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FlavorFusion® Training Manual

Publication Number: TP01070

- 16 -

© 2004-2007, IMI Cornelius Inc.

Dispenser Troubleshooting

Symptom

Cause

Remedy

Blown fuse or circuit 
breaker

Short circuit in electrical wiring

Repair Wiring

Inoperable agitator motor (shorted 
motor)

Replace gear motor

Agitator does not 
turn

No power

Restore power or plug in unit

Improperly installed upper ice chute 
assembly (Reed switch is not being 
activated)

Check the upper ice chute assembly for 
proper assembly and operation

Inoperable reed switch

Replace reed switch

Electrical board driver circuit is 
defective

Replace main control board

Gear motor has open circuit

Replace gear motor

Reed switch is not activated Improper 
assembly of upper ice chute to lower 
chute. 

Check to make sure tongue of upper 
chute engages into the back of the 
lower chute, ensure upper chute 
engages outside the lower chute, and 
snap front of chute into place.

Broken wire in the 2-wire harness 
leading to the reed switch

Repair of replace 2-wire harness

Bad connection at main control board, 
J3, pins 2 &3

Repair connection or replace 2-wire 
harness

Ice dispenses 
continuously

Ice gate mechanism is stuck in open 
position

Inspect gasket for proper position. 
Examine gate plate to see if it slides 
freely behind the lower ice chute.

Stuck or bent ice lever (does not allow 
gate to close and open reed switch)

Examine ice dispense lever to see if it is 
bent. 

Slushy ice or water 
in hopper

Blocked drains in cold plate

Remove access covers in cold plate 
cover & inspect/clean drains

Poor ice quality due to water quality or 
ice maker problems

Correct water quality or repair ice maker

Beverage does not 
dispense

No 24VAC to valves

Restore 24 VAC to valves

No CO

2

 pressure

Restore CO

2

 pressure

Beverage is too 
sweet

Valve brix requires adjustment

Adjust valve brix

Carbonator is not operating

Repair carbonator

No CO

2

 in carbonator

Restore CO

2

 pressure in carbonator

Summary of Contents for Flavorfusion TP01070

Page 1: ...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...

Page 2: ...t It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met in addition to the information contained in this manual To inquire a...

Page 3: ...ter Ratio Brix 5 Setting a Button to Dispense Non carbonated Water Only 5 Setting a Button to Dispense Carbonated Water Only 5 Mechanical 6 Disassembly 6 Control Box Components 6 Valve Removal 7 Valve...

Page 4: ...FlavorFusion FlavorOverload Training Manual Publication Number TP01070 ii 2004 2007 IMI Cornelius Inc...

Page 5: ...ice chute and gate mechanism The ice agitation gear motor is removable from the gear box to ease removal of the motor during ser vice and lower repair cost The unit has six nozzles for dispensing bra...

Page 6: ...ipping Weight lb 330 Capacity 250 lb ice bin capacity cube ice only Indoor installation only 40 to 90 o F ambient temperature Electrical Rating 103 132 Volts 11 Amps Water supply pressure 50 60 psi at...

Page 7: ...d The six 6 dispense types are described below and shown in a timing diagram in FIGURE 1 Dispense Type 1 Carbonated water dispense Solid LED Dispense Type 2 Non carbonated dispense Flashing LED 1 5 se...

Page 8: ...ted water There should be approximately 10 oz dispensed 4 If necessary adjust the water flow control see FIGURE 2 empty ratio cup and repeat step 3 Otherwise empty ratio cup and repeat step 3 using th...

Page 9: ...and 4 5 Repeat for all syrups in valve bank 6 Exit 4 second pour mode by simultaneously pressing and holding Flavor 1 and Flavor 4 buttons until the flash pattern for all for buttons changes 7 Exit p...

Page 10: ...MECHANICAL DISASSEMBLY Control Box Components FIGURE 4 FIGURE 5 FIGURE 6 FIGURE 7 Ballast for Merchandiser Light 24 Volt Transformer 2 Starter Merchandiser Light Main Control Board Agitator Timer Moto...

Page 11: ...so the switch panel will rotate out of the way see FIGURE 9 FIGURE 8 FIGURE 9 2 Unscrew the switch panel one on each side FIGURE 10 FIGURE 11 3 Place the tabs into the slot over the merchandiser ligh...

Page 12: ...s Inc 5 Tilt the valve removal tool up to release the latch FIGURE 15 FIGURE 16 6 Pull the valve off the back block FIGURE 17 7 Push the valve on the back block and push up on the back block release l...

Page 13: ...enoid loose from the valve body 4 To remove the tubing squeeze the spring clip together and pull off FIGURE 19 CARBONATOR TANK Always disconnect water and CO2 and relieve the carbonator pressure befor...

Page 14: ...FlavorFusion Training Manual Publication Number TP01070 10 2004 2007 IMI Cornelius Inc SYSTEM PLUMBING DIAGRAM...

Page 15: ...AMBIENT NON CHILLED SYRUP FLAVOR XX OUTLET LINE B7 B8 B5 B6 CARB WTR IN PLAIN WTR IN IN OUT CARB TANK OUTLET OUTLET 1 2 3 4 5 6 7 W2 W3 W2 W1 8 9 10 11 12 13 14 W3 W2 W3 W1 SYRUP INLETS INLET 7 6 5 4...

Page 16: ...al Publication Number TP01070 12 2004 2007 IMI Cornelius Inc INTERFACE BOARD AND HARNESS PIN OUT DETAIL 12 11 10 9 8 7 6 5 4 3 2 1 C C C C C W C C P W S 4 S 3 S 2 S 1 CW PW S4 S3 S2 S1 TO SOLENOID VAL...

Page 17: ...GIT MOTOR POWER CORD HEATER BLK WHT CARB MOTOR PUMP ASY ICE GATE SWITCH BALLAST CAPACITOR TRANSFORMER TRANSFORMER YEL BLU LT BLU RED GRN WHT YEL LT BLU GRN RED RED YEL WHT GRN LT BLU BLU LT BLU WHT GR...

Page 18: ...E BOARD 1 INTERFACE BOARD 2 INTERFACE BOARD 3 INTERFACE BOARD 4 INTERFACE BOARD 5 INTERFACE BOAR 6 24V 24V BALLAST LIGHT STARTER CARB MOTOR CARB MOTOR RELAY AGIT TIMER RELAY ICE DISP SWITCH ORG BRN BL...

Page 19: ...s that interconnect the right side of all interface boards together Turn back the keyswitch to reconnect power 2 Bonus Flavor Icon and or Drink Icon LEDs see FIGURE 3 are not in sync with the lighting...

Page 20: ...the lower chute and snap front of chute into place Broken wire in the 2 wire harness leading to the reed switch Repair of replace 2 wire harness Bad connection at main control board J3 pins 2 3 Repair...

Page 21: ...er pressure switch deactivates carbonator pump 2 after 5 minutes reset and retry carbonator pump If water supply is restored the 5 minute timeout will not occur Repeat reset a second time but on a thi...

Page 22: ...nutes Unplugging the unit and plugging it in will reset the unit and start the carbonator pump Carbonator pump is short cycling with every drink drawn Lower liquid level probe reads dry while upper pr...

Page 23: ...HIGH probe reads wet and LOW probe reads dry THIS IS AN ERROR CONDITION Check electrical connections at the carbonator tank and at connector J4 on the main control board Black wire should be connecte...

Page 24: ...IMI Cornelius Inc www cornelius com...

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