FlavorFusion Installation Manual
INSTALLATION MANUAL
FlavorFusion with Cold Carbonation
DESCRIPTION
The FlavorFusion series of dispensers solves your ice and beverage service needs in a sanitary, space
saving, economical way. Designed to be manually filled with ice from any remote ice–making source,
these dispensers will dispense cubes (up to 1–1/4 inch in size), cubelets, and compressed (not flaked)
ice. In addition, the units include beverage faucets, a cold plate, an internal carbonator tank and an
external pump for the carbonator, and are designed to be supplied direct from syrup tanks with no
additional cooling required.
CAUTION: Dispenser cannot be used with crushed or flaked ice. Use of bagged ice which has
frozen into large chunks can void warranty. The dispenser agitator is not designed to be an ice
crusher. Use of large chunks of ice which “jam up” inside the hopper will cause failure of the agitator
motor and damage to the hopper. If bagged ice is used, it must be carefully and completely broken
into small, cube-sized pieces and left to “temper” or warm up for a minimum of 20 minutes in room
temperature before loading into the dispenser hopper.
SPECIFICATION
Model Descriptions:
B=Beverage
C=Coldplate
H=Internal Cold Carb
Z=No Drip Tray
Ice Storage:
255 Pounds
Maximum Number of Faucets
Available:
4 nozzles with 4 brands each = 16 brands
2 nozzles with 4 bonus flavors each = 8 bonus flavors
Built–in Cold Plate:
Electrical:
Yes
120/1/60,
9.3 Amps of Total Unit Draw
220/1/50,
4.7 Amps of Total Unit Draw
Dimensions:
30 inch
30-11/16 inch
39 inch (to top of bin)
41-10/16 inch (to top of lid)
Z-Models
30 inch
23-1/16 inch
39 inch (to top of bin)
41-10/16 inch (to top of lid)
CO2 Operating Pressure
75-psig (max) for carb tank and brand syrup pumps
25-psig (max) for bonus flavor pumps
Revision Date: February 6, 2006
© 2005-2006, IMI Cornelius Inc.
Revision: B
Publication Number: 621057601INS
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FlavorFusion Installation Manual
INSTALLATION
IMPORTANT: TO THE INSTALLER.
It is the responsibility of the Installer to ensure that the water supply to the dispensing equipment
is provided with protection against backflow by an air gap as defined in ANSI/ASME A112. 1.2–
1979; or an approved vacuum breaker or other such method as proved effective by test.
Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed,
and maintained according to Federal, State, and Local laws.
1.
Locate the dispenser indoors on a level counter top.
A. LEG OPTION
Unpack the four (4) legs and install them into the threaded holes provided in the bottom of the
unit. The installer must provide flexibility in the product and utility supply to permit shifting the
position of the dispenser sufficiently to clean the area beneath it.
B. COUNTER MOUNTING
The ice drink dispenser must be sealed to the counter. The template drawing (see FIGURE 6)
indicates where openings can be cut in the counter. Locate the desired position for the
dispenser, then mark the outline dimensions on the counter using the template drawings. Cut
openings in counter.
Apply a continuous bead of NSF International (NSF) silastic sealant (Dow 732 or equal) approximately 1/
4-inch inside of the unit outline dimensions and around all openings. Then, position the unit on the
counter within the outline dimensions. All excess sealant must be wiped away immediately.
2.
The beverage tubes, drain tube and power cord are routed through the large opening in the bottom
of the unit. See the MOUNTING TEMPLATE (FIGURE 6) for locating the required clearance
opening in the counter for these utility lines.
3.
DRIP TRAY DRAIN ASSEMBLY (see FIGURE 7): Route the drain tube to an open drain with the
end of the tube above the “flood” level of the drain. Use the tubing, fittings, clamps, and insulation
provided with the Dispenser to assemble the drain. The completed drain line must pitch
continuously downward and contain no “traps” or improper drainage will result.
NOTE: IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in
the plain water inlet supply line. A Cornelius Water Filter (P/N 313860000) and QUICK
DISCONNECT SET (P/N 313867000) are recommended.
CAUTION: Check the minimum flow rate and the maximum pressure of the plain water inlet supply
line. MINIMUM FLOW RATE MUST BE AT LEAST 125-GALLONS PER HOUR. If flow rate is less
than 125-gallons per hour, starving off the carbonator water pump will occur. Starving will allow the
carbonator water pump to overheat causing the safety thermostat on the pump outlet to stop the
water pump motor. Overheating could occur if the plain water supply line flow rate drops below 125-
gallons per hour. INCOMING PLAIN WATER INLET SUPPLY LINE WATER TO PUMP PRESSURE
MUST REMAIN A MINIMUM OF 10 psi BELOW THE CARBONATED CO2 OPERATING
PRESSURE. (Example: Carbonator CO2 operating pressure is 75 psi and the maximum water
pressure can be no more than 65 psi, etc.). Water over pressure (higher CO2 operating pressure)
can cause carbonator flooding, malfunction, and leakage through the carbonator relief valve. If
water is exceeding maximum pressure specifications, a Water Pressure Regulator Kit must be
installed in the plain water inlet supply line. If fitting connector is not available, tap into the plain
water supply line with a 3/8 flare saddle valve.
4.
5.
Locate the carbonator pump assembly and connect to power cord from the Ice/Drink Unit to the
pump. The cord is connected to the unit’s electrical box and has an electrical connector on the end
that plugs into a receptacle in the junction box at the carbonator pump assembly. Connect inlet
water to pump and pump outlet to Ice/Drink Unit using 3/8-inch food-grade tubing. Disable the pump
from operating by switching the switch in the carbonator pump assembly junction box to the OFF
position.
Connect the beverage system product tubes as indicated in applicable Flow Diagram FIGURE 8.
This work should be done by a qualified service person.
© 2005-2006, IMI Cornelius Inc.
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Publication Number: 621057601INS
FlavorFusion Installation Manual
NOTE: See applicable Flow Diagram (see FIGURE 8) or Decal on the lower front of the unit for the
location of syrup and water connections.
6.
7.
Clean the hopper interior (see CLEANING INSTRUCTIONS in Owner’s Manual).
Connect the unit power cord to a 120 volt, 60 cycle, 3–wire grounded receptacle. For 220-240 Volt
International Units, a 3-wire power cord is provided. An adapter plug for the particular country will
need to be provided by the Installer.
ADJUST CARBONATOR CO2 REGULATOR AND TURN WATER INLET SUPPLY
LINE ON
CAUTION: Before connecting the CO2 regulator assembly to a CO2 cylinder, turn the regulator
adjusting screw to the left (counterclockwise) until all tension is relieved from the adjusting screw
spring.
1.
2.
Open (counterclockwise) CO2 cylinder valve slightly to allow lines to slowly fill with gas, then open
the valve fully to back-seat the valve. (Back-seating the valve prevents leakage around the valve
shaft).
The carbonator CO2 regulator is fixed at a nominal 75 psi.
3.
4.
Open one of the post-mix dispensing valves to exhaust trapped air inside the carbonator tank.
Open the water inlet supply line shutoff valve.
UNIT OPERATION
WARNING: The unit must be electrically grounded to avoid possible fatal electrical shock or serious
injury to the operator. The unit power cord is equipped with a three-prong plug. If a three-hole
(grounded) electrical outlet is not available, use an approved method to ground the unit.
CAUTION: Never operate the carbonator pump with the water inlet supply line shutoff valve
closed. “Dry running” the water pump will burn out the pump. A pump damaged in this manner is
not covered by warranty.
1.
2.
Connect electrical power to the Unit.
Locate the switch on the junction box of the carbonator pump, and turn it ON. The water pump will
start and fill the carbonator tank with carbonated water. The water pump will stop when the
carbonator tank is full.
3.
4.
Check for water and CO2 leaks, and tighten any loose connections
Dispense several drinks until the carbonator pump cycles on. The refill time should be about 5-7
seconds.
5.
If the carbonator pump appears to be short-cycling, meaning a refill time of 1-2 seconds, refer to the
Troubleshooting section.
Publication Number: 621057601INS
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© 2005-2006, IMI Cornelius Inc.
FlavorFusion Installation Manual
GATE RESTRICTOR PLATE AND ADJUSTMENT
The rate at which ice is dispensed can be adjusted by varying the opening of the gate restrictor plate as
illustrated in FIGURE 1. Reducing the dispense rate of ice is especially desirable when using glasses or
other containers with small openings. To adjust the gate restrictor plate, loosen the (4) nuts that hold the
ice chute assembly to the bin. The restrictor plate can now be moved up or down. When the restrictor
plate is fully up, the ice gate opening is 2-1/2” in height, and the maximum rate of ice dispense is
available (approximately 3 oz/sec). Retighten the (4) nuts to set the desired restrictor plate opening. DO
NOT EXCEED 40 IN-LB of torque.
DISCONNECT POWER BEFORE INSTALLING,
REMOVING, OR ADJUSTING RESTRICTOR.
!
RESTRICTOR
PLATE
INSTALL PLATE
ON STUDS AS
SHOWN
ADJUSTMENT
4X
MAX TORQUE
40 in.-lb.
FIGURE 1. Gate Restrictor Plate
NOTE: Tighten (4) nuts for fastening lower ice chute in place to 40 in-lbs (max). Draw all four nuts
tight uniformly.
© 2005-2006, IMI Cornelius Inc.
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Publication Number: 621057601INS
FlavorFusion Installation Manual
PROGRAMMING MODE
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 4) 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. All
keypad LEDs will flash off for approximately 1 second, resuming normal operation mode.
Programming Mode Flashing Sequences
Once in programming mode, each dispense button LED flashes in a sequence cycle according to one (1)
of six (6) dispense types. For Brand Keypads, only dispense types 1 and 2 are used. For Bonus Flavor
Keypads, dispense types 3 through 6 are used. The six (6) dispense types are described below, and
shown in a timing diagram in FIGURE 2:
•
•
•
Dispense Type 1, Carbonated water dispense: Solid LED
Dispense Type 2, Non-carbonated dispense: Flashing LED 1.5 seconds ON, 1.5 seconds OFF
Dispense Type 3, 1-second flavor shot: LED flashes once for ¼ second, followed by 3 seconds
OFF
•
•
•
Dispense Type 4, 2-second flavor shot: LED flashes twice for ¼ second ON, ½ second OFF,
followed by 3 seconds OFF
Dispense Type 5, 3-second flavor shot: LED flashes three (3) times for ¼ second ON, ½ second
OFF, followed by 3 seconds OFF
Dispense Type 6, 4-second flavor shot: LED flashes four (4) times for ¼ second ON, ½ second
OFF, followed by 3 seconds OFF
Start
proramming
mode
Exit
programming
mode
1. Carbonated water dispense
2. Non-carbonated dispense
3. 1-second flavor shot
4. 2-second flavor shot
5. 3-second flavor shot
6. 4-second flavor shot
0
1
2
Time
3
4
5
(seconds)
FIGURE 2
Publication Number: 621057601INS
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© 2005-2006, IMI Cornelius Inc.
FlavorFusion Installation 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 4). The LED’s for
flavors 1-4 should flash off and then back
on. The drink icon should turn off.
2.
3.
4.
Set the valve block to a 4 second pour
mode by simultaneously pressing and
holding Flavor 1 and Flavor 4 buttons until
the flash pattern for all four buttons
changes.
Flow Adjuster Detail
(Water)
Place an empty ratio cup under the
appropriate nozzle and press the left
program button for a 4 second dispense of
carbonated water. There should be
approximately 10 oz. dispensed.
If necessary, adjust the water flow control
(see FIGURE 3), empty ratio cup, and
repeat step 3. Otherwise empty ratio cup
and repeat step 3 using the right program
button for plain water.
FIGURE 3. Valve with Flow Adjusters
(see plumbing diagram for plumbing and valve
configuration)
5.
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.
Exit programming mode by simultaneously pressing and holding both programming buttons for 4
seconds.
Brand Flavor
Programming
Buttons
(Left and
Right)
Bonus Flavor
Programming Buttons
(Left
and Right)
Optional
Drink Icon
Bonus Flavor Icon
Optional
Bonus Flavor Button 1
Optional
Brand Flavor Button 1
Brand Flavor Button 2
Bonus Flavor Button 2
Optional
Bonus Flavor Button 3
Optional
Brand Flavor Button 3
Brand Flavor Button 4
Bonus Flavor Button 4
Optional
Bonus Flavor Nozzle
Optional
Brand Flavor Nozzle
FIGURE 4
© 2005-2006, IMI Cornelius Inc.
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Publication Number: 621057601INS
FlavorFusion Installation Manual
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 4). The LED’s for flavors 1-4 should flash off and
then back on. The drink icon should turn off.
2.
3.
4.
Set the valve block to a 4 second pour mode by simultaneously pressing and holding Flavor 1 and
Flavor 4 buttons until the flash pattern for all for buttons changes.
Place the water end of the ratio cup under the appropriate nozzle and press the left program button
for a 4 second dispense of carbonated water. (Push the right program button for still water pour.)
Place the syrup end of the ratio cup under the nozzle and press the appropriate flavor button for a 4
second dispense of syrup. The fill line should be the same for both water and the syrup. Adjust the
syrup flow control if necessary, then empty cup and repeat steps 3 and 4.
5.
6.
Repeat for all syrups in valve bank.
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 programming mode by simultaneously pressing and holding both programming buttons for 4
seconds.
Setting a Button to Dispense Non-carbonated Water Only
1.
Program the designated button to dispense non-carbonated water (see Programming Mode.)
2.
Do not connect a syrup source to the inlet circuit of the designated button (1-14 or A1-A2.) If circuit
1 through 14 is chosen leave the coldplate inlet circuit plugged with the red cap. If circuit A1 or A2 is
chosen, plug the end of the inlet tube with a red cap from the coldplate, or with tape.
Setting a Button to Dispense Carbonated Water Only
1.
Program the designated button to dispense carbonated water (see Programming Mode.)
2.
Do not connect a syrup source to the inlet circuit of the designated button (1-14 or A1-A2.) If circuit
1 through 14 is chosen leave the coldplate inlet circuit plugged with the red cap. If circuit A1 or A2 is
chosen, plug the end of the inlet tube with a red cap from the coldplate, or with tape.
NOTE: The ambient circuits A1 and A2 do not give up a cold plate circuit.
Back Room Package Position (BRP)
C
E
D G H
K
L
O
P
R
S
T W X
Pumps
F
I
J
N Q
V
Y
Z
M
U
C
D
F
S
T
K
L
N
P
R
E
G
I
M
O
Q
U
W
Y
V
X
Z
BIB Racks
H
J
FIGURE 5
Publication Number: 621057601INS
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© 2005-2006, IMI Cornelius Inc.
FlavorFusion Installation Manual
MOUNTING TEMPLATE
7/16 DIA.
30
1 13/16
26 3/8
1 5/16
12
9
18 5/8
21 1/4
31 1/2
30
23 1/16
3 1/2
11
9 1/2
Z Style
23
REMOVABLE SINK
RECOMMENDED COUNTER OPENING SIZE
9 X 12 FOR UTILITIES AND BEVERAGE
TUBING. OPENING CAN BE LOCATED
ANYWHERE WITHIN SHADED AREA.
FIGURE 6. FlavorFusion Mounting Template
© 2005-2006, IMI Cornelius Inc.
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Publication Number: 621057601INS
FlavorFusion Installation Manual
DRIP TRAY DRAIN ASSEMBLY
HOSE CLAMP
DRAIN LINE
1" I.D. PLASTIC TUBING
(6') WITH INSULATION
FIGURE 7. Drip Tray Drain Assembly
Publication Number: 621057601INS
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© 2005-2006, IMI Cornelius Inc.
FlavorFusion Installation Manual
DIAGRAMS
Flow Diagram
PW
CW
CW
PW
FIGURE 8. Flow Diagram
© 2005-2006, IMI Cornelius Inc.
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Publication Number: 621057601INS
FlavorFusion Installation Manual
Wiring Diagram
W H T
B L K
B L K
W H T
B L K
R E D
B L K
W H T
X F O R M R
L 2 _
Y E L
R E D
L 2 _ I N
B A L S T
L 2 _
H E A T R
L 2
B L K
W H T
B L K
Y E L
W H T
W H T
B L U
B L K
W H T
R E D
R E D
B L U L T
B L K
W H T
Y E L
G R N
Y E L
Y E L
W H T
W H T
R E D
B L K
W H T
Y E L
W H T
B L U
B L K
B L K
R E D
Y E L
B L K
W H T
R E D
FIGURE 9. Wiring Diagram - 120V Unit
Publication Number: 621057601INS
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© 2005-2006, IMI Cornelius Inc.
FlavorFusion Installation Manual
Wiring Schematic
L1
L2
L2_IN
L1_IN
EARTH
CARB MOTOR
CARB MOTR_L2
CARB MOTR
CARB EARTH
AGITATOR MOTOR
AGITATOR
AGITATOR_L2
AGITATOR EARTH
OPTIONAL LIGHTING
FLOURESCENT LIGHT
BALLAST
BALLAST_L2
L1_BALLAST
STARTER
HEATER
HEATER_L2
L1_HEATER
XFORMER_L1
L2_XFORMER
120V Pri
80 VA
XFRMR1
E-BOARD
E-BOARD
24V Sec
KEY
LOCK
INTERFACE BOARD
VALVE (6)
INTERFACE BOARD
INTERFACE
BOARD
VALVE (6)
TOUCHPAD
TOUCHPAD
VALVE (6)
TOUCHPAD
80 VA
120V Pri
XFRMR2
24V Sec
KEY
LOCK
INTERFACE BOARD
INTERFACE BOARD
ICE CUBE
LED
INTERFACE
BOARD
VALVE (6)
VALVE (6)
TOUCHPAD
TOUCHPAD
E-BOARD
VALVE (6)
J7
TOUCHPAD
ICE GATE SWITCH
J3
CARB TANK
HIGH LEVEL PROBE
LOW LEVEL PROBE
GROUND
J4
FIGURE 10. Wiring Schematic
© 2005-2006, IMI Cornelius Inc.
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Publication Number: 621057601INS
FlavorFusion Installation 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. If repairs are to be made to the refrigeration system, make sure
electrical power is disconnected from the unit.
Should your unit fail to operate properly, check that there is power to the unit and that the hopper contains
ice. If the unit does not dispense, check the following chart under the appropriate symptoms to aid in
locating the defect.
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
Publication Number: 621057601INS
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© 2005-2006, IMI Cornelius Inc.
FlavorFusion Installation Manual
Beverage does not
dispense
No 24VAC to valves
Restore 24 VAC to valves
No CO2 pressure
Restore CO2 pressure
Adjust valve brix
Beverage is too
sweet
Valve brix requires adjustment
Carbonator is not operating
No CO2 in carbonator
Repair carbonator
Restore CO2 pressure in carbonator
City water pressure supply low or
inconsistent
Booster pump must be used if dynamic
water pressure drops below 40 psig.
Unit will not
dispense
carbonated drinks.
Dispenses syrup
only.
CO2 pressure in carbonator tank is too
high.
Check CO2 pressure regulator setting.
75 psig recommended. Relieve
pressure from carbonator tank.
Water valve will not open
Check electrical connection to water
valve. Check resistance of coil (should
be 9 ohms). Check for voltage at coil
when brand button is depressed.
Unit will not
Carbonator tank is empty, because tank
was emptied while power was applied
to unit. 5 minute time-out of carbonator
pump/motor occurred, and carbonator
pump is locked off.
Unplug the unit and reconnect the unit.
Main control board will reset, ice
agitation will occur, and carbonator tank
will refill to normal level.
dispense
carbonated drinks.
Spurts CO2 and
syrup only.
Note that this can occur while the water
filter system is serviced or water supply
is shutoff. If drinks are drawn from the
dispenser while water pressure is
shutoff, the carbonator pump starts and
runs continuously, then shuts off on the
5 minute timeout.
1) low water 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 third time,
then lockout carbonator pump, which
will generate a service call.
Carbonated drinks
are flat (low on
carbonation)
CO2 is out
Replace CO2
Carbonator tank is 100% filled because
the city water pressure exceeds the
carbonator tank CO2 pressure regulator
CO2 setting for the carbonator tank is
75 psig, max water pressure is 60 psig.
If necessary, install a water pressure
regulating valve.
setting.
Low water pressure
Could be caused by excessively long
runs (over 40 ft.) of 3/8” water supply
line.
Increase line size to 1/2”
Low water pressure
Add water pressure booster pump
Change water filter
Plugged water filter.
Water booster bladder has burst
Replace water booster tank/bladder
© 2005-2006, IMI Cornelius Inc.
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Publication Number: 621057601INS
FlavorFusion Installation Manual
No Syrup or
Watered down drink
dispensed
Syrup supply is empty
Replace BIB
BIB pump not working
Replace BIB pump
No CO2 or compressed air supply to
BIB pump, or not enough pressure
Check CO2 pressure regulator setting.
65 psig recommended. Replace CO2
tank or fix compressor.
Carbonator Troubleshooting
Symptom
Cause
Remedy
Carbonator pump
does not start to fill
tank
Power cord for the carbonator pump
motor is not connected.
Carbonator pump is powered off the
main control board inside the electrical
box of the unit. Check that the umbilical
cord is connected from the unit to the
pump motor terminal box.
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.
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 probe reads “wet”
Check color of leads going to probes.
Black should go to bottom probe and
white to top probe. Reverse if incorrect.
Carbonator tank
overfills, overflows
through relief valve,
and pump shuts off
after 5 minutes.
A. Poor electrical connections between
carbonator tank and main control board
A. Check connections at carbonator
tank and at connector J4 on the main
control board.
B. Broken wires between carbonator
tank and main control board
B. Replace wire harness
C. Defective liquid level probes
C. Replace both liquid level probes
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© 2005-2006, IMI Cornelius Inc.
FlavorFusion Installation Manual
DIAGNOSTICS GUIDE FOR THE MAIN CONTROL BOARD
Observed State
of Red LED
State
Sensor Input
Control Response
Service Remedy
0
Flash rate 3
seconds
Both probes read “wet”
Standby mode. Pump
= OFF
No service required
1
Flash rate
1/2 second
Pump is OFF and
HIGH probe reads “dry”
and LOW probe reads
“wet”
Waiting for level to
drop below LOW
probe. Pump = OFF
No service required
2
3
Flash rate
Both HIGH and LOW
probes read “dry”
Normal mode.
Pump = ON
No service required
No service required
1/2 second
Flash rate
1/2 second
Entered when HIGH
probe does not detect
liquid, and LOW probe
does detect liquid, and
pump is ON
Normal mode.
Pump = ON
4
Flash rate 1
second
Entered when 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
connected to the LOW
probe and also to Pin 4
of Connector J4
- Reverse the
connections if incorrect
- Replace harness if
necessary
5
6
ON
Poor signal connection
to the carbonator tank.
May result in short
cycling of the
Able to continue to
function but
Check the harness
continuously,
but “flickers”
every 3
connections of the red
signal wire at both ends:
1) at the carbonator ring
carbonator pump
short-cycles. Pump
seconds
carbonator pump.
will come on each time
a drink is drawn. THIS
SITUATION SHOULD
BE CORRECTED.
terminal and
2) at Pin 5 of the J4
connector at the main
control board
ON
continuously
Entered when pump
has run continuously
for 5 minutes
THIS IS AN ERROR
CONDITION.
Unplug the unit and plug
it back in. This will reset
the unit's main control
board and restart the
carbonator pump.
© 2005-2006, IMI Cornelius Inc.
- 17 -
Publication Number: 621057601INS
FlavorFusion Installation Manual
DIAGNOSTICS GUIDE FOR FLAVORFUSION KEYPAD LIGHTING
Observations of LED Lighting on Customer Interface Keypad
Symptom
Cause
Remedy
1
Bonus Flavor Icon and/
or Drink Icon LEDs (see
FIGURE 4) are ON
continuously with four
quick flashes every 30
seconds.
A. This indicates a poor
connection in the lighting
synchronization harness
that connects the interface
boards together.
A. Turn the keyswitch to disconnect
power to the interface boards. Check the
electrical connections between the
harnesses that interconnect the right
side of all interface boards together. Turn
back the keyswitch to reconnect power.
2
3
Bonus Flavor Icon and/
or Drink Icon LEDs (see
FIGURE 4) are not in
sync with the lighting
sequence,
B. This may result over time
as the lighting sequence
between push button pads
can become slightly out of
synchronization.
B. Unplugging the unit and performing a
power up will re-synchronize the lighting
sequence.
Keypad LED lighting is
not working
A. Poor connection between
interface board and keypad
PCB
A. Turn the keyswitch to disconnect
power at the interface boards. Check
harness connections at each interface
board.
B. Keypad LED's are burnt
out
B. Turn the keyswitch to disconnect
power at the interface boards. Unplug
the ribbon cable from one interface
board and test it by plugging it into the
neighboring interface board. If the
keypad still doesn't light up replace the
keypad PCB.
C. Interface board is
defective.
C. Turn the keyswitch to disconnect
power at the interface boards. Unplug
the ribbon cable from one interface
board and test it by plugging it into the
neighboring interface board. If the LED's
light up the interface board is defective.
Replace the interface board.
D. Corrosion at connector
between keypad and ribbon
cable.
D. Replace keypad circuit board and
ribbon cable.
E. Main control board is
defective.
E. Replace the main control board.
4
During standby mode,
the brand and bonus
LED icons do not
alternate back and forth
- instead they light
together.
Bonus buttons are
incorrectly programmed as
brand buttons, or vice versa.
Check the programming of each keypad
and set each button as CW, PW, or
timed dispense based upon the flavor
lineup.
Contact your local syrup or beverage equipment distributor for additional information and troubleshooting
of beverage system.
Publication Number: 621057601INS
- 18 -
© 2005-2006, IMI Cornelius Inc.
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