Multiplex DIL Operator’s Manual

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

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

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

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

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

1522

2323

SYRUP

BIB Syrup Pump

1800

Cylinder

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

1522

NON-CARBONATED WATER

Carbonator Tank

CARBONATED WATER

Cylinder

SYRUP

1800

2323

BIB Syrup Pump

90100

SYRUP

Typical External Carbonation (Ambient) Beverage Dispensing System

Bag-In-Box

Syrup

Carton

8 Part Number 020005256 10/15

Section 2 Installation

UNIT DIMENSIONS

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)

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

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

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

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

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/NONCARB 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

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

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)

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

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