution.

Step 3 - Prepare Dispenser for Use

1. Replace sanitizing solution container with a concentrate container and close the door.

2. Press and hold the dispense button until juice appears from the nozzle. Next dispense and discard at least two 8
oz. (236.6ML) cups of juice in order to prime the system and prepare it for operation.

SEMI-ANNUAL

The following procedures require removal of the dispenser side panel(s). Disconnect the power cord
from the receptacle prior to proceeding.

Clean Water Inlet Strainer:

1. Remove the right side panel from the dispenser.

2. Turn off the water supply to the dispenser.

3. Remove the access port from the “Y” shaped water inlet solenoid located on the right
side of the dispenser.

4. Clean and reinstall the stainless steel water strainer.

Clean Chassis Interior:

1. Clean the condenser cooling fins.

2. Clean the air inlet grilles located on the rear and top panels of the dispenser.

3. Clean the interior base.

4. Wipe the fan blade clean.

5. Reinstall the right side panel, turn on the water supply, and plug the dispenser into the power receptacle.

Check and Top-Off Water Ice Bath:

1. Remove the drip tray and lower splash panel.

2. If the Ice bath level is below the “Full” indicator, top it off with water. Refer to the Filling the Ice Bath procedure in
the Installation section of this manual.

ANNUALLY

Replace Pump Tubing:

A replacement pump tubing kit, part#45098, is available. The
kit consists of one pre-cut length of pump tubing, two white
plastic hose clamps, and instructions.

Removing Pump Platform(s):

1. Remove the concentrate containers from the dispenser
and place them in a refrigerator.

2. Remove the cabinet shelf that the concentrate containers
sit on.

Publication Number: 85312001INS - 8 - © 2002-2014, Cornelius Inc.

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

3. Flush the system prior to removing the pump platform (refer to the
Daily section located at the beginning of the Planned Maintenance
Schedule). Remove the dispense nozzles and static mixers.

4. Unplug the water line quick disconnect by pressing the gray button
(see Fig. 1&2).

5. Slide the locking latch forward. Lift the platform slightly and pull for­ward to gain access to the electrical connector (see Fig.1).

6. Unplug the electrical connector by squeezing the locking tabs on
either side and pulling out the connector. Lift and remove the pump
platform (see Fig.1).

Replacing Pump Tubing:

1. Remove pump platform (refer to the Removing Pump Platform(s) proce­dure located earlier in this section).

2. Remove the two white plastic hose clamps from the pump tube connections
(see Fig. 1&2). Remove the concentrate delivery tubes from the hose ends.

3. Loosen and remove the four thumb screws from the pump body.

4. Remove the rear pump body half only to reveal the pump tube and rollers.

5. Remove the old pump tube from the pump body. If the roller assembly comes
out with the tubing, place it back into the pump housing being sure to align
the roller assembly shaft keyway to the motor shaft so that the two interlock.

6. Firmly press the new hose into the pump body around the roller assembly,
being sure to keep the protruding ends even with each other.

7. Once the tubing is in place, hold the tubing with one hand, capture the lower
part of the tubing with the outer housing, then proceed to capture the shaft of
the roller assembly and push the rear pump housing into place. Make sure to
capture the tubing within the body and not pinch it between the halves. Do not
use any tool other than your finger tips to manipulate the tubing into the hous­ing or you may damage the tube.

8. While holding the pump halves together with your hand, reinsert the four
thumb screws and tighten using a criss-cross pattern as shown. The thumb
screws should be tightened about 1/4 turn beyond snug.

9. Insert the two concentrate delivery tubes into the pump tubing ends and
secure them using the new hose clamps supplied in the kit. Be sure to use pli­ers to squeeze and tighten the hose clamps.

© 2002-2014, Cornelius Inc. - 9 - Publication Number: 85312001INS

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

TROUBLE-SHOOTING GUIDE

The following pages contain trouble-shooting information intended to aid an experienced service person in
diagnosing operational problems that may occur. For further assistance, contact the Cornelius Technical Services
department at 1-888-248-5568 [phone] outside the United States) between the hours of 7:30A.M. and
5:00P.M. Central Standard Time. You must have the model and serial number (Located on the right side of the
dispenser) prior to calling.

PROBLEM PROBABLE CAUSE REMEDY

Totally Inoperative

No cooling

No water dispensed, con­centrate only

• No power to dispenser due to
tripped circuit breaker

• Loose or broken power supply
connection inside dispenser.

• Line voltage is not within +/- 10%
of nameplate specifications causing
compressor overload to trip

• No water in water ice bath or water
level extremely low exposing the ice
bank sensing probe

• Defective Ice Bank Control or
sensing probe

• Cabinet fan is inoperative resulting
in warm concentrate (water contin­ues to cool)

• Compressor short cycles on over­load

• Compressor starts but hums and
trips overload

• Defective compressor overload or
start capacitor

• Compressor starts but does not
switch off of start winding

• Refrigerant leak • Repair leak, evacuate and

• No water to dispenser • Restore Water

• 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 the rear of dispenser is
clogged, binding or defective

• Water supply pressure is greater
than 80 psi (5.5 bar) forcing the brix
flow control closed

• Reset circuit breaker. Confirm that
breaker is correct size and no other
equipment is operating on the same
circuit. Also confirm that supply volt­age is +/- 10% of nameplate specifi­cations.

• Repair connection.

• Contact an electrician

• Fill ice bath to proper water level

• Replace

• Replace

• Excessively high discharge pres­sure due to restricted condenser or
inoperative condenser fan motor

• Seized or shorted compressor,
replace

• Test and replace

• Relay or compressor is defective.
Test and replace faulty item

recharge system

• Reconnect

• Disassemble and clean solenoid.
Replace if necessary.

• Remove and clean strainer. Con­firm 28VDC is present at solenoid
during dispense. Confirm solenoid
coil is not open. Disassemble and
clean solenoid.

• Add external regulator and lower
pressure to 50 psi (3.5 bar)

Publication Number: 85312001INS - 10 - © 2002-2014, Cornelius Inc.

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

PROBLEM PROBABLE CAUSE REMEDY

No water and no concen­trate, refrigeration is work­ing

No concentrate dis­pensed, water only

Warm Drink

Water continuously drips
from nozzle when in OFF
mode

Concentrate warm, water
cold

• Freeze-up of water coil in ice bath • Unplug dispenser and allow 2-4
hours to thaw. Check operation of
agitator motor and ice bank control.

• • Refrigeration system may be low
on charge resulting in a deformed ice
bank and freeze-up of the water coil
in the ice bath.

• Black service switch located on

• Turn on switch

the rear of the cabinet door in OFF
position

• White door switch open • Door switch must be closed in
order to dispense. Check switch
operation and replace if necessary.

• 6.25 amp fuse inside front electri-

cal box blown

• Replace with 6.25, 250VAC slow
blow fuse and test

• No output from Transformer • Confirm transformer output by of
26VAC +/- 2. Replace transformer if
necessary.

• Defective voltage regulator board

(VRB) located inside front electrical
box

• Measure across the VDC output of
the board. There should be 28VDC
present when the dispense button is
pressed. Replaced VRB if neces­sary.

• Defective dispense push button or

• Test and replace if necessary

portion control board

• Concentrate container not fully

engaged into receptacle on pump

• Refer to Concentrate Loading sec­tion of this manual

platform

• Dispense/Flush lever in FLUSH

• Move lever to DISPENSE position

position

• Concentrate too cold, not properly

thawed

• Concentrate should be 35-40°F
(1.7-4.5°C) prior to loading

• Defective pump motor • Replace pump motor

• Ambient air around dispenser is

• Relocate dispenser

too warm

• Excessive demand on dispenser • Add water pre-cooler or second
dispenser

• Dirty condenser coil • Clean condenser coil

• Inoperative condenser fan • Replace condenser fan motor

• Defective Ice Bank Control • Test and replace if necessary

• Loss of refrigerant charge due to

• Repair leak and recharge system

leak in system

• Main water solenoid at base of

unit or water solenoid on pump plat­form not shutting off tightly

• Clean solenoid(s), replace parts
as necessary (refer to the Planned
Maintenance Section)

• Cabinet fan inoperable • Check/replace fan

• Agitator motor/pump inoperable or

• Check/replace agitator motor

restricted

• Loss of refrigerant charge due to

• Repair leak and recharge system

leak in system

© 2002-2014, Cornelius Inc. - 11 - Publication Number: 85312001INS

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

PROBLEM PROBABLE CAUSE REMEDY

Brix Problem

Pump Inoperative

Machine continues to dis­pense after dispense but­ton is released or
dispenses without operator
input

• Water supply pressure too low,
less than 20 psi (1.4 bar) flowing
water pressure fluctuates sharply

• Water flow control binding or
spring is defective

• Improperly thawed concentrate.
Brix changes as the concentrate

• Correct water supply problem to
ensure a constant 50 psi (3.5 bar)
flowing to the dispenser

• Clean and/or replace parts as nec­essary

• Concentrate should be 35-40°F

(1.7-4.5°C) prior to loading
temperature changes (concentrate
becomes thinner as temperature
rises)

• Pump motor defective • 28VDC should be present at pump

motor during dispense. If voltage is

present and motor does not start,

replace pump motor

• No power to transformer or no
28VAC output from transformer

• Confirm transformer has line volt-

age present on primary side. If no

28VAC output from the secondary

replace transformer

• Defective voltage regulator board
(VRB) located inside front electrical
box

• Confirm board produces 28VDC

present when the dispense button is

pressed (refer to the Electrical Box

Wiring Diagram for VDC output loca-

tion). Replace VRB if necessary

• Defective dispense control board

• Test and replace if necessary

(Push button or portion control)

• Push button or portion control pad
stuck in on position

• Disconnect the wire harness from

the rear of the portion control and

close the door. If unit does not dis-

pense on its own the dispense con-

trol board is bad (stuck on)

• Relay on voltage regulator board
(VRB) stuck on.

• Disconnect the 4-wire harness

from the lower right corner of the

VRB. If the unit continues to dis-

pense on its own the VRB is defec-

tive (relay stuck on)

Publication Number: 85312001INS - 12 - © 2002-2014, Cornelius Inc.

ASSEMBLY DRAWINGS

SYSTEM WIRING DIAGRAM QST 2000

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

© 2002-2014, Cornelius Inc. - 13 - Publication Number: 85312001INS

QLT 180/1000-1, 1002-1, & 1001-1 Installation Manual

MAIN ELECTRICAL BOX WIRING DIAGRAM QST 2000

Publication Number: 85312001INS - 14 - © 2002-2014, Cornelius Inc.

Cornelius Inc.

www.cornelius.com