Cornelius 2 Flavor Training Manual Download

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QUEST JUICE

2 and 4 Flavor

Training Manual

Release Date: April 12, 2004

Publication Number: TP00968

Revision Date: November 23, 2004

Revision: C

Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

Summary of Contents for 2 Flavor

Page 1: ...E 2 and 4 Flavor Training Manual Release Date April 12 2004 Publication Number TP00968 Revision Date November 23 2004 Revision C Visit the IMI Cornelius web site at www cornelius com for all your Literature needs ...

Page 2: ...t 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 about current revisions of this and other documentation or for assistance with any Cornelius product contact IMI Cornelius Inc Phone 800 238 3600 Internet www cornelius com Trademarks and copyrights Aurora Cornelius Deca...

Page 3: ...cation 5 Filling the Ice Bath 5 Connecting Water Supply 5 Priming Flushing Water System 5 Concentrate Handling Loading 6 Loading Concentrate 6 Changing Concentrate Containers 6 Supplies 7 Checking Adjusting the Brix Setting 7 Programming the Portion Control 8 Cancel Pour Button 8 Planned Maintenance Schedule 9 Daily 9 Flush System 9 Clean Splash Zones Dispense Nozzles 9 Weekly 9 Sanitize the Juice...

Page 4: ...moval of the Agitator Motor 24 Removal of the Refrigeration Chassis 24 Removal of the Ice Control Probe 26 Major Component Review 27 Electrical Box 27 Pump Speed Switch 28 Ice Bank Control 28 Operational Overview 28 Validating Operation 28 Transformer 29 Water Inlet Solenoid 29 Door Switch 72 B Serial Number 29 Door Switch 72 E Serial Number 30 Platform Components 30 Water Valve Flow Control 30 Bo...

Page 5: ... cools the stainless steel water coils and circulates the cold water through a heat exchanger to cool the cabinet This gives us colder drinks for longer periods of time and eliminates the need to have to defrost the cooling cabinet A lighted merchandiser is standard Ice bath Door harness Pump deck harness 1 and 2 Dispensing nozzles Left Side Transformer Condenser fan motor and bracket Compressor R...

Page 6: ...ndenser clearance 4 back 12 top Water Connection 3 8 SAE male flare Water Pressure 80 psi max static 20 psi min dynamic For best results it should be regulated to 45 to 50 psi Quest Two Flavor Dimensions 10 4 W Operating weight 120 lbs Quest Four Flavor Dimensions 15 W Operating weight 160 lbs IPD Times Quest 4 4 5 hours Quest 2 3 hours Ice Bath Capacity Quest 4 3 6 gallons 15 16 lbs of ice IPD Qu...

Page 7: ...ate is important Improper loading is a major source of service calls Concentrates vary in viscosity and mixing valves must be adjusted accordingly When changing concentrate be sure to check the concentrate container O ring for damage It should be clean and wet with concentrate or a food grade lubricant Shake or stir pulp based concentrates When changing flavors be sure to flush the system and rese...

Page 8: ... False 5 O rings may be installed dry lubrication is not recommended _____ True _____ False KEY THINGS TO KNOW DO Work Safely Always unplug disconnect the power to the dispenser before servicing and get help lift ing the unit if it must be removed from the counter Make certain that the water line has adequate pressure at all times Learn to use a good quality volt ohm meter Proper electrical troubl...

Page 9: ...proper water quality standards neutral pH of 7 0 to 8 0 and should not be connected to a water softener It is the installers responsibility to ensure that all water connections to the dispenser are sized installed and maintained according to Federal State and Local Laws Secure the 3 8 0 95 cm swivel nut on the flexible supply tubing to the water inlet located at the rear of the dispenser Make sure...

Page 10: ...ate containers on the dispensing platform shelf inside the refriger ated cabinet 3 Engage the concentrate container by pressing it downward into the bottle adapter opening on the dispensing platform NOTE Be sure to lubricate the o ring seal on the container nozzle This will ensure a good seal and allow the pumps to draw concentrated from the containers more easily Failure to create a good seal at ...

Page 11: ...hermometer target is 35 45 F or 1 6 7 2 C Discard this drink after checking temperature NOTE If drink temperature is not within the target range refer to the basic troubleshooting sec tion When setting up the unit with warm concentrate and hot water 90 F it will take longer to get the 35 45 F finished drink 3 Dispense a 12 oz 354 8 ml drink sample into a clean dry cup Thoroughly stir the sample us...

Page 12: ... to its new setting PROGRAMMING THE PORTION CONTROL If your dispenser has optional portion controls they have been pre programmed from the factory to pour 7 12 and 16 ounce drinks The extra large pitcher icon size has also been pre programmed to pour 16 ounces To change the pour sizes please follow the instructions below 1 Simultaneously press and hold small and extra large push button switches on...

Page 13: ...y do not soak them in sanitizing solu tion longer than 2 minutes WEEKLY Check concentrate to water brix ratio refer to the Brixing Procedure in this manual Sanitize the Juice Dispenser Step 1 Rinse With Hot Water 1 Prepare two 2 oz packets of Stera Sheen Green Label sanitizing solution or similar brand by dis solving each packet in 1 gallon 3 8L of potable water to insure 200 ppm of available chlo...

Page 14: ...CAUTION The following procedures require removal of the dispenser side panel s Disconnect the power cord from the receptacle prior to proceeding Clean Water Inlet Strainer 1 Remove the right side panel from the dispenser 2 Turn off the water supply to the dispenser 3 Remove the access port from the Y shaped water inlet solenoid located on the right side of the dispenser 4 Clean and reinstall the s...

Page 15: ...eplacing Pump Tubing 1 Remove pump platform refer to the Removing Pump Platform s procedure located earlier in this section 2 Remove the two white plastic hose clamps from the pump tube con nections see Fig 1 2 Remove the concentrate delivery tubes from the hose ends 3 Loosen and remove the four screws from the pump body see fig 3 4 Remove the rear pump body half only to reveal the pump tube and r...

Page 16: ...hand reinsert the four screws and tighten using a crisscross pattern as shown The screws should be tightened about 1 4 turn beyond snug 9 Insert the two concentrate delivery tubes 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 Fig 3 ...

Page 17: ...de of the door as shown NOTE You now have access to the ballast and light panel NOTE Remember the door switch is used to reset the refill light NOTE The pumps can not be operated with the door in the open position NOTE Trying to bypass the door switch dur ing the Brixing Ratio procedure will result in longer pull down times and improper set tings 3 4 6 5 1 2 Ballast Assembly ...

Page 18: ...or tabs and the 2 screws from the front underside of the switch panel assembly NOTE The switch harness is marked 1 4 and the connectors are indexed 2 Remove 3 screws to replace a dispensing switch if necessary NOTE If a change of dispensing venue is required push to portion Cornelius makes available a complete lower door assembly to expedite this change 3 4 1 2 ...

Page 19: ...F THE PUMP PLATFORMS 1 Remove the cabinet shelf by lifting it up and pulling it forward 2 Pull the front flap out and up 3 Remove the dispensing nozzles by turning them 1 4 turn clockwise and pulling down 4 Pull the locking latch forward and lift the platform up and pull it forward slightly ...

Page 20: ...rnelius Inc 5 Press the release button on the water connector to release the platform 6 Disconnect the platform electrical connector by squeezing the release tabs on either side of the con nector and pulling straight back The platform can now be removed from the cabinet ...

Page 21: ...o this you will have to pull the wire leads gently through the back of the cabinet 3 Disconnect the wire leads and remove the ground wire as shown 4 Remove 4 screws from the fan mounting bracket NOTE When installing a new fan always make sure the label is facing the front of the cabinet When reinstalling the panel it will be necessary to pull back through the wire lead connected to the fan Fan Lab...

Page 22: ...e top panel 2 Open the front door 3 Lift the rear of the top panel and slide forward and remove 4 Slide the drip tray forward and remove 5 Remove the 2 screws on the front panel and remove the front panel 6 Slide the panel up and pull out to remove On the 2 flavor unit it will be necessary to remove 2 screws from the back panel ...

Page 23: ... removed B Left Panel The door must be open while removing the left panel Once the screws are removed pull the panel clear off the frame and tip forward Slide panel forward and up until it clears the mounting tab insert Move the panel down and back Once it is clear of the door the panel will release 1 Remove the nozzles 2 Remove the screw on the right side of the electrical box 3 Pull the electric...

Page 24: ... will release the standoff and allow it to be pushed back through the hole in the bracket 5 The VRB board can now be removed from the electrical box itself 6 The standoffs 4 can be removed by gently squeezing the tip with needle nose pliers and at the same time pushing through the board NOTE The nut and insulation must be assembled as illustrated Failure to assemble and tighten correctly can resul...

Page 25: ...ill come forward only as far as the cables will allow NOTE The electrical box and nozzles must be removed to remove the ice bank control 2 The connectors are very tight To successfully remove use a crescent wrench to grip the outside of the connector rocking gently up and down while pulling up to release The best way to work from right to left 1 The nozzle guide gaskets can be removed for cleaning...

Page 26: ...ctions uses 2 nuts only 2 Cut the wire tie from the wire bundle in the rear of the unit just above the condenser 3 Disconnect the cooling cabinet wire harness 4 Remove the insulation from around the inlet and outlet fittings of the heat exchange Remove the locking clips from the inlet and outlet fittings 5 Insert the screwdriver blade against the lock ing ring and pull down on the hose ...

Page 27: ...TP00968 6 Remove the inlet water line from the cabinet manifold 7 Remove 4 screws that secure the cooling to the frame NOTE For best results use a screw driver that has at least an 8 blade 8 After you lift the cabinet off the frame you can service the agitator motor 2 1 3 4 ...

Page 28: ...tator motor 2 Lift the motor out of the ice bath Disconnect the wire lead from the ice bank control Note You will have to feed the water tubes through the refrigeration frame to completely remove 1 With the cabinet removed remove 2 screws from the lower front and 2 screws from the lower rear of the water bath housing 2 Unsnap the wire harnesses red and white connectors from the bracket mounted to ...

Page 29: ...and leads Remove the top ground wire from the post Red White from transformer 1 Blue from transformer 2 Lead from inlet solenoid 3 4 Slide the refrigeration chassis out from the frame 5 Remove 4 screws from the base of the refrigeration chassis and lift off of the water bath Red White Blue Lead Ground Wire Post 2 1 4 3 ...

Page 30: ...be assembly off the bracket DO NOT REMOVE THE BRACKET 2 The connector must be disassembled to pass the wire leads through the water bath cover 3 Carefully remove the grommet from the water bath cover 4 With the wire loose pass the connectors first through the grommet and the water bath cover itself BE SURE TO REMEMBER THE WIRE ORDER WHEN RE ASSEMBLING Yellow Orange Purple Blue Brown Green Yellow C...

Page 31: ...latform push button RED CONNECTOR OUTPUT CABLE 28 VDC Pump motors Platform solenoid Water inlet solenoid Speed Switch 4 Pump 4 Pump 3 Pump 2 Pump 1 Pump 1 2 3 4 SOLD OUT FUNCTION JUMPER 3 pin connector J5 PIN Enabled dispense light only LK PIN Disabled dispense pump head stops when light is on BOARD INPUT 26VAC from Transformer 2 pin connector Sold out from platform 2 pin connector Touch pad SWITC...

Page 32: ...will not activate without having sufficient water in the water bath tank See chapter on installation water bath filling THERE IS A 3 MINUTE DELAY BUILT INTO EACH CONTROL AS A SAFTEY PRECAUTION The default mode is an open circuit Any break in the continuity i e broken wire and the system reads it as a no water condition Control is powered by line voltage All connectors are label and keyed for prope...

Page 33: ... the dispense button is pressed The water inlet solenoid prevents backflow and is equipped with a strainer screen that needs to be removed and cleaned once a year NOTE THE INLET SOLENOID COIL IS ACTIVED FROM THE VRB BOARD USING THE 28VDC OUTPUT AN AC COIL WILL NOT WORK IN THIS APPLICATION The door switch on the 72B serial number units is a combination of a door latch and switch The primary functio...

Page 34: ...ert field units to this configuration The sold out feature however will be inoperable with the use of this kit Water Valve Flow Control The flow control is a ceramic spool and sleeve It must move freely to regulate the water flow and maintain brix Be sure the o ring is in place and sealing prop erly Bottle Adaptor O rings When doing any assembly work on the bottle adaptor be sure to use a small am...

Page 35: ...pposites across from each other Be sure the are fully tighten to prevent leaking Bottle Adaptor Sold Out Sensors The sold out sensors are located in the bottle adaptor neck The do not get cleaned during normal flushing procedures They are cleaned only during sani tizing Be sure there is no build up of pulp or concen trate on the pins themselves The results will be an erratic operation of the refil...

Page 36: ...iods can cause the pump tubing to split at the inlet of the pump Static Mixers The Quest dispenser has static mixer option The DN MIXER part number 720703202 is used for high viscosity concentrates It helps promote proper mixing The cone top mixer is the standard Both are interchangeable with each other All feet must be attached for proper operation If all or any are missing the mixer should be re...

Page 37: ...Quest Juice Training Manual 2004 IMI Cornelius Inc 33 Publication Number TP00968 WIRING DIAGRAM ...

Page 38: ...Quest Juice Training Manual Publication Number TP00968 34 2004 IMI Cornelius Inc ...

Page 39: ...nk sensing probe Fill ice bath to proper water level Defective Ice Bank Control or sensing probe Replace Cabinet fan is inoperative result ing in warm concentrate water continues to cool Replace Compressor short cycles on overload Excessively high discharge pres sure due to restricted condenser or inoperative condenser fan motor Compressor starts but hums and trips overload Seized or shorted compr...

Page 40: ...d Test and replace if necessary No concentrate dis pensed water only Concentrate container not fully engaged into receptacle on pump platform Refer to Concentrate Loading sec tion of this manual Dispense Flush lever in FLUSH position Move lever to DISPENSE position Concentrate too cold not properly thawed Concentrate should be 35 40 F 1 7 4 5 C prior to loading Defective pump motor Replace pump mo...

Page 41: ...nsformer has line voltage present on primary side If no 28VAC output from the secondary replace transformer Defective voltage regulator board VRB located inside front electri cal box Confirm board produces 28VDC present when the dispense button is pressed refer to the Electrical Box Wiring Diagram for VDC output loca tion Replace VRB if necessary Defective dispense control board Push button or por...

Page 42: ...____________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ ___...

Page 43: ...www cornelius com ...

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