International Carbonic Premier 2000 - Soda
Contents
1. atre ree dee tia dre 5 6 CHANGING WATER FILTER CARTRIDGE 2 0 5 6 ADJUSTMENTS HIGH PRESSURE 07 nnns 5 7 LOW PRESSURE CO2 7 nnns 5 7 DIET SYRUP TANK CO2 REGULATOR pp 5 7 BRIX INSTRUGT IONS cnn Per tnde anun u n e eur ena aee eae eren eene e 5 8 BRIXING PFC II 0 02 2 22 200000 nennen nennen nnns nennen terrier nennen nns 5 9 MAINTENANCE ERI ti arbat e ture tte itr tte ta 5 9 CLEANING AND 5 10 CHAPTER VI TROUBLESHOOTING GOOLINGPUUNL22 ii tionen rir ree er ete d eR Pete tO GR PO reed to ds 6 1 WATER PUMP MOTOR WILL NOT OPERATE 6 1 WATER PUMP MOTOR WILL NOT SHUT OFF 6 1 WATER PUMP MOTOR WILL NOT SHUT OFF AND PRESSURE 6 1 SHORT CYCLING OF WATER PUMP MOTOR 6 2 WATER PUMP CAPACITY TOO nennen nnns nnn nennen 6 2 WATER PUMP OPERATES BUT WATER PUMP DOES NOT PUMP 6 2 FROZEN WATER nenne nnns 6 2 COOLING CONDENSING UNIT NOT OPERATIONAL seen 6 2 AGITATOR MOTOR NOT 6 2 COMPRESSOR DOES NOT OPERATE2. 3 2 ADJUST WATER TO SYRUP 3 2 ADJUST SIZE OF DRINK DISPENSED 3 2 CHAPTER IV OPERATORS INSTRUCTIONS DAILY PRE OPERATION 8 ta huhu E 4 1 REPLENISHING 4 1 REPLENISHING SYRUP SUPPLY 2 4 1 COOLING UNIT nennen nnn 4 1 CHECKING WATER 7 4 2 CHANGING WATER 4 2 Ge aa a TA 4 2 ADJUSTING WATER FLOW RATE pp 4 2 ADJUSTING WATER TO SYRUP RATIO OF DISPENSED PRODUCT 4 2 ADJUSTING SIZE OF DRINK 000 001 4 2 TESTING FOR ende ee ede 4 2 TABLE CONTENTS Continued Page CHAPTER V SERVICE AND MAINTENANCE PERIODIC INSPECTION AND CLEANING pp 5 1 PREMIER 2000 CABINET 5 1 CLEANING CONDENSER 5 2 CHECKING CHANGING WATER BATHH 5 2 CARBONATOR 5 3 SERVICING CHECK 0 5 4 COMPOSITE EXPLODED VIEW CHECK VALVES pp 5 5 REPLENISHING 2 5 6 REPLENISHING SYRUP 2 5 6 SYRUP FLAVOR CHANGE
3. eee 3 5 Amps Circuit Ampacity J uice 110 2 8 Amps Condensing Unit da ben Mg e gen p e 2 2 Amps Plain Water Pump 1 12 2 nn 7 Amps M Eee 5 Amps edu 1 amps Water Filter Recommended But Optional See Manufacturer Specifications For Operating Conditions Incoming Water Pressure Regulator Optional Pressure 25 40 C02 High Pressure Regulator Carbonated units only PSI Pressure 75 85 C02 Low Pressure Regulator Carbonated Flavored units only mre eme nus t Approx 40 PSI FIGAL iii ip p fet Approx 30 PSI CO2 Low Pressure Regulator Optional Pressure FIGAL approx 30 PSI CO2 Diet Drink Pressure Regulator if required Pressure 6 10 PSI DISPENSING VALVES Ambient Operating Temperature 40 F to 100 F Electrical Requirements Operating Voltage 24VAC 60Hz 1 2 INTERNATIONAL CARBONIC INC ADELANTO CALIFORNIA TITLE PREMIER 2000 DATE 12 09 04 DRN BY APPR BY GLW PREMIER 2000 SYM Q
4. 6 3 COMPRESSOR WORKS CONTINUOUSLY BUT DOES NOT FORM 6 3 COMPRESSOR WILL STOP AFTER SUFFICIENT ICE E 6 3 CONDENSER MOTOR NOT 6 3 DISPENSING VALVES WATER OR SYRUP LEAKING FROM NOZZLE AFTER ACTUATION 6 4 NO WATER NO SYRUP LEAKING FROM NOZZLE AFTER ACTUATION 6 4 NO WATER NO SYRUP BEING DISPENSED FROM 6 4 NO SYRUP BEING 87 nire nnns 6 4 NO WATER BEING 8 6 5 DISPENSED PRODUCT CARBONATED TOO 6 5 DISPENSED PRODUCT MAKES FOAM AS IT LEAVES DISPENSING VALVE ant Qa ee eui 3 6 5 DISPENSED PRODUCT COMES OUT CLEAR BUT FOAMS IN CUP OR Low 6 5 WATER TO SYRUP RATIO TOO LOW OR TOO HIGH nennen 6 5 ADJUSTMENT OF SYRUP METERING PIN DOES NOT PRODUCE DESIRED WATER TO SYRUP 6 5 CARBONATION TROUBLE SHOOTING FLOW CHART 1 6 6 CARBONATION TROUBLE SHOOTING FLOW CHART 2 6 7 CARBONATION TROUBLE SHOOTING FLOW CHART 8 3 6 8 NOTE SECTION pee 6 9 PREFACE INTERNATIONAL CARBONIC INC has enjoyed over 53 years of manufacturing
5. 1 8 INTERNATIONAL CARBONIC ADELANTO CALIFORNIA TITLE PREMIER 2000 PRE COOLER DATE 12 09 04 DRN BY GLW APPR BY PREMIER 2000 PRE COOLER SYMIQTY PART NO DESCRIPTION 1 1 S1544 R LID REMOTE WITH INSULATION 211 50783 UNIT ON OFF SWITCH 3 1 1541 SERVICE PANEL REAR 411 51542 SERVICE PANEL LEFT SIDE 5 1 S1543 SERVICE PANEL RIGHT SIDE 6 1 G0016 TY RAP LARGE 711 3 8 CLEAR TUBING 6 8 2 50741 EVAPORATOR COIL RETAINER 9 1 S0833 AGITATOR 10 2 S1323 EVAPORATOR GUIDE WEDGE 11 2 S1540 EVAPORATOR COIL SUPPORT BRKT 12 3 1324 POSITIONING BAR 13 1 1533 R WATER COIL 14 1 1547 STANDPIPE 6 3 4 WHITE 15 1 1546 OVERFLOW 7 GRAY 16 1 S0513 A ELECTRONIC ICE BANK CONTROL 17 1 1304 U ICE BANK CONTROL BULB BRACKET 18 1 S1532 EVAPORATOR COIL ASSEMBLY 19 1 50509 ACCUMULATOR 4 VERTICAL 20 1 lacu CAP TUBE 12 031 21 1 1531 BUCKET ASSY WITH INSULATION 22 1 1539 R VALVE MOUNTING PLATE BLANK 23 1 1535 CONDENSATE DRAIN NIPPLE 24 1 m 6 CLEAR TUBING 1 4 I D X 3 8 2511 51534 CONENSATE DRAIN ELBOW 26 1 1530 FRAME COMPLETE 27 11 51325 SQUARE GROMMET NUT 28 2 A0046 5 16 X 18 FLANGE WHIZ LOCK SCREW 3 4 29 1 JAZAO37OVXAXAJCONDENSING UNIT 1 9 AZA0370YXA COMPRESSOR
6. excellence in the field of carbonation in the beverage related industry We have had a long and proud history with quality as our standard and innovation as our goal Originally started just after World War in Canfield Ohio as Carbonic Dispensers We enjoyed patents on the first Sodajet type carbonator This method of carbonation instantaneously carbonated the water to 100 saturation We developed the 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 systems for the future such as electronic interrogatable portion controls to electronic liquid level controls We hope you enjoy this piece of equipment which has been produced to give many years of trouble free service We thank you for your purchase and hope we may serve you in the future 1 GENERAL DESCRIPTION This chapter gives the description theory of operation and design data for the PREMIER 2000 and related components The PREMIER 2000 series utilizes one cabinet but can be manufactured in many configurations The following data will refer to four of the basic types of configuration As a remote cooling unit w
7. INSTALL WATER FILTER ASSY OPTIONAL 1 Install water filter assembly on wall or other supporting structure 2 Connect water filter assembly to inlet of valve on water supply line using minimum 3 8 I D water line 3 Connect water filter assembly outlet to PREMIER 2000 plain water inlet fitting using minimum 3 8 I D waterline See CONNECTING WATER INLET When a water filter is used it is important that it has a minimum 100 gallons per hour capacity and should be thoroughly flushed before it is connected to the water inlet connection INSTALL WATER PRESSURE REGULATOR OPTIONAL If water pressure exceeds 40 psi a water pressure regulator or water pressure reducing valve must 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 orifice opening INSTALL WATER HOLDING TANK OPTIONAL When no water pressure is available or where the water supply system is inadequate a water holding tank may be installed above the pump level The pump will pump water from the holding tank to the carbonator WATER REGULATOR 1 2 GATE VALVE WATER FILTER SUGGESTED WATER FLOW INSTALLATION 2 4 INSTALL B I B OR SYRUP TANKS AND ACCESSORIES OPTIONAL Place B I B or syrup tanks as close as
8. a direct relationship between dispensed temperature and the volumes of C02 that can be held in liquid form 1 14 CHAPTER II INSTALLATION This chapter covers unpacking and inspection selecting location installing PREMIER 2000 and related components connecting water inlet and electrical requirements UNPACKING AND INSPECTION Upon receiving unit immediately remove unit from shipping carton and inspect for shipping damage NOTE Before leaving the factory all PREMIER 2000 units were carefully inspected and the carrier has accepted and signed for them Any damage or irregularities should be noted at the time of delivery and immediately reported to delivering carrier Request a written inspection report from claims inspector to substantiate any 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 02 Regulator C 1 3 65 221 Low Pressure C02 Regulator C F 1 4 S 1149 Drip Trav l 5 S 1149A Cup Rest 1 65 5 105 6 Gas Line Inner Braid 1 7 e Product Decals 1 per flavor 8 S 208 Water Pressure Regulator 1 9 Water filter 1 10 S 208A Water Pressure Regulator 1 Optional C Carbonated Unit C F Carbonated Flavored uni
9. carbonator circuit 4 connections including cylinder valve should be coated with a soap solution If bubbles appear a leak is apparent S Always be sure that the low pressure adjusting screw is completely backed off before testing carbonator circuit for leaks Otherwise gas going into syrup tanks would cause this high pressure gauge needle to balance with pressure in syrup tanks which would be a false indication of a leak in the carbonator circuit 6 After it has been determined that there are no leaks in the carbonator circuit open 2 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 downward there is leak in the low pressure circuit Check all connections with a soap solution paying particular attention to syrup tank covers If low pressure gauge needle remains stationary there is no leak 4 3 CHAPTER V SERVICE AND MAINTENANCE This chapter describes service and maintenance procedures to be performed on PREMIER 2000 units and related components PERIODIC INSPECTION AND CLEANING Daily 1 Clean any syrup from storage tanks B I B racks connecting sockets Q C D s and general syrup storage area with warm water 2 Check the C02 gas supply If cylinder pressure is below 500 P S I rep
10. object in water pump or 4 Clear restrictions and check pump strainer restriction to water pump for debris Water pump 1 Water supply to low or turned off 1 Inlet water supply must be a minimum of operates but 3 8 water pump 2 water pump 2 Replace water Pump does not pump 3 Water supply filter clogged 3 Replace filter 4 Water pump strainer clogged 4 Clean water pump strainer 6 1 Frozen water 1 Bad ice bank control 1 Replace bad ice bank control bath 2 Refrigerant leak causing 2 Repair leak evacuate and re charge undercharge 3 Defective agitator motor 3 Replace defective agitator 4 Dirty water bath 4 Melt ice empty amp clean bath Replenish w fresh water Cooling or 1 No electrical power 1 Plug power cord into electrical box Check condensing unit on off switch non operational 2 Defective ice bank control 2 ice bank control 3 Dirty condenser unit 3 Clean condenser unit w vacuum cleaner 4 voltage amperage 4 Check for proper voltage amperage 5 Loss of refrigerant 5 Repair leak and replenish refrigerant 6 Bad overload and relay 6 Replace overload and relay 7 Compressor bad 7 Replace compressor 8 Restriction pinched or crimped 8 Repair straighten or replace defective line line Agitator motor 1 Agitator propeller obstructed or 1 Remo
11. possible to PREMIER 2000 unit preferably not farther than 5 feet Lay out syrup lines from unit to syrup pumps or tanks Connect lines from low pressure regulator for B I B or transfer tank installations Connect line from low pressure regulator to Q C D for B I B or install quick disconnect for transfer tank type installations Install incoming syrup line to unit on Q C D for B I B Install quick disconnect on incoming line to accommodate transfer tank installs Activate Q C D or install quick disconnects to transfer tanks Check all connections for leaks See Chapter IV CONNECTING WATER INLET WATER PIPE CONNECTIONS AND FIXTURES DIRECTLY CONNECTED TO POTABLE WATER SUPPLY SHALL BE SIZED INSTALLED AND MAINTAINED ACCORDING TO FEDERAL STATE AND LOCAL LAWS The water connection on the PREMIER 2000 is made to a flexible water line by means of a flare nut 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 but prior to connecting water supply to cabinet be sure to thoroughly flush all incoming water lines to remove all scale any impurities that may be in the lines It is important to remember that the PREMIER 2000 has a carbonator capacity of a minimum of 60 gallons per hour Therefore it is imperative that the f
12. water following the flexible tube into syrup section This formed S will also hold syrup in tube for a more reliable brix reading Actuate valve allowing the soda water to flow into large section of cup and syrup into smaller section Adjust the syrup metering pin flow control as necessary to secure a proper brix When proper brix syrup adjustments have been made the two sections of the cup should fill to the desired ration 5 8 Instructions Continued BRIXING VALVE The water syrup flows individually adjusted by their respective metering pin or flow controls Located under the valve cover on the top rear of the valve see illustration One recommended method utilizes the ratio brix cup The brix cup is divided into two sections one to hold up to 9 parts water and the smaller section to hold one or two parts of syrup When adjusting a flavor with a ratio of more than 9 to 1 syrup 2 line must be used When using syrup 2 line the waterside is doubled to 18 to 1 vs 9 to 1 When facing the valve the syrup is always to the right and the water soda is to the left To decrease syrup or water flow turn metering pin clockwise To decrease syrup or water flow when using flow control valves turn counter clockwise To increase reverse rotation respectively The ultimate goal is to achieve a proper ratio of water vs syrup This ratio can and will vary with differing products TOP VIEW 1
13. 1 1547 STANDPIPE 6 3 4 WHITE 15 1 1546 OVERFLOW 7 GRAY 16 1 50513 ICE CONTROL 17 1 S1304 U ICE BANK CONTROL BULB BRACKET 18 1 1330 SWITCH LOCK W KEYS 19 1 1531 BUCKET ASSY WITH INSULATION 20 1 1532 EVAPORATOR COIL ASSEMBLY 21 1 50509 ACCUMULATOR 4 VERTICAL 22 1 X0121 CAP TUBE 12 031 23 1 1539 2 VALVE MOUNTING PLATE 24 1 1535 CONDENSATE DRAIN NIPPLE 25 1 6 CLEAR TUBING 1 4 I D X 3 8 O D 26 1 1534 CONDENSATE DRAIN ELBOW 1 7 PREMIER 2000 J UICE SYM QTY PART NO DESCRIPTION PAGE 2 CONTINUED 27 1 E0276 A TRANSFORMER 24V 40VA 28 1 1530 FRAME COMPLETE 29 11 1325 SQUARE GROMMET NUT 30 2 A0046 5 16 X 18 FLANGE WHIZ LOCK SCREW 3 4 31 1 AZA0370YXAXA JCONDENSING UNIT 1 9 AZA0370YXA COMPRESSOR ONLY 32 2 PFC II PA DISPENSING VALVE W PUSH ARM 33 11 A0014 SCREW 10 X 1 2 PHILLIPS T H SS COMBO 34 1 1551 DRAIN TUBE HOLD DOWN BRACKET 35 1 A0025 10 24 X 1 2 TH SCREW 36 1 0743 DRAIN PAN HARDWARE SET 37 1 1552 DRAIN TUBE 5 16 X 4 S S TUBING 38 1 1318 CUSHIONED FEET SET OF 4 39 1 0141 12 CORD 40 1 S1549 DRAIN PAN W CUP REST 41 4 1335 TERMINAL BOARD SPACER NYLON 42 1 1537 TERMINAL BOX WITH COVER 43 1 5 7 8 HOLE PLUG 44 1 S1309 TERMINAL BOARD 45 5 S0046 BUSHING UNIVERSAL 46 1 S1538 TERMINAL BOX COVER ONLY 47 4 0020 8 32 X 3 8 SCREW S S 48 1 E0664 STRAIN RELIEF BUSHING
14. 3 Tighten connection and or repair open 4 Loose electrical connection 4 circuit Check line voltage and or open electrical circuit Water pump 1 Defective water pump 1 Replace water pump motor will not 2 Electrode inside carbonator tank 2 Replace carbonator tank electrode shut off defective 3 L L C assembly inoperable 3 Replace L L C assembly 4 Loose electrical connection and 4 Tighten connection and or repair open or open electrical circuit ground circuit 5 Carbonated water leak 5 Find and repair leak Water Pump 1 Electrode inside carbonator does 1 Replace defective electrode or check and motor will not not sense ground tighten ground connection at control box shut off and 2 L L C assembly inoperable 2 Replace L L C assembly pressure relief engaged Short cycling of 1 Ground connection loose or 1 Attach or tighten ground connection water pump disconnected motor 2 Electrode inside carbonator tank 2 Replace carbonator tank electrode defective 3 Carbonated water leak in system 3 Repair carbonated water leak 4 L L C assembly inoperable 4 Replace L L C control assembly Water pump 1 Inlet water volume supply to low 1 Increase diameter of supply line install capacity to low holding tank 2 Water motor pump worn out 2 Replace water pump 3 Kinked or restricted water supply 3 Clear or replace restricted water supply line line 4 Foreign
15. 3 8 MP X 1 4 H 38 1 AZA0370YXAXA CONDENSING UNIT 1 9 H P 1 AZA0370YXA COMPRESSOR ONLY 1 9 H P 39 1 50743 DRAIN PAN HARDWARE SET 40 1 A0025 10 24 X 1 2 TH SCREW 41 1 1551 DRAIN TUBE HOLD DOWN BRACKET 42 1 1523 CARB PUMP AND MOTOR ASSY 43 1 1318 CUSHIONED FEET SET OF 4 44 1 E0141 12 CORD 45 1 1549 DRAIN PAN W CUP REST 46 4 1335 TERMINAL BOARD SPACER NYLON 47 1 1537 CONTROL BOX WITH COVER 48 1 1552 DRAIN TUBE 5 16 X 4 SS TUBING 49 1 S0068 B ELECTRONIC LIQUID LEVEL CONTROL 50 2 S 7 8 HOLE PLUG 51 7 50046 BUSHING UNIVERSAL 52 1 1538 CONTROL BOX COVER ONLY 53 2 A0049 8 32 X 3 8 PH TYPE F SELF TAP 54 1 E0664 STRAIN RELIEF BUSHING 55 2 A0020 8 32 X 3 8 TH SCREW S S 56 1 A0067 8 32 X 3 8 HEX HD GREEN GROUND SCREW A 2 INTERNATIONAL CARBONIC INC PERLE PREMIER 2000 J UICE DATE 12 09 04 DRN BY GLW CHK BY GLW APPR BY ADELANTO CALIFORNIA GLW 1 6 PREMIER 2000 J UICE SYM QTY PART JDESCRIPTION 1 1 1544 LID WITH INSULATION 2 1 50783 UNIT ON OFF SWITCH 3 1 1541 SERVICE PANEL REAR 4 1 1542 SERVICE PANEL LEFT SIDE 5 1 1543 SERVICE PANEL RIGHT SIDE 6 1 G0016 TY RAP LARGE 7 1 3 8 CLEAR TUBING 6 8 2 S0741 EVAPORATOR COIL RETAINER 9 2 1323 EVAPORATOR GUIDE WEDGE 10 2 1540 EVAPORATOR COIL SUPPORT BRKT 11 1 50833 AGITATOR PUMP 12 2 1324 POSITIONING BAR 13 1 1533 R WATER COIL 14
16. 8 PARTS WATER valve cover removed DECREASE d INCREASE N De SYRUP 1 WATER METERING PN uos SYRUP 2 SYRUP METERING PIN 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 regular basis nightly recommended the possibility of foamy and off tasting drinks is greatly increased 1 Turn off key switch normally located on valve plate or side of cabinet Or disconnect tower from electrical supply 2 Clean all exposed areas of valve with mild soap or sanitizing solution and warm water 3 Remove nozzle and place in warm water Do not soak nozzle in bleach water this will turn the nozzle yellow and cause deterioration It is recommended to use a soft bristle brush part No S 1064 to clean any hard to get areas of valve or nozzle Do not soak nozzle in extremely hot water nozzle will warp 5 9 SANITIZING PROCEDURES Your local health department rules and general area cleanliness should determine the frequency at which the unit should be sanitized EQUIPMENT REQUIRED Stainless Steel containers product tanks or large volume container CO2 Supply if applicable Same as used with dispensing unit Cleaning Agent Sanitizing Solution Phenolphthalein VR WN NOTE One recommended cleaning agent and sanitizing agent is manufactured by MT HOOD CHEMICAL CORP 4444 N W Yeon Avenue Portland Oregon 97210
17. MPRESSOR GSIGREEN GROUND TERMINAL SCREW IN CONTROL BOX 110 VAC ON OFF S SWITCH ILLUMINATION OPTIONAL BLACK RIBBED CONDENSING UNIT ICE BANK CONTROL TITLE 5 1309 ELECTRICAL MA DATE 1 29 99 DRN BY GLW CHK BY GLW APPR BY ADELANTO CALIFORNIA GLW INTERNATIONAL CARBONIC INC 1 12 VALVE SCHEMATIC 24 VOLT 24 VOLT SINGLE 24 VOLT VALVES ae q A KEY SWITCH 77 24 VOLT TRANSFORMER ELECTRICAL SCHEMATIC 24 VOLT 1 13 THEORY OF OPERATION The PREMIER 2000 was designed to manufacture and dispense carbonated or a non carbonated beverage much like your local bottling plant that cans or bottles your favorite carbonated or non carbonated drink The Premier 2000 cabinet is essentially divided into three separate areas The water bath area the valve area and the condensing unit and electrical area For J uice or non carbonated beverages the water is routed through a water coil which is submerged in an ice cold water bath and then directed to a valve For a carbonated beverage the water is also routed through this submerged water coil and then to a carbonator tank which is also submerged in this ice cold water bath At this carbonator tank CO2 is introduced and then mixed with the water to form a mild form of acid carbonic acid This mild form of acid must be refrigerate
18. ONLY 30 11 A0014 SCREW 10 X 1 2 PHILLIPS T H S S COMBO 31 1 50743 DRAIN PAN HARDWARE SET 32 1 A0025 10 24 X 1 2 TH SCREW 33 1 1551 DRAIN TUBE HOLD DOWN BRACKET 34 1 51519 REMOTE DRIP PAN 35 1 1552 DRAIN TUBE 5 16 X 4 S S TUBING 36 1 51318 CUSHIONED FEET SET 4 37 1 0141 12 CORD 38 4 S1335 TERMINAL BOARD SPACER NYLON 3911 1537 TERMINAL BOX WITH COVER 40 1 S 7 8 HOLE PLUG 41 1 51309 TERMINAL BOARD 42 5 S 46 BUSHING UNIVERSAL 43 1 1538 TERMINAL BOX COVER ONLY 44 1 E0664 STRAIN RELIEF BUSHING 45 2 0020 8 32 3 8 SCREW S S 1 10 5 68 ELECTRICAL SCHEMATIC 120 VOLT Or MOTOR ICE BANK CONTROL _ SS COMPRESSOR TRANSFORMER WHITE 120 VAC BLACK INTERNATIONAL CARBONIC INC 22 G4 PI 35 D ON OFF JAB B4 B5 MOTORS CONDENSING R MOTORI BLACK UNIT AGITATOR PUMP SHORT LONG HITE BLACK ELECTRODE GROUND TERMINAL SCREW IN CARB CONTROL BOX MOTOR PUMP Note Ground Terminals Carbonator Tank and Water Bath Must be Commonly Grounded NOTE IF USING EXTRA 120V ACCESSORIES SUCH AS RECIRCULATING MOTOR ILLUMINATIO 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 TERMINALSGROUND TERMINALS ARE Gl G2 G3 G4 1 11 MOTOR CO
19. PREMIER 2000 Installation Service Manual 16630 Koala Rd Adelanto California 92301 1 800 854 1177 INTERNATIONAL CARBONIC INC IMPORTANT This manual is guide for installing 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 trouble shooting this equipment TABLE CONTENTS Page i CHAPTER GENERAL 1 1 GENERAL DESCRIPTIONS t tihi cn tek ai ca nega eu e saad d eeu eR dat 1 1 SYSTEM DE SORIP THON 1 1 DESIGN DATAS i ia p a E a eara E SAEI 1 2 PREMIER 2000 EXPLODED VIEW kea tuai tanakka aei Tkan 1 3 PREMIER 2000 EXPLODED VIEW DESCRIPTION pp 1 4 PREMIER 2000 JUICE EXPLODED VIEW pp 1 6 PREMIER 2000 JUICE EXPLODED VIEW 1 7 PREMIER 2000 PRE COOLER EXPLODED VIEW pp 1 9 PREMIER 2000 PRE COOLER EXPLODED VIEW DESCRIPTION 1 10 S 68 B ELECTRICAL 5 8 1 11 1309 ELECTRICAL SCHEMATIC 1 12 24 VOLT ELECTRICAL 5 1 13 THEORY OF 99 1 14 CHAPTE
20. R 2 1 UNPACKING AND 2 1 SELECTING 2 1 LOCATION RECOMMENDATIONS FOR PREMIER 2000 2 2 INSTALLATION a aunts eee Lined aere ea ada 2 2 INSTALL COOLING 2 2 INSTALL HIGH PRESSURE CO2 REGULATOR CO2 CYLINDER 2 2 3 INSTALL LOW PRESSURE REGULATOR AND LINES eese 2 3 INSTALL WATER FILTER ASSY 2 4 INSTALL WATER PRESSURE REGULATOR 2 4 INSTALL WATER HOLDING TANK OPTIONAL sees 2 4 INSTALL BIB OR SYRUP TANKS AND 2 5 CONNECTING WATER 2 5 ELECTRICAL 2 5 CHAPTER III PREPARATION PREPARING SYSTEM FOR 3 1 PREPARING AND STARTING REFRIGERATION UNIT 2 22 2 2 242 3 1 PURGE DISPENSING nennen nnns 3 1 ACTIVATE HIGH PRESSURE 2 SYSTEM 3 1 ACTIVATE LOW PRESSURE CO2 GAS AND SYRUP SYSTEMS 3 2 ADJUST WATER FLOW
21. TY PART NO DESCRIPTION 1 1 1544 LID WITH INSULATION 2 1 50783 UNIT ON OFF SWITCH 3 1 1541 SERVICE PANEL REAR 4 1 1542 SERVICE PANEL LEFT SIDE 5 1 1543 SERVICE PANEL RIGHT SIDE 6 1 50073 48 SENSING PROBE ASSY 7 1 S1536 CARBONATOR TANK ASSY 8 2 50741 EVAPORATOR COIL RETAINER 9 2 1323 EVAPORATOR GUIDE WEDGE 10 2 1540 EVAPORATOR COIL SUPPORT BRKT 11 1 G0016 TY RAP LARGE 12 1 3 8 CLEAR TUBING 6 13 1 S0833 AGITATOR PUMP 14 UP TO3 1347 SYRUP COIL 15 UP TO 2 S0588 A SYRUP COIL 16 1 1533 R WATER COIL 17 2 1324 POSITIONING BAR 18 1 1547 STANDPIPE 6 3 4 WHITE 19 1 1546 OVERFLOW 7 GRAY 20 1 50513 ICE CONTROL 21 1 S1304 U ICE BANK CONTROL BULB BRACKET 22 1 S1330 SWITCH LOCK W KEYS 23 1 1531 BUCKET ASSY WITH INSULATION 24 1 1532 EVAPORATOR COIL ASSEMBLY 25 1 50509 ACCUMULATOR 4 VERTICAL 26 1 CAP TUBE 12 031 27 1 S1539 2 VALVE MOUNTING PLATE 28 1 S1535 CONDENSATE DRAIN NIPPLE 29 1 6 CLEAR TUBING 1 4 1 D X 3 8 O D 1 4 PREMIER 2000 5 PART DESCRIPTION PAGE 2 CONTINUED 30 1 1534 CONDENSATE DRAIN ELBOW 31 1 E0276 A TRANSFORMER 24V 40VA 32 1 1530 FRAME COMPLETE 33 11 1325 SQUARE GROMMET NUT 34 2 A0046 5 16 18 X 3 4 FLANGE WHIZ LOCK SCREW 35 2 PFC II PA DISPENSING VALVE W PUSH ARM 36 11 A0014 SCREW 10 X 1 2 PHILLIPS T H SS 37 2 50169 90 DEGREE ELBOW BRASS
22. Trade names are STAR CHLORINATED CLEANER CROWN 12 5 SODIUM HY POCHLORITE BLEACH Use STAR at 18 oz per 1 gallon of water yields 2 Sodium Hydroxide Solution Use Crown at 2 ounce per 9 gallons of water gives 200 PPM of available chlorine at a minimum contact time of 10 minutes 1 Disconnect syrup containers and remove product from tubing by purging with carbon dioxide or flushing with warm water 2 Visually inspect valve by removing nozzle and inspecting nozzle and valve cavity Clean nozzle with cleaning agent then sanitizing solution then with potable water Inspect valve cavity and if 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 completely filled and allow standing for at least 10 minutes 4 Flush the detergent solution from the syrup lines with clean water Continue rinsing until testing with phenolphthalein shows that the rinse water is free of residual detergent 5 Fill the syrup lines with a low PH 7 0 chloride solution containing maximum 200 PPM chlorine Make sure that lines are completely filled and allow standing for 30 minutes 5 10 6 Reconnect sy
23. adjustment is 40 psi for BIB 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 installations and should be set from 6 to 10 psi depending on length of run In some cases where a vertical run is encountered pressures may be set as high as 15 psi Excessive C02 pressure may cause diet syrup to carbonate resulting in foam 5 7 BRIX INSTRUCTIONS sure carbonator water flow an operating condition i e high pressure regulators set water and power on and refrigeration in a ready to go mode Inthe case of juice systems make sure water flow is un restricted It is also recommended that a water pressure regulator be utilized on all systems Water bath systems must have an ice bank formed Adjust water flow to 6 ounces in 5 seconds Remove nozzle twist and pull down then insert syrup separator through nozzle be it S type or plastic tube and on plastic syrup outlet located inside hidden nozzle area Then press nozzle back in position 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
24. all on any open A terminal Check electrode Remove spade from wires to ensure long amp short elect they are not connection at LLC Re connect reversed electrical Y Re connect electrical Motor Pump should engage Motor Pump does Change electrode engage engage Motor Pump does not Re install motor Possible bad motor spade to terminal Pump replace Motor 1 Go to electrode Bad LLC replace Return motor spade to terminal Motor 1 CARBONATION TROUBLE SHOOTING FLOW CHART 2 MOTOR PUMP DOES NOT COME ON Non carbonated water amp syrup being dispensed only CO2 Supply Check water pressure Water greater than or close to CO2 pressure will C02 cylinder is empty stop the process 02 cylinder Install or adjust water regulator 1 Hi pressure regulator is set to low or malfunctioning Adjust CO2 pressure at a minimum of 25 PSI above water pressure CARBONATION TROUBLE SHOOTING FLOW CHART 3 CARBONATOR NOT OPERATIONAL Water Pump Motor runs continuously NO EXCESSIVE PRESSURE AT EXCESSIVE PRESSURE AT VALVE VALVE OR PRESSURE RELIEF SYMPTONS SYMPTONS Valve will dispense syrup only and or Valve will dispense syrup and gas pressure relief may engage only Possible loud noise from water pump Little or no water volume No groun
25. ation through the condenser coil is required to cool the compressor Air is drawn in through grills on the sides of the cooling unit through condenser coil and exhausted out grills on the backside of unit Restricting air circulation through the cooling unit will decrease its cooling capacity NOTE Cleaning condenser coil should be done during non use periods 1 Unplug refrigeration unit power cord from electrical socket 2 Remove lid of unit 3 Remove 8 screws securing service panels and then remove panels Remove panels in preparation for service 4 Vacuum or use a soft brush to clean fins of condenser coil Use low pressure compressed air or C02 gas to blow through condenser fins This should only be performed after normal business hours to prevent dust contamination A damp cloth on backside of condenser coil will prevent some dust contamination S Replace service panels and lid 6 Plug refrigeration unit power cord in electrical socket 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 time to perform this operation is when the system is being sanitized 1 Unplug refri
26. connection 24 4 Tighten connection and or repair open volt circuit 5 Water pump motor worn out or 5 Replace motor damaged 6 Water pump worn out or 6 Replace water pump damaged 7 Frozen water bath 7 See Frozen water bath Volumes of 1 High pressure regulator out of 1 Adjust high pressure regulator as 2 to low in adjustment instructed finished product 2 CO2 cylinder empty 2 Replace 2 cylinder 3 Water oil or dirt in C02 supply 3 Clean contaminated CO2 system lines regulator etc and sanitize as instructed 4 Temperature above quality limits 4 See refrigeration machine specifications vs volume requirements Dispensed 1 Pressure of CO2 to high 1 Adjust high pressure regulator as product makes instructed foam as it 2 Syrup over carbonated with CO2 2 Remove syrup tank quick disconnects leaves Relieve pressure shake tank vigorously dispensing as necessary to remove over carbonation valve 3 Dirty nozzle and valve cavity 3 Clean contaminated nozzle and sanitize as instructed 4 Temperature above quality limits 4 See refrigeration machine specifications vs volume requirements Dispensed 1 Oil film or soap scum in cup or 1 Use clean cups and glasses product comes glass out clear but 2 Ice used for finished drink is sub 2 Do not use ice directly from freezer Allow foams in cup or class cooled ice to become wet bef
27. d at LLC Repair _ Install holding tank increase water feed I D Electrode bad replace Restrictions at water pump Clear restrictions Defective LLC Replace Defective Motor Water Pump Replace Frequently Called Numbers CO2 SETTINGS High Pressure Low Pressure Product Setup 1 NOTE SECTION PSI PSI 2 2 99 Revised 12 04 Revised 4 05
28. d to retain the acidic bite associated with a carbonated drink The PREMIER 2000 also performs the task of refrigerating The carbonated water is routed to the individual valve that combines the water and syrup in the proper ratio and then dispenses the finished product 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 02 cylinder through high pressure regulator S 101 The high pressure regulator should be set at 70 75 PSI for the PREMIER 2000 units The gas after leaving the high pressure regulator is teed at a low pressure regulator to go in two directions One path takes the gas to the carbonator tank This gas must be at a pressure greater than the incoming water by at least 25 PSI to assure the proper function of the carbonator The second line of 02 is routed through low pressure regulator The low pressure regulator may be set at many different settings but primarily the settings are directed towards B I B or transfer tank type installations The average settings may vary from 10 to 60 PSI this of course will be influenced by temperature and baume of product Typically B I B installations are set at an average of 40 PSI and transfer tank installations are set at an average of 30 PSI Plain water enters the PREMIER 2000 through the incoming water line This water proceeds through the water coil where it is chilled p
29. emperature of 75 degree F initial pull down or formation of complete ice bank will take approximately 3 5 hrs When full ice bank has been formed compressor and condenser fan motor will stop Agitator will continue to operate circulating water in water bath PURGE DISPENSING VALVES Dispense water from dispensing valves until all air is purged from soda water and non carbonated waterlines ACTIVATE HIGH PRESSURE C02 SYSTEM 1 Open valve on the 02 cylinder sure to open valve completely or until valve is back seated 2 Turn high pressure 02 regulator screw clockwise until the pressure is 75 to 85 psi Carbonated units only 3 1 3 Dispense water from dispensing valves until the carbonator activates Carbonated units only 4 Allow carbonator to run until it automatically shuts off Pump is fully primed and carbonator is now ready for use Carbonated units only S Check all connections on high pressure C02 system for leaks Repair any leaks that are found ACTIVATE LOW PRESSURE C02 GAS AND SYRUP SYSTEMS OPTIONAL 1 Make sure high pressure C02 regulator pressure is 75 to 85 psi 2 Make sure all B I B racks or syrup tanks are full 3 Make sure all Q C D s are in an operational position or gas and syrup quick disconnects are connected tightly with syrup tanks 4 Turn low pressure C02 regulator screw clockwise until the pressure is approx 40 psi for B I B and approx 30 psi for FIGAL NOTE These p
30. er square inch indicator of high pressure C02 regulator on C02 cylinder is in shaded portion of the dial 02 cylinder is almost empty and should be changed C02 supply must be checked daily and if necessary replenished as instructed see CHAPTER 11 REPLENISHING SYRUP SUPPLY Syrup supply must be checked daily and if necessary replenished as instructed see CHAPTER 11 COOLING UNIT MAINTENANCE NOTE Air circulation through the condenser coil required to cool the condenser coil compressor is drawn in through grills on the sides of the cooling unit through condenser coil and is exhausted out grills on the back side of the unit Restricting air circulation through the cooling unit will decrease its cooling capacity To avoid needless and sometimes costly repairs it is imperative to keep condenser fins clean This may be accomplished by one of three methods One method is use of a condenser brush a longhaired soft bristle brush to gently sweep fins of condenser clean Second method is to use a strong vacuum The third method is to use C02 or an air hose to blow out condenser The latter method should only be attempted after normal business hours to avoid dust contamination 4 1 WATER Periodically check water level water bath If it is low more water should be added as instructed for maximum product cooling This dehydration will normally not occur in normal temperate climate zones With norma
31. ew seal gasket MAKE SURE NEW WASHER IS INSIDE REGULATOR ASSEMBLIES COUPLING NUT BEFORE CONNECTING TO CYLINDER WARNING To avoid personal injury and or property damage always secure CO2 cylinder with safety chain to prevent cylinder from falling It is recommended that 02 cylinder be installed away from heavily traveled areas such as doors passageways corridors etc 2 Connect 1 4 inner braided plastic tubing from outlet of high pressure C02 regulator S 101 on C02 cylinder to Tee connection at low pressure regulator S 221 using prefabricated 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 74 inner braid plastic tubing from outlet of tee at low pressure regulator S 221 optional furnished with unit to supplied line from unit marked gas INSTALL LOW PRESSURE REGULATOR AND LINES OPTIONAL 1 Install low pressure C02 regulator on the wall or another supporting structure in general vicinity of cooling unit CO2 cylinder B I B rack or syrup tanks 2 Connect 1 4 inner braided plastic tubing from outlets of low pressure C02 regulator S 221 to inlets of B I B pump or syrup tanks HIGH PRESSURE C02 REGULATOR LOW PRESSURE C02 REGULATOR S 101 S 221 2 3
32. geration unit power cord from electrical socket 2 Remove lid from unit 3 Look down into water bath if necessary use flashlight and inspect water bath ice bank and all components for cleanliness Water ice bank and all components should be clear and free of foreign particles If ice bank is clear of foreign particles it does not have to be melted down Proceed to step 10 if foreign particles are present in the ice bank proceed to step 4 5 2 4 Siphon out water with short hose 5 Allow ice bank to melt Hot water may be used to speed melting CAUTION Never use an ice pick or other sharp instruments to remove ice from evaporator coil Such practice can result in puncture to the refrigeration circuit 6 Use fiber brush and carefully clean mineral deposit from all components 7 Wash evaporator coil with a mild soap solution Copper cleans well with mild solution of citric acid 1 cup of citric acid for 2 gallons of water Stainless steel cleans well with carbonated water Then rinse with clean water 8 Rinse out water bath with clean water until water running out of siphon hose is clean 9 Fill water bath to within 1 2 of top of water bath 10 Replace lid 11 Plug refrigeration unit power cord in electrical socket CARBONATOR MAINTENANCE 1 Unplug refrigeration unit power cord from electrical socket 2 Remove lid from unit 3 Look down into water bath if necessary use flashlight and inspect carbona
33. ith or without built in carbonator and would be used with a remote tower or bar gun As a pre cooling unit without built in carbonator and would be used strictly to pre cool water prior to going to another unit As a self contained juice dispenser With up to 4 valves These valves could be a combination of one and two flavor valves that would allow the unit to dispense up to 6 flavors This type unit would dispense a non carbonated beverage The use of postmix syrup cooling coils would be optional As a self contained carbonated unit This type unit would dispense carbonated drinks This unit will accommodate three valves These valves can be two flavors allowing up to 6 carbonated flavors SYSTEM DESCRIPTION The PREMIER 2000 is a complete self contained remote cooling and carbonation unit which when combined with related components will produce a variety of cooled carbonated and non carbonated beverages The PREMIER 2000 consists of a condensing unit a water reservoir water cooling coil a carbonator tank carbonated systems only an agitator pump and optional syrup cooling coil s and dispensing valve s For proper function the PREMIER 2000 must have a water supply and electrical supply The PREMIER 2000 is designed with a unique lift off drain pan that can be emptied at any convenient drain outlet Other items that will be required if used in B I B Bag in Box or transfer tank FIGAL installations will be High pressure reg
34. l humidity the opposite will occur therefore a condensate drain is installed Any extra water in the water bath will exit the unit via the drain outlet When unit is building it s first ice bank it is normal to have water overflow the into the drain hose CHANGING WATER BATH Drain water bath a minimum of twice a year This can be accomplished by siphoning water with short hose into bucket Once water is drained and ice bank is melted water bath water coils bath walls tank etc should be cleaned Fill water bath to within 1 2 of the top of the water bath USTMENTS Periodically CO2 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 ADJ USTING WATER FLOW RATE If adjustment of water flow rate should be necessary adjust as instructed USTING WATER TO SYRUP RATIO BRIX OF DISPENSED PRODUCT Water To Syrup BRIX of dispensed product should be checked if necessary adjust as instructed AD USTING SIZE OF DRINK DISPENSED FOR PORTION CONTROL VALVES PCT ONLY Drink size of dispensed product should be checked and if necessary adjust as instructed TESTING FOR LEAKS 1 Completely back off adjusting screw on low pressure 02 regulator 2 Close valve on top 02 cylinder 3 Wait for 5 minutes or more If pressure on high pressure gauge decreases excessively there is leak in the
35. lace the cylinder NOTE Readings should be taken at normal room temperature approximately 70 degrees F and above If CO2 cylinder is stored in a walk in refrigerator the P S I indicator will read below 500 psi even when cylinder is full 3 Check the 02 gas pressure supplying 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 1 Order syrup to maintain proper inventory 2 Check all CO2 gas connections for leaks 3 Measure the water to syrup ratio on all beverages adjust ratio if necessary 4 Check condenser coil for obstructions or dirt Monthly 1 Clean condenser fins or filter to make sure the refrigeration unit has adequate air flow 2 Inspect components of cooling unit water bath for cleanliness 3 Check entire system for leaks or damaged components Repair as necessary 5 1 PREMIER 2000 CABINET MAINTENANCE PERIODIC CLEANING Periodically wash all external surfaces of PREMIER 2000 cabinet rinse with clean water and then wipe dry with a clean soft cloth DO NOT USE ABRASIVE TYPE CLEANERS CLEANING CONDENSER COIL IMPORTANT Air circul
36. mage replace if damaged h Reassemble by reversing above procedure No water no 1 No electrical power 1 Plug power cord into electrical box Check syrup being line voltage dispensed from 2 Frozen water bath 2 See Frozen water bath valve 3 Pinched or crimped lines 3 Repair defective line 4 Broken sub miniature switch 4 Replace defective switch 5 Bad transformer 5 Replace defective transformer 6 Disconnected wire 6 Attach disconnected wire 6 3 being 1 Syrup container empty 1 Replenish syrup supply dispensed 2 Syrup lines crimped 2 Straighten syrup lines 3 CO2 cylinder empty 3 Change CO2 cylinder 4 QCD of syrup installed in 4 Re install QCD correctly correctly 5 Low pressure regulator defective 5 Repair or replace low pressure regulator or plugged 6 Syrup disconnect not attached 6 Lubricate and attach correctly 7 Loose electrical connection of 7 Tighten connection and or repair open syrup solenoid and or open circuit Check proper voltage electrical connection 8 Frozen water bath 8 See Frozen Water Bath No water being 1 Plain water inlet supply shutoff 1 Open plain water inlet supply line shut off dispensed closed valve 2 Water filter fouled clogged 2 Replace filter or cartridge 3 Pinched or crimped line 3 Repair defective line 4 Loose electrical
37. nder water escaping from high pressure C02 regulator S 101 during cylinder change and possibly water in syrup containers If any of the above symptoms occur proceed 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 5 13 any damaged or suspicious parts and replace with new parts during reassembly 4 Reassemble each check valve as shown in check valve illustration ALWAY S INSTALL NEW O RING S 13 5 Connect water inlet line to double check valve assembly 6 Activate the system as outlined in CHAPTER III 5 4 ii ousine cueck varve arme ESESETM SEAT O RING CHECK VALVE s12 JSLEEVE SEAT RETAINER CHECK VALVE pals su eatucneckvatve 00000000 s 3 sao serinc cueck vave e so seercukvawe s 1 sis ApAPTOR HOUSING DOUBLE CHECK VALVE s 1 sas HOUSING creck varve serme 1011 1 4 1 S S INLET PLUNGER WITH SEAT S S S S S 5 S S 14 13 12 11 10 9 16 15 5 2 1 5 1 8 COMPOSITE EXPLODED VIEW OF CHECK VALVES 5 5 REPLENISHING C02 SUPPLY 1 Close empty 02 c
38. ore using Note crushed ice also causes foaming of beverage Carbonation is released on sharp edges of the ice 6 4 Water to syrup ratio to low or too high Syrup flow regulator not properly adjusted 2 gas pressure in syrup tanks insufficient Syrup tubing 1 0 insufficient Adjust water to syrup ratio see dispensing station installation instructions Adjust low pressure regulator as instructed Increase syrup tubing 1 0 Note see Brix instructions Adjustment of syrup metering pin does not produce desired water to syrup ratio No syrup supply Syrup tank quick disconnects not secure Low pressure CO2 regulator 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 Replenish syrup supply as instructed Secure quick disconnects Adjust low pressure CO2 regulator as instructed Connect disconnect securely Clear restriction or replace restricted line Disassemble and clean syrup flow control Adjust water to syrup ratio see Brix instruction 6 5 CARBONATION TROUBLE SHOOTING FLOW CHART 1 MOTOR PUMP NOT OPERATIONAL Valves dispensing gas amp syrup only Electrode Disconnect electrical Disconnect Check ground electrical connection at board and box Remove spades from terminal Motor 1 on LLC amp inst
39. resh water conduit has not less than 3 8 I D passageway for any distance greater than ten feet from the PREMIER 2000 It can be reduced to 3 8 O D copper tubing and connected to the water inlet connection with in ten feet of the PREMIER 2000 All water inlet connections are clearly tagged ELECTRICAL REQUIREMENTS The PREMIER 2000 requires a 115 VAC single phase 60 Hertz power circuit and must be wired in accordance with N E C or local ordinance NOTE Check CHAPTER for running amperage and connect to appropriate electrical circuit 2 5 CHAPTER III PREPARATION All steps in previous chapters should be understood and carried out before proceeding PREPARING SYSTEM FOR OPERATION Be sure that electrical power is unplugged valve on 02 cylinder is closed and valve on water supply line is closed and release pressure of CO2 gas and water from carbonator tank PREPARING AND STARTING REFRIGERATION UNIT 1 PREMIER 2000 refrigeration is pre set at factory and ready to operate 2 Remove lid 3 Fill water bath with clean water until water runs out of condensate drain outlet above drain pan approximately 12 from top of water bath 4 Open water inlet supply line 5 Plug PREMIER 2000 power cord into electrical receptacle box 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 t
40. ressures will vary depending on baume of product type of pumps etc S If diet drink regulator is required turn CO2 diet drink pressure regulator screw clockwise until the pressure is 6 to 10 psi Carbonated units only 6 Dispense syrup from dispensing valves until all air is purged from syrup lines and syrup is dispensed 7 Check for syrup and gas leaks Repair any leaks that may be found ADJ UST WATER FLOW RATE Adjust dispensing valves water flow rate as instructed in chapter IV OPERATORS INSTRUCTIONS ADJ UST WATER TO SYRUP RATIO Adjust dispensing valves for Water to syrup Ratio of dispensed product as instructed in chapter IV OPERATOR INSTRUCTIONS ADJUST SIZE OF DRINK DISPENSED FOR PORTION CONTROL VALVES PCT ONLY Adjust size of drink dispensed as instructed in chapter IV OPERATOR INSTRUCTIONS 3 2 CHAPTER IV OPERATORS INSTRUCTIONS This chapter covers operator s responsibilities for daily pre operation check adjustments replenishing 02 and syrup supplies cleaning and sanitizing DAILY PRE OPERATION CHECK 1 Make sure high pressure C02 regulator s pound per square inch indicator is not in shaded portion of dial If so CO2 cylinder is almost empty and must be replaced NOTE This reading should be carried out at normal room temperature Make sure there is a sufficient syrup supply in all syrup containers If not replenish syrup supply REPLENISHING C02 SUPPLY NOTE If pound p
41. rior to entering the carbonator tank or in the case of non carbonated drinks chilled prior to going directly to a valve Prior to entering the carbonator tank an optional regulator S 208A may be installed This assembly is utilized to maintain water pressure feeding a non carbonated valve when used in conjunction with carbonated valves The water source should be regulated this is normally performed by the use of an in line water regulator With water at a lower pressure than that of the incoming C02 the gas will prevent the water from entering the carbonator tank To overcome the gas pressure the carbonator will use the water pump in conjunction with a liquid level control to pump the water into the carbonator tank at a greater pressure than exists in the tank As a result a marriage of water and 02 takes place known as carbonation This process is almost instantaneous and can occur at lower pressures than competitive units due to the reduced temperature of incoming water The water bath holds approximately 3 5 gallons of water A certain amount of this water will be transformed to ice approximately 6 Ibs This water reserve and ice bank will act as a reservoir for refrigeration This reserve is utilized during peak periods when the BTU output of the compressor is not sufficient to meet the demand of the draw It should be recognized that without refrigeration your carbonation system will not produce a drink that will hold carbonation There is
42. rup containers ready Unit for operation 7 Draw drinks to refill syrup lines and flush the chloride solution from the dispenser 8 Taste the beverage to verify that there is no off taste NOTE WHEN SANITIZING A TWO FLAVOR VALVE BOTH SYRUPS SHOULD BE FLUSHED SIMUTAINEOUSLY BOTH SYRUPS SHOULD CLEANED DETERGENT SOLUTION SIMUTAINEOUSLY BOTH SYRUPS SHOULD BE FLUSHED UNTIL FREE OF DETERGENT SIMUTAINEOUSLY AND BOTH SYRUPS SHOULD BE SANITIZED SIMUTAINEOUSLY 5 11 TROUBLE SHOOTING IMPORTANT Only qualified personnel should service the PREMIER 2000 unit and components WARNING To avoid personal injury and or property damage always disconnect electrical power shut off plain water and CO2 supplies before starting any repairs If repairs are to be made to the carbonated water system bleed carbonated water system pressure before proceeding If repairs are to be made to syrup system remove quick disconnects from syrup tanks or remove QCD from BIB then bleed system pressure before proceeding CARBONATOR Trouble Probable Cause Remedy Water pump 1 Inoperable water pump motor 1 Replace water pump motor motor will not Overheated motor cut off by Check for proper line voltage Allow motor operate thermal overload protector time to cool 2 Electrode inside carbonator tank 2 Replace carbonator tank electrode defective Replace L L C assembly 3 L L C assembly Inoperable
43. sure 02 regulator will have two gauges that extend above and to the side of the bell housing screw area The P S I gauge will show graduated indications up to 2000 psi and be the gauge the farthest from the C02 cylinder connection This gauge will normally have a Red area indicating 500 psi to 0 psi This gauge will be used to check volume of liquid in the C02 cylinder The other gauge will show regulated pressure that will be delivered to our PREMIER 2000 s carbonation system This gauge can be indicated from 0 160 psi up to 0 300 psi By turning the high pressure regulator adjustment screw clockwise we will increase pressure supplied to our carbonator that will be indicated on this gauge To lower pressure to carbonation system it is recommended that the adjustment screw be turned counter clockwise several full turns and then the relief valve S 215 be lifted lowering pressure in carbonating system now readjust When adjusting C02 high pressure regulator a setting of 75 85 psi is recommended INLET 02 PRESSURE TO CARBONATION SYSTEM SHOULD NOT EXCEED 90 PSI LOW PRESSURE C02 REGULATOR The low pressure C02 regulator setting can and will vary dramatically from one installation to the next Variables such as distance from syrup containers to point of serving horizontal or vertical runs baume of product to whether B I B or transfer tanks are used will influence where the low pressure regulator is adjusted A good starting point as an
44. t SELECTING LOCATION IMPORTANT Ambient temperature for PREMIER 2000 should not exceed 100 degrees Operation of cooling unit in ambient above 100 degrees F and will contribute to early failure of condensing unit and poor quality of finished product 2 1 LOCATION RECOMMENDATIONS FOR PREMIER 2000 1 Position unit as close as possible to proper electrical source 115V 60HZ 2 Position unit with a minimum of 2 space between bulkhead and cabinet for sufficient space for ventilation Allow enough space between ceiling and unit for lid removal 3 Position unit as close as possible to water source Half inch gate valve recommended for water connection 4 Enough space must be allowed to install CO2 cylinder syrup containers racks pumps water filter etc 110 volt 1 2 Gate Valve Hi Pressure Reg Water Reg ow Pressure Reg PS SU CO2 Vessel N BIB Pump Water Filter er BIB Rack SAMPLE OF POSSIBLE INSTALLATION INSTALLATION INSTALL COOLING UNIT 1 Make all connections C02 gas plain water and syrups 2 Place PREMIER 2000 in position Make sure sufficient space between bulkheads walls and overheads is available for proper air circulation around cooling unit 2 2 INSTALL HIGH PRESSURE C02 REGULATOR C02 CYLINDER AND LINES FOR CARBONATED UNITS ONLY 1 Install high pressure C02 regulator S 101 on C02 cylinder using a n
45. tom of evaporator upward A refrigerant leak or insufficient charge might show ice at bottom and not at top of evaporator Compressor will not stop after sufficient ice bank is produced 1 Ice bank control defective 1 Replace ice bank control Note During overload protector shut off condenser fan motor will continue to work Otherwise troubleshooting condenser fan motor problems is the same as Compressor does not operate paragraph in addition to the following Condenser fan 1 Electrical cord loose or 1 Tighten connections or replace cord motor not disconnected from condenser fan operating motor or compressor terminals 2 blade obstructed 2 Remove obstruction 3 Inoperative condenser fan motor 3 Replace condenser fan motor DISPENSING VALVES Water or syrup 1 Foreign debris under plunger seat 1 Disconnect syrup or water from leaking from or bent creased stem affected valve nozzle after b Relieve pressure by activating valve actuation 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 wall f Valve stem seat should be inspected for any foreign debris If debris is found remove at this time also check E 730 stem Movement should be unrestricted and free g Inspect E 730 plunger seat for da
46. tor tank for leak Air bubbles will arise from place of leak if leak is below surface of water If leak is above surface of water soap bubbles should be used to find any leak 4 Shut off plain water supply to water pump by closing shutoff valve in water supply line 5 Shut off CO2 supply to refrigerating unit by closing shutoff valve on CO2 cylinder 6 Pull up on carbonator tank relief valve plastic cap to relieve 02 pressure from tank 7 Eliminate leak tighten bad connections or replace defective Probe assembly S 78 20 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 necessary 10 Replace lid 11 Plug refrigeration unit power cord in electrical socket 5 3 12 Turn plain water supply to water pump by opening shutoff valves water supply line 13 Turn on 02 supply to refrigerating unit by opening shutoff valve on 02 cylinder 14 Activate all systems as outlines in CHAPTER III SERVICING CHECK VALVES It is not recommended to disassemble the check valves unless it is absolutely necessary As stated before earthquakes disruption of water service etc would prompt this necessity The symptoms of a malfunctioning check valve would be Water check valve carbonation through out water supply i e basins toilets etc or an activated vent valve Gas check valve water in C02 cyli
47. ulator Low pressure regulator connecting lines quick couplers or disconnects and C02 WARNING Before shipping or relocating a PREMIER 2000 into a freezing ambient environment empty plain and carbonated water Syrup systems should be flushed ice bank melted and water drained from water bath A freezing ambient environment will cause existing water in unit to freeze possibly resulting in damage to pump motor assembly syrup coils water coil water bath valve s etc 1 1 TABLE I I DESIGN DATA COOLING UNIT Overall cabinet dimensions Heights ee 16 inches Widthi eb las EE cree 1134 inches AEEA DC 17 inches Weights Shipping 85 pounds 80 Pounds J uice Dry weight 75 pounds 70 Pounds uice Operational Weight 105 pounds 100pounds J uice Ice Bank et eM t eet vt ets 6 pounds Capacities Unit water bath no ice 21 1 2 5 gallons Refrigerant requirement R 134 A L nn 90 grams Ambient operating temperature me 40 F to 100 F Electrical Requirements The cooling unit requires a 115 VAC single phase 60 Hertz power circuit Circuit Ampacity
48. ve obstruction or re not operating lost Attach propeller 2 Low voltage 2 Voltage must be at least 110 volt at terminals 3 Loose unplugged or broken 3 Tighten connection or replace broken wiring wiring 4 Bad agitator motor 4 Replace agitator motor Compressor 1 No power source 1 Plug power cord to electrical box Check does not operate line voltage 2 Electrical power to cooling unit 2 Turn on power switch to unit turned off 3 Low voltage 3 Voltage must be at least 110 V at compressor terminals at start 4 Loose disconnected or broken 4 Tighten connection or replace broken wire wiring 5 ice bank control 5 Replace ice bank control 6 Inoperative overload protector or 6 Replace defective part start relay 7 lnoperative compressor 7 Replace compressor 8 Full ice bank 8 Refrigeration not called for Compressor 1 Cooling capacity is exceeded by 1 Reduce amount of drinks taken per given works over drawing time of install higher volume unit continuously but 2 Cooling unit located in 2 Relocate cooling unit does not form excessively hot area sufficient ice 3 Air circulation through condenser 3 Check and if necessary clean condenser bank coil is restricted coil 4 Loss of refrigerant or in sufficient 4 Repair leak and or recharge with sufficient charge refrigerant 6 2 Note Ice bank freezes from bot
49. ylinder shutoff valve 2 Disconnect high pressure 02 regulator then remove empty 02 cylinder 3 Install CO2 cylinder and connect high pressure 02 regulator See installation procedure in CHAPTER Il MAKE SURE 2 CYLINDER IS POSITIONED IN UPRIGHT POSITION AND FASTENED WITH SAFETY CHAIN ALWAYS OPEN 02 VALVE COMPLETELY OR UNTIL BACK SEATED DURING OPERATION WHEN BOTTLE IS EMPTY ALWAYS CLOSE VALVE ASSEMBLY COMPLETELY REPLENISHING SYRUP SUPPLY 1 Remove Q C D s from empty B I B or syrup amp C02 quick disconnects from empty syrup tank 2 Install full syrup container in position rinse Q C D s or quick disconnects in warm water then connect Q C D s or syrup amp C02 quick disconnects to tank 3 Activate valve until syrup flows from valve normally See CHAPTER Il SYRUP FLAVOR CHANGE 1 Remove Q C D s from applicable B I B or syrup quick disconnects from applicable syrup tank 2 Sanitize applicable syrup system in accordance with instructions See paragraph CLEANING AND SANITIZING in this chapter 3 Install full syrup container in position rinse Q C D s or quick disconnects in warm water then connect Q C D s or syrup amp C02 quick disconnects to container 4 Activate valve until syrup flows from valve normally See CHAPTER ll CHANGING WATER FILTER CARTRIDGE Follow manufacturer s instructions for water filter 5 6 USTMENTS HIGH PRESSURE C02 REGULATOR The high pres
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