Cornelius Beverage Dispenser Cold Beverage Dispenser User Manual

INTELLICARB

Training Manual

Release Date: April 29, 2004

Publication Number: TP01071

Revision Date: NA

Revision: A

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InelliCarb Training Manual

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Delivery Inspection and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Cornelius IntelliCarb Carbonator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Carbonator Time Out Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Carbonator Relief Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Mechanical Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Gate Restrictor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Ice Diverter Kit 02394 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Removal and Replacement of Agitators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

To Remove Agitators For Cleaning (300 shown) . . . . . . . . . . . . . . . . . . . . . . . .10

Post-Mix Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Set-up Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Dimensions & Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

System Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Adjusting Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Calculating Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Syrup/Concentrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Setting Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Shurflo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Shurflow Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Shurflow Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Plumbing Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Flow Diagram 1xx (Six Flavor Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Flow Diagram 1XX (Eight Flavor Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Flow Diagram 2xx (Eight Flavor Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Flow Diagram 2xx (Ten Flavor Models)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Flow Diagram 300 (Twelve Flavor Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

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Electrical Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Carbonator Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Wiring Diagram 1xx (120V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Schematic 1xx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Wiring Diagram 2xx (120V Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Wiring Diagram 2xx (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Wiring Diagram 2xx (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Wiring Diagram 300 (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Wiring Diagram 300 (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Schematic 300 (120V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Schematic 300 (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SHURflow Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Pumping Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Pumps in Series for Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pump Sanitizing / Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

DOES NOT OPERATE / GAS APPLIED / DISPENSER VALVE OPEN . . .37

OPERATES BUT WILL NOT PRIME / DISPENSER VALVE OPEN . . . . . . 37

DOES NOT ACHIEVE SOLD-OUT WITH EMPTY B-I-B . . . . . . . . . . . . . . . 37

AIR IN INLET AND/OR OUTLET TUBING . . . . . . . . . . . . . . . . . . . . . . . . . . 37

STROKES WITH DISPENSER VALVE CLOSED . . . . . . . . . . . . . . . . . . . . 37

FLUID FROM EXHAUST OR VISIBLE WITHIN GAS INLET TUBING . . . . . 37

GAS BLOWING FROM EXHAUST CONTINUOUSLY . . . . . . . . . . . . . . . . . 37

Dispenser Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Valve Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Excess Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Off Taste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

No Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Carbonator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Solid State Carbonator Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Test Solid State Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Publication Number: TP01071

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INTRODUCTION

UNIT DESCRIPTION

•

Built-in cold carbonator produces bottle-quality drinks every time

•

No seasonal CO₂adjustments required for changes in water temperature

•

A complete system for simplified installation

Reduces service frequency and lowers equipment life cost

Generates increased beverage sales and greater consumer satisfaction

Illuminated merchandiser delivers unique, high impact marketing message

Ice used to cool cold plate kept separate from ice dispensed into cups

One piece ABS thermoformed plastic ice storage hopper. Durabide™ design provides durability and

ensures all ice in the hopper is dispensable

•

Unit readily accepts top mount cubers with manual ice fill capability

THEORY OF OPERATION

The rate of CO₂solubility increases with cold water. IntelliCarb System provides pre–chilled cold water

from the cold plate and mix with CO₂in the carbonator tank. The water is introduced into the tank with a

high volume 125gph Procon pump and high torque motor.

The amount of carbonated water reserve is controlled by a probe mounted in the tank. The probe is

called a “liquid level probe”. The liquid level probe senses the water level in the tank. Probe controls the

pump “ON” and “OFF” cycle through the electronic board called “liquid level board”.

NOTE: The probe works on a 5 M.V. D.C. current that continually reverses direction to prevent

probe corrosion.

DESCRIPTION

The “Enduro IntelliCarb” series of ice dispensers solves your ice and beverage service needs in a

sanitary, space saving, economical way. Designed to be automatically filled with ice from a top mounted

ice machine or 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 hard-chipped or cracked 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.

IMPORTANT: For dispensing compressed or extruded style ice, an Ice Diverter Kit must be installed on

the dispenser, see FIGURE 13 on page 9.

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SPECIFICATIONS

ED150

ED175

ED200

ED250

ED300

B=(Beverage)

C=(Coldplate)

H=(Internal

Carb)

B=(Beverage)

C=(Coldplate)

H=(Internal

Carb)

B=(Beverage)

C=(Coldplate)

H=(Internal

Carb)

B=(Beverage)

C=(Coldplate)

H=(Internal

Carb)

B=(Beverage)

C=(Coldplate)

H=(Internal

Carb)

Model

Descriptions:

Z=(No DripTray) Z=(No DripTray) Z=(No DripTray) Z=(No DripTray) Z=(No DripTray)

150 Pounds

175 Pounds

200 Pounds

250 Pounds

300 Pounds

Ice Storage:

Maximum

Number of

Faucets

Available:

Yes

Built-in Cold

Plate:

ꢀꢁꢂꢃꢀꢃꢄꢂꢅꢆꢇꢈꢂꢆ$PSVꢆ7RWDOꢆ8QLWꢆ'UDZ

120/1/60, 3.5 Amps Total Unit Draw

230/1/50, 2.0 Amps Total Unit Draw

120/1/60, 4.0

Amps Total Unit

Draw

Electrical:

230/1/50, 3.0

Amps Total Unit

Draw

Outlet should be within 6 feet of dispenser.

Width 22”

Width 24.5”

Width 22”

Width 24.5”

Deep 30–11/16”

High 39–5/8”

Width 44–3/8”

Deep 31–1/2”

High 37”

Deep 30--11/16” Deep 30--11/16” Deep 30–11/16”

High 35--5/8”

High 35–5/8”

Dimensions: Z--Models

Width 22”

Z–Models

Width 24--1/2”

Deep 23--1/16”

High 35--5/8”

75--psig (max)

Width 22”

Width 24–1/2”

Deep 23–1/16”

High 39–5/8”

75–psig (max)

Width 44–3/8”

Deep 23–1/16”

High 37”

Deep 23--1/16”

Deep 23–1/16”

High 35–5/8”

75–psig (max)

High 35--5/8”

75--psig (max)

75–psig (max)

CO2 Operating

Pressure

REQUIREMENTS

•

Weight: counter must be level and able to support 450 lbs.

•

Environment: Indoor installation only

•

Temperature: 40 to 100^oF

CO2: 75 psi at unit

Syrup: 60 psi., 0.70 -- 0.75 ounces per sec. (0.6 gpm) at unit

Water: 60 psi at pump

Electrical: See name plate

DELIVERY INSPECTION AND UNPACKING

Upon delivery inspect the unit for damage or irregularities and immediately report problems to the

delivering carrier and file a claim with that carrier.

•

Open loose parts packages and inspect parts.

Part No.

Description

Qty.

710000030

Pump and Motor Assy

70970

4”Legs

70750

Clamps

Brush

Drain Pan Drain Line

Drain Line Insulation

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)LWWLQJꢆꢇꢃꢋꢆ0SWꢆ[ꢆꢀµ%DUE

620702201

51774

50335

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INSTALLATION

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

If counter mounted the ice drink dispenser must be sealed to the counter. The template drawing

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) approxi-

mately 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 immedi-

ately.

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 for locating the required clearance opening in the counter for

these utility lines.

3. Drip tray assembly: 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. Must have a 4 inch air gap between drain line and drain.

NOTE: This equipment must be installed with adequate backflow protection to comply with fed-

eral, state, and local codes.

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 DISCON-

NECT SET (P/N 313867000) are recommended.

CAUTION: Check the minimum flow rate and the maximum pressure of the plain water inlet supply line.

MINUMUM FLOW RATE MUST BE AT LEAST 125--GALLONS PER HOUR. If flow rate is less than 125-

-gallons per hour, starving of the carbonator water pump will occur. Starving will damage the water pump

and could cause the carbonator to time out. INCOMING PLAIN WATER INLET SUPPLY LINE WATER

TO PUMP PRESSURE MUST REMAIN A MINIMUM OF 10--PSI BELOW THE CARBONATOR 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 than CO2 operating pres-

sure) can cause carbonator flooding, malfunction, and leakage through the carbonator relief valve. If

water is exceeding maximum pressure specifications, a Water Pressure Regulator Kit (P/N 310150000)

or equivalent must be installed in the plain water inlet supply line. If fitting connector is not available,

water line must be 1/2” or 3/4” diameter with a shut off valve within 6 feet of the dispenser.

4. Locate the carbonator pump assembly and connect probe wires from Ice/Drink Unit and pump. Con-

nect inlet water to pump and pump outlet to Ice/Drink Unit using 3/8--inch food--grade tubing.

NOTE: Locate carbonator assembly within 6 feet of the dispenser. Do not lengthen the control

board harness.

5. Connect the beverage system product tubes as indicated in applicable Plumbing Flow Diagram, see

page 19. This work should be done by a qualified service person.

NOTE: Water pressure for non carbonated beverages must be 60 P.S.I. minimum.

NOTE: See applicable Flow Diagram or Decal on the lower front of the unit for the location of

syrup and water connections.

6. Clean the hopper interior.

7. Connect the two power cords 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.

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Drains

Use a 1 - 1/2” rigid pipe (e.g. ABS on P.V.C.) this is to prevent kinking or collapsing. Make sure to leave a

4 inch air gap between the drain line and the floor drain.

CORNELIUS INTELLICARB CARBONATOR ASSEMBLY

1. Ice Drink / Drop-In Carbonator Pump & Motor Unit

Vent to Atmosphere Check Valve

125 G.P.H. ProCon Water Pump

High Torque Pump Motor

Liquid Level Control Box

Preset CO2 Regulator (75P.S.I.)

FIGURE 1

Carbonator Time Out Reset Switch

The board can be set to turn the carbonator off after three or seven minutes of continuos time. The fea-

ture can also be disabled. See the carbonator instruction in this manual.

Carbonator

Time Out Reset

Switch

Time Out

Selector Pins

Liquid Level

Control Board

FIGURE 2

FIGURE 3

1. Locate carbonator assembly below dispenser no more than 6 feet away. Important: Make

sure there is clearance for the liquid level control reset switch on the side of the control box

to avoid accidentally tripping the switch. The control board has an internal timer to prevent the

pump motor from running continuously. In the event of a water supply interruption or malfunction of

the water level probe and/or motor relay circuit. If there is a time-out event, make necessary repairs

to what caused the time out, then depress and release the reset switch to put the control board

back in service. By moving a jumper on the control you can select either a 7 minute or 3 minute time

out or this feature can also be disabled.

A. Hook-up a 3/8 ID water supply line 125 G.P.H. minimum (60 psig. max.) to pump inlet. Minimum

flowing pressure is 30 psig. Important: Tap for non-carb water supply must be upstream of

pump inlet. Do not tap in the pump outlet.

B. Hook-up a 3/8 (.375 ID) CO₂supply line (100 psig.) to the inlet of the pre-set CO₂regulator (75

psig.) on the Pump & Motor base. Note: If using a bulk CO₂tank as supply, tank pressure

regulator must be set to 100-105 psig. The regulator on the bulk tank should be a second-

ary.

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C. Initial start-up procedure for carbonated water system: Turn on the CO₂supply to the car-

bonator tank, vent air from carbonator tank by pulling the tank relief valve. Turn on water supply to

the pump. Connect electrical power to the pump and motor unit. Bleed the air out of the system

by energizing a beverage valve until carbonated water is flowing from the valve.

NOTE:If the carbonator Pump and Motor does not cycle (turn on and off) properly, check that the

probe harness connector and ground lead are secured to the carbonator tank connection points.

D. If service is required on Ice Drink units, it will be necessary to lower the beverage valve panel to

gain access to the probe and ground connection. Remove the lower front panel (2 screws) from

the cabinet and the ice chute cover (“snap” fit). Remove the 6 screws that secure the beverage

panel to the cabinet. The panel can now be moved downward due to the flexibility of the beverage

tubing to expose the carbonator tank connections.

Carbonator Relief Valve Locations

The carbonator tank is located behind the splash panel, on the right side of the dispenser. You will need

to pull the relief valves to purge air from the system after the CO₂supply has been hooked up. Failure to

do this will cause low carbonation volume and popping of the relief valves.

Agitator

Motor

Relief

Valve Ring

Carbonator

Tank

Carbonator

Tank Relief

Valve

FIGURE 7

FIGURE 6

2. Dispenser

Ice Drink Model ED175BCH (Lower Front Panel Removed)

Insulated Cold Plate

Cover & Carbonator

Tank Assembly

Total Flex Manifold

(with insulation)

Total Flex Manifold

(insulation removed)

Cold Plate Inlets

(3/8 Barb)

Carb Tank CO

Supply Line

Carb. Tank Liquid

Level Probe Harness

FIGURE 8

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Ice Drink Model ED150/175/300 Coldplate Cover

Ice Drink Model ED200/250 Coldplate Cover

Liquid Level Probe

In-line CO Check Valve

Probe

Ground Plate/Stud

CO Check Valve with Ground Stud

FIGURE 10

FIGURE 9

3. Total Flex System for Ice Drink Models ED150/175/200/250/300

Total Flex Manifold (Insulation Removed)

Water Line

Plugs

Retainer Clip

Manifold Block

FIGURE 11

Total Flex is a system of water manifold blocks located at the front of the cold plate, adjacent to the cold

plate inlets, for easy switch over of carbonated / non-carbonated beverage drinks. The right hand mani-

fold block is for the beverage valves located to the right side of the ice chute, and the left block is for the

left bank of valves. Each beverage valve on the dispenser can be set up for either carbonated or non-car-

bonated drinks. Refer to the unit’s plumbing diagram for the factory carbonated / non-carbonated valve

locations. The procedure for switching carbonated / non-carbonated water lines on a beverage valve is

as follows:

A. Shut off the water supply to the dispenser. Depressurize and drain both the carbonated and non-

carbonated water circuits.

B. Remove the retainer clip (2 screws) from the manifold block. Switch the plug and water line fitting

to their respective carbonated / non-carbonated outlet locations on the block.

C. Replace the retainer clip. Turn on the water supply and energize the “switched” valve(s). Check

for water leaks.

4. Important: Route the dispenser’s drain line to an open drain with the end of the tube above the flood

level of the drain. The drain line must pitch downward and contain no “traps”.

5. Connect both the carbonator pump and motor unit and the dispenser to a grounded electrical sup-

ply outlet.

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6. Check list for proper “finished” drink carbonation:

A. Fill ice storage hopper with ice.

B. Water supply must be from a continuous source (no tank supply).

C. Use only filtered water.

D. Supply water line to the carbonator pump must be a minimum of .375 ID.

E. Syrup supply lines must be a minimum of .265 ID.

F. Water inlet pressure range: 45-60 max. static psig. with a minimum flowing pressure of 30 psig.

G. Syrup CO₂secondary regulator pressure set to 60 psig.

H. CO₂supply must be high quality, food grade.

I. Purge all water, carb-water, and product lines of air before brixing valves.

J. Important: Brix valves with cold product. Allow at least 15-20 minutes for ice to cool down the

coldplate on initial start-up before brixing the valves.

K. Dispense at least (2) 12 oz. drinks before taking a carbonation level reading.

L. Carbonation tester thermometer must read 32-33^oF. for accurate carb-level reading. Store tester

in ice water bath during use.

M. Hold cup at valve nozzle for drink to be tested. Pour drink slowly down the side wall into the carb-

tester to avoid agitation during pouring. Press vent valve once on carb-tester after tightening lid.

N. Shake carb-tester in vertical motion until peak pressure reading is obtained. Use Pepsi chart for

carbonation level reading.

NOTE: Carbonator troubleshooting procedure located on page 43.

- 7 -

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MECHANICAL SECTION

GATE RESTRICTOR PLATE

NOTE: Disconnect power to dispenser before installing, removing, or adjusting restrictor.

ADJUSTMENT

INSTALL PLATE

ON STUDS AS

SHOWN

FIGURE 12

Adjustment

This plate may be adjusted as shown to reduce or increase the dispensing rate of ice, especially

desirable when using glasses or other containers with small openings. Adjustment can be made by

sliding up or down with nuts loosened, to obtain the desired amount of restriction.

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ICE DIVERTER KIT 02394

NOTE: For dispensing Scotsman, Wilshire, and Hoshizaki compressed ice cubes:

1. Disconnect power to dispenser.

2. Remove Merchandiser from dispenser.

3. Remove ice chute and discard gate restrictor.

4. Install ice diverter on gate mounting plate as shown below.

5. Apply RTV to back surface of ice diverter, to seal to gate mounting plate.

6. Reinstall gasket and ice chute.

7. Reinstall merchandiser and energize unit.

GATE MOUNTING PLATE

S TOR AGE HOPPE R

FLANGE E XTE NDS

INTO S TOR AGE HOP -

PE R THR OUGH GATE

OPE NING

ICE DIVE R TE R

ICE CHUTE

COVE R

APPLY R TV TO

THIS S UR FACE TO

S E AL TO HOPPE R

GATE MOUNTING

PLATE

10 -32 WAS HE R

GAS K E T

ICE CHUTE

10 -32 NUT

FIGURE 13

- 9 -

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REMOVAL AND REPLACEMENT OF AGITATORS

To Remove Agitators For Cleaning (300 shown)

NOTE: All other models have only one agitation Assembly.

RIGHT HAND AGITATOR

WITH HOLE IN UPRIGHT

LEFT HAND

AGITATOR

O–RING

COUNTERCLOCKWISE

ROTATION

CLOCKWISE

ROTATION

FRONT (VALVE SIDE) VIEW FROM TOP OF DISPENSER

FIGURE 14

1. Lift agitator and disc from unit.

2. Remove O-Ring starting at notch. Warm the O-Ring with water to ease removal.

3. Lift the plastic agitator disc off of the stainless-steel agitator.

4. Replace by reversing steps.

NOTE: Refer to Sanitize Procedure in the Owners Instruction for complete cleaning and sanitiz-

ing instructions.

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POST-MIX VALVE SECTION

SET-UP INSTRUCTIONS

Concentrate valve sleeve

has only one hole

Syrup valve sleeve

has six holes

FIGURE 15

A side water lever kit can be added to a valve allowing for

dispensing of water without syrup or concentrate. The side

water lever can be added to either a carbonated drink valve

or a noncarbonated drink valve.

Mounting

screw

Water

lever

Post-mix valves control:

•

the ON–OFF of syrup and water,

the flow rates of syrup and water,

FIGURE 16

the mixing of the two ingredients as they pour into the

cup, and

•

in some instances - dispensed portion.

Dimensions & Capacities

Fast Flow............................................................................................................... 1 ½ to 3 oz./sec.

UFB-1 ......................................................................................................................... 2 to 4 oz./sec.

Ultra Flow .............................................................................................................. 3 to 4 ½ oz./sec.

Operational temperature range: ......................................................... 10°C (50°F) to 43°C (110° F)

Voltage requirements:................................................................................ 22 to 27 VAC (50/60 Hz)

Transformer (electronic valves) ........................................................................................80 VA min.

Operating Pressure (flowing)...............................................................................syrup = 20 psi min.

.............................................................................................................................water = 35 psi min.

Concentrates and juices that contain particulates must be dispensed from a juice valve.

A slanted drip tray is necessary when using an Optifill valve.

SYSTEM DETAILS

Water

Water Quality

Water quality issues have an affect on dispensing valves. Chloramine, a combination of chlorine and

ammonia is responsible for some degradation of rubber components. Chloramine is used in many U. S.

water supplies. Its affects can be minimized by installing and maintaining a water filtration system.

Ultra pure water affects the sensitivity of the Optifill™ valve. Because ultra pure water has less mineral

content, it reduces the conductivity of the water keeping the circuit open and overfilling the beverage

container.

Water Flow

The size of the orifice in the piston varies depending on whether the piston is used for syrup or water, and

whether it is high flow or ultra flow valve.

- 11 -

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NOTE: The notched water piston on the Ultra Flow and UFB-1 valve.

results in at least one orifice in the sleeve always open. This elimi-

nates pulsating and smooths water flow at higher flow rates.

Notch in

piston

In operation the liquid flows through the knife–edged orifice in the bottom

of the piston and then out the orifices in the sleeve. The outlet orifice size

in the sleeve is regulated by the position of the piston. In the illustration,

the piston is restricting approximately 1/2 of the outlet orifices.

FIGURE 17

UFB-1 Flow Module

Orifice

Sleeve

Piston

FIGURE 18

Lower Fluid Pressure BUT

Larger Orifice Openings

Higher Fluid Pressure BUT

Smaller Orifice Openings

Same Volume Of

Syrup/Water Flows

From Orifices

Higher Fluid

Lower Fluid

Pressure Pushing

Against Piston &

Spring

Pressure Push-

ing Against Pis-

ton & Spring

Knife

edge

Syrup/Water Flow

FIGURE 19

The position of the piston inside the sleeve is determined by the upward pressure of the liquid against the

base of the piston and the downward pressure of the spring inside the piston (not shown here). The

pressure of the spring is regulated by the adjusting screw.

If the pressure of the liquid increases, the flow rate through the knife–edged orifice will increase. The

piston is moved upward closing off more of the outlet orifices. The same flow rate is thereby maintained.

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Adjusting Flow Rates

Flow rates of the water and syrup are adjusted based on the desired ratio. For example: if the desired

ratio is 5:1, then the flow rate of the water is 5 times that of the syrup.

If the desired finished drink total flow rate is 3.0 ounces per second, then the water flow rate is 2.5 oz./

sec and the syrup flow rate is 0.5 oz./sec. (The water at 2.5 oz./sec is five times the 0.5 oz./sec syrup flow

rate.)

NOTE: Always adjust water within its range.

Water Flow Rates At Selected Ratios

Water To Syrup

Ratio

Water at 1.5 oz./ Water at 3.0 oz./ Water at 3.75 oz./ Water at 4.5 oz./

sec. Total Flow

2 to 1

3 to 1

4 to 1

5 to 1

6 to 1

7 to 1

1.00 oz./sec.

1.13 oz./sec.

1.20 oz./sec.

1.25 oz./sec.

1.29 oz./sec.

1.31 oz./sec.

2.00 oz./sec.

2.25 oz./sec.

2.40 oz./sec.

2.50 oz./sec.

2.57 oz./sec.

2.63 oz./sec.

2.50 oz./sec.

2.81 oz./sec.

3.00 oz./sec.

3.13 oz./sec.

3.21 oz./sec.

3.28 oz./sec.

3.00 oz./sec.

3.38 oz./sec.

3.60 oz./sec.

3.75 oz./sec.

3.86 oz./sec.

3.94 oz./sec.

Calculating Flow Rates

The most frequent ratio is 5:1. The charts above list the breakdown for many ratios and flow rates. It is

useful to be able to calculate flow rates when a chart is not available.

An example of calculating the water and syrup flow rates given the finished drink flow rate and the water

to syrup ratio:

Given:

1. Finished Drink Flow Rate = 3.0 oz./sec.

2. Water to Syrup Ratio = 5 to 1

To calculate Water Flow Rate:

1. Calculate the Total Portions = Water Portion + Syrup Portion

(example 5 + 1 = 6)

2. Calculate Syrup Flow Rate = Finished Drink Flow Rate ÷ Total Portions

(example 3.0 oz./sec ÷ 6 = .5 oz./sec)

3. Calculate Water Flow Rate = Finished Drink Flow Rate – Syrup Flow Rate

(example 3.0 oz./sec - .5 oz./sec = 2.5 oz./sec)

Prove the calculation is correct by adding water flow rate of 2.5 oz./sec + syrup flow rate of .5 oz./sec =

finished drink flow rate of 3.0 oz./sec.

Water flowing at 2.5 oz./sec and syrup flowing at .5 oz./sec achieves a ratio of 5:1 and 3.0 oz./sec. flow

rate.

Syrup/Concentrate

Syrup should always be precooled before setting the ratio. Syrup takes a path through the valve

parallel to the water path. It is introduced in the block, travels through a syrup flow control, banjo, valve

head and out the nozzle. Note, concentrate is not cooled.

High sugar syrups are more viscous (thicker) than diet syrups and consequently have more

pressure drop within a system. This pressure drop results in less flow at the valve and therefore a slower

fill time. Increasing the pump pressure will help overcome the pressure drop caused by high sugar

syrups.

- 13 -

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Setting Ratios

If the ratio varies and must be adjusted often, it is probably the result of a restricted syrup

system. It is then time to clean and sanitize the syrup tubing and cooling coils and check for other

problems such as syrup pumps, etc.

NOTE: Try raising the pressure on the pump before cleaning.

Set the water flow rate first, then adjust the syrup to the desired ratio. This gives the most accurate

valve flow setting possible. Measure the ratio and adjust the syrup flow, if necessary. This will result in

uniform flow, better carbonation retention, and improved drink quality.

When using a ratio cup always take these precautions to ensure accuracy:

•

After installing the separator tube, open the valve to fill the syrup tube before starting the ratio test.

Clean the cup thoroughly between tests so there is no carry–over from one test to the next.

Fill the cup to approximately 3/4 full and use approximately the same quantity for each test to ensure

accurate settings.

•

Take another sample to verify the settings.

Ratio Cup and Syrup Separator

FIGURE 20

NOTE: Valve troubleshooting information is available on page 39.

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SHURFLO

SHURFLOW OVERVIEW

SHURflo’s Beverage Gas Pump supplies syrup under pressure to a post-mix dispenser, which mixes the

syrup with water to an exact ratio (brix). The pump is used in conjunction with non-pressurized Bag-In-

Box (B-I-B) containers and a bag connector (Q.D.) fitting.

The pump can be operated on regulated C^O2, nitrogen or compressed filtered air. The compressed gas

drives the pump and is not in contact with the syrup. Separate syrup and gas chambers prevent

contamination, foaming, and purging of the tubing when the B-I-B has emptied.

The pump retains pressure in the outlet line, operating only when syrup is needed. When the dispenser

valve is opened, the pump reacts to the pressure drop by operating to maintain pressure in the line.

When the dispenser is closed, the incoming gas and output syrup pressures equalize and the pump

stops. Actual dynamic line pressure is dependant upon system losses as outlined in the section

"Pumping Capability".

The automatic "sold-out" feature within the pump ensures consistent syrup delivery right up to the

moment the B-I-B is empty. Vacuum produced by the pump evacuates the syrup within the bag. Once the

preset vacuum point is achieved and held, incoming gas pressure to the pump is shutoff causing the

outlet syrup pressure to drop to zero. When a new B-I-B is installed, the vacuum drops, the pump

automatically restarts and pressurizes the system. The SHURflo Beverage Gas Pump ensures quality

from the first drink to the last.

Beverage Gas Pumps are intended for soda syrups and low viscosity concentrates that do not contain

solids.

The use of a SHURflo Juice Pump (-09) is recommended for concentrates containing soft solids, classed

as round, up to 0.025 in. [0.6 mm] or that are of higher viscosity than soda syrups.

When concentrates contain pulp classed as long/stringy, seed particles or are exceptionally viscous, the

Particulate Juice Pump (-10) should be used as it can handle soft solids up to ^{1 /}4" [6 mm] cubed.

Standard gas pump models are for installations where geographic elevation is less than 5000 ft.[1523M].

For elevations above 5000 ft. specific high altitude models with a reduced sold-out spring rate must be

used to compensate for the loss in atmosheric pressure.

For further application and model information please contact SHURflo.

NOTE: Shurflow Troubleshooting information available on page 35.

- 15 -

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SHURFLOW INSTALLATION

•

As indicated on the pump, the outlet port is to be mounted up.

•

Pumps are to be mounted at the same level or higher than the B-I-B. The best choice is to have the

pump above the B-I-B.

•

INLET tubing from the B-I-B to the pump use; 3/8" I.D. [10mm] minimum, heavy wall (1/8"

[3mm]) clear, NSF listed vacuum tubing. Inlet tubing should not have excessive length. Tub-

ing that is allowed to drape down can trap air in the B-I-B creating a potential for pump "sold-

out" problems. The maximum vertical distance from the bottom of the B-I-B to the pump must

not exceed 5 ft [1.5 M ]. Maximum inlet tubing length is 10 ft. [3 M ].

•

If plumbing multiple B-I-B’s to a pump, B-I-B's should be "Teed" side-by-side horizontally,

rather than one on top of the other (vertically).

OUTLET tubing from the pump to the dispenser should be high pressure rated and NSF

listed. Consult "Pumping Capability" (see page 2) for appropiate tubing I.D.

Always cut CO2 and outlet tubing at least 2 ft. [.6 M] longer to provide a "service loop" so the

B-I-B rack can be moved for cleaning or service.

Use new (clean), 1/4" I.D. [6 mm], flexible, high pressure, braided tubing from the CO2 / air

regulator to the pump.

NEVER connect a transfer tank "system" in series with a B-I-B system. Syrup contaminants in

old components may work their way through the air supply causing premature failure of the gas

pump. Gas used to operate pumps MUST be clean and contain no contaminants (syrup, oil, rust,

water, etc). Air compressors may be used with proper particle filters and moisture separators. Air storage

tanks should be drained regularly. Pumps subjected to contaminated air are not covered by warranty.

High concentrations of CO2 can be fatal as it will displace the air from non-ventilated areas.

Pumps operated by CO²must be in ventilated areas.

If placed in a confined area (basement, closet, cooler box, etc.), exhaust fans capable of changing

the room air on a continuous basis should be used.

•

All tubing connections must be secured with stainless steel, stepless Oetiker clamps.

Cable-tie all tubing securely to prevent kinks or sags that inhibit performance or cause damage to the

pump fittings.

START-UP PROCEDURE

1. Confirm that all tubing connections are properly clamped, fittings are tight, and tubing is not kinked.

Install bag connector to the B-I-B.

2. Adjust gas regulator to about 20 psi. [1.4 bar] allowing the pump to stroke slowly.

3. Operate the valve until all air trapped within the tubing has been purged.

4. Once the air has been purged, adjust the CO2 regulator to the pressure necessary to main-

tain the desired brix. The most efficient gas usage occurs at 40 psi. [2.8 bar]. MAXIMUM

static gas pressure to the pump is 85 psi. [5.8 bar], minimum 20 psi. [1.4 bar].

Flowrates that result in a stroke-rate of more than two strokes per second will decrease pump

life. (Consult factory) Pump failure due to "overrunning" is not covered by the limited warranty.

To prevent air from entering the system always leave the bag connector attached to the empty

B-I-B until a new B-I-B can be installed. Air entered into the system, via air in the bags or

vacuum leaks, may cause brix fluctuation, foaming, spitting, non-operation of the vacuum sold-

out or pump "run-on" with the valve closed. Symptoms of this kind can lead to a misdiagnosis of the

pump.

Publication Number: TP01071

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PLUMBING

TYPICAL INSTALLATION

FIGURE 21. Typical Installation

- 17 -

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PLUMBING LAYOUT

Connection Legend

3/8" Female Fir Nut

3/8" Barb Conn

1/4" Barb Conn

3/8" Hose Barb - 3/4" NP

1/4" Female Flr Nut

Direct Conn to SUR

Outlet on BIB Pmp

Direct Conn to CO2

Inlet on BIB Pmp

Syr Inlet BIB Pmp

3/4" NPT TEE

CO2 Supply

Carb

Pump

Regulator

100 psi

Regulator

55-60 psi

Water Filter

BIB Syrup

BIB Pump

6-10 Brand

Flavors

BIB Pump

BIB Syrup

Tubing Legend

3/8" Bev Tubing

1/4" Bev Tubing

3/8" Tycon Tubing

FIGURE 22. Plumbing Layout

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DOUBLE CHECK

VALVE

FAUCETS

W1,

VALVES 1,2,

3,6

OPTIONAL

PRESSURE

REGULATOR

POTABLE

WATER

FILTER

SUPPLY

CARBONATOR

PUMP

INSTALL FOR

NON -CARB AS

REQUIRED

W2,

VALVES 4,5

CHECK

VALVE

NON -CARB

WATER

COLDPLATE

INLET

CONNECTIONS

OPTIONAL FOR

DIET DRINKS

OR ROOT BEER

5-15

PSIG

PLUGGED

75 PSI

PRESSURE

REGULATORS

SYRUP TANKS

15-50 PSIG

COLD PLATE

CO2

CYLINDER

ITEMS INSIDE BROKEN LINE

INCLUDED WITH UNIT

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DOUBLE CHECK

VALVE

FAUCETS

W1,

VALVES 1,2,

3,7,8

OPTIONAL

PRESSURE

REGULATOR

POTABLE

WATER

SUPPLY

FILTER

CARBONATOR

PUMP

INSTALL FOR

NON -CARB AS

REQUIRED

W2,

VALVES 4,

5,6

CHECK

VALVE

NON -CARB

WATER

COLDPLATE

INLET

CONNECTIONS

OPTIONAL FOR

DIET DRINKS

OR ROOT BEER

5-15

PSIG

75 PSI

PRESSURE

REGULATORS

SYRUP TANKS

15 -50 PSIG

COLD PLATE

CO2

CYLINDER

ITEMS INSIDE BROKEN LINE

INCLUDED WITH UNIT

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DOUBLE CHECK

VALVE

FAUCETS

OPTIONAL

PRESSURE

REGULATOR

VALVES 1,2

3,6,7,8

POTABLE

WATER

FILTER

SUPPLY

VALVES 4,5

CARBONATOR

INSTALL FOR

NON–CARB AS

REQUIRED

CHECK

VALVE

Non–Carb Water

COLDPLATE

INLET

CONNECTIONS

OPTIONAL FOR

DIET DRINKS

OR ROOT BEER

75 PSI

5–15

PSIG

COLD PLATE

SYRUP TANKS

15–50 PSIG

PRESSURE

REGULATORS

CO2

ITEMS INSIDE BROKEN LINE

INCLUDED WITH UNIT

Cylinder

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FLOW DIAGRAM 2XX (TEN FLAVOR MODELS))

CARBONATOR

TANK

FAUCETS VIEWED FROM THIS SIDE

FIGURE 26. Flow Diagram 2xx (Ten Flavor Models)

Publication Number: TP01071

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FAUCETS

DOUBLE CHECK

VALVE

COLD PLATE

OPTIONAL

PRESSURE

REGULATOR

S12

POTABLE

WATER

S11

S10

SUPPLY

FILTER

CARBONATOR

PUMP

INSTALL FOR

NON–CARB AS

REQUIRED

S10

CHECK

VALVE

COLDPLATE

INLET

NON–CARB WATER

S11

S12

CONNECTIONS

TO COLDPLATE

SYRUP INLETS

FAUCETS

COLD PLATE

CO2

75 PSI

COLDPLATE

INLET

OPTIONAL FOR

DIET DRINKS

OR ROOT BEER

5–15

CONNECTIONS

S12

S11

S10

PSIG

SYRUP TANKS

15–50 PSIG

PRESSURE

REGULATORS

CO2

CYLINDER

ITEM INSIDE BROKEN LINE

INCLUDED WITH UNIT

CARBONATOR TANK

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ELECTRICAL SECTION

Control Box Single Transformer Will Power

up to Three Valves Simultaneously.

Transformer

FIGURE 28. Electrical Box 1xx Single Transformer

One Transformer Powers the Left Bank

FIGURE 29. Electrical Box 2xx Single Transformer

and the Other Powers the Right Bank.

Will Power All Valves Simultaneously.

Transformers

FIGURE 30. Electrical Box 2XX Dual Transformer

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CARBONATOR WIRING DIAGRAM

- 25 -

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Publication Number: TP01071

SERVICE INFORMATION

TO HINGE

MOTOR

DANGER!

ELECTRIC SHOCK HAZARD. DISCONNECT

POWER BEFORE SERVICING UNIT.

CCW

AGITATOR

MOTOR

HEATER

GRN

TO BEVERAGE FAUCET

DISPENSE

SWITCH

Q.C.

GATE

CONNECTOR

SOLENOID

(106VDC)

KEY SWITCH

T’STAT

GRD

115V

SUPPLY

LIGHT

YELLOW

- -

RED

BLUE

B B B B B

L L

YELLOW

A A A U U

WHT

C C C E E

K K K

W G

WHITE

H R

ICE LEVEL

OPTION

C T E

E N

BLACK

WHITE

BLACK

OPTIONAL

WHITE

BLACK

RED

PINK

OPTIONAL

NOCOM

WHITE

BLACK

OPTIONAL

PINK

RED

COM

WHITE

BLUE

WHITE

BLACK

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SCHEMATIC 1XX

TIMER

MOTOR HEATER

A GITATOR MOTOR

N.O.

N.C.

VEND SWITCH

CA PA CITOR

RECTIFIER

GATE

SOLENOID

OPTIONA L

B A LLA ST

OPTIONA L LIGHT

OPTIONA L

STA RTER

B EVERA GE TRA NSFORMER

OPTIONA L LOW ICE LEVEL

LIGHT

T’STAT

B EVERA GE

VA LVES

B EVERA GE

VA LVES

B EVERA GE PA NEL

FIGURE 32. Schematic 1xx

- 27 -

Publication Number: TP01071

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MOTOR

HEATER

T’STAT

LIGHT

AGITATOR

MOTOR

SERVICE INFORMATION

BLUE

GRN

ICE LEVEL SIGNAL

OPTION

DANGER! ELECTRIC SHOCK HAZARD. DISCONNECT

POWER BEFORE SERVICING UNIT.

Q.C. CONNECTOR

TO BEVERAGE VALVES

TO 24V

TRANSFORMER

TO HINGE

DISPENSE

SWITCH

GATE

SOLENOID

(106VDC)

KEY SWITCH

BLUE

YELLOW

OPTIONAL

LIGHT BALLAST

BLACK

RED

BLACK

MOTOR START

CAPACITOR

BEVERAGE

TRANSFORMER

(OPTIONAL)

E C

BLACK

TRANSFORMER

(OPTIONAL)

WHITE

BLACK

B B

WHITE

U U

E E

WHITE

RECTIFIER

WHITE

BLACK

MOTOR

START

RELAY

BLACK

WHITE

COM

- -

AGITATION

TIMER

W B

OPTIONAL

LIGHT

STARTER

NOCOM

C T

WHITE

BLACK

WHITE

BLACK

WHITE

OPTIONAL

LIGHT SOCKET

OPTIONAL

LIGHT SOCKET

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WIRING DIAGRAM 2XX (220/240V MODELS)

BLK

FIGURE 34. Wiring Diagram 2xx (220/240V Models)

- 29 -

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WIRING DIAGRAM 2XX (220/240V MODELS)

TIMER

RECTIFIER

MOTOR HEATER

AGITATOR MOTOR

N.O.

N.C.

VEND SWITCH

GATE

SOLENOID

OPTIONAL

BALLAST

OPTIONAL LIGHT

OPTIONAL

STARTER

OPTIONAL

BEVERAGE TRANSFORMER

OPTIONAL ICE LEVEL

OPTIONAL

BEVERAGE

VALVES

OPTIONAL

BEVERAGE

VALVES

BEVERAGE PANEL

FIGURE 35. Wiring Diagram 2xx (220/240V Models)

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WIRING DIAGRAM 300 (220/240V MODELS)

FIGURE 36. Wiring Diagram 300 (220/240V Models)

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WIRING DIAGRAM 300 (220/240V MODELS)

FIGURE 37. Wiring Diagram 300 (220/240V Models)

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SCHEMATIC 300 (120V MODELS)

TIMER

RECTIFIER

MOTOR HEATER

AGITATOR MOTOR

N.O.1

VEND SWITCH

N.C.1

CAPACITOR

GATE

SOLENOID

BALLAST

OPTIONAL LIGHT

STARTER

OPTIONAL

BEVERAGE TRANSFORMER

OPTIONAL ICE LEVEL

OPTIONAL

BEVERAGE

VALVES

BEVERAGE PANEL

MOTOR HEATER

AGITATOR MOTOR

N.O.2

VEND SWITCH

N.C.2

CAPACITOR

GATE

SOLENOID

BALLAST

OPTIONAL LIGHT

STARTER

OPTIONAL

BEVERAGE TRANSFORMER

OPTIONAL ICE LEVEL

OPTIONAL

BEVERAGE

VALVES

BEVERAGE PANEL

FIGURE 38. Schematic 300 (120V Models)

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SCHEMATIC 300 (220/240V MODELS)

EMC

LINE

FILTER

E–BOX GD.

MOTOR HEATER

TIMER

RECTIFIER

GATE

SOLENOID

POWER

PUSH BUTTON

SWITCH

N.C1

VEND SWITCH

N.O1

AGITATOR MOTOR

OPTIONAL

BALLAST

OPTIONAL LIGHT

OPTIONAL STARTER

OPTIONAL

BEV. TRANSFORMER

BEVERAGE

KEYLOCK SWITCH

24V

BEV. FAUCETS

EMC

GATE

SOLENOID

N.C2

VEND SWITCH

N.O2

AGITATOR MOTOR

OPTIONAL BALLAST

OPTIONAL LIGHT

OPTIONAL STARTER

OPTIONAL BEV. TRANSFORMER

24V

BEV. FAUCETS

FIGURE 39. Schematic 300 (220/240V Models)

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TROUBLESHOOTING

SHURFLOW TROUBLESHOOTING

Pumping Capability

The distance syrup can be delivered is

MAXIMUM HORIZONTAL TUBING

limited by inherent factors (restrictions) within

the inlet & outlet sides of the beverage

dispensing system. Due to variances in

system configuration and equipment, an

accurate determination of pressure drop is

difficult. Before deciding on a system’s

tubing size, SHURflo recommends

estimating system losses by considering the

following:

LENGTHS VISCOSITY

Distances shown are intended as a guidline only.

(cPs.=Centipose)

¹/"I.D.

[6m m ]

³/"I.D.

[10m m ]

¹/"I.D.

[13m m ]

FLOW RATE

/SEC.

OZ.

m L

15 500+ 152+ 500+ 152+ 500+ 152+

Feet Meter Feet Meter Feet Meter

.75

1.0

1.5

2.0

2.5

3.0

3.5

22.5 500

152 500+ 152+ 500+ 152+

138 500+ 152+ 500+ 152+

453

212

102

Diet

Soda

Syrup

(5 cPs. 3)

500+ 152+ 500+ 152+

152 500+ 152+

500

398

297

212

500

388

193

127

500

345

239

127

•

Syrup viscosity and temperature (coldplate,

re-circ., etc.).

121 500

152

500

Total syrup flow rate of valve(s) connected

to a pump.

105

500

152

152 500+ 152+

.75

1.0

1.5

2.0

22.5 133

Standard

Soda

Syrup

(20 cPs. 3)

Inside diameter of the inlet/outlet tubing,

fittings, bag connector, etc.

118

500

366

152

112

Horizontal & vertical distance of the outlet

tubing.

129

152 500+ 152+

105 500+ 152+

Heavy

Soda

Syrup

(35 cPs. 3)

.75

1.0

1.5

22.5

Vertical tubing runs will reduce total achievable

tubing run length. To estimate the losses within

the vertical distance, use the chart to the

right. Take 1% of the distance in feet [3% if

meters]. The resulting number is multiplied by

the vertical distance. This product is then

subtracted from the maximum horizontal

distance. The resulting length is the total

horizontal/vertical (horz./vert.) tubing run that is

obtainable for that flow rate, tubing I.D. and

viscosity.

500

425

152

129

Distances shown are the results of tests conducted at 70°F

[21°C] ambient with a static pressure of 85 psi. [5.8 bar] to the

pump. All distances assume a dynamic pressure of 35 psi. [2.38

bar] at the dispenser to maintain brix.

For example:

FAST FLOW VALVE

oz./sec. [15 mL]

(syrup flow only)

GAS IN

/₈" I.D. [10mm]

TUBING

22 ft. [6.7M]

VERTICAL

TOTAL TUBING RUN

HEAVY SODA

370 ft. [113M]

SYRUP

/₈" I.D. [10mm]

TUBING (min.)

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The chart indicates that heavy syrup with 1/2 oz./sec [15mL] flow-rate (per the illustration) can be

sustained over a horizontal distance of 500 ft. [152M] when 3/8" I.D. [10mm] tubing is used.

Feet: Take 1% of 500 ft. (500 x 1%) = 5. Which then is multiplied by the 22 ft. vertical, (22 x 5) =

110 ft.

Subtract this product from the 500 ft. (500 - 110) =390. The results indicate a 390 ft. tubing run

(horz./vert.) is possible, while the example only requires a distance of 370 ft.

Meters: Take 3% of 152M (152 x 3%) = 4.56. Which then is multiplied by the 6.7M vertical, (4.56 x

6.7) = 30.5M.

Subtract this product from the 152M (152-30.5)=121.5. The results indicate a 121.5M tubing run

(horz./vert.) is possible, while the example only requires a distance of 113M.

NOTE: Had the example above resulted in a value that was equal to, or less than the nec-

essary total tubing run, consider a larger I.D. tubing or installation of a pump(s) in series

using a SHURflo Vacuum Regulator.

Pumps in Series for Long Distances

Long tubing runs or high vertical lift can be achieved by installing pumps in series. Standard

SHURflo Beverage pumps are not designed to have positive pressure on the inlet side. The

SHURflo Vacuum Regulating Valve (VRV) allows the pump to receive liquid from a pressurized

source. By positioning a VRV at the inlet of the secondary pump, incoming pressure is reduced

to zero, permitting syrup to be drawn in under vacuum.

SHURflo can recommend several other methods to meet the requirements for a particular installation,

including Pressurized Inlet Pumps or Accumulators. Contact SHURflo for more information.

FIRST

PUMP

TO NEXT

VRV/PUMP

SECOND

PUMP

GAS IN

DISPENSER

B-I-B

VRV

GAS TO NEXT

PUMP

Pump Sanitizing / Winterizing

Sanitization of the SHURflo Beverage Gas Pump is required. The frequency of Sanitization is

dependant on the concentrate type and its manufacturer’s requirements. Factors which also

affect the frequency of this procedure are: temperature, concentrate volatility, facility conditions,

installation and equipment. The sanitizing procedure fulfills a required 10 minute contact time

with a 200 ppm Sodium Hypochlorite solution. Refer to SHURflo Service Bulletin #1025 for the

N.S.F. listed sanitizing procedure for the SHURflo pump (only). Pumps that are subjected to

freezing (below 32° F [0°C]) must be purged of fluid to prevent damage. Refer to SHURflo

Service Bulletin #1025 for complete winterizing procedure. Refer to the equipment

manufacturer’s instructions for sanitizing and winterizing procedure for carbonators, dispensers

and tubing.

Pumps that have been winterized and/or out of service for a period of time should be sanitized prior to

being placed back in service.

Never apply pressure to the pump’s liquid inlet. Pressurized tanks may damage internal

components if used to sanitize or purge fluid from the pump (operating or not).

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Pump Troubleshooting

DOES NOT OPERATE / GAS APPLIED / DISPENSER VALVE OPEN

•

B-I-B empty or inlet tubing pinched off activating vacuum "sold-out".

Gas regulator over-pressurizing. (Pump stalled)

Outlet tube kinked or restricted.

Operated without fluid for excessive period. (Dry run)

Transfer tube and gas lines contaminated (syrup, rust, oil, etc.) [ensure clean gas supply, change

out all contaminated pumps]

•

Internal damage of control cover.

OPERATES BUT WILL NOT PRIME / DISPENSER VALVE OPEN

[consult Start-up Procedure for proper priming]

•

Pump valves have no moisture/dry (add water/syrup to the inlet port with pump stroking slowly).

Vacuum leaks at Q.D., barb fitting clamps, or inlet fitting o-ring.

Debris in valve seats or warped/swollen valves.

DOES NOT ACHIEVE SOLD-OUT WITH EMPTY B-I-B

•

Vacuum leaks at Q.D., barb fitting clamps, or inlet fitting o-ring.

Excessive amount of air in B-I-B from improper packaging.

Air trapped in outlet tubing and/or pump fluid chambers.

AIR IN INLET AND/OR OUTLET TUBING

•

Vacuum leaks at Q.D. o-ring or barb fitting clamps.

Vacuum leaks at inlet fitting; o-ring pinched or missing.

Large amounts of air noticed only in the outlet tubing when pump operates (diaphragm/piston assem-

blies ruptured).

STROKES WITH DISPENSER VALVE CLOSED

•

Air trapped in outlet tubing and/or pump fluid chambers (open outlet and purge air, check for vacuum

leaks, or air in B-I-B).

•

Debris in outlet valves or warped/swollen valves.

FLUID FROM EXHAUST OR VISIBLE WITHIN GAS INLET TUBING

•

Carbonator check valve.

Ensure clean gas supply.

Diaphragm/piston assemblies ruptured.

[change out all contaminated pumps]

GAS BLOWING FROM EXHAUST CONTINUOUSLY

•

Control cover subjected to contaminated gas supply or damaged (ensure clean gas supply, change

out all contaminated pumps).

- 37 -

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DISPENSER TROUBLESHOOTING

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.

Trouble

BLOWN FUSE OR CIRCUIT

BREAKER.

Probable Cause

A. Short circuit in wiring

Remedy

A. Repair wiring.

B. Inoperable gate solenoid.

B. Replace gate solenoid.

C. Inoperable agitator motor.

A. No power.

C. Replace agitator motor.

A. Restore power.

GATE DOES NOT OPEN.

AGITATOR DOES NOT

TURN.

B. Bent depressor plate (does not

actuate switch).

B. Replace depressor plate.

C. Inoperable dispensing switch.

A. Inoperable gate solenoid.

C. Replace dispensing switch.

A. Replace gate solenoid.

GATE DOES NOT OPEN OR

IS SLUGGISH. AGITATOR

TURNS.

B. Excessive pressure against gate

slide.

B. Adjust gate slide.

C. Replace rectifier.

C. Inoperable rectifier.

A. Stuck or bent depressor plate

(does not release switch).

ICE DISPENSES CONTINU-

OUSLY.

A. Replace depressor plate.

B. Inoperable dispensing switch.

C. Improper switch installation.

B. Replace dispensing switch.

C. Make sure switch is installed

properly.

A. Unplug drain.

SLUSHY ICE. WATER IN

HOPPER.

A. Blocked drain.

B. Unit not sitting level.

B. Level the unit.

C. Poor ice quality due to water qual- C. Correct water quality or repair ice-

ity or icemaker problems.

maker.

D. Improper use of flaked ice.

A. No 24 volts power to faucets.

D. Call Service Person.

BEVERAGES DO NOT DIS-

PENSE

A. Restore 24 volt power to faucets.

B. No CO 2 pressure.

A. Carbonator not operating.

B. Restore CO 2 pressure.

A. Repair carbonator.

BEVERAGES TOO SWEET

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VALVE TROUBLESHOOTING

Excess Foam

Problem:

excess foam

Check

product

temperature

Check

system

Temp

above 40°

below 40°

Remove

nozzle

Check flow

Clean

yes

rates

Check

system

Correct

yes

Clean

Problem

corrected

Set flow rate

and ratio

Problem

corrected

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Off Taste

Problem:

off taste

Remove

nozzle

Clean

yes

Check ratio

Check

system

Correct

yes

Clean

Problem

corrected

Set ratio

Problem

corrected

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Valve Stuck Open

Problem: valve

stuck open

Check

solenoid

visually

Check for

damaged

banjos

working

yes

(solenoid up)

(solenoid down)

Undetermined

problem call

800-238-3600

Damage

Check for

power at

solenoid

yes

Replace

dispensing

switch

Replace

banjos

Power

yes

Problem

corrected

Clean or

replace

solenoid

Problem

corrected

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No Product

Problem:

no product

Check

solenoid

visually

Check

system

Working

yes

Check

voltage

(22-27 AC)

Check

transformer

Check

resistance

of coil

Power

yes

Replace

switch

Check

switch

Check

system

40 ohms

yes

Problem

corrected

Replace

solenoid

Problem

corrected

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CARBONATOR TROUBLESHOOTING

WARNING: Disconnect electrical power to the unit to prevent personal injury before attempting any

internal maintenance. Only qualified personnel should service the internal components or the elec-

trical wiring.

If repairs to the carbonated water or the plain water systems must be made, disconnect electrical

power to the Unit, then shut off CO2 and plain water sources. Dispense from dispensing valve until

carbonator tank CO2 pressure has been relieved.

Trouble

Probable Cause

Remedy

CARBONATOR WILL NOT

A. Power cord unplugged or circuit

breaker open in panel box.

Inoperative carbonator.

A. Plug in power cord or reset circuit

OPERATE.

breaker.

B. Call a qualified Service Person.

A. Call a qualified Service Person.

B. Inoperative carbonator.

A. Carbonator internal problem.

WATER PUMP MOTOR

WILL NOT SHUT OFF.

ERRATIC CYCLING OF

A. Carbonator internal problem.

CARBONATOR.

WATER PUMP MOTOR

OPERATES BUT WATER

PUMP DOES NOT PUMP

WATER.

A. Carbonator internal problems or a

water supply line problem.

A. Call a qualified Service Person.

CARBONATOR CARBON-

ATED WATER CAPACITY

TOO LOW

A. Carbonator internal problems or a

water supply line problem.

A. Call a qualified Service Person.

B. Replace water filter.

B. Water filter clogged.

Solid State Carbonator Level Control

MATING CONNECTION

GREEN

ORANGE

RED

GROUND

TERMINAL

WIRING

HARNESS

PROBE ASS’Y

SHORT ELECTRODE

LONG ELECTRODE

CARBONATOR TANK

CARBONATED LIQUID

LEVEL CONTROL

FIGURE 40

NOTE: Carbonators that are equipped with a pump safety thermostat will have a black wire

instead of green connected to the C terminal.

Test Solid State Level Control

2ND JUMP

1. Remove all wires and:

Carb. motor should run.

1ST JUMP

2. Jumper C to HI:

HI ORANGE

LO RED

Carb. motor should stop. Do not remove jumper wire.

3. Jumper LO to C:

Motor should remain stopped.

4. Remove 1st jumper from C and HI:

Motor should remain stopped.

FIGURE 41

5. Remove 2nd jumper from C and LO:

Motor should start.

If level control passes all above test, replace probe.

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IMI Cornelius Inc.

www.cornelius.com

800-238-3600

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