Download Cornelius Flavor Fusion 620053922 Technical information

®
FLAVORFUSION™
Training Manual
Release Date: February 6, 2004
Publication Number: TP01070
Revision Date: September 26, 2005
Revision: D
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
FLAVOR FUSION
TRAINING MANUAL
The products, technical information, and instructions contained in this manual are subject
to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation,
operation or maintenance of this equipment. This manual assumes that the person(s)
working on the equipment have been trained and are skilled in working with electrical,
plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety
precautions are taken and that all local safety and construction requirements are being
met, in addition to the information contained in this manual.
To inquire about current revisions of this and other documentation or for assistance with
any Cornelius product contact:
www.cornelius.com
800-238-3600
Trademarks and Copyrights:
Aurora, Cornelius, FlavorFusion, Hydro Boost, Optifill, Pinnacle, and Vanguard are registered trademarks of IMI Cornelius Inc.
This document contains proprietary information and it may not be
reproduced in any way without permission from Cornelius.
Printed in U.S.A.
Copyright © 2004-2005, All Rights Reserved, IMI Cornelius Inc.
FlavorFusion™ Training Manual
TABLE OF CONTENTS
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming Mode Flashing Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Water Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Syrup/Water Ratio (Brix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting a Button to Dispense Non-carbonated Water Only . . . . . . . . . . . . . . . . .
Setting a Button to Dispense Carbonated Water Only . . . . . . . . . . . . . . . . . . . .
3
3
4
5
5
5
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Carbonator Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Plumbing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Plumbing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Interface Board and Harness Pin-out Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Point-Point Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ladder Type Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Diagnostics Guide for the Main Control Board (see FIGURE 22) . . . . . . . . . . . . . . 19
© 2004, IMI Cornelius Inc.
-i-
Publication Number: TP01070
FlavorFusion™ Training Manual
Publication Number: TP01070
- ii -
© 2004, IMI Cornelius Inc.
FlavorFusion™ Training Manual
PRODUCT OVERVIEW
•
Brand density - 16 brands (14 chilled, 2 ambient) plus up to 8 bonus flavors in 30” wide;
•
255 lbs capacity cube ice only hopper;
•
Internal cold carbonation with remote pump;
•
Total carb/non-carb flexibility on each brand;
•
Eye catching merchandising;
•
Improved serviceability of agitator motor;
•
Bonus flavors programmable for 1-4 second dispense;
•
Valve positions programmable without special tools or PDA;
•
Front inlet fittings;
•
Key lock switch;
•
10” cup clearance;
•
30% more drip tray capacity;
THEORY OF OPERATION
•
The FlavorFusion™ machine is an above counter ice/beverage unit with multi flavor nozzles and the
capability to inject bonus flavors into the finished drink.
•
The beverage is cooled via ice melting on an aluminum cold plate. Ice is kept on the cold plate by
means of an opening in the hopper that drops ice onto the surface during agitation of the ice in the
hopper.
•
The unit contains a mechanical ice chute and gate mechanism.
•
The ice agitation gear motor is removable from the gear box to ease removal of the motor during service and lower repair cost.
•
The unit has six nozzles for dispensing brand and bonus flavors.
•
Each brand nozzle serves four discreet flavors fed by four syrup valves, one plain water, and one carb
water valve. Every position is flexible for use with either carb or non-carb water.
•
Each bonus nozzle serves four individual flavors intended for injection into the finished drink. Bonus
nozzles are fed by four syrup valves only. There is no option to dispense water out of the bonus nozzle
without significant plumbing changes.
•
Bonus flavors require a separate regulator setting on their BIB pumps (20 psi maximum).
•
Brand and bonus flavors are controlled by means of six interface boards (one interface board per nozzle). The interface boards are common for each nozzle. Valve positions are configured on the membrane switch. No special tool or PDA is required.
•
Valve flow rates are adjustable for 3.0-3.75 oz/sec finished drink dispense rate.
•
Unplug the unit or turn off the key switch before attempting any electrical service on the unit, failure to
do this can cause damage to the electrical components!
© 2004-2005, IMI Cornelius Inc.
-1-
Publication Number: TP01070
FlavorFusion™ Training Manual
SYSTEM REQUIREMENTS
Dimensions (in): . . . . . . . . 29 x 30 x 39 (l x w x h). Height is measured to top of bin. Lid adds 3 in to
height.
Counter Weight (lb): . . . . . 320 (plus ice weight)
Shipping Weight (lb): . . . . 330
Capacity: . . . . . . . . . . . . . 250 lb ice bin capacity (cube ice only)
Indoor installation only
40 to 90 oF ambient temperature
Electrical Rating: . . . . . . . . 103-132 Volts
11 Amps
Water supply pressure: . . 50-60 psi at pump
Water volume: . . . . . . . . . 125 gph
CO2: . . . . . . . . . . . . . . . . . 75 psi at carbonator tank
Syrup (brands): . . . . . . . . 60 psi min
Syrup (bonus): . . . . . . . . 20 psi max
Syrup supply lines: . . . . . . .375” ID tubing min
NOTE: If water pressure is below 50 psi a water pressure booster is required for still water drinks.
Publication Number: TP01070
-2-
© 2004-2005, IMI Cornelius Inc.
FlavorFusion™ Training Manual
PROGRAMMING
The programming mode is exactly the same for both brand and bonus keypads.
To enter the programming mode, press and hold the two program buttons (see FIGURE 3) at the top of
the keypad for approximately 4 seconds. All keypad LEDs will flash off for approximately 1 second to
indicate the start of the programming mode.
To exit programming mode, press and hold the two program buttons for approximately 4 seconds. All
keypad LEDs will flash off for approximately 1 second, resuming normal operation mode.
Programming Mode Flashing Sequences
Once in programming mode, each dispense button LED flashes in a sequence cycle according to one (1)
of six (6) dispense types. For Brand Keypads, only dispense types 1 and 2 are used. For Bonus Flavor
Keypads, dispense types 3 through 6 are used. The six (6) dispense types are described below, and
shown in a timing diagram in FIGURE 1:
•
•
•
Dispense Type 1, Carbonated water dispense: Solid LED
Dispense Type 2, Non-carbonated dispense: Flashing LED 1.5 seconds ON, 1.5 seconds OFF
Dispense Type 3, 1-second flavor shot: LED flashes once for ¼ second, followed by 3 seconds
OFF
• Dispense Type 4, 2-second flavor shot: LED flashes twice for ¼ second ON, ½ second OFF,
followed by 3 seconds OFF
• Dispense Type 5, 3-second flavor shot: LED flashes three (3) times for ¼ second ON, ½ second
OFF, followed by 3 seconds OFF
• Dispense Type 6, 4-second flavor shot: LED flashes four (4) times for ¼ second ON, ½ second
OFF, followed by 3 seconds OFF
Start
proramming
mode
Exit
programming
mode
1. Carbonated water dispense
2. Non-carbonated dispense
3. 1-second flavor shot
4. 2-second flavor shot
5. 3-second flavor shot
6. 4-second flavor shot
0
1
2
3
4
5
Time
(seconds)
FIGURE 1
© 2004-2005, IMI Cornelius Inc.
-3-
Publication Number: TP01070
FlavorFusion™ Training Manual
Setting Water Flow Rate
Setting the water flow rate will require a timed dispense. To accomplish this, the following procedure
should be followed:
1.
Enter programming mode for the valve
block by simultaneously pressing and
holding both programming buttons for 4
seconds (see FIGURE 3). The LED’s for
flavors 1-4 should flash off and then back
on. The drink icon should turn off.
2.
Set the valve block to a 4 second pour
mode by simultaneously pressing and
holding Flavor 1 and Flavor 4 buttons until
Flow Adjuster Detail
the flash pattern for all four buttons
(Water)
changes.
3.
Place an empty ratio cup under the
appropriate nozzle and press the left
program button for a 4 second dispense of
carbonated water. There should be
approximately 10 oz. dispensed.
4.
If necessary, adjust the water flow control
FIGURE 2. Valve with Flow Adjusters
(see FIGURE 2), empty ratio cup, and
(see plumbing diagram for plumbing and valve
repeat step 3. Otherwise empty ratio cup
configuration)
and repeat step 3 using the right program
button for plain water.
5.
Exit 4 second pour mode by simultaneously pressing and holding Flavor 1 and Flavor 4
buttons until the flash pattern for all for buttons changes.
6.
Exit programming mode by simultaneously pressing and holding both programming buttons
for 4 seconds.
Brand Flavor
Programming
Buttons
(Left and
Right)
Bonus Flavor
Programming
Buttons
(Left
and Right)
Drink Icon
Bonus Flavor Icon
Bonus Flavor Button 1
Brand Flavor Button 1
Bonus Flavor Button 2
Brand Flavor Button 2
Bonus Flavor Button 3
Brand Flavor Button 3
Brand Flavor Button 4
Bonus Flavor Button 4
Bonus Flavor Nozzle
Brand Flavor Nozzle
Publication Number: TP01070
-4-
© 2004-2005, IMI Cornelius Inc.
FlavorFusion™ Training Manual
FIGURE 3
Adjusting Syrup/Water Ratio (Brix)
Timed Dispense Procedure
1.
Enter programming mode for the valve block by simultaneously pressing and holding both
programming buttons for 4 seconds (see FIGURE 3). The LED’s for flavors 1-4 should flash off and
then back on. The drink icon should turn off.
2.
Set the valve block to a 4 second pour mode by simultaneously pressing and holding Flavor 1 and
Flavor 4 buttons until the flash pattern for all for buttons changes.
3.
Place the water end of the ratio cup under the appropriate nozzle and press the left program button
for a 4 second dispense of carbonated water. (Push the right program button for still water pour.)
4.
Place the syrup end of the ratio cup under the nozzle and press the appropriate flavor button for a 4
second dispense of syrup. The fill line should be the same for both water and the syrup. Adjust the
syrup flow control if necessary, then empty cup and repeat steps 3 and 4.
5.
Repeat for all syrups in valve bank.
6.
Exit 4 second pour mode by simultaneously pressing and holding Flavor 1 and Flavor 4
buttons until the flash pattern for all for buttons changes.
7. Exit programming mode by simultaneously pressing and holding both programming buttons
for 4 seconds.
Setting a Button to Dispense Non-carbonated Water Only
1.
2.
Program the designated button to dispense non-carbonated water (see Programming Mode.)
Do not connect a syrup source to the inlet circuit of the designated button (1-14 or A1-A2.) If circuit
1 through 14 is chosen leave the coldplate inlet circuit plugged with the red cap. If circuit A1 or A2 is
chosen, plug the end of the inlet tube with a red cap from the coldplate, or with tape.
Setting a Button to Dispense Carbonated Water Only
1.
2.
Program the designated button to dispense carbonated water (see Programming Mode.)
Do not connect a syrup source to the inlet circuit of the designated button (1-14 or A1-A2.) If circuit
1 through 14 is chosen leave the coldplate inlet circuit plugged with the red cap. If circuit A1 or A2 is
chosen, plug the end of the inlet tube with a red cap from the coldplate, or with tape.
NOTE: The ambient circuits A1 and A2 do not give up a cold plate circuit.
© 2004-2005, IMI Cornelius Inc.
-5-
Publication Number: TP01070
FlavorFusion™ Training Manual
MECHANICAL
DISASSEMBLY
Control Box Components
Valve Flow Controls
Ballast for Merchandiser
Light
24 Volt Transformer (2)
Starter Merchandiser Light
Motor Start Capacitor
Main Control Board/Agitator Timer
FIGURE 4
FIGURE 5
Adjustment Pots
Agitation Board
Interface
Board
FIGURE 6
Publication Number: TP01070
FIGURE 7
-6-
© 2004-2005, IMI Cornelius Inc.
FlavorFusion™ Training Manual
VALVE REMOVAL
1.
Pull on retaining bracket (both sides) so the switch panel will rotate out of the way (see FIGURE 9).
Retaining
Bracket
FIGURE 8
FIGURE 9
2.
Unscrew the switch panel (one on each side).
3.
Place the tabs into the slot over the merchandiser lights.
4.
Place the valve removal tool on the back
block release latch, keep the handle flat.
FIGURE 10
FIGURE 11
FIGURE 12
FIGURE 13
Valve Removal Tool
FIGURE 14
© 2004-2005, IMI Cornelius Inc.
-7-
Publication Number: TP01070
FlavorFusion™ Training Manual
5.
Tilt the valve removal tool up to release the latch.
Back Block
Release Latch
Valve Removal Tool
FIGURE 15
FIGURE 16
6.
Pull the valve off the back block.
7.
Push the valve on the back block and push
up on the back block release latch to
replace the valve.
FIGURE 17
FIGURE 18
Publication Number: TP01070
-8-
© 2004-2005, IMI Cornelius Inc.
FlavorFusion™ Training Manual
VALVE SERVICE
NOTE: Before servicing the valve the BIB connector must be disconnected an the pressure must
be relieved.
1.
Remove the locking screw after removing the valve from its mounting block.
2.
3.
4.
Twist the solenoid 90o.
Pull the solenoid loose from the valve body.
To remove the tubing squeeze the spring
clip together and pull off.
Locking Screw
Spring Clip
FIGURE 19
CARBONATOR TANK
Always disconnect water and CO2 and relieve
the carbonator pressure before removing the carbonator probe.
Grounding Connection/
CO2 Inlet
Upper and Lower Level
Control Probes
Relief
Valve
FIGURE 20
MOTOR REMOVAL
Heater, Agitation
Motor, & Gear Box
NOTE: Apply anti seizing lubricant to the
threads of mounting bolts when service is
required.
Heater Spring
Motor
Mounting
Screws
FIGURE 21
© 2004-2005, IMI Cornelius Inc.
-9-
Publication Number: TP01070
FlavorFusion™ Training Manual
SYSTEM PLUMBING DIAGRAM
Publication Number: TP01070
- 10 -
© 2004-2005, IMI Cornelius Inc.
© 2004-2005, IMI Cornelius Inc.
5.500
W2
2
N1
PW
W2
N1
CW
W3
3
2
1
- 11 B1
B2
CARB WTR IN
7
6
5
4
2
1 14 13 12 11 10 9
SYRUP INLETS
3
COLDPLATE
8
8
10.000
THIS EQUIPMENT MUST BE INSTALLED WITH ADEQUATE BACKFLOW PROTECTION
TO COMPLY WITH APPLICABLE FEDERAL, STATE AND LOCAL CODES.
W3
9
W2
W3
9
N4
PW
8
N4
CW
N4
N4
N5
B8
B5
B6
N5
B7
N5
N5
N5
10
11
OUTLET
12
VALVE BACK BLOCK
A2
N4
10
N4
BONUS FLAVORS
A2
10
N4
9
8
13
12
N6
11
N6
B5-N5
B6-N5
B7-N5
B8-N5
14
W3
N6
CW
13
N6
13
11
W2
N6
PW
14
N6
N6
W3
14
12
W2
PW
OUTLET
6
PW
W2
CW
4
7
W2
W3
6
ICE
CHUTE
NOZZLES
KEYPAD
BUTTONS
CW
5
A1
N3
PW
N3
7
N3
N3
A1
6
N3
CW
7
5
N3
5
N2
B4
B3
N2
N3
N2
N2
VALVE BACK BLOCK
4
N1
3
N1
BONUS FLAVORS
N2
B1-N2
B2-N2
B3-N2
B4-N2
W3
W1
OUT
IN
CARB TANK
CW = CARBONATED WATER
PW = PLAIN WATER
N# = NOZZLE #1-6
B# = AMBIENT (NON-CHILLED)
BONUS SYRUPS 1-8
XX = OUTLET LINE
CARB TANK OUT
620920670 REV. 7
1
N1
N1
4
3
N1
2
1
A = AMBIENT (NON-CHILLED)
SYRUP FLAVOR
CARB TANK IN
INLET
PLAIN WTR IN
W1
NOZZLES
KEYPAD
BUTTONS
FLAVOR FUSION -16 BRAND
FlavorFusion™ Training Manual
PLUMBING DIAGRAM
Publication Number: TP01070
FlavorFusion™ Training Manual
INTERFACE BOARD AND HARNESS PIN-OUT DETAIL
C
C
C
C
C
W
P
W
C
S
4
S
3
S
2
S
1
C
12
11
10
9
8
7
6
5
4
3
2
1
CW
PW
S4
S3
S2
S1
TO SOLENOID VALVES
INTERFACE BOARD DETAIL
Publication Number: TP01070
- 12 -
© 2004-2005, IMI Cornelius Inc.
6.000
LIGHT
SOCKET
BLK
BLK
KEY
SWITCH
YEL
YEL
BLK
BLK
CW
W3
PW
W2
YEL
WHT
GRN
WHT
LT BLU
1
WHT
2
BRAND
SYRUP
KEY PAD
TRANSFORMER
BLK
WHT
WHT
4
3
WHT
BLK
WHT
WHT
SOLENOID
VALVE BLOCK
B1
B3
BONUS
SYRUP
KEY PAD
TRANSFORMER
WHT
B2
B4
6
5
YEL
CW
GRN
BLK
BLU
W3
WHT
WHT
7
PW
LT BLU
W2
A1
BRAND
SYRUP
KEY PAD
BLK
LED.
ICE CUBE
GRAPHIC
ICE
GATE
SWITCH
CAPACITOR
BLK
ORG
WHT
BLK
RED
WHT
LT BLU
YEL
WHT
WHT
YEL
WHT
BLK
CW
BRAND
SYRUP
KEY PAD
8
W3
RED
PW
BLK
BLK
WHT
BLK
RED
W2
9
WIRING DIAGRAM FLAVOR FUSION
LT BLU
GRN
YLW
A2
10
BRN
YEL
WHT
WHT
YEL
BLK
GRN
GRN
BLK
B1
B3
GRN
GRN
RED
B2
B4
SOLENOID
VALVE BLOCK
LT BLU
BONUS
SYRUP
KEY PAD
GRN/YLW
L2
HEATR
L2_
BALST
620920673 REV 5
RED
BLU
12
11
WHT
BLK
WHT
BLK
WHT
WHT
BLK
BLK
BLK
BRN
WHT
CW
GRN
13
BLK
W3
LT BLU
PW
BRAND
SYRUP
KEY PAD
W2
14
BLU
BALLAST
HEATER
BLK
ELECTRIC SHOCK HAZARD.
DISCONNECT POWER
BEFORE SERVICING UNIT.
J7
BLU
WHT
L2_
XFORMR
L2_IN
RED
YEL
J4
J3
WHT
OFF
TIME
ON
TIME
BLU
AGIT
WHT
L2_AGIT
YEL
AGIT
EARTH
YEL
L1_IN
L1_BALST
L1
XFORMR
L1
HEATR
CARB MOTR
EARTH_IN
- 13 -
WHT
STARTER
POWER
CORD
CARB.
MOTOR
PUMP
ASY
ICE
AGIT.
MOTOR
BLK
WHT
LIGHT
SOCKET
CARB.
TANK
RED
CARB MTR
EARTH
RED
© 2004-2005, IMI Cornelius Inc.
CARB MOTR L2
10.250
FlavorFusion™ Training Manual
POINT-POINT WIRING DIAGRAM
Publication Number: TP01070
BLK
WHT
FlavorFusion™ Training Manual
LADDER TYPE WIRING DIAGRAM
L1
N
KEY SWITCH
BEV. X-FRMR
24V
24V
INTERFACE
BOARD-1
INTERFACE
BOARD-4
INTERFACE
BOARD-2
INTERFACE
BOARD-5
INTERFACE
BOARD-3
INTERFACE
BOAR-6
BALLAST
LIGHT
STARTER
SWITCHING PERFORMED
ON PC BOARD
CARB MOTOR
RELAY
CARB MOTOR
BLK
BLK
AGIT TIMER
RELAY
YELLOW
BRN
BRN
RED
ORG
ORG
WHT
AGIT MOTOR
ICE DISP.
SWITCH
AGIT HEATER
WIRING LADDER SCHEMATIC 115V- FLAVOR FUSION
Publication Number: TP01070
- 14 -
© 2004-2005, IMI Cornelius Inc.
FlavorFusion™ Training Manual
TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
WARNING: If repairs are to be made to a product system, remove quick disconnects from the
applicable product tank, then relieve the system pressure before proceeding. If repairs are to be
made to the CO2 system, stop dispensing, shut off the CO2 supply, then relieve the system
pressure before proceeding. If repairs are to be made to the electrical system, make sure
electrical power is disconnected from the unit or the key switch has been turned off.
Should your unit fail to operate properly, check that there is power to the unit and that the hopper contains
ice. If the unit does not dispense, check the following chart under the appropriate symptoms to aid in
locating the defect.
Troubleshooting the LED Lighting on Customer Interface Keypad (see page 19)
Symptom
Cause
Remedy
1
Bonus Flavor Icon and/
or Drink Icon LEDs (see
FIGURE 3) are ON
continuously with four
quick flashes every 30
seconds.
A. This indicates a poor
connection in the lighting
synchronization harness
that connects the interface
boards together.
A. Turn the keyswitch to disconnect
power to the interface boards. Check the
electrical connections between the
harnesses that interconnect the right
side of all interface boards together. Turn
back the keyswitch to reconnect power.
2
Bonus Flavor Icon and/
or Drink Icon LEDs (see
FIGURE 3) are not in
sync with the lighting
sequence,
B. This may result over time
as the lighting sequence
between push button pads
can become slightly out of
synchronization.
B. Unplugging the unit and performing a
power up will re-synchronize the lighting
sequence.
3
Keypad LED lighting is
not working
A. Poor connection between
interface board and keypad
PCB
A. Turn the keyswitch to disconnect
power at the interface boards. Check
harness connections at each interface
board.
B. Keypad LED's are burnt
out
B. Turn the keyswitch to disconnect
power at the interface boards. Unplug
the ribbon cable from one interface
board and test it by plugging it into the
neighboring interface board. If the
keypad still doesn't light up replace the
keypad PCB.
C. Interface board is
defective.
C. Turn the keyswitch to disconnect
power at the interface boards. Unplug
the ribbon cable from one interface
board and test it by plugging it into the
neighboring interface board. If the LED's
light up the interface board is defective.
Replace the interface board.
D. Corrosion at connector
between keypad and ribbon
cable.
D. Replace keypad circuit board and
ribbon cable.
E. Main control board is
defective.
E. Replace the main control board.
Bonus buttons are
incorrectly programmed as
brand buttons, or vice versa.
Check the programming of each keypad
and set each button as CW, PW, or
timed dispense based upon the flavor
lineup.
4
During standby mode,
the brand and bonus
LED icons do not
alternate back and forth
- instead they light
together.
Contact your local syrup or beverage equipment distributor for additional information and troubleshooting
of beverage system.
© 2004-2005, IMI Cornelius Inc.
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Publication Number: TP01070
FlavorFusion™ Training Manual
Dispenser Troubleshooting
Symptom
Blown fuse or circuit
breaker
Agitator does not
turn
Ice dispenses
continuously
Slushy ice or water
in hopper
Beverage does not
dispense
Beverage is too
sweet
Publication Number: TP01070
Cause
Remedy
Short circuit in electrical wiring
Repair Wiring
Inoperable agitator motor (shorted
motor)
Replace gear motor
No power
Restore power or plug in unit
Improperly installed upper ice chute
assembly (Reed switch is not being
activated)
Check the upper ice chute assembly for
proper assembly and operation
Inoperable reed switch
Replace reed switch
Electrical board driver circuit is
defective
Replace main control board
Gear motor has open circuit
Replace gear motor
Reed switch is not activated Improper
assembly of upper ice chute to lower
chute.
Check to make sure tongue of upper
chute engages into the back of the
lower chute, ensure upper chute
engages outside the lower chute, and
snap front of chute into place.
Broken wire in the 2-wire harness
leading to the reed switch
Repair of replace 2-wire harness
Bad connection at main control board,
J3, pins 2 &3
Repair connection or replace 2-wire
harness
Ice gate mechanism is stuck in open
position
Inspect gasket for proper position.
Examine gate plate to see if it slides
freely behind the lower ice chute.
Stuck or bent ice lever (does not allow
gate to close and open reed switch)
Examine ice dispense lever to see if it is
bent.
Blocked drains in cold plate
Remove access covers in cold plate
cover & inspect/clean drains
Poor ice quality due to water quality or
ice maker problems
Correct water quality or repair ice maker
No 24VAC to valves
Restore 24 VAC to valves
No CO2 pressure
Restore CO2 pressure
Valve brix requires adjustment
Adjust valve brix
Carbonator is not operating
Repair carbonator
No CO2 in carbonator
Restore CO2 pressure in carbonator
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© 2004-2005, IMI Cornelius Inc.
FlavorFusion™ Training Manual
Unit will not
dispense
carbonated drinks.
Dispenses syrup
only.
Unit will not
dispense
carbonated drinks.
Spurts CO2 and
syrup only.
Carbonated drinks
are flat (low on
carbonation)
Low water pressure
No Syrup or
Watered down drink
dispensed
City water pressure supply low or
inconsistent
Booster pump must be used if dynamic
water pressure drops below 40 psig.
CO2 pressure in carbonator tank is too
high.
Check CO2 pressure regulator setting.
75 psig recommended. Relieve
pressure from carbonator tank.
Water valve will not open
Check electrical connection to water
valve. Check resistance of coil (should
be 9 ohms). Check for voltage at coil
when brand button is depressed.
Carbonator tank is empty, because tank
was emptied while power was applied
to unit. 5 minute time-out of carbonator
pump/motor occurred, and carbonator
pump is locked off.
Unplug the unit and reconnect the unit.
Main control board will reset, ice
agitation will occur, and carbonator tank
will refill to normal level.
Note that this can occur while the water
filter system is serviced or water supply
is shutoff. If drinks are drawn from the
dispenser while water pressure is
shutoff, the carbonator pump starts and
runs continuously, then shuts off on the
5 minute timeout.
1) low water pressure switch
deactivates carbonator pump, 2) after 5
minutes reset and retry carbonator
pump. If water supply is restored, the 5
minute timeout will not occur. Repeat
reset a second time, but on a third time,
then lockout carbonator pump, which
will generate a service call.
CO2 is out
Replace CO2
Carbonator tank is 100% filled because
the city water pressure exceeds the
carbonator tank CO2 pressure regulator
setting.
CO2 setting for the carbonator tank is
75 psig, max water pressure is 60 psig.
If necessary, install a water pressure
regulating valve.
Could be caused by excessively long
runs (over 40 ft.) of 3/8” water supply
line.
Increase line size to 1/2”
Low water pressure
Add water pressure booster pump
Plugged water filter.
Change water filter
Water booster bladder has burst
Replace water booster tank/bladder
Syrup supply is empty
Replace BIB
BIB pump not working
Replace BIB pump
No CO2 or compressed air supply to
BIB pump, or not enough pressure
Check CO2 pressure regulator setting.
65 psig recommended. Replace CO2
tank or fix compressor.
Carbonator Troubleshooting
Symptom
© 2004-2005, IMI Cornelius Inc.
Cause
Remedy
- 17 -
Publication Number: TP01070
FlavorFusion™ Training Manual
Carbonator pump
does not start to fill
tank
Power cord for the carbonator pump
motor is not connected.
Carbonator pump is powered off the
main control board inside the electrical
box of the unit. Check that the umbilical
cord is connected from the unit to the
pump motor terminal box.
Power cord is
connected but
carbonator pump
does not run.
Carbonator pump motor is disabled.
Check the enable/disable switch on the
carbonator pump terminal box and
enable it, if necessary.
Probes were dry, unit was powered up,
water was not turned on, and
carbonator did not fill.
This results in a 5 minute timeout.
Unplugging the unit and plugging it in
will reset the unit and start the
carbonator pump.
Water service was interrupted for more
than 5 minutes.
Unplugging the unit and plugging it in
will reset the unit and start the
carbonator pump.
Carbonator pump is
short cycling with
every drink drawn
Lower liquid level probe reads “dry”
while upper probe reads “wet”
Check color of leads going to probes.
Black should go to bottom probe and
white to top probe. Reverse if incorrect.
Carbonator tank
overfills, overflows
through relief valve,
and pump shuts off
after 5 minutes.
A. Poor electrical connections between
carbonator tank and main control board
A. Check connections at carbonator
tank and at connector J4 on the main
control board.
B. Broken wires between carbonator
tank and main control board
B. Replace wire harness
C. Defective liquid level probes
C. Replace both liquid level probes
Publication Number: TP01070
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© 2004-2005, IMI Cornelius Inc.
FlavorFusion™ Training Manual
DIAGNOSTICS GUIDE FOR THE MAIN CONTROL BOARD (SEE FIGURE 22)
State
0
1
2
3
Observed State
of Red LED
Flash rate 3
seconds
Flash rate
1/2 second
Flash rate
1/2 second
Flash rate
1/2 second
Sensor Input
Control Response
Both probes read “wet”
Pump is OFF and HIGH
probe reads “dry” and LOW
probe reads “wet”
Both HIGH and LOW
probes read “dry”
Entered when HIGH probe
does not detect liquid, and
LOW probe does detect
liquid, and pump is ON
Entered when HIGH probe
reads “wet” and LOW probe
reads “dry”
4
Flash rate 1
second
5
ON
continuously,
but “flickers”
every 3
seconds
Poor signal connection to
the carbonator tank. May
result in short cycling of the
carbonator pump.
6
ON
continuously
Entered when pump has
run continuously for 5
minutes
Service Remedy
Standby mode.
Pump = OFF
Waiting for level to
drop below LOW
probe. Pump = OFF
Normal mode.
Pump = ON
Normal mode.
Pump = ON
No service required
THIS IS AN ERROR
CONDITION.
- Check electrical
connections at the
carbonator tank, and at
connector J4 on the main
control board
- Black wire should be
connected to the LOW
probe and also to Pin 4 of
Connector J4
- Reverse the connections
if incorrect
- Replace harness if
necessary
Check the harness
connections of the red
signal wire at both ends:
1) at the carbonator ring
terminal and
2) at Pin 5 of the J4
connector at the main
control board
Able to continue to
function but
carbonator pump
short-cycles. Pump
will come on each
time a drink is drawn.
THIS SITUATION
SHOULD BE
CORRECTED.
THIS IS AN ERROR
CONDITION.
No service required
No service required
No service required
Unplug the unit and plug it
back in. This will reset the
unit's main control board
and restart the carbonator
pump.
LED
FIGURE 22
© 2004-2005, IMI Cornelius Inc.
- 19 -
Publication Number: TP01070
IMI Cornelius Inc.
www.cornelius.com