Cornelius FlavorFusion Series User Manual

FlavorFusion Installation Manual  
INSTALLATION MANUAL  
FlavorFusion with Cold Carbonation  
DESCRIPTION  
The FlavorFusion series of dispensers solves your ice and beverage service needs in a sanitary, space  
saving, economical way. Designed to be manually filled with ice from any remote ice–making source,  
these dispensers will dispense cubes (up to 1–1/4 inch in size), cubelets, and compressed (not flaked)  
ice. In addition, the units include beverage faucets, a cold plate, an internal carbonator tank and an  
external pump for the carbonator, and are designed to be supplied direct from syrup tanks with no  
additional cooling required.  
CAUTION: Dispenser cannot be used with crushed or flaked ice. Use of bagged ice which has  
frozen into large chunks can void warranty. The dispenser agitator is not designed to be an ice  
crusher. Use of large chunks of ice which “jam up” inside the hopper will cause failure of the agitator  
motor and damage to the hopper. If bagged ice is used, it must be carefully and completely broken  
into small, cube-sized pieces and left to “temper” or warm up for a minimum of 20 minutes in room  
temperature before loading into the dispenser hopper.  
SPECIFICATION  
Model Descriptions:  
B=Beverage  
C=Coldplate  
H=Internal Cold Carb  
Z=No Drip Tray  
Ice Storage:  
255 Pounds  
Maximum Number of Faucets  
Available:  
4 nozzles with 4 brands each = 16 brands  
2 nozzles with 4 bonus flavors each = 8 bonus flavors  
Built–in Cold Plate:  
Electrical:  
Yes  
120/1/60,  
9.3 Amps of Total Unit Draw  
220/1/50,  
4.7 Amps of Total Unit Draw  
Dimensions:  
30 inch  
30-11/16 inch  
39 inch (to top of bin)  
41-10/16 inch (to top of lid)  
Z-Models  
30 inch  
23-1/16 inch  
39 inch (to top of bin)  
41-10/16 inch (to top of lid)  
CO2 Operating Pressure  
75-psig (max) for carb tank and brand syrup pumps  
25-psig (max) for bonus flavor pumps  
Revision Date: February 6, 2006  
© 2005-2006, IMI Cornelius Inc.  
Revision: B  
Publication Number: 621057601INS  
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FlavorFusion Installation Manual  
INSTALLATION  
IMPORTANT: TO THE INSTALLER.  
It is the responsibility of the Installer to ensure that the water supply to the dispensing equipment  
is provided with protection against backflow by an air gap as defined in ANSI/ASME A112. 1.2–  
1979; or an approved vacuum breaker or other such method as proved effective by test.  
Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed,  
and maintained according to Federal, State, and Local laws.  
1.  
Locate the dispenser indoors on a level counter top.  
A. LEG OPTION  
Unpack the four (4) legs and install them into the threaded holes provided in the bottom of the  
unit. The installer must provide flexibility in the product and utility supply to permit shifting the  
position of the dispenser sufficiently to clean the area beneath it.  
B. COUNTER MOUNTING  
The ice drink dispenser must be sealed to the counter. The template drawing (see FIGURE 6)  
indicates where openings can be cut in the counter. Locate the desired position for the  
dispenser, then mark the outline dimensions on the counter using the template drawings. Cut  
openings in counter.  
Apply a continuous bead of NSF International (NSF) silastic sealant (Dow 732 or equal) approximately 1/  
4-inch inside of the unit outline dimensions and around all openings. Then, position the unit on the  
counter within the outline dimensions. All excess sealant must be wiped away immediately.  
2.  
The beverage tubes, drain tube and power cord are routed through the large opening in the bottom  
of the unit. See the MOUNTING TEMPLATE (FIGURE 6) for locating the required clearance  
opening in the counter for these utility lines.  
3.  
DRIP TRAY DRAIN ASSEMBLY (see FIGURE 7): Route the drain tube to an open drain with the  
end of the tube above the “flood” level of the drain. Use the tubing, fittings, clamps, and insulation  
provided with the Dispenser to assemble the drain. The completed drain line must pitch  
continuously downward and contain no “traps” or improper drainage will result.  
NOTE: IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in  
the plain water inlet supply line. A Cornelius Water Filter (P/N 313860000) and QUICK  
DISCONNECT SET (P/N 313867000) are recommended.  
CAUTION: Check the minimum flow rate and the maximum pressure of the plain water inlet supply  
line. MINIMUM FLOW RATE MUST BE AT LEAST 125-GALLONS PER HOUR. If flow rate is less  
than 125-gallons per hour, starving off the carbonator water pump will occur. Starving will allow the  
carbonator water pump to overheat causing the safety thermostat on the pump outlet to stop the  
water pump motor. Overheating could occur if the plain water supply line flow rate drops below 125-  
gallons per hour. INCOMING PLAIN WATER INLET SUPPLY LINE WATER TO PUMP PRESSURE  
MUST REMAIN A MINIMUM OF 10 psi BELOW THE CARBONATED CO2 OPERATING  
PRESSURE. (Example: Carbonator CO2 operating pressure is 75 psi and the maximum water  
pressure can be no more than 65 psi, etc.). Water over pressure (higher CO2 operating pressure)  
can cause carbonator flooding, malfunction, and leakage through the carbonator relief valve. If  
water is exceeding maximum pressure specifications, a Water Pressure Regulator Kit must be  
installed in the plain water inlet supply line. If fitting connector is not available, tap into the plain  
water supply line with a 3/8 flare saddle valve.  
4.  
5.  
Locate the carbonator pump assembly and connect to power cord from the Ice/Drink Unit to the  
pump. The cord is connected to the unit’s electrical box and has an electrical connector on the end  
that plugs into a receptacle in the junction box at the carbonator pump assembly. Connect inlet  
water to pump and pump outlet to Ice/Drink Unit using 3/8-inch food-grade tubing. Disable the pump  
from operating by switching the switch in the carbonator pump assembly junction box to the OFF  
position.  
Connect the beverage system product tubes as indicated in applicable Flow Diagram FIGURE 8.  
This work should be done by a qualified service person.  
© 2005-2006, IMI Cornelius Inc.  
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Publication Number: 621057601INS  
FlavorFusion Installation Manual  
NOTE: See applicable Flow Diagram (see FIGURE 8) or Decal on the lower front of the unit for the  
location of syrup and water connections.  
6.  
7.  
Clean the hopper interior (see CLEANING INSTRUCTIONS in Owner’s Manual).  
Connect the unit power cord to a 120 volt, 60 cycle, 3–wire grounded receptacle. For 220-240 Volt  
International Units, a 3-wire power cord is provided. An adapter plug for the particular country will  
need to be provided by the Installer.  
ADJUST CARBONATOR CO2 REGULATOR AND TURN WATER INLET SUPPLY  
LINE ON  
CAUTION: Before connecting the CO2 regulator assembly to a CO2 cylinder, turn the regulator  
adjusting screw to the left (counterclockwise) until all tension is relieved from the adjusting screw  
spring.  
1.  
2.  
Open (counterclockwise) CO2 cylinder valve slightly to allow lines to slowly fill with gas, then open  
the valve fully to back-seat the valve. (Back-seating the valve prevents leakage around the valve  
shaft).  
The carbonator CO2 regulator is fixed at a nominal 75 psi.  
3.  
4.  
Open one of the post-mix dispensing valves to exhaust trapped air inside the carbonator tank.  
Open the water inlet supply line shutoff valve.  
UNIT OPERATION  
WARNING: The unit must be electrically grounded to avoid possible fatal electrical shock or serious  
injury to the operator. The unit power cord is equipped with a three-prong plug. If a three-hole  
(grounded) electrical outlet is not available, use an approved method to ground the unit.  
CAUTION: Never operate the carbonator pump with the water inlet supply line shutoff valve  
closed. “Dry running” the water pump will burn out the pump. A pump damaged in this manner is  
not covered by warranty.  
1.  
2.  
Connect electrical power to the Unit.  
Locate the switch on the junction box of the carbonator pump, and turn it ON. The water pump will  
start and fill the carbonator tank with carbonated water. The water pump will stop when the  
carbonator tank is full.  
3.  
4.  
Check for water and CO2 leaks, and tighten any loose connections  
Dispense several drinks until the carbonator pump cycles on. The refill time should be about 5-7  
seconds.  
5.  
If the carbonator pump appears to be short-cycling, meaning a refill time of 1-2 seconds, refer to the  
Troubleshooting section.  
Publication Number: 621057601INS  
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© 2005-2006, IMI Cornelius Inc.  
FlavorFusion Installation Manual  
GATE RESTRICTOR PLATE AND ADJUSTMENT  
The rate at which ice is dispensed can be adjusted by varying the opening of the gate restrictor plate as  
illustrated in FIGURE 1. Reducing the dispense rate of ice is especially desirable when using glasses or  
other containers with small openings. To adjust the gate restrictor plate, loosen the (4) nuts that hold the  
ice chute assembly to the bin. The restrictor plate can now be moved up or down. When the restrictor  
plate is fully up, the ice gate opening is 2-1/2” in height, and the maximum rate of ice dispense is  
available (approximately 3 oz/sec). Retighten the (4) nuts to set the desired restrictor plate opening. DO  
NOT EXCEED 40 IN-LB of torque.  
DISCONNECT POWER BEFORE INSTALLING,  
REMOVING, OR ADJUSTING RESTRICTOR.  
!
RESTRICTOR  
PLATE  
INSTALL PLATE  
ON STUDS AS  
SHOWN  
ADJUSTMENT  
4X  
MAX TORQUE  
40 in.-lb.  
FIGURE 1. Gate Restrictor Plate  
NOTE: Tighten (4) nuts for fastening lower ice chute in place to 40 in-lbs (max). Draw all four nuts  
tight uniformly.  
© 2005-2006, IMI Cornelius Inc.  
- 5 -  
Publication Number: 621057601INS  
FlavorFusion Installation Manual  
PROGRAMMING MODE  
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 4) 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 2:  
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
Time  
3
4
5
(seconds)  
FIGURE 2  
Publication Number: 621057601INS  
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© 2005-2006, IMI Cornelius Inc.  
FlavorFusion Installation 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 4). The LED’s for  
flavors 1-4 should flash off and then back  
on. The drink icon should turn off.  
2.  
3.  
4.  
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 four buttons  
changes.  
Flow Adjuster Detail  
(Water)  
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.  
If necessary, adjust the water flow control  
(see FIGURE 3), empty ratio cup, and  
repeat step 3. Otherwise empty ratio cup  
and repeat step 3 using the right program  
button for plain water.  
FIGURE 3. Valve with Flow Adjusters  
(see plumbing diagram for plumbing and valve  
configuration)  
5.  
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.  
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)  
Optional  
Drink Icon  
Bonus Flavor Icon  
Optional  
Bonus Flavor Button 1  
Optional  
Brand Flavor Button 1  
Brand Flavor Button 2  
Bonus Flavor Button 2  
Optional  
Bonus Flavor Button 3  
Optional  
Brand Flavor Button 3  
Brand Flavor Button 4  
Bonus Flavor Button 4  
Optional  
Bonus Flavor Nozzle  
Optional  
Brand Flavor Nozzle  
FIGURE 4  
© 2005-2006, IMI Cornelius Inc.  
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Publication Number: 621057601INS  
FlavorFusion Installation Manual  
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 4). The LED’s for flavors 1-4 should flash off and  
then back on. The drink icon should turn off.  
2.  
3.  
4.  
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.  
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.)  
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.  
6.  
Repeat for all syrups in valve bank.  
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.  
Program the designated button to dispense non-carbonated water (see Programming Mode.)  
2.  
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.  
Program the designated button to dispense carbonated water (see Programming Mode.)  
2.  
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.  
Back Room Package Position (BRP)  
C
E
D G H  
K
L
O
P
R
S
T W X  
Pumps  
F
I
J
N Q  
V
Y
Z
M
U
C
D
F
S
T
K
L
N
P
R
E
G
I
M
O
Q
U
W
Y
V
X
Z
BIB Racks  
H
J
FIGURE 5  
Publication Number: 621057601INS  
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© 2005-2006, IMI Cornelius Inc.  
FlavorFusion Installation Manual  
MOUNTING TEMPLATE  
7/16 DIA.  
30  
1 13/16  
26 3/8  
1 5/16  
12  
9
18 5/8  
21 1/4  
31 1/2  
30  
23 1/16  
3 1/2  
11  
9 1/2  
Z Style  
23  
REMOVABLE SINK  
RECOMMENDED COUNTER OPENING SIZE  
9 X 12 FOR UTILITIES AND BEVERAGE  
TUBING. OPENING CAN BE LOCATED  
ANYWHERE WITHIN SHADED AREA.  
FIGURE 6. FlavorFusion Mounting Template  
© 2005-2006, IMI Cornelius Inc.  
- 9 -  
Publication Number: 621057601INS  
FlavorFusion Installation Manual  
DRIP TRAY DRAIN ASSEMBLY  
HOSE CLAMP  
DRAIN LINE  
1" I.D. PLASTIC TUBING  
(6') WITH INSULATION  
FIGURE 7. Drip Tray Drain Assembly  
Publication Number: 621057601INS  
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© 2005-2006, IMI Cornelius Inc.  
FlavorFusion Installation Manual  
DIAGRAMS  
Flow Diagram  
PW  
CW  
CW  
PW  
FIGURE 8. Flow Diagram  
© 2005-2006, IMI Cornelius Inc.  
- 11 -  
Publication Number: 621057601INS  
FlavorFusion Installation Manual  
Wiring Diagram  
W H T  
B L K  
B L K  
W H T  
B L K  
R E D  
B L K  
W H T  
X F O R M R  
L 2 _  
Y E L  
R E D  
L 2 _ I N  
B A L S T  
L 2 _  
H E A T R  
L 2  
B L K  
W H T  
B L K  
Y E L  
W H T  
W H T  
B L U  
B L K  
W H T  
R E D  
R E D  
B L U L T  
B L K  
W H T  
Y E L  
G R N  
Y E L  
Y E L  
W H T  
W H T  
R E D  
B L K  
W H T  
Y E L  
W H T  
B L U  
B L K  
B L K  
R E D  
Y E L  
B L K  
W H T  
R E D  
FIGURE 9. Wiring Diagram - 120V Unit  
Publication Number: 621057601INS  
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© 2005-2006, IMI Cornelius Inc.  
FlavorFusion Installation Manual  
Wiring Schematic  
L1  
L2  
L2_IN  
L1_IN  
EARTH  
CARB MOTOR  
CARB MOTR_L2  
CARB MOTR  
CARB EARTH  
AGITATOR MOTOR  
AGITATOR  
AGITATOR_L2  
AGITATOR EARTH  
OPTIONAL LIGHTING  
FLOURESCENT LIGHT  
BALLAST  
BALLAST_L2  
L1_BALLAST  
STARTER  
HEATER  
HEATER_L2  
L1_HEATER  
XFORMER_L1  
L2_XFORMER  
120V Pri  
80 VA  
XFRMR1  
E-BOARD  
E-BOARD  
24V Sec  
KEY  
LOCK  
INTERFACE BOARD  
VALVE (6)  
INTERFACE BOARD  
INTERFACE  
BOARD  
VALVE (6)  
TOUCHPAD  
TOUCHPAD  
VALVE (6)  
TOUCHPAD  
80 VA  
120V Pri  
XFRMR2  
24V Sec  
KEY  
LOCK  
INTERFACE BOARD  
INTERFACE BOARD  
ICE CUBE  
LED  
INTERFACE  
BOARD  
VALVE (6)  
VALVE (6)  
TOUCHPAD  
TOUCHPAD  
E-BOARD  
VALVE (6)  
J7  
TOUCHPAD  
ICE GATE SWITCH  
J3  
CARB TANK  
HIGH LEVEL PROBE  
LOW LEVEL PROBE  
GROUND  
J4  
FIGURE 10. Wiring Schematic  
© 2005-2006, IMI Cornelius Inc.  
- 13 -  
Publication Number: 621057601INS  
FlavorFusion Installation 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 refrigeration system, make sure  
electrical power is disconnected from the unit.  
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.  
Dispenser Troubleshooting  
Symptom  
Cause  
Remedy  
Blown fuse or circuit  
breaker  
Short circuit in electrical wiring  
Repair Wiring  
Inoperable agitator motor (shorted  
motor)  
Replace gear motor  
Agitator does not  
turn  
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 dispenses  
continuously  
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.  
Slushy ice or water  
in hopper  
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  
Publication Number: 621057601INS  
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© 2005-2006, IMI Cornelius Inc.  
FlavorFusion Installation Manual  
Beverage does not  
dispense  
No 24VAC to valves  
Restore 24 VAC to valves  
No CO2 pressure  
Restore CO2 pressure  
Adjust valve brix  
Beverage is too  
sweet  
Valve brix requires adjustment  
Carbonator is not operating  
No CO2 in carbonator  
Repair carbonator  
Restore CO2 pressure in carbonator  
City water pressure supply low or  
inconsistent  
Booster pump must be used if dynamic  
water pressure drops below 40 psig.  
Unit will not  
dispense  
carbonated drinks.  
Dispenses syrup  
only.  
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.  
Unit will not  
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.  
dispense  
carbonated drinks.  
Spurts CO2 and  
syrup only.  
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.  
Carbonated drinks  
are flat (low on  
carbonation)  
CO2 is out  
Replace CO2  
Carbonator tank is 100% filled because  
the city water pressure exceeds the  
carbonator tank CO2 pressure regulator  
CO2 setting for the carbonator tank is  
75 psig, max water pressure is 60 psig.  
If necessary, install a water pressure  
regulating valve.  
setting.  
Low water pressure  
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  
Change water filter  
Plugged water filter.  
Water booster bladder has burst  
Replace water booster tank/bladder  
© 2005-2006, IMI Cornelius Inc.  
- 15 -  
Publication Number: 621057601INS  
FlavorFusion Installation Manual  
No Syrup or  
Watered down drink  
dispensed  
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  
Cause  
Remedy  
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: 621057601INS  
- 16 -  
© 2005-2006, IMI Cornelius Inc.  
FlavorFusion Installation Manual  
DIAGNOSTICS GUIDE FOR THE MAIN CONTROL BOARD  
Observed State  
of Red LED  
State  
Sensor Input  
Control Response  
Service Remedy  
0
Flash rate 3  
seconds  
Both probes read “wet”  
Standby mode. Pump  
= OFF  
No service required  
1
Flash rate  
1/2 second  
Pump is OFF and  
HIGH probe reads “dry”  
and LOW probe reads  
“wet”  
Waiting for level to  
drop below LOW  
probe. Pump = OFF  
No service required  
2
3
Flash rate  
Both HIGH and LOW  
probes read “dry”  
Normal mode.  
Pump = ON  
No service required  
No service required  
1/2 second  
Flash rate  
1/2 second  
Entered when HIGH  
probe does not detect  
liquid, and LOW probe  
does detect liquid, and  
pump is ON  
Normal mode.  
Pump = ON  
4
Flash rate 1  
second  
Entered when HIGH  
probe reads “wet” and  
LOW probe reads “dry”  
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  
5
6
ON  
Poor signal connection  
to the carbonator tank.  
May result in short  
cycling of the  
Able to continue to  
function but  
Check the harness  
continuously,  
but “flickers”  
every 3  
connections of the red  
signal wire at both ends:  
1) at the carbonator ring  
carbonator pump  
short-cycles. Pump  
seconds  
carbonator pump.  
will come on each time  
a drink is drawn. THIS  
SITUATION SHOULD  
BE CORRECTED.  
terminal and  
2) at Pin 5 of the J4  
connector at the main  
control board  
ON  
continuously  
Entered when pump  
has run continuously  
for 5 minutes  
THIS IS AN ERROR  
CONDITION.  
Unplug the unit and plug  
it back in. This will reset  
the unit's main control  
board and restart the  
carbonator pump.  
© 2005-2006, IMI Cornelius Inc.  
- 17 -  
Publication Number: 621057601INS  
FlavorFusion Installation Manual  
DIAGNOSTICS GUIDE FOR FLAVORFUSION KEYPAD LIGHTING  
Observations of LED Lighting on Customer Interface Keypad  
Symptom  
Cause  
Remedy  
1
Bonus Flavor Icon and/  
or Drink Icon LEDs (see  
FIGURE 4) 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
3
Bonus Flavor Icon and/  
or Drink Icon LEDs (see  
FIGURE 4) 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.  
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.  
4
During standby mode,  
the brand and bonus  
LED icons do not  
alternate back and forth  
- instead they light  
together.  
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.  
Contact your local syrup or beverage equipment distributor for additional information and troubleshooting  
of beverage system.  
Publication Number: 621057601INS  
- 18 -  
© 2005-2006, IMI Cornelius Inc.  

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