ICI TOPPER Installation And Service Manual Download Page 3

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TABLE OF CONTENTS

PAGE
PREFACE ................................................................................................................... 1

CHAPTER I GENERAL DESCRIPTION .................................................................... 1-1
SYSTEM

DESCRIPTION............................................................................... 1-1

THEORY OF OPERATION ............................................................................ 1-10

CHAPTER II INSTALLATION ..................................................................................... 2-1
UNPACKING

AND

INSPECTION .................................................................. 2-1

SELECTING

LOCATION ............................................................................... 2-1

LOCATION

RECOMMENDATIONS FOR TOPPER...................................... 2-2

INSTALLATION.............................................................................................. 2-2

INSTALL HIGH-PRESSURE CO2 REGULATOR, CO2 CYLINDER

AND

LINES .................................................................................................... 2-3

INSTALL LOW-PRESSURE REGULATOR AND LINES............................... 2-3

INSTALL WATER FILTER ASSEMBLY, (OPTIONAL).................................. 2-4

INSTALL WATER PRESSURE REGULATOR, (OPTIONAL) ....................... 2-4

INSTALL WATER HOLDING TANK, (OPTIONAL)........................................ 2-4

INSTALL

DRAIN LINE ................................................................................... 2-5

INSTALL B.I.B. OR SYRUP TANKS AND ACCESSORIES .......................... 2-5

CONNECTING

WATER INLET...................................................................... 2-5

ELECTRICAL

REQUIREMENTS................................................................... 2-5

CHAPTER III, PREPARATION .................................................................................. 3-1

PREPARING SYSTEM FOR OPERATION ................................................... 3-1

PREPARING AND STARTING REFRIGERATION UNIT.............................. 3-1

PURGE

DISPENSING VALVES .................................................................... 3-1

ACTIVATE

HIGH-PRESSURE CO2 SYSTEM .............................................. 3-1

ACTIVATE LOW-PRESSURE CO2 GAS AND SYRUP SYSTEMS.............. 3-2

ADJUST

WATER

FLOW RATE ..................................................................... 3-2

ADJUST

WATER-TO-SYRUP “RATIO”......................................................... 3-2

ADJUST SIZE OF DRINK DISPENSED ........................................................ 3-2

CHAPTER IV OPERATORS INSTRUCTIONS.......................................................... 4-1
DAILY

PRE-OPERATION CHECK ................................................................ 4-1

REPLENISHING

CO2 SUPPLY..................................................................... 4-1

REPLENISHING

SYRUP SUPPLY................................................................ 4-1

COOLING

UNIT

MAINTENANCE.................................................................. 4-1

CHECKING

WATER BATH............................................................................ 4-2

CHANGING

WATER BATH ........................................................................... 4-2

ADJUSTMENTS............................................................................................. 4-2
ADJUSTING

WATER

FLOW RATE............................................................... 4-2

ADJUSTING WATER-TO-SYRUP “RATIO” OF DISPENSED PRODUCT ... 4-2

ADJUSTING SIZE OF DRINK DISPENSED.................................................. 4-2

TESTING

FOR LEAKS .................................................................................. 4-2

CHAPTER V SERVICE AND MAINTENANCE.......................................................... 5-1
PERIODIC

INSPECTION

AND CLEANING................................................... 5-1

TOPPER CABINET MAINTENANCE ............................................................ 5-2

CLEANING

CONDENSER COIL ................................................................... 5-2

CHECKING/CHANGING

WATER BATH ....................................................... 5-2

WATER PUMP MAINTENANCE ................................................................... 5-3

CARBONATOR

MAINTENANCE .................................................................. 5-4

LUBRICATION ............................................................................................... 5-5
SERVICING

CHECK VALVES....................................................................... 5-5

REPLENISHING

CO2 SUPPLY..................................................................... 5-7

Summary of Contents for TOPPER

Page 1: ...TOPPER INSTALLATION AND SERVICE MANUAL INTERNATIONAL CARBONIC INC 16630 KOALA ROAD ADELANTO CALIFORNIA 92301 800 854 1177 CI I ...

Page 2: ...lling operating servicing and maintaining this equipment Refer to Table of Contents for page location of detailed information to answer questions that arise during installation operating service and maintenance or installation of this equipment ...

Page 3: ...RTING REFRIGERATION UNIT 3 1 PURGE DISPENSING VALVES 3 1 ACTIVATE HIGH PRESSURE CO2 SYSTEM 3 1 ACTIVATE LOW PRESSURE CO2 GAS AND SYRUP SYSTEMS 3 2 ADJUST WATER FLOW RATE 3 2 ADJUST WATER TO SYRUP RATIO 3 2 ADJUST SIZE OF DRINK DISPENSED 3 2 CHAPTER IV OPERATORS INSTRUCTIONS 4 1 DAILY PRE OPERATION CHECK 4 1 REPLENISHING CO2 SUPPLY 4 1 REPLENISHING SYRUP SUPPLY 4 1 COOLING UNIT MAINTENANCE 4 1 CHEC...

Page 4: ...M SUFFICIENT ICE BANK 6 2 COMPRESSOR WILL NOT STOP AFTER SUFFICIENT ICE BANK IS PRODUCED 6 3 CONDENSER FAN MOTOR NOT OPERATING 6 3 DISPENSING VALVES 6 3 WATER OR SYRUP LEAKING FROM NOZZLE AFTER ACTUATION 6 3 NO WATER NO SYRUP BEING DISPENSED FROM VALVE 6 4 NO SYRUP BEING DISPENSED 6 4 NO WATER BEING DISPENSED 6 4 DISPENSED PRODUCT CARBONATED TO LOW 6 4 DISPENSED PRODUCT MAKES FOAM AS IT LEAVES NOZ...

Page 5: ...0 2 1 SAMPLE OF A POSSIBLE INSTALLATION 2 2 2 2 HIGH PRESSURE CO2 REGULATOR S 101 2 3 2 3 LOW PRESSURE CO2 REGULATOR S 121 2 3 2 4 SUGGESTED WATER FLOW INSTALLATION 2 4 5 1 WATER PUMP Y STRAINER SCREEN 5 5 5 2 CHECK VALVES 5 6 5 3 COMPOSITE EXPLODED VIEW OF CHECK VALVES AND RELIEF VALVE 5 7 LIST OF TABLE 1 1 DESIGN DATA 1 1 2 1 LOOSE SHIPPED PARTS 2 1 ...

Page 6: ...he first patented dispensing valve to dispense bulk beverage with carbonation equal to or in excess of bottled beverages A valve with three flavors and soda was another first We were the first to incorporate the total postmix package i e carbonation refrigeration and the ability to dispense from one self contained unit We have pioneered many such firsts and will continue to develop advanced system...

Page 7: ...ther items that will be required if used in B I B Bag in Box or transfer tank FIGAL installations will be High pressure regulator Low pressure regulator connecting lines quick couplers or disconnects and C02 WARNING Before shipping or relocating a TOPPER into a freezing ambient environment empty plain and carbonated water Syrup systems should be flushed ice bank melted and water drained from water...

Page 8: ... for Operating Conditions Pressure Incoming Water Pressure Regulator Optional 25 40 C02 High pressure Regulator Carbonated units only PSI 70 75 C02 Low pressure Regulator Carbonated Flavored units only BIB Approx 40 PSI C02 Low pressure Regulator Carbonated Flavored units only FIGAL Approx 30 PSI C02 Low pressure Regulator Optional FIGAL Approx 30 PSI C02 Diet Drink Pressure Regulator if required ...

Page 9: ...LIFORNIA TITLE DATE DRN BY CHK BY APPR BY TOPPER 1 4 05 GLW ICI 16 37 18 20 21 22 23 24 25 26 30 31 35 53 1 6 5 7 9 12 8 10 11 14 15 13 19 3 4 17 32 36 39 38 45 46 48 40 47 44 52 54 43 42 49 51 50 2 28 29 27 41 33 34 GLW GLW FIGURE 1 1 1 3 ...

Page 10: ... BRASS 3 8 M P X 1 4 M F 11 1 S0650 STRAINER BRASS 12 1 S0199 MOTOR SHIELD 13 1 S0106 CLAMP V BAND 14 1 S0096 MOTOR CARBONATOR 15 2 A0045 5 16 X 18 FLANGE WHIZ LOCK SCREW 1 2 16 1 S0513 A ICE BANK CONTROL 17 2 A0046 5 16 X 18 FLANGE WHIZ LOCK SCREW 3 4 18 1 E0276 TRANSFORMER 40 VA 19 1 E0664 STRAIN RELIEF 20 1 S0068 B LIQUID LEVEL CONTROL LLC 21 4 S1335 TERMINAL BOARD SPACER NYLON 3 8 22 1 S 7 8 H...

Page 11: ...1 S0781 CONDENSER MOUNTING BASE 38 3 S1323 EVAPORATOR GUIDE WEDGE 39 1 S0768 SWITCHLOCK W KEYS 40 1 S0778 STANDPIPE 41 1 S0799 WRAPPER BUCKET ASSEMBLY W INSULATION 42 5 PFC II QR DISPENSING VALVES W QUICK RELEASE 43 1 S0789 5 VALVE MOUNTING PLATE 44 1 Z0010 CAP TUBE 12 050 45 3 S0795 EVAPORATOR COIL RETAINER 46 1 S0766 UNIT ON OFF SWITCH 47 3 S0793 EVAPORATOR SUPPORT BRACKET 48 1 S0765 LEGS 4 SET ...

Page 12: ...NIC INC ADELANTO CALIFORNIA TITLE DATE DRN BY CHK BY APPR BY TOPPER JUICE 1 4 5 GLW ICI 14 23 5 7 8 9 10 11 12 13 17 18 21 35 1 6 3 4 15 19 22 24 27 37 28 40 25 38 36 34 39 29 30 31 33 32 2 26 16 20 GLW GLW FIGURE 1 3 1 6 ...

Page 13: ...A WATER REGULATOR OPTIONAL 19 1 AEA1360YXAXA CONDENSING UNIT 1 5 H P AEA1360YXA COMPRESSOR ONLY 1 5 H P 20 1 S0835 AGITATOR PUMP 21 1 S0784 WATER COIL COPPER 22 1PR S0681 SUPPORT HINGE 23 1 S0781 CONDENSER MOUNTING BASE 24 1 S0768 SWITCHLOCK W KEYS 25 1 S0778 STANDPIPE 26 1 S0799 WRAPPER BUCKET ASSEMBLY W INSULATION 27 3 S1323 EVAPORATOR GUIDE WEDGE 28 1 S0766 UNIT ON OFF SWITCH 29 1 S0789 VALVE M...

Page 14: ...nk and Water Bath Must be Commonly Grounded 120 VAC GREEN GREEN GREEN GREEN GREEN ELECTRICAL SCHEMATIC 120 VOLT NOTE IF USING EXTRA 120V ACCESSORIES SUCH AS RECIRCULATING MOTOR ILLUMINATION ETC MAKE CONNECTIONS AT TERMINAL A4 A5 FOR POWER BLACK LEG TERMINALS B4 B5 FOR NEUTRAL WHITE LEG AND GROUND AT BOX OR ANY GROUND TERMINAL NOT IN USE TERMINALS ICE BANK CONTROL GROUND TERMINALS ARE G1 G2 G3 G4 S...

Page 15: ... ELECTRICAL SCHEMATIC 1 29 99 GLW ICI GLW GLW GROUND TERMINAL SCREW IN CONTROL BOX GREEN GREEN GREEN GREEN GREEN WHITE WHITE WHITE WHITE WHITE BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK RIBBED ILLUMINATION OPTIONAL BLACK BLACK ON OFF SWITCH ICE BANK CONTROL CONDENSING UNIT S C R M S 1 3 1 FAN MOTOR COMPRESSOR 110 VAC FIGURE 1 6 1 9 ...

Page 16: ... C NO NC C NO NC RED WHITE BLUE YELLOW 24 VOLT 24 VOLT BLACK WHITE SYRUP SYRUP WATER WATER SINGLE DUAL VALVE SCHEMATIC 24 VOLT TRANSFORMER KEY SWITCH 24 VOLT VALVES ELECTRICAL SCHEMATIC 24 VOLT FIGURE 1 7 1 10 ...

Page 17: ...here is a direct relationship between dispensed temperature and the volumes of C02 that can be held in liquid form The following will give a general overview of the flow of individual circuits and a clearer understanding of our mini bottling plant Carbon dioxide gas CO2 passes from a C02 cylinder through high pressure regulator S 101 The high pressure regulator regulates the CO2 feeding the TOPPER...

Page 18: ...peration fresh water enters the carbonator through the soda jet after passing through a short tube to the water pump inlet fittings The water pump has impellers which drives the water through a dual check valve and then through the soda jet and into the carbonator tank The position and angle of the soda jet is fixed to direct an extremely high velocity jet of fresh water so as to impinge upon the ...

Page 19: ...necessary claim File claim with delivering agency not International Carbonic Inc Unpack LOOSE SHIPPED PARTS At this time make sure all parts listed are present and in good condition If any parts are missing notify factory TABLE 2 1 LOOSE SHIPPED PARTS Item Part No No Name Qty 1 Installation Service Manual 1 2 S 101 High pressure C02 Regulator 1 3 S 221 Low pressure C02 Regulator 1 4 S 1156 Drain p...

Page 20: ...s possible to water source Half inch gate valve recommended for water connection 4 Enough space must be allowed to install C02 cylinder syrup containers racks pumps water filter etc 5 Position unit as close as possible to floor drain FIGURE 2 1 SAMPLE OF POSSIBLE INSTALLATION INSTALLATION 1 Make all connections C02 gas plain water and syrups 2 Place TOPPER in position Make sure sufficient space be...

Page 21: ...cated gas charging line S 105 3 A line must be fabricated at this time Cut inner braid tubing to size and install nipple S 145 and nut S 150 to each end of tubing making sure either oetiker or ferrule is previously installed on line Secure these connections by use of proper tool Connect inner braid plastic tubing from outlet of tee at low pressure regulator S 221 optional furnished with unit to su...

Page 22: ...EGULATOR OPTIONAL If water pressure exceeds 40 psi a water pressure regulator or water pressure reducing valve should be installed in the water supply line and adjusted to maintain a pressure of 25 to 40 psi The water regulator must have an orifice of at least 3 16 so as not to restrict the water flow through the valve Valves that are built with 1 2 pipe thread connection usually have a sufficient...

Page 23: ...LLED AND MAINTAINED ACCORDING TO FEDERAL STATE AND LOCAL LAWS The water connection on the TOPPER is made to a flexible water line by means of a 3 8 male flare Due to the large capacity of the pump any restriction of the incoming fresh water supply would starve the water pump and create noise within the pump poor carbonation and extremely long running time After all primary water lines are made up ...

Page 24: ...ox turn power switch to the ON position Make sure compressor condenser fan motor agitator motor start The process of cooling the water bath will now commence With ambient and water temperature of 75 degree F initial pull down or formation of complete ice bank will take approximately 4 5 5 hrs When full ice bank has been formed compressor and condenser fan motor will stop Agitator will continue to ...

Page 25: ...kwise until the pressure is approx 40 psi for B I B and approx 30 psi for FIGAL NOTE These pressures will vary depending on baume of product type of pumps etc 5 If diet drink regulator is required turn C02 diet drink pressure regulator screw clockwise until the pressure is 6 to 10 psi 6 Dispense syrup from dispensing valves until all air is purged from syrup lines and syrup is dispensed 7 Check fo...

Page 26: ... necessary replenished as instructed see CHAPTER II REPLENISHING SYRUP SUPPLY Syrup supply must be checked daily and if necessary replenished as instructed see CHAPTER II COOLING UNIT MAINTENANCE NOTE Air circulation through the condenser coil required to cool the condenser coil compressor is drawn in through vents at the top and sides through condenser coil and is exhausted out grills at the rear...

Page 27: ...lls tank etc should be cleaned Fill water bath to the top of the standpipe S 778 ADJUSTMENTS Periodically C02 regulators should be checked for proper pressure settings and if necessary adjust as instructed These settings can be recorded in NOTE section of this manual ADJUSTING WATER FLOW RATE If adjustment of water flow rate should be necessary adjust as instructed ADJUSTING WATER TO SYRUP RATIO B...

Page 28: ...eak in the carbonator circuit 6 After it has been determined that there are no leaks in the carbonator circuit open C02 cylinder valve and adjust low pressure regulator to 15 psi Allow enough time for the syrup tanks to fill completely with gas 5 minutes or longer 7 Next completely back off low pressure regulator adjusting screw and if gauge needle of low pressure regulator commence to move downwa...

Page 29: ...g the carbonator and syrup tanks These pressures should not change If a change occurs repeatedly contact your local service agency It is suggested to make a comment about this occurrence in NOTE SECTION of manual 4 Clean the beverage dispensing area 5 Remove and clean nozzles and all exposed areas on valves 6 Wipe exterior of unit with moist towel Stainless cleans well with carbonated water Weekly...

Page 30: ... CHECKING CHANGING WATER BATH Periodically check water level in water bath If it is low more water should be added for maximum product cooling Before adding more water water bath and ice bank should be checked for excessive mineral deposit build up NOTE The water in water bath should be changed and all components in water bath should be cleaned as often as necessary to keep it clean A convenient t...

Page 31: ...ystems that might cause clogged flow of water through system Water pump with no screen or a defective screen in the strainer would allow foreign particles into water system and create a health hazard 1 Unplug power cord from electrical socket 2 Shut off plain water supply to water pump by closing shutoff valves in water supply line 3 Shut off CO2 supply to TOPPER by closing shutoff valve on CO2 cy...

Page 32: ...line 5 Shut off C02 supply to refrigerating unit by closing shutoff valve on C02 cylinder 6 Pull up on carbonator tank relief to relieve C02 pressure from tank 7 Eliminate leak tighten bad connections or replace defective Probe assembly water double check valve S 20 gas single check valve S 22 or valve relief S 215 8 Service check valves as outlined in SERVICING CHECK VALVES 9 Reassemble as necess...

Page 33: ...eed with the following 1 Disconnect water line from double check valve outlet Remove double check from water pump outlet fitting 2 Remove one check valve from other then disassemble each check valve as shown in Figure 5 2 3 Wipe each part with clean lint free cloth Inspect each part especially the ball for burrs nicks corrosion deterioration and other damage Discard ball O ring S 13 and any damage...

Page 34: ...NER CHECK VALVE 4 3 S 11 BALL CHECK VALVE 5 3 S 10 SPRING CHECK VALVE 6 3 S 9 GASKET CHECK VALVE 7 2 S 6 1 8 BODY BASE CHECK VALVE 8 1 S 29 OFF SET TEE 9 1 S 16 ADAPTOR HOUSING DOUBLE CHECK VALVE 10 1 S 15 HOUSING CHECK VALVE 3 8 M F 11 1 1 4 M P I S S INLET 12 1 PLUNGER WITH SEAT 13 1 SPRING 275 P S I 14 1 SAFETY UPPER CAP 15 1 LEVER HANDLE 16 1 LEVER PIN S 2 1 5 1 8 FIGURE 5 3 EXPLODED VIEW CHEC...

Page 35: ...ck disconnects in warm water then connect Q C D s or syrup C02 quick disconnects to container 4 Activate valve until syrup flows from valve normally See CHAPTER II CHANGING WATER FILTER CARTRIDGE Follow manufacturer s instructions for water filter ADJUSTMENTS HIGH PRESSURE C02 REGULATOR The high pressure C02 regulator will have two gauges that extend above and to the side of the bell housing screw...

Page 36: ...int as an adjustment is 40 psi for B I B and 30 psi for transfer tanks NOTE After primary adjustment on low pressure regulator always go to farthest serving station from syrup storage area and adjust heaviest baume syrup normally ORANGE If adjustment can be made proceed with all other flavors DIET SYRUP TANK C02 REGULATOR S 121 The diet C02 regulator is normally used only on transfer tank installa...

Page 37: ...ype or plastic tube and on plastic syrup outlet located inside hidden nozzle area Then press nozzle back in position 4 Actuate valve until syrup separator is full of syrup Hold brix cup close enough to valve outlet to form S on the flexible plastic tube so as to prevent any water following the flexible tube into syrup section This formed S will also hold syrup in tube for a more reliable brix read...

Page 38: ...verse rotation respectively The ultimate goal is to achieve a proper ratio of water vs syrup This ratio can and will vary with differing products INCREASE DECREASE WATER METERING PIN SYRUP METERING PIN 18 PARTS WATER SYRUP SYRUP 1 SYRUP 2 TOP VIEW valve cover removed 18 to 1 Brix Cup Maintenance Cleaning your valve is recommended to insure a constant quality drink If a valve is not sanitized on a ...

Page 39: ...f dirty clean with soft bristle brush Clean exteriors of valve with a soft clothe and warm water Replace valve nozzle then go to step 3 3 Fill syrup lines with a caustic based low sudsing non perfumed and rinsed detergent solution STAR The solution should be prepared in accordance with the manufacturers recommendations but should be at least 2 percent sodium hydroxide Make sure the syrup lines are...

Page 40: ...ion and or open electrical circuit Carbonated water leak 1 2 3 4 5 Replace water pump Replace carbonator tank electrode Replace L L C assembly Tighten connection and or repair open ground circuit Find and repair leak Water Pump motor will not shut off and pressure relief engaged 1 2 Electrode inside carbonator does not sense ground L L C assembly inoperable 1 2 Replace defective electrode or check...

Page 41: ...uction or re Attach propeller Voltage must be at least 110 volt at terminals Tighten connection or replace broken wiring Replace agitator motor Compressor does not operate 1 2 3 4 5 6 7 8 No power source Electrical power to cooling unit turned off Low voltage Loose disconnected or broken wire Inoperative ice bank control Inoperative overload protector or start relay Inoperative compressor Full ice...

Page 42: ...motor DISPENSING VALVES Water or syrup leaking from nozzle after actuation 1 Foreign debris under plunger seat or bent creased stem 1 a Disconnect syrup or water from affected valve b Relieve pressure by activating valve c Remove E 623 nut from syrup or water solenoid d Remove e 525 coil assembly from e 527 stem e Remove E 527 stem from valve body Note care should be taken not to dent smooth E 527...

Page 43: ...Frozen water bath Volumes of CO2 to low in finished product 1 2 3 4 High pressure regulator out of adjustment CO2 cylinder empty Water oil or dirt in C02 supply Temperature above quality limits 1 2 3 4 Adjust high pressure regulator as instructed Replace CO2 cylinder Clean contaminated CO2 system lines regulator etc and sanitize as instructed See refrigeration machine specifications vs volume requ...

Page 44: ...not produce desired water to syrup ratio 1 2 3 4 5 6 No syrup supply Syrup tank quick disconnects not secure Low pressure CO2 reg ulator out of adjustment B I B QCD disconnected or improperly installed Syrup line restricted Dirty or inoperative metering pin or piston in syrup flow control 1 2 3 4 5 6 Replenish syrup supply as instructed Secure quick disconnects Adjust low pressure CO2 regulator as...

Page 45: ...motor spade to terminal Motor 1 CARBONATION TROUBLE SHOOTING FLOW CHART 1 Motor Pump does engage Re install motor spade to terminal Motor 1 Go to electrode Electrode Disconnect electrical Remove spade from long short elect connection at LLC Re connect electrical Motor pump Comes on Motor Pump does not come on Bad LLC replace Change electrode Carbonator short cycles Check ground connection at board...

Page 46: ...heck CO2 supply C02 cylinder is empty Change C02 cylinder Hi pressure regulator is set to low or malfunctioning Adjust CO2 pressure at a minimum of 25 PSI above water pressure Check water pressure Water pressure greater than or close to CO2 pressure will stop the carbonation process Install or adjust water regulator 6 7 ...

Page 47: ...essure relief may engage NO EXCESSIVE PRESSURE AT VALVE OR PRESSURE RELIEF SYMPTONS Valve will dispense syrup and gas only Possible loud noise from water pump No ground at LLC Repair Little or no water volume Install holding tank increase water feed I D Electrode bad replace Restrictions at water pump Clear restrictions Defective Motor Water Pump Replace 6 8 Defective LLC Replace ...

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