Cornelius Post Mix Valves UFB 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:

www.cornelius.com

Email:

[email protected]

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.

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UF-1 Valves Manual

NOTES:

_____________________________________________________________________________

UF-1 and UFB-1 Valves Training Manual

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Preview Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Key Things To Know / Do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Dimensions & Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SYSTEM DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Adjusting Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Calculating Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Syrup/Concentrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Setting Ratio s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Mechanical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

UF-1 Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Mounting Block Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Controls and Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

UF-1 Portion Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Portion Control Valve Programmin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3

UF-1 Optifill^TMValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Optifill^TMValve Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Requirements Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Installation & Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

UF-1 Valve Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Retrofitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Mounting Block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Preventative Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Cleaning Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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UF-1 and UFB-1 Valves Training Manual

ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

REVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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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.

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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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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 Optifill^TMvalve 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

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

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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 Optifill^TMvalve.

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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

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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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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.

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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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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.

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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

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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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.

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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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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.

3 sec.

4 sec.

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)

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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”.

5.2 UF-1 and UFB-1 Optifill Valve

The Optifill^TMValve 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 Optifill^TMvalve.

Optifill Valve Programming

The Optifill^TMmodule 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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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 Optifill^TMvalve does not have an adjustment for sensitivity.

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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 CO₂and water supply to the unit.

2. Release pressure in lines by activating valves and lifting relief valve of carbonator

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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. CO₂pressure 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, CO₂leaks.

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.

- 17 -

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

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

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 -

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

Check

system

Correct

yes

Clean

Problem

corrected

Set flow rate

and ratio

Problem

corrected

- 19 -

UF-1 and UFB-1 Valves Training Manual

Off Taste

Problem:

off taste

Remove

nozzle

Clean

yes

Check ratio

Check

system

Correct

yes

Clean

Problem

corrected

Set ratio

Problem

corrected

- 20 -

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)

(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

- 21 -

UF-1 and UFB-1 Valves Training Manual

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

- 22 -

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

- 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 -

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.

- 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 CO₂pressure

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 -

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.

- 27 -

UF-1 and UFB-1 Valves Training Manual

NOTES:

_______________________________________________________________________

- 28 -

IMI Cornelius Inc.

www.cornelius.com

Part No. 315222001

February 2, 2005

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