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® 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. - 15 - 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 - 16 - © 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 - 18 - © 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