® FLAVORFUSION®/ FLAVOROVERLOAD Training Manual Publication Number: TP01070 Revision Date: November 16, 2007 Revision: F Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
FLAVORFUSION®/FLAVOROVERLOAD 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 maintenance of this equipment.
FlavorFusion®/FlavorOverload Training Manual TABLE OF CONTENTS Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FlavorFusion®/FlavorOverload Training Manual Publication Number: TP01070 - ii - © 2004-2007, IMI Cornelius Inc.
FlavorFusion®/FlavorOverload Training Manual 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
FlavorFusion® Training Manual 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: . . . .
FlavorFusion®/FlavorOverload Training Manual 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.
FlavorFusion® Training Manual 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.
FlavorFusion®/FlavorOverload Training Manual 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.
FlavorFusion® Training Manual MECHANICAL DISASSEMBLY Control Box Components Valve Flow Controls Ballast for Merchandiser Light 24 Volt Transformer (2) Starter Merchandiser Light Motor Start Capacitor Main Control Board/Agitator Timer FIGURE 4 FIGURE 5 Adjustment Pots Agitation Board Interface Board FIGURE 6 Publication Number: TP01070 FIGURE 7 -6- © 2004-2007, IMI Cornelius Inc.
FlavorFusion®/FlavorOverload Training Manual 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). 3. Place the tabs into the slot over the merchandiser lights. 4. Place the valve removal tool on the back block release latch, keep the handle flat.
FlavorFusion® Training Manual 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. 7. Push the valve on the back block and push up on the back block release latch to replace the valve. FIGURE 17 FIGURE 18 Publication Number: TP01070 -8- © 2004-2007, IMI Cornelius Inc.
FlavorFusion®/FlavorOverload Training Manual 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. 3. 4. Twist the solenoid 90o. Pull the solenoid loose from the valve body. To remove the tubing squeeze the spring clip together and pull off.
FlavorFusion® Training Manual SYSTEM PLUMBING DIAGRAM Publication Number: TP01070 - 10 - © 2004-2007, IMI Cornelius Inc.
© 2004-2007, IMI Cornelius Inc. 5.500 W2 2 N1 PW W2 N1 CW W3 3 2 1 - 11 B1 B2 CARB WTR IN 7 6 5 4 2 1 14 13 12 11 10 9 SYRUP INLETS 3 COLDPLATE 8 8 10.000 THIS EQUIPMENT MUST BE INSTALLED WITH ADEQUATE BACKFLOW PROTECTION TO COMPLY WITH APPLICABLE FEDERAL, STATE AND LOCAL CODES.
FlavorFusion® Training Manual INTERFACE BOARD AND HARNESS PIN-OUT DETAIL C C C C C W P W C S 4 S 3 S 2 S 1 C 12 11 10 9 8 7 6 5 4 3 2 1 CW PW S4 S3 S2 S1 TO SOLENOID VALVES INTERFACE BOARD DETAIL Publication Number: TP01070 - 12 - © 2004-2007, IMI Cornelius Inc.
6.000 LIGHT SOCKET BLK BLK KEY SWITCH YEL YEL BLK BLK CW W3 PW W2 YEL WHT GRN WHT LT BLU 1 WHT 2 BRAND SYRUP KEY PAD TRANSFORMER BLK WHT WHT 4 3 WHT BLK WHT WHT SOLENOID VALVE BLOCK B1 B3 BONUS SYRUP KEY PAD TRANSFORMER WHT B2 B4 6 5 YEL CW GRN BLK BLU W3 WHT WHT 7 PW LT BLU W2 A1 BRAND SYRUP KEY PAD BLK LED.
FlavorFusion® Training Manual 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.
FlavorFusion®/FlavorOverload Training Manual 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.
FlavorFusion® Training Manual Dispenser Troubleshooting Symptom Blown fuse or circuit breaker Agitator does not turn Ice dispenses continuously Slushy ice or water in hopper Beverage does not dispense Beverage is too sweet Publication Number: TP01070 Cause Remedy Short circuit in electrical wiring Repair Wiring Inoperable agitator motor (shorted motor) Replace gear motor No power Restore power or plug in unit Improperly installed upper ice chute assembly (Reed switch is not being activated)
FlavorFusion®/FlavorOverload Training Manual Unit will not dispense carbonated drinks. Dispenses syrup only. Unit will not dispense carbonated drinks. Spurts CO2 and syrup only. Carbonated drinks are flat (low on carbonation) Low water pressure No Syrup or Watered down drink dispensed Carbonator pump does not start to fill tank © 2004-2007, IMI Cornelius Inc. City water pressure supply low or inconsistent Booster pump must be used if dynamic water pressure drops below 40 psig.
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.
FlavorFusion®/FlavorOverload Training Manual DIAGNOSTICS GUIDE FOR THE MAIN CONTROL BOARD (SEE FIGURE 22) State 0 1 2 3 Observed State of Red LED Flash rate 3 seconds Flash rate 1/2 second Flash rate 1/2 second Flash rate 1/2 second Sensor Input Control Response Both probes read “wet” Pump is OFF and HIGH probe reads “dry” and LOW probe reads “wet” Both HIGH and LOW probes read “dry” Entered when HIGH probe does not detect liquid, and LOW probe does detect liquid, and pump is ON Entered when HIGH probe
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