DI, DIL, & CT SERIES
Beverage Dispensers
Installation, Use & Care Manual
This manual is updated as new information and models are released.
Leader in Ice & Beverage Dispensers
Part Number 020005256 5/15
Visit our website for the latest manual. www.manitowocfsg.com
Safety Notices
! Warning
!
Caution
Important
!
Caution
Important
! Warning
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:
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.
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 proc eeding, 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:
Read These Before Proceeding:
Proper installation, care and maintenance are
essential for maximum performance and troublefree operation of your Manitow oc 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.
Routine adjustments and maintenance procedures
outlined in this manual are not covered by the
warranty.
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.
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 th e pr oce dur e yo u
are performing.
We reserve the right to make product improvements at any time.
Specifications and design are subject to change without notice.
Section 1
General Information
Read This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Model Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section 2
Installation Instructions
General System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Step by Step Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Table of Contents (continued)
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Carb/NON-Carb Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Counter top Footprints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Placing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Carbonator Purge Tube Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Plumbing Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Starting System & Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Section 3
Operation
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Post-Mix Drop-Ins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Pre-Mix Drop-Ins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Cold Plate Beverage Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Beverage Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
CO2 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Carbonated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Syrup Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Back Room Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figal Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Racking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
B-I-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Part Number 020005256 5/15
i
Section 4
Maintenance
Table of Contents (continued)
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Auto Bag Selectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Disassemble for Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Daily Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Monthly Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Cleaning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Beverage System Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Bag-In-Box System Sanitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Figal Beverage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figal Beverage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Shipping, Storage and Relocation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Section 5
Before Calling for Service
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Pump Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drink Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ii Part Number 020005256 5/15
Section 1
!
Warning
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
Model Numbers
This manual covers the following models:
Beverage Dispensers
CT-6, CT-8, DI-1522, DI-2323, DIL-2323
Thoroughly inspect the unit upon delivery. Immediately
report any damage that occurred during tr ansportation to
the delivery carrier. Request a written inspection report
from a claims inspector to document any necessary
claim.
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 5/15 1-1
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.
1-2
Part Number 020005256 5/15
Section 2
Important
1800
75
SYRUP
CO
2
CO
2
Cylinder
CO
2
SYRUP
60
Tap Water
Tap Water
Typical Drop-In
Internal Carbonation
Beverage Dispensing System
Bag-In-Box
Syrup
Carton
BIB Syrup Pump
NOTE:
This is a simplified schematic to
show the basic operation of the
beverage system.
Countertop
CT-8
1522
2323
CT-6
Carbonator Tank
Carbonate, Non-carbonate
Beverage Manifold
Carbonate, Non-carbonate
Beverage Manifold
Carbonator Tank
Installation Instructions
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.
Failure to follow these installation guidelines may
affect warranty coverage.
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 CO
2 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.
Part Number 020005256 5/15 2-1
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 CO
2 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)
Installation Instructions Section 2
Typical Drop-In Ambient
Beverage Dispensing System
90-
1800
60
100
CO
2
CO
2
CO
2
SYRUP
CARBONATED WATER
NON-CARBONATED WATER
SYRUP
SYRUP
SYRUP
Carbonator Tank
Tap Water
Tap Water
Carbonate, Non-carbonate
Beverage Manifold for DI-1522
2323
1522
NOTE:
This is a simplified schematic to
show the basic operation of the
beverage system.
Carbonate, Non-carbonate
Beverage Manifold
BIB Syrup Pump
CO
2
Cylinder
Bag-In-Box
Syrup
Carton
CT-6 CT-8
Typical External Carbonation (Ambient) Beverage Dispensing System
2-2
Part Number 020005256 5/15
Section 2 Installation Instructions
B
A
E
G
D H
C
F
!
Warning
UNIT DIMENSIONS
MODEL A B C* D E F G H
CT-6 N/A N/A
CT-8 N/A N/A
DI-1522
DI/DIL-2323
44.38”
(112.8 cm)
56.75”
(144.2cm)
38.38"
(97.5cm)
46.75"
(118.8cm)
9.50"
(24.2 cm)
9.50"
(24.2 cm)
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
N/A
23.54”
(59.80cm)
DI = 18.00”
(45.72cm)
DIL= 21.50”
(54.61cm)
22.50”
(57.2 cm)
22.85”
(58.1 cm)
22.00"
(55.9 cm)
23.00"
(58.5 cm)
ELECTRICAL
General
Voltage
The standard voltage for CT, DI, & DIL dispensers is
All wiring must conform to local, state and national codes.
120VAC-60Hz 1 Ph. A power cord is provided with
120V AC-60Hz models only. 220/240 Volts - 50 Hz - 1 Ph,
208/230 Volts - 60 Hz - 1 Ph are also available.
Minimum Circuit Ampacity
Minimum Circuit Amperage Chart
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.
Dispenser Voltage/Cycle
DI-1522,
CT-6
DI/DIL2323,
CT-8
120/60
220/50
120/60
220/50
120/60
Pump Deck
220/50
Circuit
Amps
2.4
3.2
8.0
Part Number 020005256 5/15 2-3
Installation Instructions Section 2
!
Warning
!
Warning
!
Warning
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.
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 th at
is properly installed and grounded in accordance with all
local codes and ordinances.
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.
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 equipmentgrounding 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. D o not
modify the plug provided with the appliance — if it will not
fit the outlet, have a proper outlet installed by a qualified
electrician.
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.
2-4
Part Number 020005256 5/15
Section 2 Installation Instructions
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
Also consider the location of the following
CO
regulator set
2
Beverage dispenser
Beverage tubing
CO
tank
2
Carbonator
Stepless (Oetiker) clamps
Chain for CO
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
tank
2
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 car to n
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 un it up on
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.
Check Beverage Flavor Line-up
Double Check
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?
Part Number 020005256 5/15 2-5
3. Inspect unit for any external damages.
If you have an internal carbonated unit the unit is preplumbed at the factory. The inlets for CO
2 and water are
located behind the splash panel. There are two inlets for
water and one inlet for CO
2. If you have questions refer
to the plumbing diagram on your equipment.
Installation Instructions Section 2
Important
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 .
OPERATION:
MANIFOLD TO CHANGE TO CARBONATED
OR NON-CARBONATED WATER
VALV ES
CARB
WATER
WATER/SODA
PLAIN
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
O
TO LOCK
Flex Manifold
1522
Plumbing
Diagram
Plumbing
Diagram
Flex Manifold
2323
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.
Step by Step Installation
To properly install the Servend Drop-In, Use these guidelines:
• Meet all local code requirements.
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.
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 sour ces such as
radiators, ovens, refrigeration equipment and direct sunlight.
Optimum Ambient Conditions are between 50°F and
95°F (10°C and 35°C).
• Completely unpack the Drop-In, removing all p adding
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.
2-6
Part Number 020005256 5/15
Section 2 Installation Instructions
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!
Caution
Cut Out Area
COUNTER TOP FOOTPRINTS
DI-1522 & DI/DIL-2323
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.
Cutting the countertop may decrease its strength. Counter
should be braced to support the dispenser countertop
weight plus ice storage capacity .
CT-6
.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)
3.625 in (9.2 cm)
6 Holes (See Notes)
1.5 in (3.8 cm)
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.
12.375 in
(31.4 cm)
4.625 in (11.7 cm)
.313 in (.8 cm)
1.625 in (4.1 cm)
Perimeter of CT-6 Base
10.5 in (26.7 cm)
1.5 in (3.8 cm)
Part Number 020005256 5/15 2-7
Installation Instructions Section 2
23.25 in (59.1 cm)
15.25 in (38.7 cm)
11.25 in (28.6 cm)
4.75 in
(12.1 cm)
.75 in (1.9 cm)
3.25 in (8.3 cm)
1.75 in (4.4 cm)
1.563 in
(4.0 cm)
1.563 in (3.8 cm)
1.563 in
(4.0 cm)
1.468 in
(3.7 cm)
8.0 in (20.3 cm)
2.25 in
(5.7 cm)
2.5 in (6.4 cm)
22.5 in (57.2 cm)
.187 in
(.5 cm)
20.25 in (51.4 cm)
Perimeter of CT-8 Base
8 Holes (See Notes)
Cut Out Area
!
Caution
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.
CT-8
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.
1. The CT-8 tower has (8) .250 inch diameter mounting
holes in the base.
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.
2-8
4. The correct counter top hole size if bolts and nuts
are used is .250 inches.
Cutting the countertop may decrease its strength. Counter
should be braced to support the dispenser countertop weight
plus ice storage capacity .
Part Number 020005256 5/15
Section 2 Installation Instructions
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 tubi n g previo u sly
removed back through openings in tower base and
opening in counter top.
6. Install lighted merchandiser per instructions shipped
with tower, ro ute 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.
1 1. Check tower’s beverage system a nd drain for leaks,
repair leaks if present.
NOTE: The tower must be sealed to the counter to
comply with the NSF International requirements.
Part Number 020005256 5/15 2-9
Installation Instructions Section 2
Drain Pan
Handles
(PN# 4340201)
Wood Blocks
C
u
t
O
u
t
A
r
e
a
Wood Block
Counter Top
Wood Block
!
Warning
DI-1522 & DI/DIL-2323
1. Set the Drop-In in place resting on the two blocks of
wood mentioned earlier.
pan. Another drain fitting is provided for the ice chest,
these must be connected separa tely.
3. Check for leaks by pouring about one pint of cold
Be careful not to pinch fingers under the edges of the unit
when lowering into place.
water into the drain pan and chest. Repair leaks if
any are found.
4. Route the clear carbonator tank purge tube from the
2. Attach the drain lines to the drain connections at the
bottom rear of the chest. There is one drain fo r the drain
relief valve to a drain, See Car bonator Purge T ube
Routing Page 2 - 11.
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.
2-10
Part Number 020005256 5/15
Section 2 Installation Instructions
Important
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.
3. The carbonator tank purge tube (A) will be routed
down through the valve leads conduit and out
bottom of unit to a drain.
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.
Follow all local and national plumbing codes when routing
carbonator tank purge tube to the drain.
Part Number 020005256 5/15 2-11
Installation Instructions Section 2
CT-6 RECOMMENDED PLUMBING
2-1-1-2 PLUMBING CONFIGUREATION
CT-6 WIRING DIAGRAM
COUNTER
TOP
5029318-0
SYRUP 1
SYRUP 2
SYRUP 3
SYRUP 4
SYRUP 5
SYRUP 6
UNIT DRAIN
CARB. OR PLAIN WATER
CARB. OR PLAIN WATER
CARB. OR PLAIN WATER
CARB. OR PLAIN WATER
LIGHTER MERCH.
POWER CORD
POWER CORD
ELECTRICAL BOX
VALVE JUMPER
HARNESS
CAUTION
ELECTRICAL SHOCK HAZARD
DISCONNECT POWER BEFORE SERVICING
CT-6 RECOMMENDED PLUMBING
2-1-1-2 PLUMBING CONFIGUREATION
CT-6 WIRING DIAGRAM
COUNTER
TOP
VARIETY VALVE
BLOCK
W-WATER
(THRU COLD PLATE)
3-SYRUP
(#4-3 AMBIENT)
2-SYRUP
(#4-2 THRU COLD PLATE)
1-SYRUP
(#4-2 AMBIENT)
*OPTIONAL*
VARIETY VALVE
ON VALVE 4
020003552-0
SYRUP 1
SYRUP 2
SYRUP 3
SYRUP 4-1
SYRUP 4-2
SYRUP 4-3
SYRUP 5
SYRUP 6
UNIT DRAIN
CARB. OR PLAIN WATER 1 & 2
CARB. OR PLAIN WATER 3
CARB. OR PLAIN WATER 4
CARB. OR PLAIN WATER 5 & 6
LIGHTER MERCH.
POWER CORD
POWER CORD
ELECTRICAL BOX
VALVE JUMPER
HARNESS
CAUTION
ELECTRICAL SHOCK HAZARD
DISCONNECT POWER BEFORE SERVICING
PLUMBING DIAGRAMS
Install the beverage tubing to the appropriate fittings, internally th e 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.)
CT-6 Post-mix
NOTE: The CO
2 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 with Variety Valve
2-12
Part Number 020005256 5/15
Section 2 Installation Instructions
CT-8 RECOMMENDED PLUMBING
3-1-1-3 PLUMBING CONFIGUREATION
CT-8 WIRING DIAGRAM
COUNTER
TOP
5029282-0
SYRUP 1
SYRUP 2
SYRUP 3
SYRUP 4
SYRUP 5
SYRUP 6
SYRUP 7
SYRUP 8
UNIT DRAIN
CARB. OR PLAIN WATER
CARB. OR PLAIN WATER
CARB. OR PLAIN WATER
CARB. OR PLAIN WATER
LIGHTER MERCH.
POWER CORD
POWER CORD
ELECTRICAL BOX
VALVE JUMPER
HARNESS
CAUTION
ELECTRICAL SHOCK HAZARD
DISCONNECT POWER BEFORE SERVICING
CT-8 Post-mix
Part Number 020005256 5/15 2-13
Installation Instructions Section 2
DI-1522 Post-mix
DI-1522 Post-Mix with 2 Blocked Valves
2-14
Part Number 020005256 5/15
Section 2 Installation Instructions
DI-1522 Pre-Mix
SERVEND RECOMMENDED PLUMBING DI1522 PREMIX
VALVE LOCATIONS
3/4” NPT
DRAIN PAN
LINE 6
LINE 5
LINE 4
LINE 6
LINE 5
LINE 4
LINE 3
LINE 2
LINE 1
LINE 3
LINE 2
LINE 1
DRAIN
BOTTOM VIEW
FOR 5 VALVE UNIT:
LINE 6 IS NOT USED
FOR 4 VALVE UNIT:
LINES 1 & 6 ARE NOT USED
INLET LINE LOCATIONS
FOR ASSISTANCE
CALL (812) 246-7000
3/4” NPT
COLD PLATE
DRAIN
5009449-0
Part Number 020005256 5/15 2-15
Installation Instructions Section 2
020006242-1
DI/DIL-2323 6 Valve Post- Mix
DI/DIL-2323 6 Valve Post-Mix with 2 Blocked Valves
2-16
Part Number 020005256 5/15
Section 2 Installation Instructions
020006242-1
020001489
DI/DIL-2323 8 Valve Post-Mix
DI/DIL-2323 8 Valve with Variety Valve Information
Part Number 020005256 5/15 2-17
Installation Instructions Section 2
020006242-1
DI/DIL-2323 10 V alve 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 1
SYRUP 2
SYRUP 3
SYRUP 4
SYRUP 5
SYRUP 6
SYRUP 6
BOTTOM VIEW
FOR 5 VALVE UNIT:
INLET 6 IS NOT USED
VALVE 6 IS NOT USED
INLET LINE LOCATIONS
FOR ASSISTANCE
CALL (812) 246-7000
3/4” NPT
COLD PLATE
DRAIN
5009394-0
2-18
Part Number 020005256 5/15
Section 2 Installation Instructions
Important
Important
Pressure
Relief Valve
Water Outlet
Water Inlet
CO
2 Inlet
Important
Panel
Internal
Carbonator
Tank
Drain Pan
Pressure
Relief Valve
Open Position
Internal Carbonator Connections
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. V alves are read fro m 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 CO
Do not energize the unit or turn on the CO2 to the unit.
2 turned OFF.
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.
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.
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 be ve ra ge
system. Check for leaks to the system and repair
any leaks found.
7. Purge air from the carbonator tank.
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 int o 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 5/15 2-19
Installation Instructions 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 4 -
3.
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 wate r
through the valve.
4. See Back Room Package Page 3 - 4 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.
2-20
Part Number 020005256 5/15
Section 2 Installation Instructions
!
Warning
5.5
to 1
8.5
to 1
9
10
8
7
6
5
4
3
2
OZ.
SYRUP
WATER
SYRUP
RATIOS
High Yield Brix Cup
SYRUP
WATER
Target
SYRUP
WATER
SYRUP
WATER
Acceptable Acceptable
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.
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.
Carbon Dioxide (CO2) displaces oxygen. Exposure to a
high concentration of CO
gas causes tremors, which are
2
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. CO
lines and pumps should not be installed in an
2
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
may build up in an area, venting of the B-I-B pumps
CO
2
and / or CO
monitors should be utilized.
2
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.
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.
6:1
5.5:1
5.5
to 1
WATER
10
OZ.
8.5
to 1
5:1
8.5:1
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.
Part Number 020005256 5/15 2-21
SYRUP
WATER
SYRUP
WATER
SYRUP
WATER
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.
Installation Instructions Section 2
THIS PA GE INTENTIO NALLY LEFT BLANK
2-22
Part Number 020005256 5/15
Component Identification
Valves
Splash Panel
Drainpan Grid
Lid
Model/Serial
Name Plate
Plumbing Diagram
Soda/Syrup
Inlet Lines
Carbonator
Pump Deck
Cold Plate
Ice Chest
Drain Pan
Key Switch
Tower
Merchandiser
Model/Serial Name Plate
NOTE: This equipment is only intended
to dispense beverages and is not
designed to be operated outdoors in
temperatures below 50° or above 105°.
Important
Section 3
Operation
Sequence of Operation
This section gives the a description of the units, theory of
operation, and service data for the Post Mix Dispensers
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.
POST-MIX DROP-INS
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
Part Number 020005256 5/15 3-1
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, noncarbonated 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 a re 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.
Operation Section 3
IN
OUT
PRE-MIX DROP-INS
Pre-mix fountain dispensing consists of a container of
beverage ready for dispensing, beverage delivery
system, carbon dioxide (CO
2) 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
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.
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 t ape (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 pre-plumbed
at the factory . The inlets for CO
2 and water are located behind
the splash panel. There are two inlets for water and one inlet
for CO
2. If you have questions refer to the plumbing diagram
on your equipment.
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.
COLD PLATE BEVERAGE COOLING
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.
3-2
Part Number 020005256 5/15
Section 3 Operation
Carbonated
Water Outlet
Pressure
Relief
CO
2
inlet
120 psi max
Water Inlet
CO2 SUPPLY
Note: CO
2 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 CO
2 pressure to the internal
carbonator is 75 psi.
• For ambient carbonated systems the CO
2 pressure to the
carbonator should be set at 100 PSI
• "Optional" A low CO
Carbonated DI series units. A RED low CO
to the tower will illuminate when the CO
2 alarm is available on all internally
2 light mounted
2 supply for the
cabonator tank starts running low .
A CO
2 cylinder delivers carbon dioxide (CO2) gas through an
adjustable CO
2 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 CO
pressure. When a dispensing valve is opened, CO
2 gas
2 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
CO
2 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.
CARBONATED WATER
Carbon Dioxide (CO
) leaves the storage tank and
2
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 CO
and the
2
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 CO
together in the tank
2
under high pressure creates the soda water. The quality
of carbonation (percent of CO
mixed in the water)
2
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 liqu id
in the tank. The water level control may be electronic
probes or a mechanical float.
SYRUP DELIVERY SYSTEM
Y our 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
level inside the tank drops, which in turn automatically start s
the carbonator water pump. When the water level inside the
tank has been replenished, carbonator water pump will stop.
The carbonator is replenished when the carbonated water
Part Number 020005256 5/15 3-3
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).
Operation Section 3
From Water Supply
T o Non-carbonated
Water Inlet Barb
Water to
Carbonator
Pump
Filter
Water Regulator
40–55 PSI
Booster System
(If Required)
To CO
2
Manifold (BIB
Pumps) from
CO
2
Supply
60 PSI
T o Syrup Inlet
Barbs on Unit
T o BIB Pumps
from BIB
To BIB
Pump
BIB
Carbonated Water to Dispenser
3/8 Syrup Lines to Dispenser
Incoming
Water
Carbonator
100 psi
CO
2
Soda Water
Pump
BACK ROOM PACKAGE
7. Primary pressure regulator - Lowers the CO
pressure, to 100 psi, so the CO
gas will be at the
2
gas
2
proper pressure to enter the carbonator regulator.
8. Lowered outgoing pressure - Set for 75 psi.
Gauge indicates lowered outgoing pressure from the
CO
cylinder after being routed through the primary
2
pressure regulator at 100 psi.
9. Secondary pressure regulator - Lowers the CO
gas pressure before the CO
pump. CO
pressure activates the syrup pump.
2
gas flows to the syrup
2
2
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 CO
sourced from a small CO
to push the beverage from the Figal tank is
2
tank.
2
1. Incoming tap water - should be at a minimum
2. Carbonator Water pump motor - Powers the water
3. Carbonator Water pump - Pumps ta p water into the
4. Internal/External Carbonator tank - Combines
5. CO
6. BIB pressure gauge - Set for a minimum of 60 psi.
dynamic pressure of 40 psi and maximum static
pressure of 55 psi.
pump. The water pump motor is part of the
carbonator pump deck.
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.
CO
gas and tap water to form carbonated water.
2
The “carbonator” is the carbonator tank, water pump
and water pump motor.
cylinder - Holds highly pressurized carbon
2
dioxide (CO
aluminum cylinder tank. CO
). The CO2 cylinder is a steel or
2
gas flows through the
2
primary pressure regulator.
Indicates CO
pressure going to B-I-B pumps.
2
3-4
Part Number 020005256 5/15
Section 3 Operation
FIGAL TANKS
The stainless steel Figal beverage tanks are easy to
store and connect. There are several items to rem ember
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 connecto r. 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 p aid 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 othe r.
B-I-B
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 th e sy r up
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 5/15 3-5
Operation Section 3
THIS PA GE INTENTIO NALLY LEFT BLANK
3-6
Part Number 020005256 5/15
Cleaning
!
Caution
!
Warning
A
C
B
D
E
!
Warning
Section 4
Maintenance
DISASSEMBLE FOR CLEANING
A. Unplug the unit from power supply.
B. Lift out the cup grid.
When using cleaning fluids or chemicals, rubber
gloves 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.
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.
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
Unplug unit before servicing or cleaning.
Electric Shock Hazard
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.
Nozzle Removal
Part Number 020005256 5/15 4-1
Maintenance Section 4
!
Caution
!
Warning
CLEANING CHECKLIST
Unplug unit before servicing or cleaning ice bin.
Ice bin contains part s tha t can move at any time and
will cause injury if hands are in the way.
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.
•Check CO
the primary regulator gauge will point to a shaded
area that reads “Low CO
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.
supply . If CO2 supply is low, an arrow on
2
” or “Change CO2
2
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 10 0 PPM of ch lori ne.
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.
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.
4-2
Part Number 020005256 5/15
Section 4 Maintenance
!
Warning
!
Warning
Bag
side
connector
Sanitizing
BEVERAGE SYSTEM CLEANING
Flush sanitizing solution from syrup system.
Residual sanitizing solution left in system could
create a health hazard.
When using cleaning fluids or chemicals, rubber
gloves and eye protection must be wor n.
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
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.
• 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. Mi xture should supply 100 PPM
available chlorine (1/4 oz. bleach to 1 gallon
water).
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
Part Number 020005256 5/15 4-3
detergent solution.
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 syr up 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.
4-4
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.
Part Number 020005256 5/15
Section 4 Maintenance
!
Caution
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 th e lines to rin se the sys te m.
Discard drinks until at least two cups of satisfactory
tasting beverage are dispensed through the valve.
Shipping, Storage and Relocation
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 5/15 4-5
Maintenance Section 4
THIS PA GE INTENTIO NALLY LEFT BLANK
4-6
Part Number 020005256 5/15
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).
Install fresh tank.
2
line pinched, kinked or
Install fresh tank.
2
line pinched, kinked or
pressure due to leaks Repair CO2 leaks.
2
Check/repair/replace CO2 line.
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.
motor, electrode or liquid level control.
Check/repair/replace CO2 line.
Adjust CO
Clean out the lines.
if necessary.
replace regulator if necessary.
pressure or change the tank.
2
pressure or replace regulator
2
supply. Reset pressure or
2
Syrup and CO
dispensing
Syrup and plain water
only dispensing setting
One valve will not
dispense anything
Beverage dispensed is
too sweet
Beverage is not sweet
enough
Drinks are foaming Are system pressures
No water, syrup or gas
dispensing
only
2
Carbonator No power Check power supply. Plug in carbonator
No pressure Out o f CO
Is there power to the
valve?
Is the ratio (brix) of the
drink correct?
Is the ratio (brix) of the
drink correct?
correct?
Is there power to the
unit?
Is power coming
through the key
switch?
Is there power to the
key switch?
Out of CO
Defective regulator(s) Check/repair/replace regulator(s).
CO
2
obstructed
Water supply Make sure water is turned “on”.
Defective carbonator Check/repair/replace carbonator pump,
HP regulator out of adjustment Adjust HP regulator to the proper setting.
Defective HP regulator Check/repair/replace HP regulator.
CO
2
obstructed
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 CO
Obstruction in the water or soda
line
Flow control out of adjustment Adjust the flow control.
Soda flow too high Reset CO
Obstruction in syrup line Clean out the syrup line.
Over carbonation Check CO
Dirty lines/valves Clean/sanitize entire system.
No power Plug in unit or reset breaker.
Power to control box Replace fuse or control box.
Key switch “off” Turn switch “on”.
Key switch defective Replace key sw itch.
No power through the transformer Reset/replace transformer.
Part Number 020005256 5/15 5-1
Before Calling for Service Section 5
1. Remove probe electronics.
2. Pass magnetic tip of screwdriver by
lower end of tube extending from
electronics package.
3. Reed switch will close.
4. Carbonator operates.
Pump Troubleshooting
Problem Possible Cause Corrective Action
Pump motor does not
shut off
Problem with probe or probe harness.
Pump motor
intermittent
Pump motor does not
pump
Problem with probe or probe harness
Water pressure from water source is not
high enough
Verify water pressure leading into pump inlet is 40 psi
minimum.
5-2
Part Number 020005256 5/15
© 2014 Manitowoc
Continuing product improvements
may necessitate change of
specifications without notice.
Part Number 020005256 5/15
Manitowoc Beverage Systems
2100 Future Drive
Sellersburg, IN 47172, USA
Ph: 812-246-7000 Fax: 812-246-7024
Visit us online at: www.manitowocfsg.com
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