Remcor UNIVERSAL 750 Installation Manual

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Installation Instructions
DISPENSER
IMI CORNELIUS INC. One Cornelius Place Anoka, MN. 55303--6234 Telephone(800) 238--3600 Facsimile (612) 422--3232
Part No. 189159000 August 20, 1964 Revised: January 22, 1991
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Installation Manual must be read and understood before starting to install or operate this equipment.
IMI CORNELIUS INC; 1964-91Ó
Printed in U.S.A.
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TABLE OF CONTENTS
GENERAL INFORMATION 1. . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION 1. . . . . . . . . . . . . . .
UNIT DESCRIPTION 1. . . . . . . . . . . . . . . . . . . .
THEORY OF OPERA TION 2. . . . . . . . . . . . . .
INSTALLA TION 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
UNP ACKING AND INSPECTION 5. . . . . . . . .
IDENTIFICA TION OF LOOSE--SHIPPED
P ARTS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELECTING LOCATION 5. . . . . . . . . . . . . . . . .
INSTALLING UNIT 5. . . . . . . . . . . . . . . . . . . . . .
LOCA TING UNIT 5. . . . . . . . . . . . . . . . . . . . .
DRAIN CONNECTIONS 6. . . . . . . . . . . . . . .
ROUTING UNIT PRODUCT INLET LINES AND DRIP TRAY DRAIN HOSE OUT OF UNIT CAB-
INET 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING UNIT PRODUCT INLET
LINES 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING DISPENSING VALVES
KNOBS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FILL EVAPORATOR TANK AND STAR T REFRIG-
ERA TION SYSTEM 6.. . . . . . . . . . . . . . . . . . . .
PREP ARING UNIT FOR OPERATION 7. . . . .
UNIT OPERATION 7. . . . . . . . . . . . . . . . . . . . . .
OPERA TORS INSTRUCTIONS 9. . . . . . . . . . . . .
OPERA TING CONTROLS 9. . . . . . . . . . . . . . .
DISPENSING VALVE LEVER 9. . . . . . . . . . .
UNIT POWER SWITCH 9. . . . . . . . . . . . . . .
DAIL Y PRE OPERATION CHECK 9. . . . . . . . .
UNIT OPERATION 9. . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS 9. . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING PRODUCT TANKS CO2 REG-
ULA TORS 9. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING DISPENSED PRODUCT FLOW
RA TE 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLENISHING CO2 SUPPLY 9. . . . . . . . . . .
REPLENISHING PRODUCT SUPPLY 9. . . . .
CLEANING AND SANITIZING 9. . . . . . . . . . . .
DAIL Y CLEANING OF UNIT 9. . . . . . . . . . . .
WEEKL Y CLEANING OF DISPENSING
V ALVES 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZING UNIT 9. . . . . . . . . . . . . . . . . . . .
CHECKING CONDENSER COIL FOR RESTRIC-
TIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING ICE WATER BATH 9. . . . . . . . . . .
SERVICE AND MAINTENANCE 11.. . . . . . . . . . .
PREP ARING UNIT FOR SHIPPING, RELOCAT-
ING, OR STORING 1 1.. . . . . . . . . . . . . . . . . . . .
PAGE
TOP COVER, ACCESS GRILLES, AND DRIP
TRA Y REMOVAL ) 1 1.. . . . . . . . . . . . . . . . . . . . .
TOP COVER REMOV AL 1 1.. . . . . . . . . . . . . .
ACCESS GRILLES REMOVAL 1 1.. . . . . . . .
DRIP TRAY REMOVAL 11. . . . . . . . . . . . . . . .
PERIODIC INSPECTION 11.. . . . . . . . . . . . . . .
ADJUSTMENTS 1 1.. . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING PRODUCT TANKS CO2 REG-
ULA TORS 11.. . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING DISPENSED PRODUCT FLOW
RA TE 1 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLENISHING CO2 SUPPLY 1 1.. . . . . . . . . .
REPLENISHING PRODUCT SUPPLY 12. . . . .
PRODUCT FLAVOR CHANGE 12. . . . . . . . . . .
CLEANING CONDENSER COIL 12. . . . . . . . . .
CHECKING ICE WATER BATH ) 12.. . . . . . . . .
CLEANING EVAPORATOR TANK ) 14. . . . .
CLEANING AND SANITIZING 15. . . . . . . . . . . .
DAIL Y CLEANING OF UNIT 15. . . . . . . . . . . .
WEEKL Y CLEANING OF DISPENSING
V ALVES ) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZING UNIT 16. . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 21. . . . . . . . . . . . . . . . . . . . .
NO PRODUCT DISPENSED. 21.. . . . . . . . . . . .
DISPENSED PRODUCT COMES OUT OF DIS­PENSING VALVE CLEAR BUT FOAMS IN CUP
OR GLASS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSED PRODUCT FOAMS AS IT LEAVES
DISPENSING VALVE. 21. . . . . . . . . . . . . . . . . . .
REFRIGERA TION SYSTEM 22. . . . . . . . . . . . . .
COMPRESSOR DOES NOT OPERA TE. 22.
COMPRESSOR WILL NOT STOP AFTER
SUFFICIENT ICE BANK IS FORMED. 22. .
COMPRESSOR OPERATES CONTINUOUSLY
BUT DOES NOT FORM SUFFICIENT ICE
BANK. 22.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER FAN MOTOR NOT
OPERA TING. 23. . . . . . . . . . . . . . . . . . . . . . . .
AGITA TOR MOTOR NOT OPERATING. 23.
COMMERCIAL WARRANTY 25. . . . . . . . . . . . . . .
LIST OF FIGURES
FIGURE 1. UNIVERSAL 750 PRE-MIX DISPENS-
ER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. FLOW DIAGRAM 3. . . . . . . . . . . . .
FIGURE 3. PAR TS IDENTIFICATION 13. . . . . .
FIGURE 4. EVAPORATOR TANK (STANDARD
UNIT SHOWN) 14. . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 5. CLEANING DISPENSING VALVE 15
FIGURE 6. WIRING DIAGRAM 18. . . . . . . . . . .
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PAGE
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TABLE OF CONTENTS CONT’D
FIGURE 7. INSTRUCTIONS FOR CRIMPING
TUBE CLAMPS 19. . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
PAGE
LIST OF TABLES
TABLE 1. DESIGN DA TA 1. . . . . . . . . . . . . . . . .
TABLE 2. LOOSE-SHIPPED P ARTS 5.. . . . .
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GENERAL INFORMATION
IMPORTANT: To the user of this manual -- This manual is a guide for installing, operating, and maintaining this equipment. Refer to Table of Contents for page location of detailed information pertaining to questions that arise during installation, operation, service and maintenance, or troubleshooting this equipment.
GENERAL DESCRIPTION
This section gives the unit description, installation requirements, theory of operation, design data, and flow diagram for the Universal 750 Four-- Flavor Pre-­Mix Dispenser (hereafter referred to as a unit).
UNIT DESCRIPTION
The dispenser (see Figure 1) is a compact unit that may be installed free standing or under a counter or bar.
Installation of the LOOSE-- SHIPPED PARTS, (see Table 2-- 1), connection to a grounded electrical outlet with proper electrical requirements, filling evaporator tank with water, and connection to product tanks with regulated CO2pressure are all that is required to set unit up for operation. A 6--inch leg kit (P/N 187416-- 000) is available. Also available is a four caster kit (P/N 316290-- 000) to make unit mobile.
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 environment will cause residual water in the Unit to freeze resulting in damage to internal components.
Table 1. Design Data
Model Numbers:
Universal 750 (domestic) 284729-- 000
Standard Unit
Universal 750 (domestic) with 284780-- 000
Sealed Evaporator Tank
Universal 750 (export) 494729-- 000
Overall Dimensions:
Height 37--1/4 inches Width 16 inches Depth (with drip tray) 22 inches
FIGURE 1. UNIVERSAL 750 PRE-MIX DISPENSER
Table 1. Design Data (cont’d)
Weights:
Shipping (1Carton) 159 pounds Dry Weight 140 pounds With Evaporator Tank full 225 pounds
of Water
Ice Bank Weight 46 pounds
Capacities:
Unit Water Bath (no ice bank) approx.
Dispensing Rate:
6-- oz. drinks @ 4/minute *763 6-- oz. drinks @ 6/minute *507 Recovery Rate 3 drinks/minute
NOTE: *Number of 6-- oz. drinks that can be dis­pensed at 40° F or below with 75° F product inlet temperature and 75° F ambient.
Ambient Operating Temperature 40°F to 100°F
Electrical Requirements:
Operating Voltage (domestic) 1 15 VAC, 60 Current Draw (domestic) 8.1 amps
Operating Voltage (export) 230 VAC, 50 Current Draw (export) 3 amps
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Hz
Hz
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THEORY OF OPERATION (see Figure 2)
A CO2cylinder delivers carbon dioxide gas (CO2) through regulated CO2regulators to product tanks. When dispensing lever is opened, CO2pressure ex­erted upon product tanks pushes product from tanks, through unit cooling coils, to dispensing valves result­ing in cold dispensed drinks.
When unit power cord has been plugged into electri­cal outlet and power switch on back of unit has been flipped to ‘‘ON’’ (up) position, compressor, condenser fan motor, and agitator motor will start and begin forming an ice bank. When full ice bank has been formed, compressor and condenser fan motor will stop but agitator motor will continue to operate circu­lating ice water bath in evaporator tank. Evaporator tank ice bank sensing bulb will cycle compressor and condenser fan motor on and off as required to main­tain full ice bank.
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FIGURE 2. FLOW DIAGRAM
CYLINDER
REGULATOR (2)
2
2
CO
CHECK VALVE (4)
CO
PRODUCT TANK (4)
DISPENSING
PRODUCT COIL (4)
ICE WATER
VALVE (4)
BATH DISPENSER
2
LINE LEGEND
PRODUCT
CO
3
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INSTALLATION
This section covers unpacking and inspection, identi­fication of LOOSE--SHIPPED PARTS, selecting loca­tion, installing unit, preparing unit for operation, and unit operation.
UNPACKING AND INSPECTION (see Figure
3)
NOTE: The unit was thoroughly inspected before leaving factory and carrier has accepted and signed for it. Any damage or irregularities should be noted at time of delivery and immedi­ately reported to delivering carrier. Request a written inspection report from Claims Inspector to substantiate any necessary claim. File claim with delivering carrier, not with IMI Cornelius Inc.
1. After unit has been removed from shipping car­ton, remove shipping tape and other packing material. Inspect for shipping damage and follow procedure in preceding NOTE if damage is evi­dent.
2. Unpack item listed in LOOSE--SHIPPED P ARTS. Make sure all items are present and in good condition.
2. CUP REST (item 2) to be installed in DRIP TRA Y (item 3).
3. DRIP TRAY (item 3) to be installed on unit by inserting rear edge of tray under lip of valve trim panel and lifting up until bottom tray supports are inserted in square holes provided in front panel. Lock drip tray in place by slight down­ward pressure.
4. DECALS, DISPENSING VALVES KNOBS (item
7) to be installed on DISPENSING V ALVES KNOBS (item 4)
5. DISPENSING VALVES KNOBS (item 4) to be installed on dispensing valves by pushing knobs down into place on valves levers.
6. Applicable ADAPTERS (item 5) to be used to connect product inlet lines from product tanks to unit product inlet lines. REDUCERS (item 6) may be used to connect unit product inlet lines directly to product tanks quick disconnects pro­vided disconnects have 1/4-- inch flare (7/16--20) male fittings.
SELECTING LOCATION
Table 2. Loose-Shipped Parts
Item
No. Part No. Name Qty.
1 188090 Leveling Legs 4 2 186642 Cup Rest 1 3 186573-- 039 Drip Tray 1 4 151741-- 039 Dispensing Valve
Knob
5 150807-- 100 Adapter, 7/16-- 20
Male by 1/2--16 Male
150807-- 200 Adapter, 1/2-- 16
Male by 1/2--16 Male (domestic unit only)
6 31 1245 Reducer, 7/16--20
Female by 1/2--16 Male
7 317904-- 999 Decal, Dispensing
V alve Knob (as ordered)
IDENTIFICATION OF LOOSE--SHIPPED PARTS (see Figure 3)
1. LEVELING LEGS (item 1) to be installed in threaded holes provided on unit base (only units installed outside the United States).
NOTE: For identification purposes, side of unit dispensing valves are on is designated ‘‘front’’ of unit. This unit may be installed free standing or under counter or bar. Locate unit so following requirements are satisfied.
1. Near a properly grounded electrical outlet with proper electrical requirements. No other electri­cal appliance should be connected to this circuit. ALL ELECTRICAL WIRING MUST CONFORM
4
4
4
4
TO NATIONAL AND LOCAL ELECTRICAL CODES.
2. Air circulation through condenser coil, required for cooling coil, is drawn in through air intake grille on front of unit and is exhausted out through grilles on sides and back of unit. When locating unit, make sure grilles are not restricted to insure proper air circulation through unit.
INSTALLING UNIT
LOCATING UNIT
4
Areas Outside United States (Canada, Europe, etc.)
Install LEVELING LEGS (item 1) in threaded holes on each corner of unit base. Adjust each leveling leg until unit sits level and stands solid. Make sure all leveling legs are in contact with floor.
Areas Within United States -- To comply with National Sanitation Foundation (NSF) requirements, unit must be sealed to floor and LEVELING LEGS (item 1) may not be used. Perform following procedure to install unit.
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NOTE: An alternate arrangement for following installation method described would be to install available 6--inch leg kit (P/N 187416--000) or four caster kit (P/N 316290--000).
1. Slide unit into operating position.
2. Tilt unit up to expose bottom of base.
3. Liberally apply silastic sealant such as Dow Corning RTV 731 or equivalent around edges on bottom of base.
NOTE: Do not move unit after positioning or seal from unit base to floor will be broken.
4. Lower unit into operating position to complete seal from unit base to floor. Apply additional sealant around bottom of unit base. Seal must have a minimum radius of 1/2--inch to prevent crevices and to insure a complete seal.
DRAIN CONNECTIONS
ROUTING UNIT PRODUCT INLET LINES AND DRIP TRAY DRAIN HOSE OUT OF UNIT CABINET
IMPORTANT: When routing product inlet lines out through side of unit, use care to see that lines do not come in contact with compressor or hot discharge line. Accidental contact may result in foaming of dispensed product.
All internal connections have been made at factory. Unit product inlet lines and drip tray drain hose may be brought out through either side or back product line access holes on unit cabinet. If either leg kit (P/N 187416-- 000) or four caster kit (P/N 316290--000) are used, product lines and drip tray drain hose may be routed out through hole in unit base.
CONNECTING UNIT PRODUCT INLET LINES
NOTE: REDUCERS (item 6) may be used to con­nect unit inlet supply lines directly to product tanks quick disconnects provided disconnects have 1/4--inch flare (7/16--20) male fittings.
NOTE: Drip tray drain hose routed to waste con­tainer is not recommended due to sanitation and cleaning problems. Connection of drain hose to permanent drain is recommended.
Drip Tray Drain Hose -- The drip tray, as provided, is self-- contained and must be emptied periodically. If permanent drain is desired, cut out center of drain connection on drip tray . Be sure to remove all plastic to open drain to its maximum inside diameter pre­venting any rough edges which will trap dirt. Install DRIP TRAY (item 3) by inserting rear edge of tray under lip of valve trim panel and lifting up until bot­tom tray supports are inserted in square holes pro­vided in front panel. Lock drip tray in place by a slight downward pressure. Connect drain hose below drip tray to drain connection on drip tray . This drain hose runs to the inside of the unit and must be brought out with unit product inlet lines and routed to permanent drain or waste receptacle.
Evaporator Tank Drain Hose -- A drain hose, con­nected to bottom of evaporator tank, is provided to drain water from tank. Plug in end of drain hose should be removed only when desired to drain tank.
Standard Unit Evaporator Tank Overflow Tube -­Overflow tube from evaporator tank is routed to wa­ter tight pan in base of unit. During initial forming of ice bank and during periods of high humidity, excess water will overflow from evaporator tank to pan and be evaporated.
Unit With Sealed Evaporator Tank Overflow Tube
--Overflow tube from evaporator tank is routed out through rear panel of unit (see Figure 3). Plug in end of overflow tube should be removed only when ice water bath is being replenished, and during initial forming of ice bank.
1. Install applicable ADAPTERS (item 5) on ends of unit product inlet lines.
NOTE: The numbered unit product inlet lines to dispensing valves are labeled to identify dis­pensing valve they serve. For example: The line labeled ‘‘1’’ must be connected to system that provides product to be dispensed from NO. 1 dispensing valve. (NO. 1 dispensing valve is valve on right side when facing front of unit.)
2. Connect .265 I.D. or larger braided tubing from product tanks to unit product inlet lines.
INST ALLING DISPENSING VALVES KNOBS
1. Install DECALS (item 7) on DISPENSING V ALVES KNOBS (item 4)
2. Install knobs on dispensing valves by pushing knobs down into place on valves levers.
FILL EVAPORATOR TANK AND START REFRIGERATION SYSTEM
1. Make sure plug is secure in end of evaporator tank drain hose inside cabinet.
2. Remove four screws securing top cover on unit, then lift cover straight up and off.
3. Standard Unit. Fill evaporator tank up to top of stainless steel product coils with approximately 10 gallons of water. USE LOW--MINERAL-­CONTENT WA TER WHERE A LOCAL WATER PROBLEMS EXISTS.
Unit with sealed evaporator tank.
A. Remove plug from end of evaporator tank
overflow tube (see Figure 3).
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B. Remove water fill hole plug from evapora-
tor tank cover.
6. Plug unit power cord into a properly grounded electrical outlet.
C. Fill evaporator tank until water starts flow-
ing from overflow tube. USE LOW--MINER­AL-- CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS.
D. Install plug in water fill hole in evaporator
tank cover.
E. Install plug in end of evaporator tank over-
flow tube after full ice bank has been formed.
4. Install cover on unit and secure with four screws.
5. Flip unit power switch (see Figure 3) to ‘‘OFF’’ (down) position.
WARNING: Unit must be electrically grounded to prevent possible fatal
electrical shock or serious injury to operator. Unit power cord is equipped with a three--prong plug. If a three--hole (grounded) electrical outlet is not available, use an approved method to ground unit.
7. Flip unit power switch to ‘‘ON’’ (up) position.
8. With unit power switch in ‘‘ON’’ position, make sure compressor, condenser fan motor, and agi­tator motor start to begin forming an ice bank. When full ice bank is formed, compressor and condenser fan motor will stop but agitator motor will continue to operate circulating ice water bath in evaporator tank.
PREPARING UNIT FOR OPERATION
1. Adjust product tanks CO2regulators as instructed.
2. Connect product tanks into systems. Check for leaks and tighten loose connections.
UNIT OPERATION
1. Dispense from dispensing valve until air is bled from system and product is dispensed.
2. Repeat step 1 preceding to purge air from re­maining systems.
3. Adjust dispensed product flow rate as instructed.
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OPERATORS INSTRUCTIONS
This section covers operating controls, daily pre-op­eration check, unit operation, adjustments, replenish­ing CO2and product supplies, cleaning and sanitiz­ing unit, checking condenser coil for restrictions, and checking ice water bath.
OPERATING CONTROLS (see Figure 3)
DISPENSING VAL VE LEVER
Dispensing valve lever need only to be pulled for­ward to dispense product and released when cup or glass is full.
UNIT POWER SWITCH
Unit power switch, located on back of unit, must be in ‘‘ON’’ (up) position before unit will operate. PLACE UNIT POWER SWITCH IN ‘‘OFF’’ (DOWN) POSI­TION BEFORE PERFORMING INTERNAL SER­VICE AND MAINTENANCE.
DAILY PRE OPERATION CHECK
1. Make sure CO2cylinder regulator assembly 2000-- psi gage indicator is not in shaded (‘‘change CO2cylinder’’) portion of dial. If so, CO2cylinder is almost empty and must be re­placed.
REPLENISHING CO2SUPPLY
NOTE: When indicator on CO2cylinder regulator as­sembly 2000--psi is in shaded (‘‘change CO2cylin­der’’) portion of the dial, CO2cylinder is almost empty and should be changed. CO2supply should be checked daily and if necessary, replenished as instructed.
REPLENISHING PRODUCT SUPPLY
Product supply should be checked daily and if neces­sary , replenished as instructed.
CLEANING AND SANITIZING
DAILY CLEANING OF UNIT
Daily cleaning of unit should be performed at end of daily operation as instructed.
WEEKLY CLEANING OF DISPENSING VAL VES
Dispensing valves should be cleaned at least once a week as instructed.
2. Sufficient product supply in all product tanks. If not, replenish product supply as instructed.
3. Make sure drip tray is clean and clean cup rest is in place in drip tray.
UNIT OPERATION
1. Make sure unit power switch, located on back of unit, is in ‘‘ON’’ (up) position.
2. Hold cup or glass under dispensing valve. Pull dispensing valve lever forward and dispense until cup or glass is full, then release lever.
ADJUSTMENTS
ADJUSTING PRODUCT T ANKS CO REGULATORS
Product tanks CO2regulators should be periodically checked for proper pressure settings and if neces­sary , adjusted as instructed.
ADJUSTING DISPENSED PRODUCT FLOW RATE
2
SANITIZING UNIT
Product systems should be sanitized as instructed every 90 days following Sanitizer Manufacturer ’s re­commendations.
CHECKING CONDENSER COIL FOR RESTRICTIONS
NOTE: Air circulation through condenser coil, required to cool coil, is drawn in through air in­take grille on unit front panel and is exhausted out through grilles on sides and back of unit. Restricting air circulation through unit will de­crease its cooling efficiency .
Area in front, sides, and back of unit must be kept free of obstructions at all times which would prevent air flow in and out of unit. Cooling unit condenser coil should be periodically cleaned to maintain cooling efficiency as instructed.
CHECKING ICE WATER BATH
Product flow rate of dispensed product should be periodically checked and if necessary, adjusted as instructed.
A ‘‘gurgle’’ heard from unit indicates water level in evaporator tank is low and more water should be added for maximum product cooling as instructed.
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SERVICE AND MAINTENANCE
This section describes service and maintenance pro­cedures to be performed on the unit.
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
PREPARING UNIT FOR SHIPPING, RELOCATING, OR STORING
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 environment will cause residual water in the Unit to freeze resulting in damage to internal components.
TOP COVER, ACCESS GRILLES, AND DRIP TRAY REMOVAL (see Figure 3)
TOP COVER REMOVAL
Remove four screws securing unit top cover, then lift cover straight up and off.
ACCESS GRILLES REMOVAL
Remove four screws securing access grille on unit, then remove grille.
DRIP TRAY REMOVAL
1. If drip tray drain hose is used, disconnect drain hose from bottom of drip tray.
2. Lift drip tray up slightly, and at same time, tip front of drip tray up to disengage its bottom sup­ports from square holes in unit front panel. Slide drip tray down to disengage its upper rear edge from under valve trim panel lip.
3. Install drip tray on unit by reversing removal pro­cedure.
PERIODIC INSPECTION
6. Check dispensing valves for dripping that indi­cates leaking and repair as necessary.
ADJUSTMENTS
ADJUSTING PRODUCT T ANKS CO REGULATORS
NOTE: To readjust CO2regulator to a lower set­ting, loosen adjusting screw lock nut, then turn screw to the left (counterclockwise) until pres­sure gage reads 5--psi lower than new setting will be. Turn adjusting screw to the right (clock­wise) until gage registers new setting, then tight­en lock nut.
Set product tanks CO2regulators, using Cornelius PRE-- MIX COMPUTER slide rule or bottling room chart, at equilibrium pressure for highest temperature encountered between product tank storage area and cooling unit plus 5-- psig operating pressure for lines 10-- feet in length or less and no vertical lift. Add one pound for every 10-- feet over initial 10--feet of prod­uct tank--to--cooling unit line length and one pound for every 2--feet of vertical lift. Add one pound for every product tank on line over three tanks. MAXI­MUM UNIT INLET PRESSURE MUST NOT EX­CEED 100--PSIG. Loosen lock nut on CO2cylinder adjusting screw, then turn adjusting screw to the right (clockwise) until gage registers desired pressure. Tighten adjusting screw lock nut.
ADJUSTING DISPENSED PRODUCT FLOW RATE
Rotate dispensing valve Compensator Adjusting Screw (Figure 3) to the left (counterclockwise) for higher product flow rate or to the right (clockwise) for lower product flow rate.
2
REPLENISHING CO2SUPPLY
NOTE: When indicator on CO2cylinder regulator assembly 2000--psi gage is in shaded (‘‘change CO2cylinder’’) portion of dial, CO2cylinder is almost empty and should be changed.
4. Check unit condenser coil for accumulation of dust, lint, and grease which will restrict air flow through condenser coil which will decrease unit cooling efficiency.
5. Check area in front, sides, and back of unit for obstructions. These areas must be kept clear at all times which would prevent air flow in and out of unit.
1. Fully close (clockwise) CO2cylinder valve.
2. Slowly loosen CO2regulator assembly coupling nut allowing CO2pressure to escape, then re­move regulator assembly from empty CO2cylin­der.
3. Unfasten safety chain and remove empty CO cylinder.
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WARNING: To avoid personal injury and/or property damage, always
secure CO2cylinder with safety chain to prevent it from falling. Should valve become accidentally damaged or broken off, CO2cylinder can become an unguided missile.
4. Position CO2cylinder and secure with safety chain.
5. Make sure gasket is in place inside CO2regula­tor coupling nut, then install regulator on CO cylinder.
6. Open (counterclockwise) CO2cylinder valve slightly to allow lines to slowly fill with gas, then open valve fully to back--seat valve. (Back--seat­ing valve prevents leakage around valve shaft).
7. Check CO2connections for leaks. Tighten loose connections.
REPLENISHING PRODUCT SUPPLY
3. V acuum or use a soft brush to clean condenser coil. If available, use low--pressure compressed air.
4. Install grille on front panel and secure with four screws.
5. Flip unit power switch to ‘‘ON’’ (up) position.
CHECKING ICE WATER BATH (see Figures 3
and 4) A ‘‘gurgle’’ heard from unit indicates water level in
evaporator tank is low and more water should be
2
added for maximum product cooling. Before adding more water, ice water bath and ice bank should be checked for cleanliness and agitator motor shaft, ice bank sensing bulb, and anode checked for excessive mineral deposit build--up.
1. Flip unit power switch, located on back of unit, to ‘‘OFF’’ (down) position.
2. Remove four screws securing unit top cover, then lift cover straight up and off.
3. Unit with sealed evaporator tank only.
1. Remove inlet (CO2) disconnect (grey) and outlet disconnect (black) from empty product tank, then remove tank.
2. Place full product tank in position, then connect inlet (CO2) disconnect (grey) and outlet discon­nect (black) to tank.
PRODUCT FLAVOR CHANGE
Sanitize applicable system as instructed, then install full tank of new flavor product.
CLEANING CONDENSER COIL
NOTE: Air circulation through condenser coil, required to cool coil, is drawn in through grille on front panel and is exhausted out through grilles on sides and back of unit. Restricting air circulation through unit will decrease its cooling efficiency .
Excessive accumulation of dust, lint, and grease on condenser coil will restrict air flow through coil and cause a loss of cooling efficiency . Perform following procedure to clean condenser coil.
1. Flip unit power switch, located on back of unit, to ‘‘OFF’’ (down) position.
2. Remove four screws securing grille on front panel, then remove grille.
A. Remove quick disconnects (black) from
product tanks outlets.
B. Relieve pressure from systems by opening
each dispensing valve.
C. Disconnect agitator motor ground wire and
power cord.
D. Disconnect product inlet lines swivel nut
connections from fittings on evaporator tank cover. Be careful not to lose tapered gaskets.
E. Remove hex nuts securing evaporator tank
coils line fittings to evaporator tank cover.
F. Remove screws securing evaporator tank
cover to unit, then lift cover straight up to remove. Be careful not to lose rubber washers on tank coils line fittings.
4. Check condition of ice water bath and ice bank. Ice water bath should be clear and ice bank free of foreign particles.
5. Check agitator motor shaft, ice bank sensing bulb, and anode for excessive mineral deposit build-- up.
6. If cleaning of evaporator tank is necessary , refer to CLEANING EVAPORATOR TANK in this sec­tion.
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*WATER FILL PLUG
VALUE TRIM
PANEL
DISPENSING VALVE (4)
2
DRIP TRAY
DRAIN HOSE
ACCESS
GRILLE (4)
ACCESS GRILLE
RETAINING SCREW (4)
COMPENSAT OR
ADJUSTING
SCREW
COVER
RETAINING SCREW (2)
*EVAPORATOR TANK
OVERFLOW TUBE
3
PLUG
EVAPORATOR TANK
DRAIN HOSE
UNIT POWER
SWITCH
*UNIT WITH SEALED EVAPORATOR TANK.
FIGURE 3. PARTS IDENTIFICA TION
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ALUMINUM
SCREW
EVAPORATOR
TANK
ANODE
FIGURE 4. EVAPORATOR TANK (STANDARD UNIT SHOWN)
7. Fill evaporator tank with water up to top of stain­less steel product coils. USE LOW--MINERAL-­CONTENT WA TER WHERE A LOCAL WATER PROBLEM EXISTS.
8. Unit with sealed evaporator tank only.
AGITATOR
MOTOR
CLEANING EVAPORATOR TANK (see Figure 4)
NOTE: Ice water bath should be changed as often as necessary to keep evaporator tank clean. A convenient time to perform this opera­tion is at time unit is being sanitized. To save time, water can be drained from the evaporator tank while unit is being sanitized.
A. Install evaporator tank cover and coils line
fittings, connect agitator motor ground wire and power cord, and connect product inlet lines swivel nut connections to fittings on evaporator tank cover.
B. Install quick disconnects (black) on product
tanks outlets.
C. Dispense from dispensing valves to bleed
air from systems.
D. Check for leaks and repair if evident.
9. Install unit top cover and secure with four screws.
10. Flip unit power switch to ‘‘ON’’ (up) position.
1. Flip power switch, on back of unit, to ‘‘OFF’’ (down) position.
2. Remove four screws securing unit top cover, then remove cover.
3. Remove four screws securing either side or back access grille, then remove grille.
4. Extend drain hose from bottom of evaporator tank inside unit out through removed access grille to waste receptacle or drain. Remove plug and allow water to drain from evaporator tank.
5. Unit with sealed evaporator tank only. Refer to step 3 CHECKING ICE WATER BA TH
and perform procedures to disconnect product tanks from systems, relieve systems pressures, and remove evaporator tank cover.
NOTE: If ice bank is clear and contains no for­eign particles, it does not have to be melted down. Skip steps 6 and 7 and proceed with step
8).
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Page 19
6. If ice bank is dirty, allow it to melt. Hot water may be used to speed melting.
CAUTION: Never use an ice pick or other instrument to remove ice from
evaporator. Such practice can result in punctured refrigerant circuit or damage to corrosion protective coating on evaporator tank.
7. Wash inside of evaporator tank with a mild soap solution.
CAUTION: Function of the anode in the ice water bath is to draw
corrosive agents to itself and away from evaporator tank. Make sure ice bank sensing bulb and anode, with its rubber insulator in place on top end, are properly placed in their respective position. Anode must be completely insulated from other metal components and only an aluminum screw must be used to secure its connecting wire to evaporator tank. If anode is allowed to contact other metal parts, its effectivity will be destroyed, allowing corrosive action to take place on evaporator tank.
8. Use fiber brush and carefully clean mineral de­posit build--up from agitator motor shaft, ice bank sensing bulb, and anode. If after cleaning anode, and it is found to be badly corroded, re­place with a new one. Make sure only an alumi­num screw is used to secure anode connecting wire to evaporator tank.
9. Rinse all parts and flush evaporator tank with clean water.
10. Install plug in drain hose, then place hose back inside unit.
1 1. Install grille and secure with four screws.
12. Fill evaporator tank (if no ice bank is present) with approximately 10 gallons of water up to top of stainless steel product coils. USE LOW-- MIN­ERAL-- CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS.
13. Unit with sealed evaporator tank only.
CLEANING AND SANITIZING
DAILY CLEANING OF UNIT
NOTE: Drip tray that is connected to drain hose routed to waste container or permanent drain need not be removed from unit to be cleaned. Remove cup rest, then wash out and rinse drip tray in place on unit allowing water to escape through drain hose to waste container or drain. Wash and rinse cup rest, then install cup rest in drip tray. If drip tray is not connected to drain, proceed as follows:
1. Lift drip tray up slightly and at the same time, tip front of drip tray up to disengage its bottom sup­ports from square holes in unit front panel. Slide drip tray down to disengage its upper rear edge from under valve trim panel lip.
2. Remove cup rest from drip tray. Wash cup rest and drip tray, then rinse them with potable wa­ter.
3. Install cup rest in drip tray, then install drip tray on unit by reversing removal procedure.
4. Rinse out sponge with clean water, then wring excess water out of sponge. Wipe off external surfaces of unit, then wipe unit dry with a clean soft cloth. DO NOT USE ABRASIVE TYPE CLEANERS.
KNOB LEVER BONNET
FRICTION WASHER
COMPENSAT OR
O-RING
SHAFT AND SEAT ASS’Y
BODY
INNER SLEEVE
OUTER SLEEVE PHILLIPS-HEAD SCREW
SPRING
COMPENSAT OR
ADJUSTING
SCREW
O-RING
LEVER
BALL WASHER
KNOB
Refer to step 8 CHECKING ICE WATER BA TH and perform procedures to install evaporator tank cover, connect product tanks into systems, bleed air from systems, and check for leaks.
14. Flip unit power switch on back of unit to ‘‘ON’’ (up) position. Make sure compressor condenser fan motor, and agitator motor are operating.
FIGURE 5. CLEANING DISPENSING VALVE
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Page 20
WEEKLY CLEANING OF DISPENSING VAL VES (see Figure 5)
Dispensing valves should be cleaned at least weekly for proper operation. A convenient time to clean dis­pensing valves is at time unit is being sanitized. Per­form following procedure to clean dispensing valves.
1. Remove quick disconnects (black) from product tanks outlets.
2. Open dispensing valves to relieve pressure on systems.
3. Remove dispensing valve knobs by pulling knobs up and off valves.
4. Using a spanner wrench, loosen and remove coupling nuts from dispensing valves, then re­move valves from unit.
5. Remove phillips--head screw on end of dispens­ing valve, then remove outer sleeve, spring, and inner sleeve.
6. Loosen and remove knob lever bonnet securing lever in dispensing valve body, then remove le­ver.
7. Slide shaft and seat assembly out through rear of dispensing valve body .
SANITIZING UNIT
NOTE: This unit should be sanitized every 90 days following Sanitizer Manufacturer’s recom­mendations. Use Chlor--Tergent (Oakite Prod­ucts, Inc.) or equivalent sanitizer. An economic practice would be to arrange any product flavor changeover to coincide with sanitizing opera­tion.
1. Remove quick disconnects from product tanks. Rinse quick disconnects in potable water.
2. Following Sanitizer Manufacturer ’s instructions, fill clean empty product tank with sanitizing solu­tion.
3. Connect tank containing sanitizing solution into system to be sanitized.
4. Place waste container under applicable dispens­ing valve. Open dispensing valve to permit sani­tizing solution to push product out of line, coil, and dispensing valve. Continue to draw from valve until only sanitizing solution is dispensed.
5. Repeat steps 3 and 4 preceding to purge prod­uct from, and install sanitizing solution in, re­maining systems.
6. Follow Sanitizer Manufacturer ’s application instructions.
8. Wash disassembled dispensing valve parts in warm potable water.
9. Assemble dispensing valve by reversing disas­sembly procedure steps 5 through 7 preceding.
10. Disassemble and clean remaining dispensing valve by performing steps 5 through 9 preced­ing.
1 1. Remove compensators from inside sleeve and
coupling nut assemblies.
12. Wash compensators in warm potable water, then install compensators in sleeve and cou­pling nut assemblies.
13. Install dispensing valves on unit. Make sure coupling nuts are tight.
14. Install quick disconnects on product tanks out­lets.
15. Open dispensing valves to bleed air from sys­tems and until product flows from valves.
WARNING: To avoid possible personal injury or property damage,
do not attempt to remove product tank cover until CO2pressure has been released from tank.
7. Remove tank containing sanitizing solution from system and install tank containing potable wa­ter.
WARNING: Flush sanitizing solution from system as instructed. Residual solution left in system could create a
health hazard.
8. Place waste container under dispensing valve. Open dispensing valve to permit flush water to purge sanitizing solution out of line, coil, and dispensing valve. Continue to draw from valve until only flush water is dispensed.
9. Install tank containing flush water on remaining systems, then repeat step 8 preceding to flush sanitizing solution from systems until only flush water is dispensed.
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Page 21
WARNING: To avoid possible personal injury or property damage,
do not attempt to remove product tank cover until CO2pressure has been released from tank.
1 1. Place waste container under applicable dispens-
ing valve and blow residual water from system.
12. Repeat step 11 preceding to blow residual water from remaining systems.
Install product tanks in systems.
10. Remove tank containing flush water from sys­tem and install clean empty product tank.
Open each dispensing valve until all gas is purged from systems and product is dispensed.
17 189159000
Page 22
AGITATION MOTOR
RECEPTACLE
POWER SWITCH
WIRE SPLICE
CAP
WHITE
POWER
CORD
GREEN
ICE BANK
CONTROL
COMPRESSOR
CONDENSER
FAN MOTOR
CONTROL BOX
FIGURE 6. WIRING DIAGRAM
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Page 23
FIGURE 7. INSTRUCTIONS FOR CRIMPING TUBE CLAMPS
19 189159000
Page 24
THIS PAGE LEFT BLANK INTENTIONALLY
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Page 25
TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
WARNING: If repairs are to be made to carbonated water system, disconnect electrical power to Cooling Unit, shut off plain water and CO2supplies, and relieve the carbonated
water system pressure before proceeding. If repairs are to be made to syrup system, remove quick disconnects from applicable syrup tank, then relieve the system pressure before proceeding. If repairs are to be made to CO2system, stop dispensing, shut off CO2supply , then relieve the system pressure before proceeding. If repairs are to be made to an existing Remote Condensing unit, disconnect the power to the condensing unit before proceeding
Trouble Probable Cause Remedy
NO PRODUCT DISPENSED. A. Product tank quick
disconnects not attached.
B. No product supply (tank
empty).
C. No CO2supply . C. Replenish CO2supply as
DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT FOAMS IN CUP OR GLASS
DISPENSED PRODUCT FOAMS AS IT LEA VES DISPENSING VALVE.
A. Oil film or soap scum in cup or
glass.
B. Ice used for finished drink is
sub-- cooled.
NOTE: Crushed ice also causes dispensing problems. When dispensed drink hits sharp edges of the ice, carbonation is released from drink.
A. Recovery rate of unit
exceeded (ice bank depleted).
B. Product tanks CO2regulator
adjusted too high.
A. Attach quick disconnects.
B. Replenish product supply as
instructed.
instructed.
A. Use clean cups and glasses.
B. Do not use ice directly from
freezer. Allow ice to become ‘‘wet’’ before using. (Refer to following NOTE)
A. Allow ice bank to recover.
B. Adjust product tanks CO
regulator to proper equilibrium pressure as instructed, then replace product supply.
2
C. Dispensing valve restricted or
dirty .
D. Tapered nylon washer inside
tube swivel nut connection distorted from being overtightened restricting product flow.
E. Oil, water, or dirt in CO
supply .
21 189159000
2
C. Clean dispensing valve as
instructed.
D. Replace nylon washer. Make sure
it is properly seated.
E. Remove contaminated CO2.
Clean CO2system (lines, regulators, etc.). Install a clean CO2supply .
Page 26
Trouble RemedyProbable Cause
REFRIGERATION SYSTEM
COMPRESSOR DOES NOT OPERA TE.
A. Ice bank sufficient. A. Refrigeration not called for.
B. Unit power cord unplugged or
unit power switch in ‘‘OFF’’ (down) position.
C. No power source (blown fuse
or tripped circuit breaker).
D. Low voltage at compressor
terminals.
E. Loose, disconnect, or broken
wiring.
F. Overload protector cut out;
over-- heated compressor.
B. Plug in power cord or flip power
switch to ‘‘ON’’ (up) position.
C. Replace fuse or reset circuit
breaker. (Note: Fuse is not part of unit)
D. V oltage must be at least 103 volts
(1 15 VAC model) or 208 volts (230 VAC model) at compressor terminals when compressor is trying to start.
E. Tighten connections or replace
broken wiring.
F. Compressor will cool enough to
Condenser fan restart. Do not overdraw cooling motor not operating as required. capacity of dispenser. Refer to ‘‘CONDENSER FAN MOTOR NOT OPERATING’’ in this section.
COMPRESSOR WILL NOT STOP AFTER SUFFICIENT ICE BANK IS FORMED. (NOTE-- ICE BANK SHOULD JUST COVER CONTROL BULB).
COMPRESSOR OPERATES CONTINUOUSL Y BUT DOES NOT FORM SUFFICIENT ICE BANK.
G. Inoperative overload protector
or start relay . H. Inoperative ice bank control. H. Replace ice bank control. I. Inoperative compressor. I. Replace compressor. A. Ice bank control cap tube
kinked or broken.
B. Ice bank control stuck in
closed position. A. Cooling capacity is exceeded
by over --drawing.
B. Unit located in excessively hot
area or air circulation through
condenser coil is restricted. C. Refrigeration system leak. C. Repair refrigeration system.
NOTE: Ice bank freezes from bottom of evaporator upward. A refrigerant leak or insufficient charge might show an ice bank at bottom and not at top of evaporator.
G. Replace inoperative part.
A. Replace ice bank control.
B. Replace ice bank control.
A. Reduce amount of drinks drawn
per given time.
B. Relocate unit or determine and
correct condenser coil restriction.
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Page 27
Trouble RemedyProbable Cause
NOTE: If overload protector cuts out compressor, condenser fan motor will continue to run; otherwise; troubleshooting condenser fan motor problems is same as for “COMPRESSOR DOES NOT OPERATE” paragraph plus the following:
CONDENSER FAN MOTOR NOT OPERATING.
AGITA TOR MOTOR NOT OPERA TING.
A. Jumper cord loose or
disconnected from motor or terminal block. Broken wire is
cord. B. Fan blade obstructed. B. Remove obstructions. C. Inoperative condenser fan
motor. A. Unit power cord or agitator
motor power cord
disconnected or unit power
switch in “OFF” position. B. No power source (blown fuse
or tripped circuit breaker).
C. Agitator motor propeller
obstructed. D. Low voltage. D. V oltage must be at least 103 volts
E. Loose, disconnected, or
broken wiring.
A. Tighten connections or replace
cord.
C. Replace condenser fan motor.
A. Plug in power cords or place unit
power switch in “ON” position.
B. Replace fuse or reset circuit
breaker. (Note: Fuse is not part of unit).
C. Remove obstructions.
(1 15 VAC model or 208 volts (230 V AC model) at compressor terminals when compressor is trying to start.
E. Tighten connections or replace
broken wiring.
F. Inoperative agitator motor. F. Replace agitator motor as
instructed.
23 189159000
Page 28
WARRANTY
IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workman­ship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire product, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number, serial number and the date of purchase.
IMI Cornelius Offices
AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166 AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930 BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT , BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307 BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829 ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644 FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201 GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438 GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491 HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222 ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814 NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361 SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604 SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379 USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (612) 421-6120 D FAX (612) 422-3255
LD004
4/21/98
24
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