DI, DIL, & CT SERIES
Beverage Dispensers
Installation, Operation and Maintenance Manual
This manual is updated as new information and models are released. Visit our website for the latest manual.
Part Number 020005256 10/15
Safety Notices
Read These Before Proceeding:
As you work on Manitowoc equipment, be sure to pay close
attention to the safety notices in this manual. Disregarding
the notices may lead to serious injury and/or damage to the
equipment.
Throughout this manual, you will see the following types of
safety notices:
Warning
n
Text in a Warning box alerts you to a potential personal
injury situation. Be sure to read the Warning statement
before proceeding, and work carefully.
Caution
,
Text in a Caution box alerts you to a situation in which
you could damage the equipment. Be sure to read
the Caution statement before proceeding, and work
carefully.
Procedural Notices
As you work on Manitowoc equipment, be sure to read the
procedural notices in this manual. These notices supply
helpful information which may assist you as you work.
Throughout this manual, you will see the following types of
procedural notices:
Caution
,
Proper installation, care and maintenance are essential
for maximum performance and trouble-free operation
of your Manitowoc equipment. Read and understand
this manual. It contains valuable care and maintenance
information. If you encounter problems not covered
by this manual, do not proceed, contact Manitowoc
Foodservice Group. We will be happy to provide
assistance.
Important
Routine adjustments and maintenance procedures
outlined in this manual are not covered by the warranty.
Warning
n
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified from
that of original manufactured specifications.
NOTE: SAVE THESE INSTRUCTIONS.
Important
Text in an Important box provides you with information
that may help you perform a procedure more efficiently.
Disregarding this information will not cause damage or
injury, but it may slow you down as you work.
NOTE: Text set off as a Note provides you with simple, but
useful, extra information about the procedure you are
performing.
Section 1
General Information
Section 2
Installation
Section 3
Operation
Table of Contents
Read This Manual ............................................................................................................... 5
Unit Inspection ................................................................................................................... 5
Model Numbers .................................................................................................................. 5
Serial Number Location ..................................................................................................... 6
Warranty Information ........................................................................................................ 6
General System Overview .................................................................................................7
Unit Dimensions .....................................................................................................................................9
Electrical ................................................................................................................................................. 10
Pre-installation Checklist ................................................................................................12
Step by Step Installation..................................................................................................13
Carb/NON-Carb Settings .................................................................................................................. 13
Counter top Footprints .....................................................................................................................14
Placing the Unit .................................................................................................................................... 16
Carbonator Purge Tube Routing .................................................................................................... 19
Plumbing Diagrams ............................................................................................................................20
Starting System & Dispenser ........................................................................................................... 29
Component Identification ...............................................................................................31
Sequence of Operation ....................................................................................................31
Post-Mix Drop-Ins ................................................................................................................................ 31
Pre-Mix Drop-Ins .................................................................................................................................. 32
Stands ...................................................................................................................................................... 32
Cold Plate Beverage Cooling ........................................................................................................... 32
Unit Inspection ..................................................................................................................................... 32
Beverage Valves ...................................................................................................................................32
CO2 Supply ............................................................................................................................................. 33
Carbonated Water ............................................................................................................................... 33
Syrup Delivery System ....................................................................................................................... 33
Water Supply ......................................................................................................................................... 33
Back Room Package ........................................................................................................................... 34
Figal System ..........................................................................................................................................34
Figal Tanks .............................................................................................................................................. 35
Racking.................................................................................................................................................... 35
B-I-B .......................................................................................................................................................... 35
Pumps ......................................................................................................................................................35
Auto Bag Selectors .............................................................................................................................. 35
Part Number 020005256 10/15 3
Section 4
Maintenance
Cleaning ............................................................................................................................ 37
Sanitizing .......................................................................................................................... 39
Shipping, Storage and Relocation ..................................................................................41
Section 5
Before Calling for Service
Checklist ............................................................................................................................ 43
Pump Troubleshooting .................................................................................................... 44
Table of Contents (continued)
Disassemble for Cleaning ................................................................................................................. 37
Daily Cleaning....................................................................................................................................... 37
Monthly Cleaning ................................................................................................................................ 38
Cleaning Checklist .............................................................................................................................. 38
Preventive Maintenance ................................................................................................................... 38
Beverage System Cleaning .............................................................................................................. 39
Bag-In-Box System Sanitation ........................................................................................................39
Figal Beverage System ....................................................................................................................... 40
Figal Beverage System ....................................................................................................................... 41
Drink Troubleshooting ......................................................................................................................43
4 PPart Number 020005256 10/15
Section 1
General Information
Read This Manual
Manitowoc Beverage Systems developed this manual as a
reference guide for the owner/operator and installer of this
equipment. Please read this manual before installation or
operation of the machine. A qualified service technician
must perform installation and start-up of this equipment,
consult Section 5 within this manual for service assistance.
If you cannot correct the service problem, call your MBS
Service Agent or Distributor. Always have your model and
serial number available when you call.
Your Service Agent
Service Agent Telephone Number
Your Local MBE Distributor
Distributor Telephone Number
Model Number
Serial Number
Installation Date
Unit Inspection
Unit Inspection
Thoroughly inspect the unit upon delivery. Immediately
report any damage that occurred during transportation
to the delivery carrier. Request a written inspection report
from a claims inspector to document any necessary claim.
Model Numbers
This manual covers the following models:
Beverage Dispensers
CT-6, CT-8, DI-1522, DI-2323, DIL-2323
Warning
n
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified from
that of original manufactured specifications.
Part Number 020005256 10/15 5
General Information Section 1
Serial Number Location
This number is required when requesting information from
your local distributor. The serial number is listed on the
SERIAL NUMBER DECAL affixed to the dispenser.
Warranty Information
Consult your local MBS Distributor for terms and conditions
of your warranty. Your warranty specifically excludes all
beverage valve brixing, general adjustments, cleaning,
accessories and related servicing.
Your warranty card must be returned to MBS to activate
the warranty on this equipment. If a warranty card is
not returned, the warranty period can begin when the
equipment leaves the MBS factory.
No equipment may be returned to MBS without a written
Return Materials Authorization (RMA). Equipment returned
without an RMA will be refused at MBS’s dock and returned
to the sender at the sender’s expense.
Please contact your local MBS distributor for return
procedures.
6 Part Number 020005256 5/15
Section 2
Installation
General System Overview
These instructions are provided to assist the qualified installer. Contact your Manitowoc Beverage Equipment Service Agent
or call Manitowoc Beverage Equipment for information regarding start-up services. CT Series dispensers follow the same
system layout but do not have an ice bin.
Important
Failure to follow these installation guidelines may affect warranty coverage.
NOTE:
Typical Drop-In
Internal Carbonation
Beverage Dispensing System
Carbonate, Non-carbonate
Beverage Manifold
CT-6
Carbonator Tank
CT-8
Carbonate, Non-carbonate
Beverage Manifold
Carbonator Tank
This is a simplified schematic to
show the basic operation of the
beverage system.
Countertop
Bag-In-Box
Syrup
Carton
Tap Water
Tap Water
1522
CO
2323
SYRUP
BIB Syrup Pump
75
1800
2
Cylinder
2
CO
60
CO
2
SYRUP
Typical Internal Carbonation Beverage Dispensing System
The carbonator in the post-mix system normally has two inlet and one outlet connection. One inlet connects to the CO2
inlet. The other inlet connects the municipal water supply. The outlet carries the carbonated water to the cold plate inlets
at the unit. The outlet of the syrup supply connects to the appropriate coldplate syrup inlet fitting. The syrup flows through
the coldplate to be chilled on its way to the valves. The water flows through the coldplate chilling the plain and carbonated
water on its way to the valves. When both fluids leave the beverage valve they are mixed in the nozzle of the valve. Out
comes a properly cooled, proper ratio soft drink.
When starting a new beverage system of either type, be sure the electrically operated valves are turned off. Assure all
connections are made, turn the water supply on to the dispenser. Open CO2 tank valve and set all pressures. Place ice on the
coldplate and allow the coldplate to cool. After the beverage has achieved a 40°F temperature, the ratio of the product (brix)
on a post-mix system may then be set. (See Adjust Syrup to Water Ratio (Brix) Page 2 - 21)
Part Number 020005256 10/15 7
Installation Section 2
NOTE:
Typical Drop-In Ambient
Beverage Dispensing System
Carbonate, Non-carbonate
Beverage Manifold for DI-1522
CT-6 CT-8
Carbonate, Non-carbonate
Beverage Manifold
This is a simplified schematic to
show the basic operation of the
beverage system.
Tap Water
Tap Water
1522
NON-CARBONATED WATER
Carbonator Tank
CARBONATED WATER
CO
2
Cylinder
SYRUP
SYRUP
1800
2
2323
BIB Syrup Pump
90100
60
CO
2
CO
SYRUP
2
SYRUP
CO
Typical External Carbonation (Ambient) Beverage Dispensing System
Bag-In-Box
Syrup
Carton
8 Part Number 020005256 10/15
Section 2 Installation
UNIT DIMENSIONS
E
F
C
A
B
G
D H
MODEL A B C* D E F G H
CT-6 N/A N/A 9.50”
(24.2 cm)
CT-8 N/A N/A 9.50”
(24.2 cm)
DI-1522 44.38”
(112.8 cm)
DI/DIL-2323 56.75”
(144.2cm)
38.38"
(97.5cm)
46.75"
(118.8cm)
9.50”
(24.2 cm)
9.50”
(24.2 cm)
14.25”
(36.2 cm)
15.50”
(39.8 cm)
15.00”
(38.2 cm)
23.00”
(58.5 cm)
17.00” (43.2
cm)
25.00”
(63.5cm)
22.38” (56.9
cm)
22.75”
(57.78cm)
16.38"
(42.8cm)
23.75"
(60.4cm)
16.38"
(42.8cm)
16.88"
(42.9cm)
N/A 22.50” (57.2
cm)
N/A 22.85” (58.1
cm)
23.54”
(59.80cm)
DI = 18.00”
(45.72cm)
DIL= 21.50”
(54.61cm)
22.00”
(55.9 cm)
23.00”
(58.5 cm)
Part Number 020005256 10/15 9
Installation Section 2
ELECTRICAL
General
Warning
n
All wiring must conform to local, state and national codes.
Minimum Circuit Ampacity
The minimum circuit ampacity is used to help select the wire size of the electrical supply. (Minimum circuit ampacity is not
the beverage/ice machine’s running amp load.) The wire size (or gauge) is also dependent upon location, materials used,
length of run, etc., so it must be determined by a qualified electrician.
Electrical Requirements
Refer to Machine Model/Serial Plate for voltage/amperage specifications.
Voltage
The standard voltage for CT, DI, & DIL dispensers is 120VAC-60Hz 1 Ph. A power cord is provided with 120VAC-60Hz models
only. 220/240 Volts - 50 Hz - 1 Ph, 208/230 Volts - 60 Hz - 1 Ph are also available.
Minimum Circuit Amperage Chart
Dispenser Voltage/Cycle Circuit Amps
DI-1522, CT-6 120/60 2.4
220/50
DI/DIL2323, CT-8 120/60 3.2
220/50
Pump Deck 120/60 8.0
220/50
10 Part Number 020005256 10/15
Section 2 Installation
Grounding Instructions
This appliance must be grounded. In the event of
malfunction or breakdown, grounding provides a path of
least resistance for electric current to reduce the risk of
electric shock.
Warning
n
Risk of electrical shock. Connect to a properly grounded
outlet only.
This appliance is equipped with a cord having an
equipment-grounding conductor and a grounding plug.
The plug must be plugged into an appropriate outlet that is
properly installed and grounded in accordance with all local
codes and ordinances.
Warning
n
Improper connection of the equipment-grounding
conductor can result in a risk of electric shock. The
conductor with insulation having an outer surface that
is green with or without yellow stripes is the equipment
grounding conductor. If repair or replacement of
the cord or plug is necessary, do not connect the
equipment-grounding conductor to a live terminal.
Check with a qualified electrician or serviceman if the
grounding instructions are not completely understood,
or if in doubt as to whether the appliance is properly
grounded. Do not modify the plug provided with the
appliance — if it will not fit the outlet, have a proper
outlet installed by a qualified electrician.
Warning
n
When using electric appliances, basic precautions should
always be followed, including the following:
a. Read all the instructions before using the
appliance.
b. To reduce the risk of injury, close supervision
is necessary when an appliance is used near
children.
c. Do not contact moving parts.
d. Only use attachments recommended or sold by
the manufacturer.
e. Do not use outdoors.
f. For a cord-connected appliance, the following
shall be included:
• Do not unplug by pulling on cord. To unplug,
grasp the plug, not the cord.
• Unplug from outlet when not in use and
before servicing or cleaning.
• Do not operate any appliance with a
damaged cord or plug, or after the appliance
malfunctions or is dropped or damaged in
any manner. Contact the nearest authorized
service facility for examination, repair, or
electrical or mechanical adjustment.
g. For a permanently connected appliance — Turn
the power switch to the off position when the
appliance is not in use and before servicing or
cleaning.
h. For an appliance with a replaceable lamp —
Always unplug before replacing the lamp.
Replace the bulb with the same type.
i. For a grounded appliance — Connect to a
properly grounded outlet only. See Grounding
Instructions.
Part Number 020005256 10/15 11
Installation Section 2
Pre-installation Checklist
When installing any system, first make sure the major
components are available. Generally the major components
necessary for an installation are:
Post Mix System:
CO2 regulator set
Beverage dispenser
Beverage tubing
CO2 tank
Carbonator
Stepless (Oetiker) clamps
Chain for CO2 tank
Carb/Non-Carb Settings
B-I-B System also:
B-I-B connectors
B-I-B regulator set
B-I-B rack
B-I-B syrup boxes
Check Beverage Flavor Line-up
Double Check:
Also consider the location of the following:
Water line
Drain
Power outlet
Heating and air conditioning ducts
Unit Inspection
This section covers unpacking, inspecting, selecting
location, installing the unit, and preparing for operation.
The Servend Drop-In is shipped in a heavy duty corrugated
carton with a wooden pallet. Inspect the Drop-In for freight
damage. If any damage is noticed, stop immediately and
contact your delivering freight company. You must file
a freight claim for your equipment. Failure to do so can
void any claims. Servend is not responsible for any freight
damage, thoroughly inspect the unit upon delivery.
Request a written inspection report from a claims inspector
to document any necessary claim.
1. After the unit has been unpacked, remove the keys.
The key will be needed to perform brixing of valves.
Hold onto the keys until such time to forward them to
the respective owner/operator. Remove tape (which
secures grid in place in drain pan) from grid and other
packing material.
2. Make sure all items are present and in good condition.
Loose shipped items in the carton include the drain kit
parts and the instructions.
3. Inspect unit for any external damages.
If you have an internal carbonated unit the unit is preplumbed at the factory. The inlets for CO2 and water are
located behind the splash panel. There are two inlets for
water and one inlet for CO2. If you have questions refer to
the plumbing diagram on your equipment.
Do you have enough space to install the dispenser?
Is the countertop level?
Can the countertop support the weight of the
dispenser plus the weight of the stored ice?
12 Part Number 020005256 10/15
Section 2 Installation
Incoming Water Supply Requirements
Manitowoc Beverage Equipment recommends that a water shutoff valve and water filter be installed in the incoming water
supply line.
The incoming water source to the equipment shall be installed with adequate backflow protection to comply with
applicable National, State, and local codes.
Water pressure should be a minimum of 45 psi or you will starve the pump of water and damage it. The maximum water
pressure should be 55 psi or you will affect the quality of the carbonation.
The carbonator pump should be located within 6 feet of a 1/2 inch water source. A minimum 3/8 inch ID water line must be
used. Before connection the water source should be flushed of approximately 5 gallons of water to purge the system of any
sediments, especially in areas of new construction.
Location
Avoid placing the dispenser near heat sources such as radiators, ovens, refrigeration equipment and direct sunlight.
Optimum Ambient Conditions are between 50°F and 95°F (10°C and 35°C).
Step by Step Installation
To properly install the Servend Drop-In, Use these guidelines:
• Meet all local code requirements.
Important
The unit must be sealed to the counter to comply with NSF requirements.
• Have a receptacle with the proper voltage at the installation site for connection to the Drop-In.
• Completely unpack the Drop-In, removing all padding and shipping retainers.
• Route the beverage tubing from the syrup racks to the location of the Drop-In.
• Make all beverage connections, if necessary, at the syrup racks.
• Double check countertop cut out dimensions before cutting countertop.
CARB/NONCARB SETTINGS
Prior to placing the unit into the counter top it is recommended to make any carb/non-carb adjustments to the Flex
Manifold according to the provided beverage flavor line-up.
Flex Manifold
Flex Manifold
1522
Plumbing
Diagram
OPERATION:
MANIFOLD TO CHANGE TO CARBONATED
OR NON-CARBONATED WATER
1) ROTATE PLUNGER 180O USING A 5/32”
ALLEN WRENCH
2) PULL PLUNGER OUT TO GET NON-CARB WATER.
PUSH PLUNGER IN TO GET CARB WATER
3) TURN PLUNGER BACK 180
VALV ES
O
TO LOCK
WATER/SODA
CARB
WATER
PLAIN
WATER
Illustration above shows the Carbonated position.
Make adjustments using a 8 mm wrench or socket.
Turn 180° clockwise to switch the beverage to Non-
carbonated Water.
Plumbing
Diagram
2323
Part Number 020005256 10/15 13
Installation Section 2
12.375 in
)
COUNTER TOP FOOTPRINTS
DI-1522 & DI/DIL-2323
DI-1522 Depth = 22.25 (56.50 cm)
DI/DIL-2323 Depth = 23.25 (59.10
DI-1522 Width = 15.25 (38.70 cm)
DI/DIL-2323 Width = 23.25 (59.10 cm)
Counter Top
DI-1522 & DI/DIL-
2323 Cut Out Area
1. Mark the counter top with the appropriate cut out opening dimensions, see illustration above.
2. Check that the cut out location is approved by the owner before any cuts are made in the counter top.
Caution
,
Cutting the countertop may decrease its strength. Counter should be braced to support the dispenser countertop weight
plus ice storage capacity.
3. Compare the marked cut out with the dispenser chest size. Double check the marked hole size to be cut.
4. Cut the marked opening in the counter top.
5. Place one block of wood on the left side of the opening at the edge of the cut out. Place another block of wood on the
right side of the opening at the edge of the cut out. See Placing the Unit Page 2 - 9.
CT-6
(31.4 cm)
.313 in (.8 cm)
1.625 in (4.1 cm)
1.188 in
(3.0 cm)
1.938 in
(4.9 cm)
.250 in
(.6 cm)
Perimeter of CT-6 Base
4.625 in (11.7 cm
.313 in (.8 cm)
1.625 in (4.1 cm)
10.5 in (26.7 cm)
3.625 in (9.2 cm)
6 Holes (See Notes)
1.5 in (3.8 cm)
1.5 in (3.8 cm)
14 Part Number 020005256 10/15
Section 2 Installation
)
1.468 in
(3.7 cm
2.25 in
(5.7 cm
1. The CT-6 tower has (6) .250 inch diameter mounting holes in the base.
2. Diameter of the 6 holes to be drilled in the countertop depends on fasteners being used to secure tower.
3. The correct counter top hole size if screws are used is .125 inches.
4. The correct counter top hole size if bolts and nuts are used is .250 inches.
CT-8
20.25 in (51.4 cm)
23.25 in (59.1 cm)
15.25 in (38.7 cm)
1.563 in
(4.0 cm)
.187 in
(.5 cm)
11.25 in (28.6 cm)
4.75 in
(12.1 cm)
1.75 in (4.4 cm)
1.563 in
(4.0 cm)
Cut Out Area
.75 in (1.9 cm)
1.563 in (3.8 cm
3.25 in (8.3 cm)
)
)
8.0 in (20.3 cm)
8 Holes (See Notes)
1. The CT-8 tower has (8) .250 inch diameter mounting holes in the base.
Perimeter of CT-8 Base
2.5 in (6.4 cm)
22.5 in (57.2 cm)
2. Diameter of the holes to be drilled in the countertop depends on fasteners being used to secure tower.
3. The correct counter top hole size if screws are used is .125 inches.
4. The correct counter top hole size if bolts and nuts are used is .250 inches.
Caution
,
Cutting the countertop may decrease its strength. Counter should be braced to support the dispenser countertop weight
plus ice storage capacity.
Part Number 020005256 10/15 15
Installation Section 2
PLACING THE UNIT
CT-6 & CT-8
CT TOWER
COUNTER TOP
PRE-CUT OPENING
1. Remove drain pan grid, splash panel and drain pan before installation.
2. Pull aside all insulated beverage tubing from openings in tower base to access tower mounting holes. (See Foot Print)
3. Use a food grade sealant to seal all around bottom perimeter of tower base and surface of counter top (e.g., Dow
Corning RTV 731).
4. Place tower on counter top over the pre-cut opening and use screws or bolts to secure tower to the counter top. (See
Foot Print)
5. Place all insulated beverage tubing previously removed back through openings in tower base and opening in counter
top.
6. Install lighted merchandiser per instructions shipped with tower, route power cord down through tower base and
below counter top to tower’s electrical box. (See Plumbing & Wiring)
7. Connect harness jumper wire from tower’s electrical box to tower’s wiring harness.
8. Connect all necessary plumbing connections and connect drain to tower. (See Plumbing & Wiring)
9. Install drain pan, splash panel and drain pan grid onto tower. Be sure drain pan is properly located over rubber drain
funnel in tower base.
10. Connect tower’s electrical box power supply cord to an electrical outlet.
11. Check tower’s beverage system and drain for leaks, repair leaks if present.
NOTE: The tower must be sealed to the counter to comply with the NSF International requirements.
16 Part Number 020005256 10/15
Section 2 Installation
DI-1522 & DI/DIL-2323
Handles
(PN# 4340201)
Cut Out
Area
Wood Blocks
Drain Pan
Counter Top
Wood Blocks
Wood Blocks
1. Set the Drop-In in place resting on the two blocks of wood mentioned earlier.
Warning
n
Be careful not to pinch fingers under the edges of the unit when lowering into place.
2. Attach the drain lines to the drain connections at the bottom rear of the chest. There is one drain for the drain pan.
Another drain fitting is provided for the ice chest, these must be connected separately.
3. Check for leaks by pouring about one pint of cold water into the drain pan and chest. Repair leaks if any are found.
4. Route the clear carbonator tank purge tube from the relief valve to a drain, See Carbonator Purge Tube Routing Page 2 -
11.
Part Number 020005256 10/15 17
Installation Section 2
Drop-In Stands
When installing a DI-1522IC in a stand it may be necessary
to turn the pump head on the pump deck to allow room for
water line connections.
1. Loosen the clamp by turning the 5/16” screw.
2. Turn the pump to the position shown and secure in
place by re-tightening the clamp screw.
18 Part Number 020005256 10/15
Section 2 Installation
CARBONATOR PURGE TUBE ROUTING
1. During installation of unit the carbonator tank purge
tube (A) must be properly routed to a drain. Once the
splash panel has been removed from unit remove twist
tie (B) that holds carbonator tank purge tube
2. Purge tube is connected to the pressure relief valve on
carbonator tank and must be routed to a drain. Route
carbonator tank purge tube (A) down through the valve
leads conduit, which is located behind the carbonator
tank. Be sure not to collapse or kink carbonator tank
purge tube during routing from unit to drain.
3. The carbonator tank purge tube (A) will be routed
down through the valve leads conduit and out bottom
of unit to a drain.
Important
Follow all local and national plumbing codes when
routing carbonator tank purge tube to the drain.
Part Number 020005256 10/15 19
Installation Section 2
CARB. OR PLAIN
CARB. OR PLAIN
CARB. OR PLAIN
CARB. OR PLAIN
CARB. OR PLAIN
CARB. OR PLAIN
CARB. OR PLAIN
CARB. OR PLAIN
PLUMBING DIAGRAMS
Install the beverage tubing to the appropriate fittings, internally the unit is pre-plumbed. Refer to the plumbing diagram
cold plate drawing on the front of the chest for your individual set up.
NOTE: The water supply must first be connected to the carbonator pump (not shown) before plumbing to connections
“A” shown on the plumbing diagram. The carbonator pump deck must be within six feet of the dispenser for optimum
performance. (See BIB installation diagram for system pressure settings.)
NOTE: The CO2 connection for the internal carbonator is located with the coldplate connections. (See Plumbing Diagram.)
Check valve must be installed to plain water connection “B”. Contact factory if not installed.
CT-6 Post-mix
CT-6 with Variety Valve
CT-6 RECOMMENDED PLUMBING
2-1-1-2 PLUMBING CONFIGUREATION
WATER
WATER
WATER
WATER
SYRUP 1
5029318-0
UNIT DRAIN
SYRUP 2
SYRUP 3
SYRUP 4
SYRUP 5
SYRUP 6
COUNTER
TOP
CT-6 RECOMMENDED PLUMBING
2-1-1-2 PLUMBING CONFIGUREATION
*OPTIONAL*
VARIETY VA LVE
ON VALVE 4
W-WATER
(THRU COLD PLATE)
3-SYRUP
(#4-3 AMBIENT)
2-SYRUP
(#4-2 THRU COLD PLATE)
1-SYRUP
(#4-2 AMBIENT)
VARIETY VA LVE
BLOCK
CAUTION
ELECTRICAL SHOCK HAZARD
DISCONNECT POWER BEFORE SERVICING
CT-6 WIRING DIAGRAM
LIGHTER MERCH.
POWER CORD
POWER CORD
ELECTRICAL BOX
CAUTION
ELECTRICAL SHOCK HAZARD
DISCONNECT POWER BEFORE SERVICING
VALVE JUMPER
HARNESS
CT-6 WIRING DIAGRAM
020003552-0
LIGHTER MERCH.
SYRUP 1
UNIT DRAIN
SYRUP 2
SYRUP 3
WATER 3
WATER 1 & 2
SYRUP 5
SYRUP 6
WATER 4
SYRUP 4-1
SYRUP 4-2
SYRUP 4-3
WATER 5 & 6
COUNTER
TOP
POWER CORD
POWER CORD
ELECTRICAL BOX
VALVE JUMPER
HARNESS
20 Part Number 020005256 10/15
Section 2 Installation
CARB. OR PLAIN
CARB. OR PLAIN
CARB. OR PLAIN
CARB. OR PLAIN
CT-8 Post-mix
CT-8 RECOMMENDED PLUMBING
3-1-1-3 PLUMBING CONFIGUREATION
WATER
5029282-0
SYRUP 1
WATER
SYRUP 3
SYRUP 2
SYRUP 4
UNIT DRAIN
WATER
WATER
SYRUP 6
SYRUP 7
SYRUP 5
SYRUP 8
COUNTER
TOP
CAUTION
ELECTRICAL SHOCK HAZARD
DISCONNECT POWER BEFORE SERVICING
CT-8 WIRING DIAGRAM
VALVE JUMPER
LIGHTER MERCH.
POWER CORD
POWER CORD
ELECTRICAL BOX
HARNESS
Part Number 020005256 10/15 21
Installation Section 2
DI-1522 Post-mix
DI-1522 Post-Mix with 2 Blocked Valves
22 Part Number 020005256 10/15
Section 2 Installation
DI-1522 Pre-Mix
SERVEND RECOMMENDED PLUMBING DI1522 PREMIX
VALVE LOCATIONS
3/4” NPT
DRAIN PAN
DRAIN
3/4” NPT
LINE 3
LINE 2
LINE 6
LINE 4
LINE 5
LINE 1
BOTTOM VIEW
COLD PLATE
DRAIN
FOR 5 VALVE UNIT:
LINE 6 IS NOT USED
FOR 4 VALVE UNIT:
LINES 1 & 6 ARE NOT USED
LINE 3
LINE 2
LINE 6
LINE 1
LINE 5
LINE 4
INLET LINE LOCATIONS
FOR ASSISTANCE
CALL (812) 246-7000
5009449-0
Part Number 020005256 10/15 23
Installation Section 2
DI/DIL-2323 6 Valve Post-Mix
DI/DIL-2323 6 Valve Post-Mix with 2 Blocked Valves
020006242-2
24 Part Number 020005256 10/15
Section 2 Installation
DI/DIL-2323 8 Valve Post-Mix
DI/DIL-2323 8 Valve with Variety Valve Information
020006242-2
Part Number 020005256 10/15 25
Installation Section 2
DI/DIL-2323 10 Valve Post-Mix
DI/DIL-2323 6 Valve Pre-Mix
SERVEND RECOMMENDED PLUMBING DI/DIL-2323
VALVE LOCATIONS
3/4” NPT
DRAIN PAN
DRAIN
SYRUP 4
SYRUP 5
SYRUP 1
SYRUP 2
SYRUP 3
SYRUP 6
BOTTOM VIEW
FOR 5 VALVE UNIT:
INLET 6 IS NOT USED
VALVE 6 IS NOT USED
3/4” NPT
COLD PLATE
DRAIN
020006242-2
SYRUP 1
SYRUP 2
SYRUP 3
SYRUP 4
SYRUP 5
SYRUP 6
INLET LINE LOCATIONS
FOR ASSISTANCE
CALL (812) 246-7000
5009394-0
26 Part Number 020005256 10/15
Section 2 Installation
Internal Carbonator Connections
Water Outlet
Water Inlet
CO2 Inlet
Pressure Relief
Valve
Important
The CO2 connection for the internal carbonator is
located with the coldplate connections. (See plumbing
diagram.) Check valve must be installed to plain water
connection “B”. Contact factory if not installed. Valves
are read from right to left.
The water supply must first be connected to the
carbonator pump (not shown) before plumbing to
connections “A” shown on the plumbing diagram.
The carbonator pump deck must be within six (6) feet of
the dispenser for optimum performance. A check valve
must be installed in the water supply line 3 feet from
the non-carbonated water connection “PW”. Contact
factory if not installed.
Purging Air from the Carbonator Tank
1. Unit must be properly plumbed before purging the
carbonator tank. (See Plumbing Diagrams Page 2 - 12),
without power, and with the CO2 turned OFF.
Important
Do not energize the unit or turn on the CO2 to the unit.
2. Remove the panel behind the drain pan to gain access
to the carbonator tank and open the vent on the
carbonator pressure relief valve.
Panel
Drain
Pan
Internal
Carbonator
Tank
1. Connect the carbonator pump deck (power supply) to
the valve connection (if equipped) at the Drop-In. The
wires are marked appropriately. Check the electric key
switch on the side of the tower. The key should be in
the “OFF” (vertical) position.
2. The outside edge of the chest flange must be sealed to
the counter top. Apply a generous amount of sealant to
the underside of the outside edge of the flange.
Important
The unit must be sealed to the counter to comply with
NSF requirements.
3. Carefully remove the two blocks of wood from under
the flange. The Drop-In will then sit flat on the counter
top.
4. Wipe excess sealant from around the outer portion of
the flange.
5. Check to be sure the entire flange edge is sealed to the
counter top.
6. Apply water and syrup pressure to the beverage
system. Check for leaks to the system and repair any
leaks found.
7. Purge air from the carbonator tank.
Pressure
Relief Valve
Open Position
3. Turn on the water to the unit, fill the carbonator with
water and close the vent on the carbonator pressure
relief valve when water begins to escape the vent.
4. Plug the power cord from the unit into a power outlet
and turn the key switch for the valves to the “ON”
position and operate any valve to remove all the air
from the water lines.
5. Plug power cord (from the carbonator motor) into
the unit power cord assembly and connect the power
supply cord from the carbonator deck box into a power
outlet.
6. Perform monthly cleaning and sanitation, See Monthly
Cleaning Page 4 - 2.
7. Fill the chest with ice. Allow the coldplate to chill the
beverage tubing inside the coldplate.
NOTE: Clean your work area while waiting for the cold plate
to cool.
8. Verify and set system pressures.
Part Number 020005256 10/15 27
Installation Section 2
Pressure Settings
1. Incoming tap water should be at a minimum static
pressure of 40 psi (2.758 bars) and a maximum of
55 psi (3.792 bars) with carbonator pump operating
(measured at inlet to pump).
2. BIB pressure gauge set for 60 psi (4.137 bars) or
according to your line run.
3. Carbonator Pressure Gauge (Use Preset Regulator):
• Cold Carbonation set for 75 psi (5.171 bars).
NOTE: If incoming dynamic water pressure is under 40 psi
(2.758 bars), a water booster is recommended. If incoming
static water pressure is over 55 psi (3.792 bars), a water
regulating valve is required.
Pre-mix Pressures
Normal pre-mix pressure regulators should be set at 60
PSI. Diet pre-mix pressure regulators should be set at 40
PSI. If you are experiencing high foaming, decreasing the
pressures may correct the problem. Spitting and popping
usually requires slightly increasing the pressures. Pre-mix
beverage valve pressures vary by type and manufacturer.
Please consult the manufacturer of the valves you are using
for specific instructions regarding operation of the valve.
Bag-in-Box (BIB) Start-up
All lines should be properly flushed and sanitized before
starting the unit. See Bag-In-Box System Sanitation page
39.
1. Connect each BIB connector to the appropriate BIB.
2. Gradually adjust the secondary regulator to 70 psi.
Never run a BIB pump without the BIB installed as the
pump could be damaged. Set final secondary regulator
pressure 70 -75 psi depending on the line size and the
distance of the run.
3. Push each valve operator one at a time. Operate each
valve long enough to obtain both syrup and water
through the valve.
4. See Back Room Package page 34 for more details on
all BIB components.
Install Labels
Install flavor labels on the dispensing valve covers.
Clean Up
1. Wipe down the Drop-In and make final inspection of
the area.
2. Clean up all work areas. Dispose of all packing material,
excess tubing and trash properly.
28 Part Number 020005256 10/15
Section 2 Installation
STARTING SYSTEM & DISPENSER
Upon completion of the beverage dispenser and / or system
installation, all tubing, dispenser, and system components
must be cleaned and sanitized prior to use.
NOTE: At installation equipment, dispensers, and tubing
get moved through many environments, dirt, dust, chases,
insulation, drywall, etc. It is an important procedure and
best practice to address cleaning to deliver the best quality
drink to your customer.
Clean and sanitize the water and syrup circuits according to
instructions provided in this manual. Clean and sanitize the
dispenser components according to instructions provided
in this manual. Consult and use local health codes if a
discrepancy occurs between this manual and your local
health codes.
Warning
n
Carbon Dioxide (CO2) displaces oxygen. Exposure to a
high concentration of CO2 gas causes tremors, which
are followed rapidly by loss of consciousness and
suffocation. If a CO2 gas leak is suspected, particularly
in a small area, immediately ventilate the area before
repairing the leak. CO2 lines and pumps should not be
installed in an enclosed space. An enclosed space can
be a cooler or small room or closet. This may include
convenience stores with glass door self serve coolers. If
you suspect CO2 may build up in an area, venting of the
B-I-B pumps and / or CO2 monitors should be utilized.
Test Draw Temperature
Draw temperature test is only to be done after the coldplate
has completely chilled.
1. Operate one valve for about 15 seconds.
2. Take a temperature reading of the beverage on the
next 15 second draw. If the sample drawn is 40°F or
lower, go to the next step. If the beverage is higher
than 40°F, wait 10 minutes longer for the beverage to
attain the proper temperatures. Then repeat this step.
3. When the beverage achieves the proper temperature
the valves syrup to water ratio (brix) can be set.
4. Install flavor labels on the dispensing valve covers then
proceed to brix the valves.
Adjust Syrup to Water Ratio (Brix)
These are general brix instructions for beverage valves
using an S-tube syrup separator and high yield brix cup,
process may vary depending on valve manufacturer. Refer
to valve manufacturer for specific brix instructions.
1. Remove nozzle and syrup diffuser from valve.
2. Use an S-tube syrup separator to separate the syrup
dispense from the water by installing the rubber tip
snuggly over the diffuser.
3. Re-attach nozzle and diffuser with S Tube in place.
4. After nozzle has been re-attached, dispense a small
amount of product to fill up the S-tube.
NOTE: This is necessary to ensure an accurate reading.
5. Position the large middle opening of the brix cup under
the valve. At the same time insert the free end of the S
tube into the proper syrup ratio chamber. Verify what
ratio is recommended for the product. The diagram
below illustrates a typical high yield brix cup.
SYRUP
RATIOS
SYRUP
WATER
6:1
5.5:1
5.5
to 1
WATER
5:1
8.5:1
10
9
8
7
6
5
8.5
to 1
4
3
2
OZ.
High Yield Brix Cup
6. Dispense product until product reaches the grid on the
Brix cup.
NOTE: The water should be clear. If the water is not clear,
the S-tube has not been attached correctly to the syrup
diffuser, correct and repeat previous step.
7. Remove filled brix cup from dispenser and tap on
counter 3 times. Place on flat surface.
8. Look a the grid lines. The water and syrup levels should
be + / - 2 bars of each other.
SYRUP
WATER
SYRUP
WATER
SYRUP
WATER
Target Acceptable Acceptable
9. Adjust dispensing valves for water-to-syrup ratio (brix)
as recommended by the syrup distributor.
10. Repeat these steps for each product that will be
dispensed.
Part Number 020005256 10/15 29
Installation Section 2
THIS PAGE INTENTIONALLY LEFT BLANK
30 Part Number 020005256 10/15
Component Identification
Model/Serial Name Plate
Merchandiser
Tower
Key Switch
Drain Pan
Ice Chest
Cold Plate
Section 3
Operation
Valves
Splash Panel
Drainpan Grid
Lid
Model/Serial
Name Plate
NOTE: This
equipment is only
intended to dispense
beverages and is not
designed to be
Carbonator
Pump Deck
Plumbing Diagram
Soda/Syrup
Inlet Lines
Sequence of Operation
This section gives the a description of the units, theory of operation, and service data for the Post Mix Dispensers.
Important
TO THE USER OF THIS SERVICE MANUAL, THIS MANUAL IS A GUIDE FOR INSTALLING THIS EQUIPMENT. REFER TO THE
TABLE OF CONTENTS FOR PAGE LOCATION FOR DETAILED INFORMATION PERTAINING TO QUESTIONS THAT ARISE DURING
INSTALLATION AND START-UP OF THIS EQUIPMENT.
POSTMIX DROPINS
The design of the Servend Drop-In is such that it provides high accessibility to the ice stored in the chest, while allowing
maximum convenience of beverage dispensing. The function of a Drop-In is to allow easy and fast access to ice for filling
beverage cups, chilling and dispensing carbonated and non-carbonated beverages. The major components of the Cold
Carbonated Servend Drop-In dispensers are the ice chest with the sealed-in cold plate, internal carbonator, the beverage
valves, valve tower, carbonator pump deck (power supply) and merchandiser (optional). The major components of the
Ambient Servend Drop-In dispensers are the ice chest with sealed in cold plate, the beverage valves, valve tower and the
merchandiser (optional). An ambient cabonator will be needed to supply carbonated water to the Ambient Drop-In.
The bottom of the ice chest is the cold plate. The cold plate is a block of aluminum, with serpentine stainless steel tubes
molded inside. The stainless steel tubes inside the cold plate carry water to the internal carbonator back through the
stainless steel tubes, non-carbonated water (plain water), and beverage syrup to the beverage valves. The water and syrup
are chilled to the proper service temperature while flowing through the stainless steel tubes in the cold plate.
The beverage valve is designed to precisely meter the flow of both water and syrup to obtain the proper mixing ratio. These
two components of the beverage are mixed as they leave the valve. The valve tower holds the valves above the ice chest and
provides a conduit for the beverage tubing and electric wires to pass between the chest and the valves.
The merchandiser assembly consists of the sign, light bulb, and merchandiser frame. The tri-view merchandiser allows
viewing the medallion from the front, back, or top.
Part Number 020005256 10/15 31
Operation Section 3
PREMIX DROPINS
Pre-mix fountain dispensing consists of a container of
beverage ready for dispensing, beverage delivery system,
carbon dioxide (CO2) propellant, beverage cooling system,
and dispenser. We shall discuss each component of this
type of system within the context of this manual.
The major advantage of a pre-mix system over most other
types is its flexibility. This flexibility is the ability to go
anywhere. Many pre-mix systems will operate without
electric power or separate water supply. Most drop-ins
are manufactured for post-mix. Unless otherwise stated,
operation and installation instructions are for post-mix.
STANDS
UNIT INSPECTION
This section covers unpacking, inspecting, selecting
location, installing the unit, and preparing for operation.
Thoroughly inspect the unit upon delivery. Immediately
report any damage that occurred during transportation
to the delivery carrier. Request a written inspection report
from a claims inspector to document any necessary claim.
1. After the unit has been unpacked, remove the keys.
The key will be needed to perform brixing of valves.
Hold onto the keys until such time to forward them to
the respective owner/operator. Remove tape (which
secures grid in place in drain pan) from grid and other
packing material.
2. Make sure all items are present and in good condition.
Loose shipped items in the carton include the drain kit
parts and the instructions.
3. Inspect unit for any external damages.
If you have an internal carbonated unit the unit is preplumbed at the factory. The inlets for CO2 and water are
located behind the splash panel. There are two inlets for
water and one inlet for CO2. If you have questions refer to
the plumbing diagram on your equipment.
Stands are designed to accommodate drop-in ice bins and
to provide an enclosure for carbonators. See instructions
provided with those items for proper installation and
connections.
COLD PLATE BEVERAGE COOLING
IN
OUT
A cold plate is a block of aluminum with serpentine
stainless steel tubes molded inside the aluminum block.
The cold plate is approximately the same length and width
as the bottom of the dispenser bin. Ice sits on top of the
cold plate and cools the cold plate. The stainless steel
tubes inside the cold plate carry carbonated water (soda
water), noncarbonated water (plain water) and syrup to
the beverage valves. While flowing through the stainless
steel tubes in the cold plate, water and syrup are chilled to
serving temperature.
BEVERAGE VALVES
Post-mix beverage valves are designed to precisely meter
the flow of both water and syrup to obtain the proper
mixing ratio. The syrup and soda water components of the
post-mix beverage are mixed as they leave the beverage
valve.
32 Part Number 020005256 10/15
Section 3 Operation
CO2 inlet
CO2 SUPPLY
NOTE: CO2 inlet for the internal carbonator is located with
the cold plate inlet lines.
(See plumbing diagram for exact plumbing location)
• CO2 pressure to the BIB pump is 60 to 75 psi.
• DI-1522, 2323 & DIL-2323 CO2 pressure to the internal
carbonator is 75 psi.
• For ambient carbonated systems the CO2 pressure to the
carbonator should be set at 100 PSI
• “Optional” A low CO2 alarm is available on all internally
Carbonated DI series units. A RED low CO2 light
mounted to the tower will illuminate when the CO2
supply for the cabonator tank starts running low.
A CO2 cylinder delivers carbon dioxide (CO2) gas through
an adjustable CO2 regulator to the syrup BIB pump and
also to an internal carbonator. Plain water also enters
the internal carbonator tank, and is carbonated by the
regulated CO2 gas pressure. When a dispensing valve is
opened, CO2 pressure exerted within the syrup BIB pump
propels syrup from the BIB, through the beverage coils, and
into the dispensing valve. Carbonated water is forced from
the carbonator tank by CO2 pressure which pushes cold
carbonated water into the dispensing valve resulting in a
carbonated drink being dispensed. A non-carbonated drink
is dispensed in the same manner as a carbonated drink with
the exception that plain water is substituted for carbonated.
120 psi max
Pressure
Relief
CARBONATED WATER
Carbon Dioxide (CO2) leaves the storage tank and arrives
at the carbonator tank through the gas inlet. Water supply
enters the carbonator pump inlet at regular street water
line pressure (minimum 20 PSI, maximum 80 PSI, dynamic
or flowing pressure). The water pump increases the pressure
of the water, which allows the water to flow into the
carbonator tank. The CO2 and the water mix together in the
carbonator to produce the carbonated water that is then
sent to the soda dispenser.
The agitation of the water and CO2 together in the tank
under high pressure creates the soda water. The quality of
carbonation (percent of CO2 mixed in the water) increases
as the water temperature decreases and exposure time
increases.
The water level in the carbonator tank is controlled by a
water level control in the tank. This control turns the pump
motor off and on to maintain a preset level of liquid in the
tank. The water level control may be electronic probes or a
mechanical float.
SYRUP DELIVERY SYSTEM
Your syrup location can vary depending on the volume of
beverages served and ease of accessibility. Your beverage
system may set in a back storage room or under the counter
of the dispenser. Configurations are almost limitless.
Check the temperatures expected for the storage location.
Adverse temperatures can affect the storage and quality
of beverage products. It is recommended the temperature
of storage location should not fall below 40°F (4°C) or rise
above 90°F (32°C).
WATER SUPPLY
Water Inlet
Carbonated
Water Outlet
For internal carbonated systems:
Incoming water supply minimum of 40 and maximum of 55
psi. If incoming (static) water supply is over 55 psi you have
to install a water regulator. If incoming (dynamic) water
pressure is under 40 psi a water booster is required.
NOTE: The incoming water supply for the carbonator, which
is the pre-chill inlet on the plumbing diagram, must first be
ran through the carbonator pump which is located on the
carbonator pump deck (power supply).
The carbonator is replenished when the carbonated water
level inside the tank drops, which in turn automatically
starts the carbonator water pump. When the water level
inside the tank has been replenished, carbonator water
pump will stop.
Part Number 020005256 10/15 33
Operation Section 3
BACK ROOM PACKAGE
Booster System
Water Regulator
40–55 PSI
Filter
To C O
Manifold (BIB
Pumps) from
2
CO2 Supply
60 PSI
To Syrup Inlet
Barbs on Unit
To BIB Pumps
from BIB
To Non-carbonated
(If Required)
From Water Supply
Water Inlet Barb
Water to
Carbonator
Pump
BIB
To BIB
Pump
8. Lowered outgoing pressure - Set for 75 psi. Gauge
indicates lowered outgoing pressure from the CO2
cylinder after being routed through the primary
pressure regulator at 100 psi.
9. Secondary pressure regulator - Lowers the CO2 gas
pressure before the CO2 gas flows to the syrup pump.
CO2 pressure activates the syrup pump.
10. Syrup pump - Draws syrup out of the bag-in-box syrup
package. Syrup flows through the syrup lines to the
dispenser for chilling, then dispensing. There is a syrup
pump for each bag-in-box syrup system.
11. Bag-In-Box syrup cartons - Box which contains a
plastic bag, filled with syrup.
FIGAL SYSTEM
Figal refers to the stainless steel tanks of pre-mix beverage
or post-mix syrup. The term “Figal” is an abbreviated word.
Originally Figal was short for “five gallons”. Today, the term
usually refers to any stainless steel tank system used in soft
drink beverage supply. The CO2 to push the beverage from
the Figal tank is sourced from a small CO2 tank.
1. Incoming tap water - should be at a minimum
dynamic pressure of 40 psi and maximum static
pressure of 55 psi.
2. Carbonator Water pump motor - Powers the water
pump. The water pump motor is part of the carbonator
pump deck.
3. Carbonator Water pump - Pumps tap water into
the carbonator tank. The water pump is part of the
carbonator. The incoming water for the carbonator
must be first run through the pump before connecting
to the proper cold plate inlet.
4. Internal/External Carbonator tank - Combines CO2
gas and tap water to form carbonated water. The
“carbonator” is the carbonator tank, water pump and
water pump motor.
5. CO2 cylinder - Holds highly pressurized carbon dioxide
(CO2). The CO2 cylinder is a steel or aluminum cylinder
tank. CO2 gas flows through the primary pressure
regulator.
6. BIB pressure gauge - Set for a minimum of 60 psi.
Indicates CO2 pressure going to B-I-B pumps.
7. Primary pressure regulator - Lowers the CO2 gas
pressure, to 100 psi, so the CO2 gas will be at the proper
pressure to enter the carbonator regulator.
Soda Water
Carbonated Water to Dispenser
Incoming
Water
Pump
3/8 Syrup Lines to Dispenser
100 psi
Carbonator
CO
2
34 Part Number 020005256 10/15
Section 3 Operation
FIGAL TANKS
The stainless steel Figal beverage tanks are easy to store
and connect. There are several items to remember when
using the Figal tanks:
• Use a gas connector for the inlet fitting of the tank.
• Use a syrup connector for the outlet fitting of the tank.
• If more than one Figal tank is connected in series, when
changing tanks, remove the tank closest to the original
gas inlet while adding the new tank to the connector
closest to the syrup outlet.
Most Figal tanks have a self-closing valve on the tank as well
as the gas and syrup connectors. This allows the operator
of the system to change tanks without having to shut
down the entire system. With this type of connector, push
down on the connector while pulling up on the snap ring
around the opening of the connector. Then simply pull the
connector off the tank.
RACKING
Regardless if you are working on a B-I-B or Figal system, a
place will be designated for placement of the product. A
rack (or shelf) system affords systematic placement and
complete usage of the beverage paid for. The B-I-B rack
allows the boxes to lay properly for syrup dispersal. Please
check with your B-I-B syrup supplier. Some boxes must be
slightly tilted down, while others may be in virtually any
position. The Figal tank rack keeps the newer and full tanks
organized at one end of the beverage line with the partial
tanks at the other.
BIB
The Bag-In-Box system refers to a plastic disposable bag.
The B-I-B normally contains 5 gallons of syrup, however
some locations offer 2-1/2 gallon B-I-B units. This plastic
bag is then held inside a cardboard or other container. B-I-B
systems are for post-mix applications only.
PUMPS
The syrup in a B-I-B system is delivered to the beverage
system through gas operated pumps. These pumps extract
the syrup out of the bags, forcing the syrup throughout the
system.
AUTO BAG SELECTORS
These are used on higher volume B-I-B systems where two
or more bags of the same product are connected to one
pump and one system. An auto bag selector is essentially a
valve that automatically changes from one bag (or series of
bags) to another bag (or series of bags) of syrup as the bags
empty, allowing a constant flow of product.
Part Number 020005256 10/15 35
Operation Section 3
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36 Part Number 020005256 10/15
Section 4
Maintenance
Cleaning
DISASSEMBLE FOR CLEANING
A
A. Unplug the unit from power supply.
Warning
n
Electric Shock Hazard
Unplug unit before servicing or cleaning.
Warning
n
When using cleaning fluids or chemicals, rubber gloves
B
C
D
E
and eye protection should be worn.
Clean the exterior and drain pan:
1. Turn off the key switch located on either right or left
side of the unit.
2. Lift the grid and remove it from the drain pan.
3. Using mild soap, warm water and a clean cloth, wipe
the drain pan and splash panel. Then, rinse with clean,
warm water. Allow plenty of warm (not hot) water to
run down the drain of the drain pan, to remove syrup
residue that can clog the drain opening.
4. Wash the grid, then rinse with clean water. Place the
grid back in the drain pan.
5. Wash all exterior surfaces of the unit with warm water
and a clean cloth. Wipe again with a clean, dry cloth.
Clean the dispensing valves:
6. Remove nozzles and diffusers from beverage valves.
B. Lift out the cup grid.
C. Lift the drain pan straight up and pull it out.
D. Remove the ice bin cover.
DAILY CLEANING
All cleaning must meet your local health department
regulations. The following cleaning instructions are
provided as a guide.
Caution
,
Use only warm soapy water to clean the exterior of the
tower. Do not use solvents or other cleaning agents.
Do not pour hot coffee into the drain pan. Pouring
hot coffee down the drain pan can eventually crack
the drain pan, especially if the drain pan is cold or still
contains ice. DO NOT clean this unit using high presure
water jets or sprayers
Nozzle Removal
7. Rinse nozzle and diffuser with warm, clean water.
8. Clean nozzles and diffusers with soapy water and a soft
bristle brush.
9. Clean the underside of the beverage valves with warm,
soapy water. Rinse with clean damp towel.
10. Replace nozzles and diffusers on valves.
11. Turn on the key switch.
Part Number 020005256 10/15 37
Maintenance Section 4
Caution
,
Unplug unit before servicing or cleaning ice bin.
Ice bin contains parts that can move at any time and will
cause injury if hands are in the way.
Warning
n
When using cleaning fluids or chemicals, rubber gloves
and eye protection must be worn.
MONTHLY CLEANING
Clean and sanitize the ice bin and cold plate:
1. Remove all ice from the ice bin.
2. Remove the ice bin strainer by lifting it straight up.
3. Prepare a mild detergent solution using warm (100°F)
water.
4. Wash the ice bin using a sponge and the mild
detergent solution.
5. Wash the cold plate using a soft, nylon bristle brush
and the mild detergent solution.
6. Pour the remaining detergent solution in the drain pan
and watch for obstruction of flow.
7. With clean cloth soaked in clean water, rinse the ice
bin and cold plate. DO NOT pour bucket water inside
cabinet.
8. Prepare 2 gallons of sanitizing solution by mixing
1 ounce of household bleach (that contains 5.25%
sodium hypochlorite) with 2 gallons of 120°F water. The
mixture should not exceed 100 PPM of chlorine.
9. With clean cloth soaked in sanitizing solution, sanitize
the ice bin and cold plate. Leave in contact on ice bin
and cold plate surface for at least 10 seconds. DO NOT
pour bucket sanitizer inside cabinet.
10. Allow to air dry. Do not rinse.
CLEANING CHECKLIST
• Check CO2 supply. If CO2 supply is low, an arrow on the
primary regulator gauge will point to a shaded area that
reads “Low CO2” or “Change CO2 Cylinder.”
• Check syrup supply.
• Clean drain pan, grid, and splash panel.
• Clean the valve nozzles and diffusers.
PREVENTIVE MAINTENANCE
Preventative maintenance is a vital part of keeping your
dispenser in top condition. Following the guidelines below
will assist you in continued trouble-free operation of your
unit.
1. Conduct daily maintenance of the machine.
2. Perform monthly maintenance of the machine.
3. Perform periodic maintenance and sanitizing of
beverage system.
4. Do not overfill the dispenser bin with ice.
5. Do not allow the dispenser to sit for prolonged periods
of non use with ice in the bin.
6. Do not allow ice to remain in the bin more than a day
in order to prevent ice from freezing together and/or
stagnant ice.
7. Do not pour bucket of water or to store water inside of
the cabinet.
Contact MBE at 1-800-367-4233 for more information about
our ProActive Maintenance Program.
38 Part Number 020005256 10/15
Section 4 Maintenance
Sanitizing
BEVERAGE SYSTEM CLEANING
Warning
n
Flush sanitizing solution from syrup system.
Residual sanitizing solution left in system could create
a health hazard.
Warning
n
When using cleaning fluids or chemicals, rubber gloves
and eye protection must be worn.
Sanitize the beverage system at initial start-up as well
as regularly scheduled cleaning. The drain pan must be
in place under soda valves, to carry away detergent and
sanitizing agents that will be flushed through valves.
BAG-IN-BOX SYSTEM SANITATION
The procedure below is for the sanitation of one syrup
circuit at a time. Repeat to sanitize additional circuits.
You will need the following items to clean and sanitize the
Bag-in-Box (BIB) beverage system:
• Three (3) clean buckets
• Plastic brush or soft cloth
• Mild detergent
• Unscented bleach (5% Na CL O) or
• Commercial sanitizer
• Bag-In-Box bag connector
1. Prepare the following in the buckets:
• Bucket 1 — warm to hot tap water for rinsing.
• Bucket 2 — mild detergent and warm to hot
water.
• Bucket 3 — mix a solution of unscented bleach
(5% Na CL O) or commercial sanitizer and warm
to hot water. Mixture should supply 100 PPM
available chlorine (1/4 oz. bleach to 1 gallon
water).
2. Disconnect the “syrup-line side” of the bag-in-box
connector.
3. Rinse connector with warm tap water.
4. Connect syrup connector to BIB connector and
immerse both into Bucket 1. A “bag-side” connector
can be created by cutting the connector from an empty
disposable syrup bag.
Bag
side
connector
5. Draw rinse water through system until clean water
is dispensed. Most beverage valves allow the syrup
side to be manually activated by depressing the syrup
pallet.
6. Connect Bucket 2 to system.
7. Draw detergent solution through system until solution
is dispensed.
8. Repeat steps 2-7 until all syrup circuits contain
detergent solution.
Part Number 020005256 10/15 39
Maintenance Section 4
9. Allow detergent solution to remain in the system for 5
minutes.
10. Connect Bucket 3 to system.
11. Draw sanitizing solution through system until solution
is dispensed.
12. Repeat step 11 until all syrup circuits contain sanitizer
solution.
13. Allow sanitizer solution to remain in system for 15
minutes.
14. Remove nozzles and diffusers from beverage valves.
15. Scrub nozzles, diffusers and all removable valve parts
(except electrical parts) with a plastic brush or a soft
cloth and the detergent solution.
16. Soak nozzles, diffusers and removable valve parts
(except electrical parts) in sanitizer for 15 minutes.
17. Replace nozzles, diffusers and valve parts.
18. Connect Bucket 1 to system.
19. Draw rinse water through system until no presence of
sanitizer is detected.
20. Attach syrup connectors to BIBs.
21. Draw syrup through system until only syrup is
dispensed.
22. Discard first 2 drinks.
FIGAL BEVERAGE SYSTEM
1. Prepare the following in three clean Figal tanks:
• Rinse tank - fill with room temperature tap
water.
• Detergent tank - mix approved beverage
system cleaner with warm water as directed.
• Sanitizing tank - mix a solution of unscented
bleach (5% Na CL O) or commercial sanitizer
and warm to hot water. Mixture should supply
100 PPM available chlorine (1/4 oz. bleach to 1
gallon water).
2. Disconnect all product and water lines from product
tanks and remove carbonator.
3. Locate the Figal syrup tank for the circuit to be
sanitized. Remove both quick disconnects from the
Figal syrup tank. Rinse quick disconnects in tap water.
4. Connect rinse tank to the syrup line. Draw clean rinse
water through the valve until syrup is flushed from the
system.
5. Connect detergent tank to the syrup line and draw
detergent through the valve for two minutes. Then,
allow remaining detergent to stay in the system for five
minutes.
6. Connect rinse tank to the syrup line. Draw clean rinse
water through the valve until detergent is flushed from
the system.
7. Remove valve nozzle and diffuser as shown in Daily
Cleaning instructions. Using a plastic brush or a soft
cloth and warm water, scrub the nozzle, diffuser,
bottom of the dispensing valve and cup lever, if
applicable.
8. Place removable valve parts (EXCEPT solenoids) in
sanitizing solution for 15 minutes.
9. Replace valve diffuser and nozzle on the beverage
valve.
10. Connect sanitizer tank to the syrup line and draw
sanitizer through the valve for two minutes. Allow
sanitizer to remain in the system for a minimum of 15
minutes.
11. Reconnect syrup and carbonated water lines.
12. Draw syrup through the lines to rinse the system.
Discard drinks until at least two cups of satisfactory
tasting beverage are dispensed through the valve.
40 Part Number 020005256 10/15
Section 4 Maintenance
FIGAL BEVERAGE SYSTEM
1. Prepare the following in three clean Figal tanks:
• Rinse tank - fill with room temperature tap
water.
• Detergent tank - mix approved beverage system
cleaner with warm water as directed.
• Sanitizing tank - mix a solution of unscented
bleach (5% Na CL O) or commercial sanitizer
and warm to hot water. Mixture should supply
100 PPM available chlorine (1/4 oz. bleach to 1
gallon water).
2. Disconnect all product and water lines from product
tanks and remove carbonator.
3. Locate the Figal syrup tank for the circuit to be
sanitized. Remove both quick disconnects from the
Figal syrup tank. Rinse quick disconnects in tap water.
4. Connect rinse tank to the syrup line. Draw clean rinse
water through the valve until syrup is flushed from the
system.
5. Connect detergent tank to the syrup line and draw
detergent through the valve for two minutes. Then,
allow remaining detergent to stay in the system for five
minutes.
6. Connect rinse tank to the syrup line. Draw clean rinse
water through the valve until detergent is flushed from
the system.
7. Remove valve nozzle and diffuser as shown in Daily
Cleaning instructions on Pages 25 and 26. Using a
plastic brush or a soft cloth and warm water, scrub the
nozzle, diffuser, bottom of the dispensing valve and
cup lever, if applicable.
8. Place removable valve parts (EXCEPT solenoids) in
sanitizing solution for 15 minutes.
9. Replace valve diffuser and nozzle on the beverage
valve.
10. Connect sanitizer tank to the syrup line and draw
sanitizer through the valve for two minutes. Allow
sanitizer to remain in the system for a minimum of 15
minutes.
11. Reconnect syrup and carbonated water lines.
12. Draw syrup through the lines to rinse the system.
Discard drinks until at least two cups of satisfactory
tasting beverage are dispensed through the valve.
Shipping, Storage and Relocation
Caution
,
Before shipping, storing, or relocating this unit, syrup
systems must be sanitized. After sanitizing, all liquids
(sanitizing solution and water) must be purged from the
unit. A freezing environment causes residual sanitizing
solution or water remaining inside the unit to freeze,
resulting in damage to internal components.
Part Number 020005256 10/15 41
Maintenance Section 4
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42 Part Number 020005256 10/15
Section 5
Before Calling for Service
Checklist
If a problem arises during operation of your dispenser, follow the checklist below before calling service. Routine adjustments
and maintenance procedures are not covered by the warranty.
DRINK TROUBLESHOOTING
Condition Investigation Check Correction
Water only dispensing No pressure Regulator(s) out of adjustment Check/adjust regulator(s).
Out of CO
Defective regulator(s) Check/repair/replace regulator(s).
CO2 line pinched, kinked or
obstructed
Syrup and CO2 only dispensing Carbonator No power Check power supply. Plug in
Water supply Make sure water is turned “on”.
Defective carbonator Check/repair/replace carbonator
Syrup and plain water
only dispensing setting
One valve will not
dispense anything
Beverage dispensed
is too sweet
Beverage is not sweet enough Is the ratio (brix) of the
Drinks are foaming Are system pressures
No pressure Out o f CO
HP regulator out of adjustment Adjust HP regulator to the proper
Defective HP regulator Check/repair/replace HP regulator.
CO2 line pinched, kinked or
obstructed
Is there power to the
valve?
Is the ratio (brix) of the
drink correct?
drink correct?
correct?
Broken wire or loose connection Replace/repair wire or connector.
Bad microswitch Replace microswitch.
Flow control out of adjustment Adjust the flow control.
Insufficient soda flow due to
low carbonator pressure
Low CO2 pressure due to leaks Repair CO2 leaks.
Obstruction in the water or
soda line
Flow control out of adjustment Adjust the flow control.
Soda flow too high Reset CO2 pressure or replace
Obstruction in syrup line Clean out the syrup line.
Over carbonation Check CO2 supply. Reset pressure or
Dirty lines/valves Clean/sanitize entire system.
2
2
Install fresh tank.
Check/repair/replace CO2 line.
carbonator or reset breaker.
Replace water filter.
Check/clean/replace pump strainer.
Check/clean/repair water check valve.
Check for frozen water line. Internal
carbonator unit only.
pump, motor, electrode or liquid level
control.
Install fresh tank.
setting.
Check/repair/replace CO2 line.
Adjust CO2 pressure or change the
tank.
Clean out the lines.
regulator if necessary.
replace regulator if necessary.
Part Number 020005256 10/15 43
Before Calling for Service Section 5
Condition Investigation Check Correction
No water, syrup or gas
dispensing
Is there power to the No power Plug in unit or reset breaker.
unit? Power to control box Replace fuse or control box.
Is power coming Key switch “off” Turn switch “on”.
through the key switch? Key switch defective Replace key switch.
Is there power to the key
switch?
No power through the
transformer
Reset/replace transformer.
Pump Troubleshooting
Problem Possible Cause Corrective Action
Pump motor does not shut off Problem with probe or probe harness 1. Remove probe electronics.
2. Pass magnetic tip of screwdriver by lower end of
tube extending from electronics package.
3. Reed switch
Pump motor intermittent Problem with probe or probe harness
Pump motor does not pump Water pressure from water source is not high
enough
Verify water pressure leading into pump inlet is 40 psi
minimum.
44 Part Number 020005256 10/15
Section 5 Before Calling for Service
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Part Number 020005256 10/15 45
Before Calling for Service Section 5
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46 Part Number 020005256 10/15
SERVEND
2100 FUTURE, SELLERSBURG, IN 47172
800-367-4233
WWW.MANITOWOCBEVERAGE.COM/US
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Part Number 020005256 10/15
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