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FlavorFusion®/FlavorOverload Training Manual

© 2004-2007, IMI Cornelius Inc.

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Publication Number: TP01070

 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 fittings;

•    Key lock switch; 

•    10” cup clearance;

•    30% more drip tray capacity;

THEORY OF OPERATION

•    The FlavorFusion®/FlavorOverload machine is an above counter ice/beverage unit with multi flavor 

nozzles and the capability to inject bonus flavors into the finished drink. 

•    The beverage is cooled via ice melting on an aluminum cold plate. Ice is kept on the cold plate by 

means of an opening in the hopper that drops ice onto the surface during agitation of the ice in the 
hopper.   

•    The unit contains a mechanical 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 brand and bonus flavors. 

•    Each brand nozzle serves four discreet flavors fed by four syrup valves, one plain water, and one carb 

water valve. Every position is flexible for use with either carb or non-carb water.

•    Each bonus nozzle serves four individual flavors intended for injection into the finished drink. Bonus 

nozzles are fed by four syrup valves only. There is no option to dispense water out of the bonus nozzle 
without significant plumbing changes.

•    Bonus flavors require a separate regulator setting on their BIB pumps (20 psi maximum).

•    Brand and bonus flavors are controlled by means of six interface boards (one interface board per noz-

zle). The interface boards are common for each nozzle. Valve positions are configured on the mem-
brane switch. No special tool or PDA is required.

•    Valve flow rates are adjustable for 3.0-3.75 oz/sec finished drink dispense rate.

•    Unplug the unit or turn off the key switch before attempting any electrical service on the unit, failure to 

do this can cause damage to the electrical components! 

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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