Remcor Pump Smart Service Manual
IMI CORNELIUS INC One Cornelius Place Anoka, MN 55303-6234
Telephone (800) 238-3600 Facsimile (763) 422-3246
Installation/Service Manual
PumpSmartCONDIMENT
SERVER
www.pumpsmart.com
The PumpSmart Compact Condiment Servers and the
PumpSmartCompact Condiment Servers Plus Condiment Servers are designed for smooth condiments
only. Attempting to pump condiments containing
particulates (such as salsa) using these servers will
void the warranty.”
Part No. 569000301
March 23, 1998
Revised: March 16, 2000
Control Code B
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 1998–2000
PRINTED IN U.S.A
TABLE OF CONTENTS
SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOGNIZE SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDERSTAND SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOLLOW SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO2 (CARBON DIOXIDE) WARNING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIPPING, STORING, OR RELOCATING UNIT 1. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM DESCRIPTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY REFERENCE INFORMATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THEORY OF OPERATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNPACKING AND INSPECTION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION OF LOOSE-SHIPPED PARTS 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
SELECTING LOCATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING UNIT 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLACING PUMPSMARTT CONDIMENT SERVER COMPONENTS IN
OPERATING POSITION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND MAINTENANCE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
PERIODIC INSPECTION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP TUBE AND CHECK VALVE ASSEMBLY SERVICE INTERVAL 11. . . . . . . .
ADJUSTMENTS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIMARY CO2/AIR REGULATOR ADJUSTMENT 11. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND MAINTAINING THE CONDIMENT BAG 11. . . . . . . . . . . . . . . . . . .
MAXIMIZING BAG EVACUATION (FOR KETCHUP AND MUSTARD
CONDIMENTS) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOADING BAG INTO THE BASKET (FOR KETCHUP AND MUSTARD
CONDIMENTS) 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTUP AFTER INSTALLING NEW BAG 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING AND SANITIZING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY CLEANING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZING PRODUCT SYSTEM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEP 1 WASH CONDIMENT SYSTEM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEP 2 FLUSH CONDIMENT SYSTEM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEP 3 SANITIZE CONDIMENT SYSTEM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEP 4 FLUSH CONDIMENT SYSTEM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEP 5 PURGE WATER OUT OF CONDIMENT SYSTEM AND RESTORE
OPERATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMPSMARTT CONDIMENT SERVER 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
569000301
TABLE OF CONTENTS (cont’d)
LIST OF FIGURES
FIGURE 1. FLOW DIAGRAM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. CIRCUIT BOARD 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. PARTS IDENTIFICATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. PUMPSMARTT CONDIMENT SERVER 18. . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES
TABLE 1. DESIGN DATA 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 1. DESIGN DATA CONT’D) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 2. LOOSE-SHIPPED PARTS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
569000301
ii
SAFETY INFORMATION
Recognize Safety Information
This is the safety-alert symbol. When you see this
symbol on our machine or in this manual, be alert to
the potentially of personal injury.
Follow recommended precautions and safe operating
practices.
Understand Signal Words
A signal word - DANGER, WARNING, OR CAUTION
is used with the safety-alert symbol. DANGER identi-
fies the most serious hazards.
DANGER
Safety signs with signal word DANGER or WARNING
are typically near specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety messages in this manual.
WARNING
CAUTION
Follow Safety Instructions
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in
good condition. Replace missing or damaged safety signs. Learn how to operate the machine and how to
use the controls properly. Do not let anyone operate the machine without instructions. Keep your machine in
proper working condition. Unauthorized modifications to the machine may impair function and/or safety and
affect the machine life.
CO2 (Carbon Dioxide) Warning
CO2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO2 (carbon dioxide)
gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is suspected, particularly in a
small area, immediately ventilate the contaminated area before attempting to repair the leak.
Personnel exposed to high concentration of CO2 gas will experience tremors which are followed
rapidly by loss of consciousness and suffocation.
Maximum CO
Operating Pressure 75–PSI
2
Shipping, Storing, Or Relocating Unit
CAUTION: Before shipping, storing, or relocating this Unit, the syrup systems must be sanitized and
all sanitizing solution must be purged from the syrup systems. All water must also be purged from
the plain and carbonated water systems. A freezing ambient temperature will cause residual water
remaining inside the Unit to freeze resulting in damage to internal components of the Unit.
1 569000301
GENERAL DESCRIPTION
This section gives the Unit description, theory of operation, and design data for the PumpSmart Condiment
Server.
This Condiments Dispensing System must be installed and serviced by a qualified Service Person. This system
contains no user serviceable parts.
IMPORTANT: To the user of this manual – This manual is a guide for installing, operating, and maintaining this equipment. Refer to the Table of Contents for page location for detailed information pertaining to questions that arise during installation, operation, service, or maintenance of this equipment.
SYSTEM DESCRIPTION
The PumpSmart Condiment Server is a system to dispense smooth condiments such as ketchup or mustard
in dining areas. The PumpSmart Condiment Server is made up of three components which are a Basket or
Bag-in-Box Shelf, a Pump Assembly, and the Dispensing Tower. Also provided with the system is the necessary
tubing and electrical wiring for interconnecting the Pump Assembly and the Condiment Dispensing Tower. The
PumpSmart Condiment Server is easily installed, maintained and cleaned.
W ARRANTY REFERENCE INFORMATION
IMPORTANT: The PumpSmart Compact Condiment Server and the PumpSmart Plus Condiment
Server are designed for smooth condiments only. Attempting to pump any other type of condiment
using these servers will void the factory warranty.
Unit Part Number:
Serial Number:
Install Date:
Local Authorized
Service Center:
Table 1. Design Data
Systems Part Numbers:
PumpSmart Compact Ketchup Server
PumpSmart Compact Mustard Server
PumpSmart Plus Compact Ketchup Server
PumpSmart Plus Compact Mustard Server
Overall Dimensions
Basket/Pump Stand Assembly
Width 20 Inches
Height 16 Inches
Depth 14 Inches
Condiment Dispensing Tower
Width 3 Inches
Height Ketchup/Mustard 8-3/4Inches
Depth 10-1/2 Inches
561500002
561500012
561500003
561500013
Ambient Operating Temperature 40F to 105F
3
569000301
Table 1. Design Data Cont’d)
Electrical Requirement
Operating Voltage 24VAC, 60 Hz
Current Draw (approximate) 300 Milliampere
Gas Requirement 90 PSI @ 1 SCFM
THEORY OF OPERATION
(See Figure 1)
WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of
CO
(carbon dioxide) gas leaks in the entire CO
2
suspected, particularly in a small area, immediately ventilate the contaminated area before
attempting to repair the leak. Personnel exposed to high concentration of CO
tremors which are followed by loss of consciouses and suffocation.
The PumpSmart Condiment Server is a device that dispenses smooth condiments such as ketchup and mustard and may be operated with either air pressure or CO2 gas. The Condiment Server uses a linear peristaltic
pump that pumps condiment from a bag-in-box container and pushes condiment through tubing to the Dispense
Tower. Upon demand (pushing dispense button on Dispense Tower), condiment will flow from the Dispense
Tower.
and condiment system. If a CO2 gas leak is
2
gas will experience
2
The Condiment Server may be configured to dispense condiment continuously while the dispense button is held
down (on demand mode) or the Server may be configured to dispense individual portions of condiment (portioncontrol mode). The size of the individual portions may also be set to any level from 0 to 6.0 ounces.
The peristaltic pump has only a few moving parts, requires little maintenance and is fully field repairable. The
straight-through condiment path makes sanitizing easy.
569000301
4
SANITIZING
ADAPTOR
DISPENSE
BUTTON
ADJUSTABLE
PRIMARY CO2/AIR
REGULATOR
SET AT 90 PSI
CONDIMENT BAG
BAG CONNECTOR
PRODUCT INLET
TUBE (30 INCHES LONG)
CHECK
VALVE
PUMP ASSEMBL Y
CHECK
VALVE
COUNTER
SURFACE
ANTI–PIVOT PIN
ELECTRICAL
CONNECTOR
CONDIMENT
DISPENSE TOWER
AIR/CO2 LINE
CHAMBER
CYLINDER
(10’ UNITS
ONLY)
PRODUCT
OUTLET TUBE
(3 FEET LONG OR
10 FEET LONG )
CO
AIR
2 OR
SOURCE
SOLENOID/RELAY
ASSEMBLY
ADJUSTABLE CO2/AIR REGULATOR
KETCHUP & MUSTARD
SHUTOFF
VALVE
SET AT 60 PSI AIR
SET AT 70 PSI CO
BLEED VALVE
CIRCUIT BOARD
(SEE FIGURE 2)
120/24 VAC CLASS 2
CO2/AIR EXHAUST
2
TRANSFORMER
FIGURE 1. FLOW DIAGRAM
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