Lipton Brewed Iced Tea Double Valve Dispenser Training, Installation, & Service Manual Safety & Specifications Installation Service Training Part No. 630460171 ©2001-2002, IMI Cornelius, Inc.
Lipton Brewed Iced Tea Training, Installation, & Service Manual 630460171 ii May 7, 2002
Lipton Brewed Iced Tea Training, Installation, & Service Manual Lipton Iced Tea Brewer Training, Installation, & Service Manual The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are neither intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation, or maintenance of this equipment.
Lipton Brewed Iced Tea Training, Installation, & Service Manual 630460171 iv May 7, 2002
Lipton Brewed Iced Tea Training, Installation, & Service Manual TABLE OF CONTENTS SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Read and follow all safety instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Recognize safety alerts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Di
Lipton Brewed Iced Tea Training, Installation, & Service Manual Normal Pour - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11 SET-UP mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11 Tank Status - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12 System Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12 Set-Up Tea Syrup - - - - - - - - - - - - -
Lipton Brewed Iced Tea Training, Installation, & Service Manual Replacing Pump Tubing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39 Service Advisory - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46 WARRANTY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47 630460171 - vii May 7, 2
Lipton Brewed Iced Tea Training, Installation, & Service Manual SAFETY SAFETY INSTRUCTIONS Read and follow all safety instructions Read and follow all safety instructions in this manual and on the machine (decals, labels, and laminated cards). Before operating the machine, read and understand all applicable OSHA (Occupation Safety and Health Administration) safety regulations available from the safety coordinator or supervisor.
Lipton Brewed Iced Tea Training, Installation, & Service Manual SAFETY TIPS • • • • • • • • • Carefully read all safety messages in this manual and safety signs on the machine. Keep safety signs in good condition and replace missing or damaged safety signs. Learn how to operate the machine and how to use the controls properly. Do not let anyone operate the machine without proper training. Keep the machine in proper working condition. Do not allow unauthorized modifications to the machine.
Lipton Brewed Iced Tea Training, Installation, & Service Manual CO2 (CARBON DIOXIDE) WARNING WARNING: CO2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO2 gas leaks in the entire CO2 and system. If a CO2 gas leak is suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO2 gas will experience tremors which are followed rapidly by loss of consciousness and death.
Lipton Brewed Iced Tea Training, Installation, & Service Manual CAUTION: PRECAUTIONS TO BE TAKEN IN HANDLING: Protect cylinders from damage. Use a suitable hand truck to move cylinders; do not drag, roll, slide, or drop cylinders. Never attempt to lift a cylinder by its cap; the cap is intended solely to protect the valve. Never insert an object (e.g. wrench, screwdriver, pry bar) into cap openings; doing so may damage the valve and cause a leak.
Lipton Brewed Iced Tea Training, Installation, & Service Manual • • • • Do not activate the heater until the water tank is full. Rinse must be performed at least once every 24 hours or the brewer will lock out and will not dispense product. The heater tank contains no replaceable parts. The entire heater tank must be replaced if service is required.
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Lipton Brewed Iced Tea Training, Installation, & Service Manual SYSTEM OVERVIEW The Lipton Iced Tea Brewer (LBIT) looks and operates like a leaf tea brewer. The LBIT instantaneously mixes and dispenses tea extract, hot water, cold water, and liquid sweetener to provide a finished tea product. Unlike leaf tea brewers, the LBIT does not have high maintenance and operational costs, and it is not as susceptible to the bacterial growth inherent to leaf tea brewers.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Rinse key WARNING: This unit dispenses HOT water (160° F. 205° F. (71°C - 96°C) during the rinse cycle. Pressing this key will place the brewer in the rinse cycle mode. In this mode the brewer will require user intervention to initiate each flush of hot water through the system. This is done by opening the spigot when prompted to do so on the display. After the rinse is completed, the brewer automatically returns to run mode.
Lipton Brewed Iced Tea Training, Installation, & Service Manual SET TIME mode SETTING THE TIME AND DATE 1. Press MENU until ENTER SET TIME? is displayed. 2. Press (#) key to enter SET TIME and press (>) to advance. 3. Press the (#) key to enter SET CLOCK?. Read the flash screens. Press (>) or (<) key to move the cursor. Press (+) or (-) keys to change settings. Press (#) key twice to save new settings. Setting the RINSE TIME Contact the manager or the “decision maker” of the restaurant.
Lipton Brewed Iced Tea Training, Installation, & Service Manual 4. Press (#) to enter or exit the sub-modes and follow the display instructions. DISPLAY ERRORS Displays most recent error first Press (>) to advance through all errors. TEA PUMP STATE This screen displays the current state of the Tea pump (ON/OFF). Pull the dispense lever to start the flow of tea. Release the dispense lever to stop the flow of tea.
Lipton Brewed Iced Tea Training, Installation, & Service Manual TEA BAG SOLD OUT STATE This screen displays the current state of the Tea Extract Bag (Sold Out or OK). SWEETENER SOLD OUT STATE This screen displays the current state of the Sweetener (Sold Out or OK). This screen is skipped if unit is installed as unsweetened. HOT WATER TEMPERATURE This screen displays the current hot water heater tank temperature.
Lipton Brewed Iced Tea Training, Installation, & Service Manual 4. Press (#) to enter or exit the sub-modes and follow the displayed instructions. CAUTION: Ensure there is water in the heater before the heater relay is turned ON. Otherwise the heater will fail and it will have to be replaced. TANK STATUS The heater tank may be filled with water in this sub-mode. Once water flows from the spigot nozzle then change the tank status to FULL.
Lipton Brewed Iced Tea Training, Installation, & Service Manual SET-UP COLD WATER Holding the spigot open during this step will cause the brewer to do a 10 second cold water only pour. This is used to calibrate the amount of cold water to be dispensed during a normal pour sequence. WARNING: This unit dispenses HOT water (160° F. 205° F.(71°C - 96°C)) during the rinse cycle. SET-UP HOT BREW WATER Holding the spigot open during this step will cause the brewer to do a 10 second hot water only pour.
Lipton Brewed Iced Tea Training, Installation, & Service Manual PUSH KEY Quick Reference Push Key Push Key Function LANGUAGE Toggles between English and Spanish MENU Scrolls to main menu functions of DATA, SET TIME, ADJUST STRENGTH, AND SERVICE RINSE Initiates RINSE function STOP Will stop and prevent further dispensing action (heater stays on) RUN Initiates normal dispense and operational functions.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Set-Up Cold Water Operator may run a 10 second calibration pour. Set-Up Hot Brew Operator may run a 10 second calibration pour. Set-Up Timed Pour Operator may run a 10 second calibration pour. Error Light Functions No Light No errors present/dispense ready Red/Blinking Light Error is present/may not dispense Possible errors - out of tea extract, out of sweetener, rinse required, high water temperature and low water temperature.
Lipton Brewed Iced Tea Training, Installation, & Service Manual • The bimetallic thermostat mounted on the heater tank acts as a redundant shut-off control in the event of a malfunction of the heater relay. Water Valves • Inlet and outlet water valves to the hot water tank are activated simultaneously to initiate flow of hot water. Sweetener Valve • The sweetener valve is activated to initiate flow of sweetener (unless deactivated during installation).
Lipton Brewed Iced Tea Training, Installation, & Service Manual INSTALLATION CAUTION: Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. INSTALLATION REQUIREMENTS Electrical Requirements Before connecting electrical power to the brewer refer to nameplate to determine the power requirements.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Environmental Requirements CAUTION: This unit is designed for indoor installation only, in a non-harsh environment, and out of direct sunlight. CAUTION: If the unit is exposed to freezing temperature water in the unit will freeze and may damage the unit.
Lipton Brewed Iced Tea Training, Installation, & Service Manual 3. Drip Tray Plumbing Procedure: • • Permanent Drain Connection: It is highly recommended that the drip tray be connected to a permanent drain tube. The drain hole in the rear of the drip tray must first be drilled out with a 5/16” (0.79 cm) drill bit. A plastic drain tube .50” (1.27 cm) outside diameter (not provided) should then be pushed into the open end of the coupling.
Lipton Brewed Iced Tea Training, Installation, & Service Manual FIGURE 1 Installation Procedure The following sections include the brewer’s installation and set up procedures. FILLING THE WATER TANK 1. Install the Water Filter supplied between the incoming water line and the brewer. 2. A Water Booster Kit should be added if the water pressure to the unit is below 40-psi static pressure or 35-psi flowing pressure. A Water Pressure Regulator should be added if the static pressure is above 70-psi. 3.
Lipton Brewed Iced Tea Training, Installation, & Service Manual 9. Press (>) key to advance to the FILL WATER TANK screen. 10. Place one of the pitchers that were supplied under the right nozzle. 11. Pull the Right Lever to fill the Hot Water Tank. Release Lever when water begins to pour from the Nozzles. It should take approximately 2 minutes to fill the tank. 12. Press (>) key twice until the Hot Water Tank screen is displayed. 13. Press (+) key to change the Hot Water Tank status to Is Set To FULL.
Lipton Brewed Iced Tea Training, Installation, & Service Manual SET-UP SWEETENER 1. Press the (#) key to enter SETUP SWEETENER. Read the flash screen. 2. Verify that the Unit is set for Sweet, if not press (+) key to set the unit for sweet. 3. Press (>) key to advance to the PRIME SWEET LINE screen. 4. Pull the Right Lever to fill the sweetener lines. Release lever when sweetener pours from the Right Nozzle. 5. Press (>) key to advance to the TEST SWEETENER screen. 6.
Lipton Brewed Iced Tea Training, Installation, & Service Manual 4. Press (>) and then the (#) key to exit SETUP. NOTE: It is necessary to have the power connected and the ON/OFF switch in the ON position for at least 20 minutes before setting the Clock and Rinse Times. This is necessary to insure the battery has sufficient power to retain the settings. SET-UP THE CLOCK AND RINSE TIMES 1. Press MENU until ENTER SET TIME? is displayed. 2. Press (#) key to enter SET TIME. 3.
Lipton Brewed Iced Tea Training, Installation, & Service Manual 6. Pour glass of tea over ice and serve the Restaurant Manager to taste. 7. If strength of tea requires an adjustment, press MENU key until ENTER SETUP? is displayed. Press and hold the STOP key and then press the RINSE key to enter the SETUP screens. 8. Press (>) key 3 times until SETUP TEA SYRUP is displayed, and then press (#) key to enter SETUP TEA SYRUP. Press (>) key twice to advance to STRENGTH - Right Spigot.
Lipton Brewed Iced Tea Training, Installation, & Service Manual • Minimum Fill Capacity: 34 oz (1.0 liter) • Diameter: 4.0 to 5.0 in. (10 cm. to 12.7 cm.) • Maximum Height: 8.0 in. (20 cm.) • Temperature Rating: 210°F (99°C.) Note: If the rinse procedure is not completed with in 1 hour after starting, it will be canceled and the entire Rinse Cycle will need to be run again. 3. Press the RINSE key and follow the instructions on the display 4.
Lipton Brewed Iced Tea Training, Installation, & Service Manual DIAGRAMS FIGURE 2 Plumbing Diagram 630460171 - 26 May 7, 2002
Lipton Brewed Iced Tea Training, Installation, & Service Manual FIGURE 3 Wiring Diagram May 7, 2002 - 27 630460171
Lipton Brewed Iced Tea Training, Installation, & Service Manual SWEETENER BIB Installation (General) WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder in upright position with a safety chain to prevent it from falling over. Should valve become accidentally damaged or broken off, CO2 cylinder can cause serious personal injury. 1. Adjust sweetener pump CO2 regulator with 100-psi gage to between 45 and 65psi (80-psi maximum). 2.
Lipton Brewed Iced Tea Training, Installation, & Service Manual 3. To replenish the sweetener supply, disconnect sweetener line connector form the empty Bag-in-Box, then connect sweetener line connector to a full box. FIGURE 4 Bag-In-Box Sweetener System Diagram 16 15 Plug FIGURE 5 Sweetener Line & Soldout Switch Inside the Unit Required Tubing Size: Standard System Distance tanks to dispenser May 7, 2002 Tubing Size (i.d.
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Lipton Brewed Iced Tea Training, Installation, & Service Manual SERVICE Service consists of: Scheduled Maintenance Preventative Maintenance Troubleshooting • • • SCHEDULED MAINTENANCE Scheduled maintenance consists of: Daily cleaning Daily system flush (hot water rinse) procedure Monthly sanitizing procedure • • • Daily Cleaning 1. Prepare the following in four clean buckets. Rinse bucket − fill with clean tap water. Detergent bucket: mix a solution of mild detergent and warm water.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Note: If the urn filler tube is being used it will need to be cleaned per these instructions. Daily System Flush (Hot Water Rinse) Procedure WARNING: This unit dispenses HOT water (160° F. - 205° F. (71°C. - 96°C.)) during the rinse cycle. Press the RINSE key to place the brewer in the rinse cycle mode. In this mode the brewer will require user intervention to initiate each flush of hot water through the system.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Rinse Cycle Program Rinse Cycle No No Is water temperature above 160 degrees F and disp valve open? Is water temperature above 160 degrees F and disp valve open? Yes Yes Blink LED & warning, flash backlight for 2 seconds, flush deadlegs for 10 seconds Blink LED & warning, flash backlight for 2 seconds, flush deadlegs for 10 seconds Wait 90 seconds Wait 80 seconds No No Is water temperature above 160 degrees F and disp valve open? Is
Lipton Brewed Iced Tea Training, Installation, & Service Manual Monthly Sanitizing Procedure 1. Prepare the following in six clean buckets: Two wash buckets − mix a solution (one Tablespoon/gallon) of mild, lowsudsing, detergent with warm water (refill as necessary). Two rinse buckets− fill with warm tap water (refill as necessary). Two sanitizing buckets − mix a solution of one Tablespoon unscented household bleach (5.25% Cl Na O concentration) with two gallons of tap water.
Lipton Brewed Iced Tea Training, Installation, & Service Manual 10. After all of the detergent solution has been run through the system. Repeat step 6 above to completely empty the Tea Sold-Out Chamber of detergent. 11. Place the connectors and end caps into the two rinse buckets that were prepared above. Repeat steps 8 and 9 to run the rinse solution through the system. 12. After all of the rinse solution has been run through the system.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Annual Pump Tubing Replacement Procedure The pump tubing must be replaced annually. A replacement pump tubing kit, part # 631500149, is available. The kit consists of one pre-cut length of pump tubing, two hose clamps, and instructions. FIGURE 6 TEA EXTRACT PUMP REPLACING PUMP TUBING Replace pump tubing as follows: 1. Remove pump/motor assembly from the metal pump mounting bracket. 2. Remove the hose clamps from the pump tube connections.
Lipton Brewed Iced Tea Training, Installation, & Service Manual FIGURE 7 5. Remove the old pump tube from the pump body. If the roller assembly comes out with the tubing, place it back into the pump housing being sure to align the roller assembly shaft keyway to the motor shaft so that the two interlock. 6. Firmly press the new hose into the pump body around the roller assembly, being sure to keep the protruding ends even with each other. FIGURE 8 7.
Lipton Brewed Iced Tea Training, Installation, & Service Manual FIGURE 9 9. Insert the extract delivery tube into the pump tubing ends and secure them using the new hose clamps supplied in the kit. Be sure to use pliers to squeeze and tighten the hose clamps. 10. Re-install the pump/motor assembly on the pump mounting bracket.
Lipton Brewed Iced Tea Training, Installation, & Service Manual TROUBLESHOOTING IMPORTANT: Only qualified Personnel should service internal components or electrical wiring. WARNING: If repairs are to be made to a syrup system, disconnect extract supply from the applicable syrup system, 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.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Trouble NO HOT WATER Probable Cause • No power to heater. • Check power supply or loose wires. • Check heater. • All new production has a manual reset on the thermostat. • Tank: When heating will draw approximately 10 amps draw, measured at the black wire on the harness to the tank. The tank will heat water at about 12°F per minute. • Low Power Mode: Unit will go into a low power mode when tank temperature reaches 170°.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Trouble NO HOT WATER (CONT.) Probable Cause Troubleshooting & Repair Procedures • Heater open or shorted (cont.). • Thermostat adjustments should be in small increments. We are only using the bottom part of the total adjustment range of the thermostat. Usually the tank is adjusted to one tick mark above medium. • Replace tank. • Defective solid state relay. • Relay is solid state.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Trouble NO HOT WATER (CONT.) 630460171 Probable Cause Troubleshooting & Repair Procedures • No water entering tank. • Check water supply. • Plugged water filter. • See “defective hot water valve” • Same coil used for Hot, Cold, and Sweetener Valve. • Utilizes standard piston and sleeve flow control. • The Ohm resistance for the coil is approximately 6 Ohms. • No power to control board. • Check power supply and 24V transformer.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Trouble NO HOT WATER (CONT.) NO COLD WATER. Probable Cause • Defective KIP Valve. • Check coil resistance. • KIP is a brand name valve. • Two KIP valves are used in the unit. Both are activated in the rinse cycle. The top one is activated in the first rinse and runs hot water through the cold water and sweetener lines. The bottom one is activated in the 2nd through 5th rinses and runs hot water through the brew tube to clean that out.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Trouble BAD TASTE Probable Cause • No extract. • Check extract supply. • Check supply lines. • Check pump motor and tubing. • Check BIB connector. • No sweetener. • Check BIB connector. • Check sweetener supply. • Check valve assembly. • Check for restrictions. • Check BIB pump and gas supply. • Poor water quality. WON’T DISPENSE • Add or replace filter. • Ratio setting wrong. • Calibrate. • Check for kinked extract tubing.
Lipton Brewed Iced Tea Training, Installation, & Service Manual Trouble Probable Cause Troubleshooting & Repair Procedures EXCESSIVE BURPING (CON- • Temperature too high. STANT DISCHARGE FROM BURP TUBE) • Re-adjust thermostat (see no Hot water). WATER IN BOTTOM OF BREWER • Examine for leaks. • Repair or replace leaking component. • Air ejector leaking. • Repair or replace. • Check to see that the ball in the air ejector is not stuck. If the ball is stuck, homogeneity problems will result.
Lipton Brewed Iced Tea Training, Installation, & Service Manual SERVICE ADVISORY PRODUCT: LIPTON BREWED ICED TEA DISPENSER (LBIT) SUBJECT: “HEATING, PLEASE WAIT” MESSAGE ADVISORY RELEASE DATE: MARCH 23, 2001 Diagnostic Overview A “Heating, Please Wait” message may appear during a programmed rinse. This message indicates that the hot water temperature is less than the minimum temperature of 160 degrees Fahrenheit needed to initiate and complete the programmed rinse cycle.
Lipton Brewed Ice Tea Dispenser Installation & Service Manual WARRANTY IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius product, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number and the date of purchase. Australia - - P.O.
Lipton Brewed Ice Tea Dispenser Installation & Service Manual 630460171 -48 May 7, 2002
IMI Cornelius Inc. One Cornelius Place Anoka, MN 55303-1592 U.S.A.
