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®
FLAVORFUSION®/
FLAVOROVERLOAD
Training Manual
Publication Number: TP01070
Revision Date: November 16, 2007
Revision: F
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
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FLAVORFUSION®/FLAVOROVERLOAD 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 varia- tions 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, plumbi
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FlavorFusion®/FlavorOverload Training Manual TABLE OF CONTENTS Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . .
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FlavorFusion®/FlavorOverload Training Manual Publication Number: TP01070 - ii - © 2004-2007, IMI Cornelius Inc.
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FlavorFusion®/FlavorOverload 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
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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 o 40 to 90 F ambient temperature Electrical Rating: . . . . . . . . 103-132 Volts 11 Amps Water supply pressure: . . 50-60 psi at pump Water
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FlavorFusion®/FlavorOverload Training Manual PROGRAMMING NOTE: 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 wil
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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 hold
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FlavorFusion®/FlavorOverload 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 fo
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FlavorFusion® Training Manual MECHANICAL DISASSEMBLY Control Box Components Valve Flow Controls Ballast for Merchandiser 24 Volt Transformer (2) Light Motor Start Capacitor Starter Merchandiser Light Main Control Board/Agitator Timer FIGURE 4 FIGURE 5 Adjustment Pots Agitation Board Interface Board FIGURE 6 FIGURE 7 Publication Number: TP01070 - 6 - © 2004-2007, IMI Cornelius Inc.
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FlavorFusion®/FlavorOverload 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). FIGURE 10 FIGURE 11 3. Place the tabs into the slot over the merchandiser lights. FIGURE 12 FIGURE 13 4. Place the valve removal tool on the back block release latch, keep the handle flat. Valve Removal Tool FIGURE 14 © 2004-2007, IMI Cornelius Inc.
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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. FIGURE 17 7. Push the valve on the back block and push up on the back block release latch to replace the valve. FIGURE 18 Publication Number: TP01070 - 8 - © 2004-2007, IMI Cornelius Inc.
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FlavorFusion®/FlavorOverload 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. o Locking Screw Spring Clip 2. Twist the solenoid 90 . 3. Pull the solenoid loose from the valve body. 4. To remove the tubing squeeze the spring clip together and pull off. FIGURE 19 CARBONATOR TANK Upper and Lower Level Grounding Connection/ Always dis
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FlavorFusion® Training Manual SYSTEM PLUMBING DIAGRAM Publication Number: TP01070 - 10 - © 2004-2007, IMI Cornelius Inc.
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FlavorFusion®/FlavorOverload Training Manual PLUMBING DIAGRAM CARBTANKIN CARBTANKOUT PW CW CW PW PLAINWTRIN CARBWTRIN © 2004-2007, IMI Cornelius Inc. - 11 - Publication Number: TP01070 A =AMBIENT(NON-CHILLED) FLAVORFUSION-16BRAND SYRUPFLAVOR B1-N2 B5-N5 XX=OUTLETLINE 1 2 5 6 8911 12 B2-N2 B6-N5 KEYPAD KEYPAD B#=AMBIENT(NON-CHILLED) BUTTONS B3-N2 BUTTONS B7-N5 BONUSSYRUPS1-8 3 4 7 10 13 14 A1 A2 B4-N2 B8-N5 N#=NOZZLE#1-6 PW=PLAINWATER N2 N5 NOZZLES N1 N3 NOZZLES N4 N6 CW=CARBONATEDWATER BONUSFLAV
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FlavorFusion® Training Manual INTERFACE BOARD AND HARNESS PIN-OUT DETAIL C P S S S S CCC C W W C 4 3 2 1 C 12 11 10 9 8 7 6 5 4 3 2 1 CW PW S4 S3 S1 S2 TOSOLENOIDVALVES INTERFACEBOARDDETAIL Publication Number: TP01070 - 12 - © 2004-2007, IMI Cornelius Inc.
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L1_IN J7 L1_BALST J3 L1 XFORMR J4 L1 HEATR OFF TIME CARBMOTR ON CARBMOTRL2 TIME CARBMTR EARTH AGIT EARTH_IN L2_AGIT AGIT EARTH FlavorFusion®/FlavorOverload Training Manual POINT-POINT WIRING DIAGRAM © 2004-2007, IMI Cornelius Inc. - 13 - Publication Number: TP01070 10.250 WIRINGDIAGRAMFLAVORFUSION ELECTRICSHOCKHAZARD. DISCONNECTPOWER BEFORESERVICINGUNIT. WHT HEATER BLK 620920673REV5 ICE AGIT. BLK WHT BLK BLK WHT ORG YLW GRN/YLW BRN MOTOR GRN BLU WHT WHT WHT WHT BRN GRN YEL YEL CARB. MOTOR PUMP A
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FlavorFusion® Training Manual LADDER TYPE WIRING DIAGRAM L1 N KEYSWITCH BEV.X-FRMR 24V 24V INTERFACE INTERFACE BOARD-1 BOARD-4 INTERFACE INTERFACE BOARD-2 BOARD-5 INTERFACE INTERFACE BOARD-3 BOAR-6 BALLAST LIGHT STARTER SWITCHINGPERFORMED ONPCBOARD CARBMOTOR CARBMOTOR RELAY BLK BLK AGITTIMER RELAY YELLOW BRN BRN RED ORG ORG WHT AGITMOTOR ICEDISP. SWITCH AGITHEATER WIRINGLADDERSCHEMATIC115V-FLAVORFUSION Publication Number: TP01070 - 14 - © 2004-2007, IMI Cornelius Inc.
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FlavorFusion®/FlavorOverload 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 CO system, stop dispensing, shut off the CO supply, then relieve the system 2 2 pressure before proceeding. If repairs are to be made to the e
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FlavorFusion® Training Manual Dispenser Troubleshooting Symptom Cause Remedy Blown fuse or circuit Short circuit in electrical wiring Repair Wiring breaker Inoperable agitator motor (shorted Replace gear motor motor) Agitator does not No power Restore power or plug in unit turn Improperly installed upper ice chute Check the upper ice chute assembly for assembly (Reed switch is not being proper assembly and operation activated) Inoperable reed switch Replace reed switch Electrical board driver c
