Cornelius UF 1 User Manual

UF-1 AND UFB-1 VALVES  
TRAINING MANUAL  
CARBON DIOXIDE  
WATER  
SYRUP/CONCENTRATE  
MECHANICAL  
REFRIGERATION  
CONTROLS & ELECTRICAL  
UF-1 and UFB-1 Valves Training Manual  
UF-1 and UFB-1 VALVES  
TRAINING MANUAL  
The products, technical information, and instructions contained in this manual are subject to  
change without notice. These instructions are not intended to cover all details or variations of the  
equipment, nor to provide for every possible contingency in the installation, operation or mainte-  
nance of this equipment. This manual assumes that the person(s) working on the equipment have  
been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical  
equipment. It is assumed that appropriate safety precautions are taken and that all local safety and  
construction requirements are being meet, in addition to the information contained in this manual.  
To inquire about current revisions of this and other documentation or for assistance with any Cor-  
nelius product contact:  
IMI Cornelius Inc.  
Internet:  
Email:  
Trademarks and copyrights:  
Aurora, Cornelius, Decade, Hydro Boost, Optifill, Sitco, Spirit, UF-1, Vanguard, Venture, and  
Vista are registered trademarks of IMI Cornelius Inc.  
This document contains proprietary information and it may not be  
reproduced in any way without permission from Cornelius.  
Printed in U.S.A.  
Copyright © 1999-2005, All Rights Reserved, IMI Cornelius Inc.  
UF-1 Valves Manual  
NOTES:  
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UF-1 and UFB-1 Valves Training Manual  
TABLE OF CONTENTS  
UF-1 OptifillTM Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14  
OptifillTM Valve Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
UF-1 and UFB-1 Valves Training Manual  
INTRODUCTION  
1. PREVIEW QUESTIONS  
Check your current knowledge by taking a few minutes to answer the following questions:  
1. What are the flow capacities of a UF-1 valve? _____________________________________  
__________________________________________________________________________  
2. What are the flow capacities of a UFB-1 valve? ____________________________________  
__________________________________________________________________________  
3. Which syrup has the greatest pressure drop, diet or sugar?____________________________  
__________________________________________________________________________  
4. How do juice valves differ from carbonated beverage valves? _________________________  
__________________________________________________________________________  
5. Can you program “top-off” on a portion control valve? ______________________________  
__________________________________________________________________________  
6. What components must be replaced when retrofitting SF-1 to UF-1 valves? ______________  
__________________________________________________________________________  
2. KEY THINGS TO KNOW / DO  
• For quality drinks — keep the nozzles and the water/syrup system clean; and have the correct  
ratio, temperature, and carbonation!  
• Set the water/syrup ratio accurately — and leave it alone!  
• To set the ratio accurately, set the water flow first, then the syrup!  
• Be sure to cool below 40°F the syrup and water before setting the ratio.  
© 1999-2005, IMI Cornelius, Inc.  
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UF-1 and UFB-1 Valves Training Manual  
3. OVERVIEW  
3.1 Product Description  
The UF-1 and UFB-1 valve provides accurate flow capability and dependability. The UF-1  
and UFB-1 valves are capable of flow rates of 1 ½ to 3 ounces per second (high flow), 2 to  
4 ounces per second (UFB-1), or 3 to 4 ½ ounces per second (ultra flow). The valve flow  
control modules are the only parts that differ in the three versions.  
Note: The flow rate is also dependent on the capacity of the dispensing, cooling, and  
carbonation systems. An ultra flow capacity valve will not make up for a slow  
system flow rate or inadequate supplies of cooled water and syrup. The following  
is a list of Cornelius units and the valve flow rates they support:  
Fast Flow  
1.5 to 3.0 oz./sec.  
Fast Flow, UFB-1, or Ultra Flow  
2 to 4 oz./sec. or 3.0 to 4.5 oz./sec.  
Vanguard  
Vanguard 245  
Value Line 2323 (10 circuit cold plate) Premium 2323 (12 circuit cold plate)  
Venture  
Vantage  
1522  
2230  
3030  
ED 150  
ED 200  
ED 250  
ED 300  
DF 150  
DF 200  
DF 250  
1722  
2224  
2230-100  
DB 90  
DB 150  
DB 200  
DB 250  
DB 275  
TJ 45  
TJ 90  
TJ 150  
TJ 200  
TJ 250  
TJ 300  
TJ 400  
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© 1999-2005, IMI Cornelius Inc.  
   
UF-1 and UFB-1 Valves Training Manual  
There are four varieties of UF-1 and UFB-1 valves:  
The cup activated valve dispenses by means of a lever engaged by the cup.  
A push button valve has a press and hold button on the front cover of the valve.  
The OptifillTM valve dispenses with an activation lever but stops after the liquid fills  
the cup and touches the lever  
A portion control valve has four programmable drink size buttons that provide timed  
deliveries, top off, and a manual dispensing button.  
Cup  
Activated  
Valve  
TM  
Optifill  
Valve  
Push  
Button  
Valve  
Portion  
Control  
Valve  
The UF-1 and UFB-1 valves are the same as described above with minor differences for  
juice applications. In the UF-1 and UFB-1 valve concentrate enters the nozzle assembly  
higher providing a better mix of concentrate and water in the cup. In addition, the orifices  
for concentrate are larger to avoid clogging. The concentrate diffuser is gray allowing for  
easy identification.  
Note: The beverage (syrup) diffuser must be installed in order to use a diversion tube to  
ratio the concentrate valve.  
Note: Concentrate valves have only one hole in their sleeve and are only offered in fast  
flow capacities of 1.5 to 3.0 oz./sec.  
Syrup outlet  
Concentrate outlet  
(better mixing)  
Black diffuser  
Gray diffuser  
© 1999-2005, IMI Cornelius, Inc.  
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UF-1 and UFB-1 Valves Training Manual  
Concentrate valve sleeve  
has only one hole  
Syrup valve sleeve  
has six holes  
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 noncarbon-  
ated drink valve.  
Mounting  
screw  
Water  
lever  
Post-mix valves control:  
the ON–OFF of syrup and water,  
the flow rates of syrup and water,  
the mixing of the two ingredients as they pour into the cup, and  
in some instances - dispensed portion.  
3.2 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 OptifillTM valve.  
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© 1999-2005, IMI Cornelius Inc.  
 
UF-1 and UFB-1 Valves Training Manual  
SYSTEM DETAILS  
1. WATER  
1.1 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 install-  
ing 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.  
1.2 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.  
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 eliminates pulsating and smooths  
Notch in  
piston  
water flow at higher flow rates.  
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.  
UFB-1 Flow Module  
Orifice  
Sleeve  
Piston  
© 1999-2005, IMI Cornelius, Inc.  
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UF-1 and UFB-1 Valves Training Manual  
Lower Fluid Pressure BUT  
Higher Fluid Pressure BUT  
Same Volume Of  
Syrup/Water Flows  
From Orifices  
Higher Fluid  
Lower Fluid  
Pressure Pushing  
Against Piston &  
Spring  
Pressure Pushing  
Against Piston &  
Spring  
Knife  
edge  
Syrup/Water Flow  
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.  
1.3 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.)  
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© 1999-2005, IMI Cornelius Inc.  
 
UF-1 and UFB-1 Valves Training Manual  
Note: Always adjust water within its range.  
Water Flow Rates At Selected Ratios  
Water To Syrup Water at 1.5 oz./ Water at 3.0 oz./ Water at 3.75 oz./ Water at 4.5 oz./  
Ratio  
sec. Total Flow sec. Total Flow sec. Total Flow sec. Total Flow  
1.00oz./sec. 2.00oz./sec. 2.50oz./sec. 3.00oz./sec.  
1.13oz./sec. 2.25oz./sec. 2.81oz./sec. 3.38oz./sec.  
1.20oz./sec. 2.40oz./sec. 3.00oz./sec. 3.60oz./sec.  
1.25oz./sec. 2.50oz./sec. 3.13oz./sec. 3.75oz./sec.  
1.29oz./sec. 2.57oz./sec. 3.21oz./sec. 3.86oz./sec.  
1.31oz./sec. 2.63oz./sec. 3.28oz./sec. 3.94oz./sec.  
2 to 1  
3 to 1  
4 to 1  
5 to 1  
6 to 1  
7 to 1  
1.4 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.  
© 1999-2005, IMI Cornelius, Inc.  
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UF-1 and UFB-1 Valves Training Manual  
2. 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.  
3. 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  
Ratio  
Cups  
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 quan-  
tity for each test to ensure accurate set-  
tings.  
Syrup  
Separator  
• Take another sample to verify the set-  
tings.  
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© 1999-2005, IMI Cornelius Inc.  
   
UF-1 and UFB-1 Valves Training Manual  
4. MECHANICAL  
4.1 UF-1 and UFB-1 Valve Disassembly  
1. Sequence for disassembly (refer to UF-1 Post-mix Dispensing  
Valve Illustrated Parts List) is as follows:  
2. Remove front cover by lifting.  
3. Remove valve cover.  
Wiring  
Harness  
4. Unplug wiring harness.  
© 1999-2005, IMI Cornelius, Inc.  
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UF-1 and UFB-1 Valves Training Manual  
5. Remove valve from mounting  
block by pushing locking tab to left  
and push down on top plate of  
block. .  
Locking tab  
Locking tab  
Mounting  
screw  
6. Remove water screw and lever (if it is installed  
on the valve).  
Water  
lever  
7. Remove nozzle – turn left ¼ turn.  
8. Remove diffuser assembly.  
Note: The diffuser must be cleaned daily. Do not use bleach,  
do not use detergent, do not put in dishwasher. Use lukewarm  
water or soak in carbonated water.  
9. Remove bottom plate by disengaging side tabs.  
Tabs  
Retainer  
wire  
10. Remove U-shaped retainer wire from back of valve.  
11. Grasp flow control module assembly and pull  
up.  
Note: O-rings on bottom of inlets and outlets.  
O-rings  
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© 1999-2005, IMI Cornelius Inc.  
UF-1 and UFB-1 Valves Training Manual  
Flow rate &  
date code  
12. Note that the flow rate (1 ½ - 3, 3 – 4 ½ or  
1 ½ - 3 juice) and date code are printed on  
the retainer plate.  
13. To disassemble the flow control:  
Remove screws and pull retainer  
forward. Remove top flow con-  
trol subassemblies exposing  
flow controls.  
Note the difference between  
high flow and ultra flow valves.  
Concentrate valve  
sleeve has one hole  
Note: Top Flow control is an  
assembly and cannot be dissas-  
embled.  
Ultra Flow  
notched  
piston for  
water  
Syrup valve sleeve  
has six holes  
14. Pop off solenoid cover. Remove solenoid assembly from valve body by prying with  
screwdriver.  
Note: Check plunger for corrosion and dirt – replace as necessary.  
Solenoid  
plunger  
Pry here  
Solenoid  
cover  
Spring  
15. Carefully remove banjo lever springs.  
© 1999-2005, IMI Cornelius, Inc.  
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UF-1 and UFB-1 Valves Training Manual  
16. Then remove 5 screws that secure the  
valve head to the valve body.  
Pry here  
17. To remove the dispensing lever return spring pry the  
end of the spring and pull up. This spring stops the  
lever from vibrating.  
4.2 Mounting Block Disassembly  
To disassemble mounting block:  
1. Turn off water and syrup supplies.  
O-rings  
2. Remove 2 screws from top plate and pull spools  
out from the bottom of the mounting plate exposing  
spools and O-rings.  
Note: When replacing mounting block use replace-  
ment O-rings for the inlet fittings.  
Block closed (up)  
3. When installing a new block, make sure  
it is locked in the open position..  
Block open (down & locked)  
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© 1999-2005, IMI Cornelius Inc.  
 
UF-1 and UFB-1 Valves Training Manual  
5. CONTROLS AND ELECTRICAL  
All UF-1 and UFB-1 valves have a 24 volt solenoid that should be powered by an 80 kVA rated  
transformer. Voltage at the coil with the solenoid energized should be 22 and 27 VAC.  
5.1 UF-1 and UFB-1 Portion Control Valve  
The UF-1 and UFB-1 Portion Control Valves are push and release  
that dispense for a programmed duration. There are four settings:  
small, medium, large, and extra-large. There is also a Cancel/Pour  
rectangular button with red and green arrows. If this button is  
pressed during dispensing, the flow stops. If the valve is not dis-  
pensing and the button is pressed, the valve dispenses as long as the  
button is held.  
The portion controls are factory programmed to the following default settings:  
Portion Size  
Pour Time  
2 sec.  
S
M
L
3 sec.  
4 sec.  
XL  
6 sec.  
Portion Control Valve Programming  
To set the amount of beverage dispensed, follow this procedure:  
1. Press the hidden program switch until the PGM light turns on. (This light shows  
only when the programming mode is turned on.)  
2. Put desired amount of ice in cup. Press and hold a portion button until the  
desired level in the appropriate sized cup is reached. Release the button.  
3. Continue with other portion buttons that need programming. Portion buttons  
may be reprogrammed as many times as necessary. Only the last time values  
entered for each button will be saved when exiting the programming mode.  
4. Press the program switch until the PGM light turns off.  
PGM lights  
(not visible unless in  
programming mode)  
Program switch  
(hidden)  
© 1999-2005, IMI Cornelius, Inc.  
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UF-1 and UFB-1 Valves Training Manual  
NOTE: The portion control valve does not have a top-off function.  
NOTE: When in programming mode, press and release any of the portion size but-  
tons to return to the factory portion settings.  
NOTE: Portion controls will not operate below 22 volts. This is known as the  
“brown-out feature”.  
TM  
5.2 UF-1 and UFB-1 Optifill Valve  
The OptifillTM Valve is activated by pressing a cup against the dispens-  
ing lever. The valve dispenses only until foam from the cup touches the  
lever*. If a top-off delay is set, the valve will dispense again after a pre-  
set delay. This “topping-off” fills the cup after the foam settles. The  
top-off delay is can be adjusted from 0 to 15 seconds, the factory  
default is 2 seconds.  
*Note: A metal rivet in the valve body supplies electricity through the  
beverage being dispensed. When the foaming beverage comes  
in contact with the metal dispensing lever it completes the elec-  
trical circuit and the flow module closes the dispensing valve —  
even though the lever is still activated.  
Note: The cup must stay in place against the lever for the top-off to operate.  
Note: A slanted cup rest must be used with an OptifillTM valve.  
TM  
Optifill Valve Programming  
The OptifillTM module provides a timed dispensing function to set water flow  
rates. To access this function:  
1. Press the program switch until the LED turns on.  
2. Hold a graduated cup under the valve nozzle without touching the lever. Press  
the large rectangular switch. The valve dispenses for 2 seconds. The dispensed  
liquid divided by 2 equals the oz./sec dispensed rate.  
3. Press the program switch to exit the program.  
4. To program the top off function follow this procedure:  
5. Remove the front valve cover.  
6. Press the program switch until the LED turns on (can be seen from the top of  
the module.)  
7. Place cup against the lever for initial dispensing. When the foam touches the  
lever the valve stops and the LED flashes.  
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© 1999-2005, IMI Cornelius Inc.  
   
UF-1 and UFB-1 Valves Training Manual  
8. When the foam in the cup has lowered, press and release the large rectangular  
button. The valve dispenses a top-off and shuts off when the foam again  
touches the lever. The LED is now on steady.  
9. Press the program switch until the LED turns off.  
10. If you wish to disable the top-off, follow steps 1 through 3. Remove the cup  
from the lever. This will enter a zero value for the delay time and disable the  
top-off fill. Press the program switch for 3 seconds.  
PGM lights  
(not visible unless in  
programming mode)  
Program switch  
(hidden)  
Note: The OptifillTM valve does not have an adjustment for sensitivity.  
© 1999-2005, IMI Cornelius, Inc.  
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UF-1 and UFB-1 Valves Training Manual  
INSTALLATION  
CAUTION Only trained and certified technicians should service this  
unit. ALL WIRING AND PLUMBING MUST CONFORM TO  
NATIONAL AND LOCAL CODES.  
1. INSTALLATION REQUIREMENTS  
1.1 Requirements Summary  
The beverage dispenser that the UF-1 or UFB-1 valve(s) will be installed on should  
be capable of supplying an adequate flow of water (for the beverage and for cool-  
ing) and syrup.  
environment: . . . . . . .indoor installation only  
temperature: . . . . . . . .50 to 110° F ambient temperature  
syrup BIB: . . . . . . . . .60 to 80 psi  
carbonated water:. . . .65 to 110 psi  
plain water:. . . . . . . . .50 to 110 psi  
electrical: . . . . . . . . . .24 volts AC (22-27 volts), 80 VA, 50/60 Hz  
1.2 Electrical Requirements  
Before connecting electrical power to the beverage dispenser refer to nameplate to  
see if it requires 50 or 60 Hz power.  
DANGER To avoid possible serious injury or death the ELCB (earth leakage  
circuit breaker) must be installed in the electrical circuit of all 50 Hz units.  
WARNING To avoid possible electrical shock the unit must be electrically  
grounded using the green grounding screw provided inside the electrical contrac-  
tor box.  
CAUTION The wiring must be properly grounded and connected through a  
15-amp disconnect switch (slow–blow fuse or equivalent HACR circuit breaker).  
ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES. MAKE  
SURE UNIT IS PROPERLY GROUNDED.  
2. INSTALLATION & START-UP  
2.1 UF-1 and UFB-1 Valve Installation Procedure  
1. Shut off syrup, unplug carbonator, shut off CO2 and water supply to the unit.  
2. Release pressure in lines by activating valves and lifting relief valve of carbonator  
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© 1999-2005, IMI Cornelius Inc.  
           
UF-1 and UFB-1 Valves Training Manual  
3. Detach current valves:  
– Remove front cover by lifting.  
– Remove valve cover.  
– Unplug wiring harness.  
– Remove valve.  
3. INSTALLATION CHECKLIST  
1. Voltage and proper grounding.  
2. Valve properly secured (latched) to block.  
3. CO2 pressure to carbonator.  
4. Water flow rate.  
5. Syrup delivery pressure.  
6. Finished product temperature less than 40°F.  
7. Water to syrup ratio.  
8. Portion size / top-off.  
9. Water, syrup, CO2 leaks.  
10. Cover secured to valve.  
11. Valves flavor correctly marked.  
4. RETROFITTING  
UF-1 and UFB-1 valves will retrofit any valve with an identical mounting block screw pattern.  
Note: Replacement of mounting block inlet fitting O-rings (part # 4073) is required when retrofit-  
ting valves.  
4.1 Mounting Block Removal  
To remove valve mounting block from the front panel, take out and save 4 screws.  
IMPORTANT: Before installing block replace O-rings on each outlet fitting. Lubricate  
with Dow 111 or equivalent silicone lubricant. Do not use petroleum jelly.  
© 1999-2005, IMI Cornelius, Inc.  
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UF-1 and UFB-1 Valves Training Manual  
SERVICE  
CAUTION Only trained and certified technicians should service this  
unit. ALL WIRING AND PLUMBING MUST CONFORM TO  
NATIONAL AND LOCAL CODES.  
1. PREVENTATIVE MAINTENANCE  
1.1 Preventative Maintenance Procedures  
Preventative Maintenance Procedure  
Procedure  
Frequency  
1. Check valve operation (does it dispense prop- 6 months  
erly)  
2. Replace worn or missing parts  
3. Clean valves  
6 months  
6 months  
6 months  
4. Check voltage (22 to 27 VAC with the valve  
activated)  
5. Check product temperature (less than 40°F)  
6 months  
6. Check water flow rate (use syrup bypass tube 6 months  
and ratio cup)  
7. Check ratio  
6 months  
6 months  
6 months  
8. Check portion size / top-off  
9. Check for leaks  
NOTE: These procedures should be performed every six months OR after a service  
call.  
1.2 Cleaning Valve  
1. Remove the valve nozzle and the syrup diffuser.  
2. Wash the nozzle and diffuser in water. Soak in carbonated water overnight if possible.  
Use a soft brush as needed to remove any accumulated syrup deposits.  
3. Remove cover and bottom plate and clean with a soft cloth and warm soapy water.  
4. Wipe the valve surface with a clean soft cloth.  
CAUTION Do not soak valve components in chlorine.  
- 18 -  
© 1999-2005, IMI Cornelius Inc.  
       
UF-1 and UFB-1 Valves Training Manual  
TROUBLE SHOOTING  
Excess Foam  
Problem:  
excess foam  
Check  
product  
temperature  
Check  
system  
Temp  
?
above 40°  
below 40°  
Remove  
nozzle  
Check flow  
Clean  
?
yes  
rates  
no  
Check  
system  
Correct  
?
yes  
Clean  
no  
Problem  
corrected  
Set flow rate  
and ratio  
Problem  
corrected  
© 1999-2005, IMI Cornelius, Inc.  
- 19 -  
 
UF-1 and UFB-1 Valves Training Manual  
Off Taste  
Problem:  
off taste  
Remove  
nozzle  
Clean  
?
yes  
Check ratio  
no  
Check  
system  
Correct  
?
yes  
Clean  
no  
Problem  
corrected  
Set ratio  
Problem  
corrected  
- 20 -  
© 1999-2005, IMI Cornelius Inc.  
UF-1 and UFB-1 Valves Training Manual  
Valve Stuck Open  
Problem: valve  
stuck open  
Check  
solenoid  
visually  
Check for  
damaged  
banjos  
working  
?
yes (solenoid up)  
no  
(solenoid down)  
Undetermined  
problem call  
800-238-3600  
Damage  
no  
Check for  
power at  
solenoid  
?
yes  
Replace  
dispensing  
switch  
Replace  
banjos  
Power  
?
yes  
no  
Problem  
Problem  
corrected  
corrected  
Clean or  
replace  
solenoid  
Problem  
corrected  
© 1999-2005, IMI Cornelius, Inc.  
- 21 -  
UF-1 and UFB-1 Valves Training Manual  
No Product  
Problem:  
no product  
Check  
solenoid  
visually  
Check  
system  
Working  
?
yes  
no  
Check  
voltage  
(22-27 AC)  
Check  
transformer  
no  
Check  
resistance  
of coil  
Power  
?
yes  
no  
yes  
Replace  
switch  
Check  
switch  
Check  
system  
40 ohms  
?
no  
yes  
no  
Problem  
corrected  
Replace  
solenoid  
Problem  
corrected  
- 22 -  
© 1999-2005, IMI Cornelius Inc.  
UF-1 and UFB-1 Valves Training Manual  
ATTACHMENTS  
The following attachments should be included with this lesson:  
UF-1 Post-Mix Dispensing Valve  
Illustrated Parts List  
Post Mix Valves Critical Grounding Information  
Service Bulletin  
© 1999-2005, IMI Cornelius, Inc.  
- 23 -  
 
UF-1 and UFB-1 Valves Training Manual  
REVIEW  
DATE: _______________________________________________  
NAME: ______________________________________________  
LOCATION: __________________________________________  
The following questions summarize important points in the training lesson on UF-1 and UFB-1  
Valves and the UF-1 and UFB-1 Product Manual.  
1. What component(s) differ between High Flow and Ultra Flow valves?  
(circle the correct answer)  
A. Sleeve  
B. Piston  
C. Spring  
D. All of the above.  
2. What two things determine the position of the flow control piston inside the sleeve?  
(circle the correct answer)  
A. Flowing pressure and spring pressure  
B. Syrup and water pressure  
C. Temperature and pressure  
D. Syrup and water flow.  
3. How might chloramine affect a dispensing valve?  
(circle the correct answer)  
A. Restriction in the flow controls  
B. Color of the valve body  
C. Cracking of the flow control  
D. Degradation of rubber components.  
4. If a ratio setting changes, what should you check for?  
(circle the correct answer)  
A. Syrup pressure  
B. Water pressure  
C. Line restriction  
D. All of the above.  
- 24 -  
© 1999-2005, IMI Cornelius Inc.  
 
UF-1 and UFB-1 Valves Training Manual  
5. Which flow rate should be set first?  
(circle the correct answer)  
A. Syrup  
B. Water  
C. Either syrup or water  
D. Both at the same time.  
6. What functions does the Cancel/Pour Button on the Portion Control Valve perform?  
(circle the two correct answers)  
A. Cancel portion  
B. Manual portion  
C. Reset default  
D. All of the above.  
7. UF-1 valves control?  
(circle the correct answer)  
A. On-Off of syrup and water  
B. Flow rates of syrup and water  
C. Mixing of syrup and water  
D. All of the above.  
8. When replacing the UF-1 valve mounting block you must?  
(circle the correct answer)  
A. Drill new holes  
B. Replace the wiring harness  
C. Replace the inlet fitting  
D. Replace the inlet fitting O-rings.  
9. If the finished drink flow rate is 4.0 oz./sec. and the desired ratio is 7 to 1. What should the  
water flow rate be?  
(circle the correct answer)  
A. 3.0  
B. 3.5  
C. 4.0  
D. 2.5.  
10. What is the function of the notch in the Ultra Flow water piston?  
(circle the correct answer)  
A. Let dirt pass through  
B. Prevent carbonation loss  
C. Used in manufacturing process  
D. Eliminates pulsing and smooths water flow.  
© 1999-2005, IMI Cornelius, Inc.  
- 25 -  
UF-1 and UFB-1 Valves Training Manual  
11. Which of the following will cause the valve ratio to change?  
(circle the correct answer)  
A. Flow control restrictions  
B. Low CO2 pressure  
C. Weak BIB pump  
D. All of the above.  
12. What two things are different between a concentrate diffuser and a syrup diffuser?  
(circle the two correct answers)  
A. Color  
B. Position of the product outer holes  
C. Size  
D. Shape.  
13. How can you identify a concentrate sleeve?  
(circle the correct answer)  
A. Number of outlet holes  
B. Color  
C. Shape  
D. Size.  
14. What is the flow rate range of a Fast Flow valve?  
(circle the correct answer)  
A. 1.0 to 2.5 oz./sec.  
B. 1.5 to 3.0 oz./sec.  
C. 2.5 to 4.0 oz./sec.  
D. 3.0 to 4.5 oz./sec.  
15. What is the flow rate range of a Ultra Flow valve?  
(circle the correct answer)  
A. 1.0 to 2.5 oz./sec.  
B. 1.5 to 3.0 oz./sec.  
C. 2.5 to 4.0 oz./sec.  
D. 3.0 to 4.5 oz./sec.  
16. What is the range of a concentrate valve?  
(circle the correct answer)  
A. 1.0 to 2.5 oz./sec.  
B. 1.5 to 3.0 oz./sec.  
C. 2.5 to 4.0 oz./sec.  
D. 3.0 to 4.5 oz./sec.  
- 26 -  
© 1999-2005, IMI Cornelius Inc.  
UF-1 and UFB-1 Valves Training Manual  
17. What are the three basic steps to set the ratio on a valve?  
(circle the three correct answers)  
A. Adjust syrup ratio  
B. Set water flow rate  
C. Set portion size  
D. Cool product.  
18. How can you identify the valve flow rate?  
(circle the correct answer)  
A. Decal on inside of cover  
B. Printed on valve body  
C. Color of valve  
D. Printed on flow control retainer.  
19. What is the minimum VA transformer required for a valve?  
(circle the correct answer)  
A. 40  
B. 60  
C. 80  
D. 100.  
20. At what intervals (frequency) should maintenance procedures be performed?  
(circle the two correct answers)  
A. Every 30 days  
B. Every 3 months  
C. Every 6 months  
D. After every service call.  
© 1999-2005, IMI Cornelius, Inc.  
- 27 -  
UF-1 and UFB-1 Valves Training Manual  
NOTES:  
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- 28 -  
© 1999-2005, IMI Cornelius Inc.  
IMI Cornelius Inc.  
Part No. 315222001  
February 2, 2005  

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