Cornelius Beverage Dispenser TP01070 User Manual

®
FLAVORFUSION®/  
FLAVOROVERLOAD  
Training Manual  
Publication Number: TP01070  
Revision Date: November 16, 2007  
Revision: F  
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FlavorFusion®/FlavorOverload Training Manual  
TABLE OF CONTENTS  
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Programming Mode Flashing Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Setting Water Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Adjusting Syrup/Water Ratio (Brix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
Setting a Button to Dispense Non-carbonated Water Only . . . . . . . . . . . . . . . . . 5  
Setting a Button to Dispense Carbonated Water Only . . . . . . . . . . . . . . . . . . . . 5  
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Control Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Carbonator Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
System Plumbing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Plumbing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
Interface Board and Harness Pin-out Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
Point-Point Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
Ladder Type Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
Diagnostics Guide for the Main Control Board (see FIGURE 22) . . . . . . . . . . . . . . 19  
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PRODUCT OVERVIEW  
Brand density - 16 brands (14 chilled, 2 ambient) plus up to 8 bonus flavors in 30” wide;  
255 lbs capacity cube ice only hopper;  
Internal cold carbonation with remote pump;  
Total carb/non-carb flexibility on each brand;  
Eye catching merchandising;  
Improved serviceability of agitator motor;  
Bonus flavors programmable for 1-4 second dispense;  
Valve positions programmable without special tools or PDA;  
Front inlet fittings;  
Key lock switch;  
10” cup clearance;  
30% more drip tray capacity;  
THEORY OF OPERATION  
The FlavorFusion®/FlavorOverload machine is an above counter ice/beverage unit with multi flavor  
nozzles and the capability to inject bonus flavors into the finished drink.  
The beverage is cooled via ice melting on an aluminum cold plate. Ice is kept on the cold plate by  
means of an opening in the hopper that drops ice onto the surface during agitation of the ice in the  
hopper.  
The unit contains a mechanical ice chute and gate mechanism.  
The ice agitation gear motor is removable from the gear box to ease removal of the motor during ser-  
vice and lower repair cost.  
The unit has six nozzles for dispensing brand and bonus flavors.  
Each brand nozzle serves four discreet flavors fed by four syrup valves, one plain water, and one carb  
water valve. Every position is flexible for use with either carb or non-carb water.  
Each bonus nozzle serves four individual flavors intended for injection into the finished drink. Bonus  
nozzles are fed by four syrup valves only. There is no option to dispense water out of the bonus nozzle  
without significant plumbing changes.  
Bonus flavors require a separate regulator setting on their BIB pumps (20 psi maximum).  
Brand and bonus flavors are controlled by means of six interface boards (one interface board per noz-  
zle). The interface boards are common for each nozzle. Valve positions are configured on the mem-  
brane switch. No special tool or PDA is required.  
Valve flow rates are adjustable for 3.0-3.75 oz/sec finished drink dispense rate.  
Unplug the unit or turn off the key switch before attempting any electrical service on the unit, failure to  
do this can cause damage to the electrical components!  
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SYSTEM REQUIREMENTS  
Dimensions (in): . . . . . . . . 29 x 30 x 39 (l x w x h). Height is measured to top of bin. Lid adds 3 in to  
height.  
Counter Weight (lb): . . . . . 320 (plus ice weight)  
Shipping Weight (lb): . . . . 330  
Capacity: . . . . . . . . . . . . . 250 lb ice bin capacity (cube ice only)  
Indoor installation only  
40 to 90 oF ambient temperature  
Electrical Rating:. . . . . . . . 103-132 Volts  
11 Amps  
Water supply pressure: . . 50-60 psi at pump  
Water volume: . . . . . . . . . 125 gph  
CO2: . . . . . . . . . . . . . . . . . 75 psi at carbonator tank  
Syrup (brands): . . . . . . . . 60 psi min  
Syrup (bonus): . . . . . . . . 20 psi max  
Syrup supply lines: . . . . . . .375” ID tubing min  
NOTE: If water pressure is below 50 psi a water pressure booster is required for still water drinks.  
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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 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 should be used. For Bonus  
Flavor Keypads, dispense types 3 through 6 are used. The six (6) dispense types are described below,  
and shown in a timing diagram in FIGURE 1:  
Dispense Type 1, Carbonated water dispense: Solid LED  
Dispense Type 2, Non-carbonated dispense: Flashing LED 1.5 seconds ON, 1.5 seconds OFF  
Dispense Type 3, 1-second flavor shot: LED flashes once for ¼ second, followed by 3 seconds  
OFF  
Dispense Type 4, 2-second flavor shot: LED flashes twice for ¼ second ON, ½ second OFF,  
followed by 3 seconds OFF  
Dispense Type 5, 3-second flavor shot: LED flashes three (3) times for ¼ second ON, ½ second  
OFF, followed by 3 seconds OFF  
Dispense Type 6, 4-second flavor shot: LED flashes four (4) times for ¼ second ON, ½ second  
OFF, followed by 3 seconds OFF  
Start  
proramming  
mode  
Exit  
programming  
mode  
1. Carbonated water dispense  
2. Non-carbonated dispense  
3. 1-second flavor shot  
4. 2-second flavor shot  
5. 3-second flavor shot  
6. 4-second flavor shot  
0
1
2
Time  
3
4
5
(seconds)  
FIGURE 1  
NOTE: It is possible to program a flavor shot into a keypad. It is also possible to program a cove  
dispense (type 1 or 2) into a flavor shot keypad. Both instances result in an incorrect operation  
and should be corrected.  
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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.  
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 2), empty ratio cup, and  
repeat step 3. Otherwise empty ratio cup  
and repeat step 3 using the right program  
button for plain water.  
FIGURE 2. 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)  
Drink Icon  
Bonus Flavor Icon  
Bonus Flavor Button 1  
Bonus Flavor Button 2  
Brand Flavor Button 1  
Brand Flavor Button 2  
Bonus Flavor Button 3  
Bonus Flavor Button 4  
Brand Flavor Button 3  
Brand Flavor Button 4  
Bonus Flavor Nozzle  
Brand Flavor Nozzle  
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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.  
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.  
Repeat for all syrups in valve bank.  
6.  
Exit 4 second pour mode by simultaneously pressing and holding Flavor 1 and Flavor 4  
buttons until the flash pattern for all for buttons changes.  
7. Exit programming mode by simultaneously pressing and holding both programming buttons  
for 4 seconds.  
Setting a Button to Dispense Non-carbonated Water Only  
1.  
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.  
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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  
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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  
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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  
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VALVE SERVICE  
NOTE: Before servicing the valve the BIB connector must be disconnected an the pressure must  
be relieved.  
1. Remove the locking screw after removing the valve from its mounting block.  
2. Twist the solenoid 90o.  
Locking Screw  
Spring Clip  
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  
Control Probes  
Grounding Connection/  
CO2 Inlet  
Always disconnect water and CO2 and relieve  
the carbonator pressure before removing the car-  
bonator probe.  
Relief  
Valve  
FIGURE 20  
MOTOR REMOVAL  
Heater, Agitation  
Motor, & Gear Box  
Heater Spring  
NOTE: Apply anti seizing lubricant to the  
threads of mounting bolts when service is  
required.  
Motor  
Mounting  
Screws  
FIGURE 21  
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SYSTEM PLUMBING DIAGRAM  
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PLUMBING DIAGRAM  
CARB TANK IN  
CARB TANK OUT  
PW  
CW  
CW  
PW  
PLAIN WTR IN  
CARB WTR IN  
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INTERFACE BOARD AND HARNESS PIN-OUT DETAIL  
S
4
S
2
C
W
P
W
S
3
S
1
C
C
C
C
9
C
6
C
1
12  
11  
10  
8
7
5
4
3
2
CW  
S3  
S1  
PW  
S4  
S2  
TO SOLENOID VALVES  
INTERFACE BOARD DETAIL  
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POINT-POINT WIRING DIAGRAM  
W H T  
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 _  
W H T  
Y E L  
L 2 _ I N  
R E D  
H E A T R  
B A L S T  
L 2 _  
L 2  
B L K  
W H T  
Y E L  
B L K  
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  
Y E L  
B L K  
G R N  
W H T  
Y E L  
Y E L  
W H T  
W H T  
R E D  
Y E L  
B L K  
W H T  
W H T  
B L U  
B L K  
W H T  
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LADDER TYPE WIRING DIAGRAM  
L1  
N
KEY SWITCH  
BEV. X-FRMR  
24V  
24V  
INTERFACE  
BOARD-1  
INTERFACE  
BOARD-4  
INTERFACE  
BOARD-2  
INTERFACE  
BOARD-5  
INTERFACE  
BOARD-3  
INTERFACE  
BOAR-6  
BALLAST  
LIGHT  
STARTER  
SWITCHING PERFORMED  
ON PC BOARD  
CARB MOTOR  
RELAY  
CARB MOTOR  
BLK  
BLK  
AGIT TIMER  
RELAY  
YELLOW  
BRN  
BRN  
RED  
ORG  
ORG  
WHT  
AGIT MOTOR  
ICE DISP.  
SWITCH  
AGIT HEATER  
WIRING LADDER SCHEMATIC 115V-
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TROUBLESHOOTING  
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.  
WARNING: If repairs are to be made to a product system, remove quick disconnects from the  
applicable product tank, then relieve the system pressure before proceeding. If repairs are to be  
made to the CO2 system, stop dispensing, shut off the CO2 supply, then relieve the system  
pressure before proceeding. If repairs are to be made to the electrical system, make sure  
electrical power is disconnected from the unit or the key switch has been turned off.  
Should your unit fail to operate properly, check that there is power to the unit and that the hopper  
contains ice. If the unit does not dispense, check the following chart under the appropriate symptoms to  
aid in locating the defect.  
Troubleshooting the LED Lighting on Customer Interface Keypad (see page 19)  
Symptom  
Cause  
Remedy  
1
Bonus Flavor Icon and/  
or Drink Icon LEDs (see  
FIGURE 3) are ON  
continuously with four  
quick flashes every 30  
seconds.  
A. This indicates a poor  
connection in the lighting  
synchronization harness  
that connects the interface  
boards together.  
A. Turn the keyswitch to disconnect  
power to the interface boards. Check the  
electrical connections between the  
harnesses that interconnect the right  
side of all interface boards together. Turn  
back the keyswitch to reconnect power.  
2
3
Bonus Flavor Icon and/  
or Drink Icon LEDs (see  
FIGURE 3) are not in  
sync with the lighting  
sequence,  
B. This may result over time  
as the lighting sequence  
between push button pads  
can become slightly out of  
synchronization.  
B. Unplugging the unit and performing a  
power up will re-synchronize the lighting  
sequence.  
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.  
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Dispenser Troubleshooting  
Cause  
Symptom  
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  
Restore 24 VAC to valves  
Beverage does not  
dispense  
No 24VAC 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  
Publication Number: TP01070  
- 16 -  
© 2004-2007, IMI Cornelius Inc.  
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FlavorFusion®/FlavorOverload Training Manual  
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  
Syrup supply is empty  
Replace water booster tank/bladder  
Replace BIB  
No Syrup or  
Watered down drink  
dispensed  
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 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.  
© 2004-2007, IMI Cornelius Inc.  
- 17 -  
Publication Number: TP01070  
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FlavorFusion® Training Manual  
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  
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.  
overfills, overflows  
through relief valve,  
and pump shuts off  
after 5 minutes.  
B. Broken wires between carbonator  
tank and main control board  
B. Replace wire harness  
C. Defective liquid level probes  
C. Replace both liquid level probes  
Publication Number: TP01070  
- 18 -  
© 2004-2007, IMI Cornelius Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FlavorFusion®/FlavorOverload Training Manual  
DIAGNOSTICS GUIDE FOR THE MAIN CONTROL BOARD (SEE FIGURE 22)  
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  
carbonator pump.  
Able to continue to  
function but  
Check the harness  
connections of the red  
signal wire at both ends:  
1) at the carbonator ring  
terminal and  
2) at Pin 5 of the J4  
connector at the main  
control board  
continuously,  
but “flickers”  
every 3  
carbonator pump  
short-cycles. Pump  
will come on each  
time a drink is drawn.  
THIS SITUATION  
SHOULD BE  
seconds  
CORRECTED.  
THIS IS AN ERROR  
CONDITION.  
ON  
continuously  
Entered when pump has  
run continuously for 5  
minutes  
Unplug the unit and plug it  
back in. This will reset the  
unit's main control board  
and restart the carbonator  
pump.  
LED  
FIGURE 22  
© 2004-2007, IMI Cornelius Inc.  
- 19 -  
Publication Number: TP01070  
Download from Www.Somanuals.com. All Manuals Search And Download.  
IMI Cornelius Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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