Cornelius 2 Flavor Juicer User Manual
Contents
1. 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 Quest Juice Training Manual The products technical information and instructions contained in this manual are subject to change without notice These instructions are not intended to cover all details or varia tions of the equipment nor to provide for every possible contingency in the installation operation or maintenance of this equipment This manual assumes that the person s working on the equipment have been trained and are skilled in working with electrical plumbing pneumatic and mechanical equipment It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met in addition to the information contained in this manual To inquire 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 Decade Hydro Boost Sitco Spirit UF 1 Vanguard Venture and Vista are registered trademarks of IMI Cornelius Inc Optifill trademark is pending This document contains proprietary information and it may not be reproduced in any way without permiss2. 24 Removal of the Ice Control Probe sik kp PER 26 Major Component REVIEW 27 1104 50 Eti i e es Be ee e e datus as 27 PUMO Speed eee 28 Ice Bank ER c RP oo ee cd ae aa e ob ed 28 Operational Overview 28 Validating ODBrallOh ss 015 2 0 ses a aci dA a Rep do dad 28 did d va arse e Pardon 29 Water Inlet Solenoid doct e Ee bre dee e Pr te d gr ed deed e 29 Door Switch 72 B Serial Number 29 Door Switch 72 E Serial Number 30 Plarorm OIIDOPGLIS 0055 A ae 0 aed hus Dur 30 Water Valv Flow Contro E ACE x E X Ear 30 Bottle Adaptor O rings 30 Bottle Adaptor Sold Out Sensors 31 Bottle Adaptor Tray 31 Bottle Adaptor Flush 32 ak d Ras oar be aa 32 re E E Sat ares 33 Troubleshooting Guide
3. 3 8 SAE male flare Water 5 80 psi max static 20 psi min dynamic For best results it should be regulated to 45 to 50 psi Quest Two Flavor DIMENSIONS L i aa 10 4 W Operating 120 Ibs Quest Four Flavor DIMENSIONS eu ai Up EDD 15 W Operating 160 Ibs IPD Times CMOS L kas aa S c et 4 5 hours CSS 3 hours Ice Bath Capacity QUESTA dT 3 6 gallons 15 16 lbs of ice IPD scsi 1 8 gallons 8 9 lbs of ice IPD Publication Number TP00968 2 2004 IMI Cornelius Inc Quest Juice Training Manual SYSTEM DETAILS WATER Water Quality Water quality has an affect on juice dispensing systems odor e taste clarity foaming Water filtration is recommended to assure the best beverage taste Water Flow Inlet water pressure should be regulated to 45 to 50 psi max 3 1 bar to prevent damage to pump tub ing Minimum flowing pressure must be 20psi Flow Rates Adequate water flow is necessary and must be at least 3 0 ounces per second 89ml at the inlet to the unit CONCENTRATE e Concentrate should be stored frozen and put into a cooler 72 hours before use Rapid cooling such as in a sink of hot water adversely affects flavor and leads to service calls
4. 35 ee edd Eee 38 Publication Number TP00968 ii 2004 IMI Cornelius Inc Quest Juice Training Manual OVERVIEW PRODUCT DESCRIPTION Left Side Rear Compressor Pump deck harness Condenser 1 and 2 fan motor Dispensing and bracket nozzles Door harness Ice path MOS Right Side Door latch Key lock Pump deck harness 3 and 4 Concentrate Water solenoid cooling cabinet and strainer The Quest Juice Dispenser uses an ice water bath system to cool both the potable water supply and the concentrate cabinet To achieve cooling capabilities we use an agitator recalculating pump and motor This 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 2004 IMI Cornelius Inc 1 Publication Number TP00968 Quest Juice Training Manual 2 DIMENSIONS 8 CAPACITIES Guest Dispense Rate 1 0 2 2 oz sec Electrical FAtING e 115 VAC 60 Hz 15 amp dedicated circuit aa TESE IAEE ATE E 220 VAC 50Hz 29 3 H 24 3 D Condenser clearance 4 back 12 top Water
5. cap from the fill tube sight glass to begin filling the ice bath Replace the cap when fin Full Water Level Cabinet drain outlet i Water bath overflow IMPORTANT Fill the water bath slowly until it runs out the overflow Failure to do so can cause back pres sure and improper water level ALWAYS FILL WITH THE UNIT UNPLUGGED Replace the cap TIGHTLY when finished filling the water bath Lock it place with its holder CONNECTING WATER SUPPLY The QST series Juice Dispenser is designed to dispense juice at a high flow rate It is very important that the incoming water line be dedicated for use by the dispenser only and does not have other machines connected which could cause a water surge i e a dishwasher coffee maker etc IMPORTANT The water supply should be consistent with 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 that the flared gasket is used tubing flared gasket are included with the installation kit IMPORTANT When securing flare nut use a backup wrench on the male side of the inlet fitting unit side t
6. Proper loading of concentrate is important Improper loading is a major source of service calls Cabinet Cooling Fan Serial Decal Lighted M rchandiser Platform Pump Left and Right Pump Platforms ON OFF ON OFF Concentrates vary in viscosity and mixing valves must be adjusted accordingly e 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 e When changing flavors be sure to flush the system and reset the pump Nozzles should be cleaned daily Remove the nozzles and wash in warm soap solution Rinse with clean water lubricate the O ring and replace nozzle e Flushing daily and sanitizing weekly is recommended SETTING THE BRIX Arefractometer must be used to measure the post mix brix e Ratio adjustment can be set with a concentrate separator and ratio cup see Brixing Procedure Ratios are sometimes set by taste but this is not recommended 2004 IMI Cornelius Inc Publication Number TP00968 Quest Juice Training Manual eines D INTRODUCTION PREVIEW QUESTIONS Check your current knowledge by taking a few minutes to answer the following questions 1 2 3 4 5 The bank control is adjustable True False The transformer does NOT control the cooling system True False Condenser airflow passes over the compressor first True
7. 10 Clean Water Inlet Strainer Ls 10 Clean Chassis ua 3 ase nar pae dod whe ood per V gee Sod 14 3 10 Check and Water Ice Bath 10 nar PPP hay a i 11 Replace Pump Tubing llle 11 Removing Pump Platform s 11 Replacing Pump Tubing 45 au kus e ORE Sce e cd S Gute ated 11 Mechanical 560011 6 205053 13 2004 IMI Cornelius Inc 1 Publication Number TP00968 Quest Juice Training Manual eines gt Removal of Merchandiser lel 13 or the Switch Panel 2 epo qe Dees adr AC GO e 14 Removal of the Pump lt 15 Removal of the Cooling Fan n 17 Henmovalor Panels ac YU ERROR ERE SEG Wa qd 18 Removal of Electrical Box ee eee 19 Removal of the VRB Boards 20 Removal of the Ice Bank Control 21 Removal of Nozzle Guide Gasket 21 Removal of the Cooling Cabinet llle 22 Removal of the Agitator Motor 24 Removal of the Refrigeration Chassis
8. False Ratio refers to the amount of water required to dilute one part of concentrate True False O rings may be installed dry lubrication is not recommended _____ False KEY THINGS KNow Publication Number TP00968 dic 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 trouble shooting is impossible without it 40 50 PSI dynamic water pressure measured at the dispenser inlet with 3 0 ounces a second Water pressure must not exceed 80 Ibs static with a minimum flowing pressure of 30 PSI Never leave the Dispense Flush lever in the Flush position it can cause the pump tubing to burst 2004 IMI Cornelius Inc Quest Juice Training Manual INSTALLATION COUNTER LOCATION The minimum airflow clearance is 4 10 16 cm in back and 12 30 48 cm on top and open to the front IMPORTANT Condenser air is drawn in from the bottom of the rear panel and discharged out the top of the rear panel Failure to maintain clearance space will reduce capacity of the unit and cause premature compressor failure FILLING THE ICE BATH The fill tube is located behind the splash panel Use the water supply line to fill the ice bath before con necting it to the unit Remove the 3 8
9. circuit Any break in the continuity broken wire and the system reads it as ano water condition Control is powered by line voltage All connectors are label and keyed for proper installation Validating Operation With box detached from the unit remove the ice bank probe connector by gently rocking the wrench up and down to loosen and pull off to remove As the probe is very low voltage insert a stan dard set of pliers into the connector gripping the middle terminal and allowing the Pliers jaws to come in contact with the outside 2 Wait the 3 minutes and the compressor and condenser fan should cycle on Run for 1 minute and remove the pliers The compressor will shutdown in 45 60 seconds If it does not then a sticking relay is a possibility and the control should be replaced Publication Number 968 28 2004 IMI Cornelius Inc Quest Juice Training Manual TRANSFORMER This is a dual stage transformer with 2 outputs The purpose of the transformer is to step the line voltage to 26 VAC primary to the electrical box and the VRB and 24 VAC secondary is to light the merchandiser Current production transformers are equipped with a thermal overload protection device that will cut out when high temperature or high amperage is detected THE OVERLOAD Primary wires are Blue RESETS AUTOMATICALLY i WATER INLET SOLENOID The water inlet solenoid is connected to the incoming water
10. concentrate prior to use 2 Place concentrate 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 this connection may result in weak drinks and or seepage of concentrate 4 Prime each pump by closing the cabinet door and press each dispense button until concentrate flows from the dispense nozzles CHANGING CONCENTRATE CONTAINERS 1 Open the cabinet door and move the valve handle from Dispense to Flush 2 Close the door Depress and hold the dispense button until clear water flows from the dispense noz zle 3 Open the cabinet door and return the handle to Dispense 4 Depress and hold the dispense button for 1 2 seconds This will relieve water pressure from the con centrate pump system 5 Load concentrate container see Loading Concentrate Publication Number TP00968 6 2004 IMI Cornelius Inc Quest Juice Training Manual BRIXING PROCEDURE NOTE If concentrate is not properly thawed it will adversely affect the amount of concentrate dispensed Thawed product should be between 35 F 1 6 C to 40 F 4 4 C NOTE You ca
11. head stops when light is on BOARD INPUT 26VAC from Transformer 2 pin connector Sold out from platform 2 pin connector Touch pad SWITCH Refill 2 pin connector 2004 IMI Cornelius Inc 27 Publication Number TP00968 Quest Juice Training Manual eines D PUMP SPEED SWITCH The pump speed switch has two settings low and high For most dispensing situations high speed will be the preferred speed Most concentrates use this setting Low speed is only used when the water pres sure is at the low end of the range 25 PSI or less and the concentrate is a very thin viscosity such as apple or cranberry Low speed cuts the output voltage to 18VDC Using a water booster system to increase the flowing pressure to the recommended pressure is a better solution PUMP PUMP E SPEED SWITCH SPEED f PUMP PUMP j ween WTCH SPEED SWITCH SPEED 106 CH Low HIGH Low 4 D 17 ICE BANK CONTROL The ice bank control is the only devise used to control the refrigeration system for both the cabinet and the water chiller Operational Overview There is no adjustment of any kind to this con trol The control will not activate without having sufficient water in the water bath tank See chapter on installation water bath filling THERE IS MINUTE DELAY BUILT INTO EACH CONTROL AS SAFTEY PRECAUTION The default mode is an open
12. only Push up and slide the probe 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 Current version m Early version GRAY wire iT BLACK wire cover v 1 Yellow T Blue Orange Publication Number TP00968 26 2004 IMI Cornelius Inc Quest Juice Training Manual MAJOR COMPONENT REVIEW ELECTRICAL Box The electrical box houses the Voltage Regulator Boards VRB that is used to convert AC voltage from the transformer to DC voltage that powers the pumping system It also incorporates the sold out logic Each flavor has its own VRB WHITE CONNECTOR INPUT CABLE Transformer 26VAC Sold out from platform push button RED CONNECTOR OUTPUT CABLE 28 VDC 17 5 Platform solenoid Water inlet solenoid 6 25 Slo Blo Fuse BOARD OUTPUT Platform solenoid and pump motor Rear water inlet solenoid 4 pin connector Second transistor for slow speed operation only No heat sink required SPEED SWITCH SOLD OUT FUNCTION JUMPER 3 pin connector J5 PIN Enabled dispense light only LK PIN Disabled dispense pump
13. Flush lever in FLUSH position e Concentrate too cold not properly thawed e Defective pump motor e Ambient air around dispenser is e too warm e Excessive demand on dispenser e Dirty condenser coil noperative condenser fan e Defective Ice Bank Control e Loss of refrigerant charge due to e leak in system e Main water solenoid at base of e unit or water solenoid on pump e Unplug dispenser and allow 2 4 hours to thaw Check operation of agitator motor and ice bank control e Refrigeration system may be low on charge resulting in a deformed ice bank and freeze up of the water coil in the ice bath e Turn on switch e Door switch must be closed in order to dispense Check switch operation and replace if necessary e Replace with 6 25 250VAC slow blow fuse and test e Confirm transformer output by of 26VAC 2 Replace transformer if necessary e Measure across the VDC output of the board There should be 28VDC present when the dispense button is pressed Replaced VRB if necessary e Test replace if necessary e Refer to Concentrate Loading sec tion of this manual e Move lever to DISPENSE position Concentrate should be 35 40 F 1 7 4 5 C prior to loading Replace pump motor Relocate dispenser Add water pre cooler or second dis penser Clean condenser coil Replace condenser fan motor Test and replace if necessary Repair leak and recharge system Clean so
14. LO3NNOO 27 Publication Number 8 aa 2004 IMI Cornelius Inc Quest Juice Training Manual LNSALYY ano NOT ie H 51 2 21 4 84 121 T TA TV 2 AHO i i i i t n 391 PTT uoivllov HLGNET NT SOL OV B 1934409510 T WINO 211101 882 9 S riE 2 AN 1 9 dno NIEVE aM HOLYLI OY SAYIT TOYWLNOD 1 T savai QIONS 1S T OVA 92 RR 21 v HS 5 1 8 5 i Beg 50 31 5 AYOSLV 01 SS3NuvH 0 4 01 SS ONUVH 105 0 21 HO FWA NNOD Hid 9 DS STI ANOS kd 34 2004 IMI Cornelius Inc Publication Number TP00968 Quest Juice Training Manual TROUBLESHOOTING GUIDE The following pages contain troubleshooting information intended to aid an experienced service person in diagnosing operational problems that may occur For further assistance contact the IMI Cornelius Technical Services department at 1 888 248 5568 630 539 6850 outside the United States between the hours of 7 30A M and 5 00P M Central Standard Time You must have the model and serial number Located on the right side of the dispenser prior to call
15. New Door Latch Configuration PLATFORM COMPONENTS 7 Water Valve Flow Control ncm 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 Adjustment Screw Bottle Adaptor O rings When doing any assembly work on the bottle adaptor be sure to use a small amount of lubri cant on each o ring This should be a food approved non petroleum based grease Publication Number TP00968 30 2004 IMI Cornelius Inc Quest Juice Training Manual Tip When re assembling the large o ring may be pinched if not installed properly Place the slide valve into the bottom of the adaptor keeping straight across Press evenly to seat the o ring It is not advisable to rotate the valve back and forth in and attempt to seat the o ring Do the same when installing the top When securing the screws do it in the X pattern tightening the opposites 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 refill lights Sold Out Contacts Bottle Adaptor Tra
16. TE 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 REMOVAL NozzLE GUIDE GASKET 1 The nozzle guide gaskets can be removed for cleaning or replacement by pulling them up and over the nozzle guides 2004 IMI Cornelius Inc 21 Publication Number TP00968 Quest Juice Training Manual REMOVAL OF THE COOLING CABINET 1 Remove 4 7 16 nuts from the under side of the cabinet frame Current productions 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 Publication Number TP00968 22 2004 IMI Cornelius Inc Quest Juice Training Manual 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 agit
17. Water supply line inside refriger ated cabinet disconnected from pump platform e Water solenoid located on pump platform clogged or defective located at the rear of dispenser is clogged binding or defective e Water supply pressure is greater than 80 psi 5 5 bar forc Main water solenoid strainer ing the brix flow control closed 2004 IMI Cornelius Inc 35 e Restore Water Reconnect Disassemble and clean solenoid Replace if necessary firm 28VDC is present at solenoid during dispense Confirm solenoid coil is not open Disassemble and clean solenoid Add external regulator and lower Remove clean strainer Con pressure to 50 psi 3 5 bar Publication Number TP00968 Quest Juice Training Manual 2 PROBLEM PROBABLE CAUSE REMEDY No water and no con centrate refrigeration is working No concentrate dis pensed water only Warm Drink Water continuously drips from nozzle when in OFF mode Freeze up of water coil in ice bath e Black service switch located on the rear of the cabinet door in OFF position White door switch open 6 25 amp fuse inside front elec trical box blown Defective voltage regulator board VRB located inside front No output from Transformer electrical box Defective dispense push button or portion control board Concentrate container not fully engaged into receptacle on pump platform Dispense
18. ator motor 2004 IMI Cornelius Inc 23 Publication Number TP00968 Quest Juice Training Manual eines D REMOVAL OF THE AGITATOR MOTOR 1 Remove the thumbscrew located at the rear of the motor before removing the agitator 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 REMOVAL OF THE REFRIGERATION CHASSIS 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 the water bath cover Publication Number TP00968 24 2004 IMI Cornelius Inc Gne Quest Juice Training Manual 3 Disconnect the following connectors and leads Remove the top ground wire from the post Red White from transformer 1 Blue from transformer 2 e 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 2004 IMI Cornelius Inc 25 Lead Publication Number TP00968 Quest Juice Training Manual REMOVAL OF THE ICE CONTROL PROBE 1 Carefully turn the chassis over to gain access to the probe assembly Cut the wire tie holding the probe assembly
19. behind the right and 2 1 left flavor 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 Publication Number TP00968 14 2004 IMI Cornelius Inc REMOVAL 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 2004 IMI Cornelius Inc 201325 Quest Juice Training Manual Publication Number TP00968 Quest Juice Training Manual 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 Publication Number TP00968 2004 IMI Cornelius Inc Quest Juice Training Manual REMOVAL OF THE COOLING FAN 1 Remove 4 screws from the cabinet rear panel 2 Turn the panel so the fan is facing you To do this you will have to
20. by pressing the gray button see Fig 1 amp 2 Slide the locking latch forward Lift the FRONT 4 REAR PUMP WATER platform slightly and pull forward to SOLENOID gain access to the electrical connector see Fig 1 Unplug the electrical connector by squeezing the locking tabs on either side and pulling out the con nector Lift and remove the pump platform see Fig 1 Replacing Pump Tubing 1 Remove pump platform refer to the Removing Pump Platform s procedure located earlier in this section Remove the two white plastic hose clamps from the pump tube con nections see Fig 1 amp 2 Remove the concentrate delivery tubes from the hose ends Loosen and remove the four screws from the pump body see fig 3 Remove the rear pump body half only to reveal the pump tube and rollers Remove the old pump tube from the pump body If the roller assem bly comes out with the tubing place it back into the pump housing being sure to align the roller assembly shaft keyway to the motor shaft so that the two interlock Firmly press the new hose into the pump body around the roller assembly being sure to keep the protruding ends even with each other Once the tubing is in place hold the tubing with one hand cap ture the lower part of the tubing with the outer housing then proceed to capture the shaft of the roller assembly and push the rear pump housing into place Make sure to capture the tubing within th
21. down and back Once it is clear of the door the panel will release REMOVAL OF ELECTRICAL Box 1 Remove the nozzles 2 Remove the screw on the right side of the electrical box 3 Pull the electrical box forward and straight Out 2004 IMI Cornelius Inc 19 Publication Number TP00968 Quest Juice Training Manual REMOVAL OF THE VRB BOARDS ae CO Remove the cover Remove the connectors Loosen and remove the nut and insulation Turn the box over and locate the standoffs on the VRB board to be removed Gently squeeze with a needle nose pliers This will release the standoff and allow it to be pushed back through the hole in the bracket board can now be removed from the electrical box itself 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 result in component overheating causing the concentrate pump not to run Publication Number TP00968 20 Lock washer Washer Insulator pad Insulator washer 2004 IMI Cornelius Inc Quest Juice Training Manual REMOVAL OF THE ICE BANK CONTROL 1 Slide the ice control toward the center of the deck to release and lift up while gently pulling forward The box will come forward only as far as the cables will allow NO
22. e body and not pinch it between the halves Do not use any tool other than your finger tips to manipulate the tubing into the housing or you may damage the tube PUMP TUBING ROLLER ASSEMBLY 2004 IMI Cornelius Inc 11 Publication Number TP00968 Quest Juice Training Manual 8 While holding the pump halves together with your 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 Publication Number TP00968 12 2004 IMI Cornelius Inc Quest Juice Training Manual MECHANICAL SECTION REMOVAL OF MERCHANDISER 1 Remove 6 screws from the top the front and the side 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 Ballast Assembly 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 2004 IMI Cornelius Inc 13 Publication Number 968 Quest Juice Training Manual REMOVAL OF THE SWITCH PANEL 1 Remove 2 screws from
23. e do sed bur ee es 4 Key THINGS 10 Dow DO 32 022 418 25 a e PEA eee o qe ee eee Re 4 installalloOnm cv xo px ees Ema s 5 Counter LOCATON ac aras dod Side ORE RAT E e CARO ROC E 5 De ICE 43 2 3 Gc ecd et adi aod oar qct aha xd pe dies el a has 5 Connecting Water Supply 5 Priming Flushing Water System clle 5 Concentrate Handling amp Loading 6 Loading C cts 2 iade sud 6 Changing Concentrate 5 6 SUD DIES se Sie ESS TET 7 Checking Adjusting the Brix Setting 7 Programming the Portion Control 8 Gancel Pour Button 415 code oe bee dat tow 8 Planned Maintenance Schedule leeren 9 dr iE IS sd sies T 9 SV SIGNI Pr we frat 9 Clean Splash Zones amp Dispense Nozzles 9 AIC 9 Sanitize the Juice Dispenser LL ias 9 2211 2101 19 S Lekas S eas DSS PRO
24. ence use only Contact your fro zen concentrate supplier for specific brix readings Caner coa TTT Teme 54 Sweetened eed Tea Juice TTT 2004 IMI Cornelius Inc 7 Publication Number TP00968 Quest Juice Training Manual eines D Pump Speed Switch The pump speed switch has two settings low and high For most dispensing situations high speed will be the preferred speed Most concentrates use this setting Low speed is only used when the water pres sure is at the low end of the range 25 PSI or less and the concentrate is a very thin viscosity such as apple or cranberry Low speed cuts the output voltage to 18VDC Using a water booster system to increase the flowing pressure to the recommended pressure is a better solution SPEED SWITCH SPEED SWITCH HIGH LOW SPEED SWITCH PUMP SPEED SWITCH Low HIGH LOW HIGH 4 5 change the brix setting simply readjust the water flow rate Located on each of the valve assemblies inside the refrigerated compartment are the adjusting screws for the water flow rate one per valve If the brix reading is too high or low rotate the appropriate water flow control according to the diagram below Repeat steps 1 5 until the brix setting is achieved Lowers Brix by increasing water Lg Raises Brix by reducing water IMPORTANT When making changes to the water flow control do not rotate more than 1 4
25. gs Additionally 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 chlorine IMPORTANT Use potable water at 80 F 100 F 26 7 C 37 8 C Water above this range will break down the chlorine count and minimize sanitation 2 Remove the juice concentrate containers and place them in separate refrigerated compartment 3 Flush the system by following the instructions in the Daily Section 4 Filla clean empty concentrate container with one quart of extremely hot tap water approximately 140 F 60 C and place into unit Dispense all of the hot water into a large container Repeat for the remaining dispense valves 5 Remove the mixing chambers nozzles and static mixers Rinse in hot water to remove excess pulp and concentrate 6 Place the mixing chambers nozzles and static mixers in a separate container of sanitizing solution and agitate vigorously Allow the parts to soak for two minutes Rinse thoroughly with fresh tap water 7 Reinstall the static mixer nozzles and mixing chambers 2004 IMI Cornelius Inc 9 Publication Number TP00968 Quest Juice T
26. ing PROBLEM REMEDY PROBABLE CAUSE No power to dispenser due to tripped circuit breaker Totally Inoperative Loose or broken power supply connection inside dispenser Reset circuit breaker Confirm that breaker is correct size and no other equipment is operating on the same circuit Also confirm that supply volt age is 10 nameplate specifi cations Repair connection No cooling Line voltage is not within 10 of nameplate specifications causing compressor overload to trip No water in water ice bath or water level extremely low exposing the ice bank sensing probe Defective Ice Bank Control or sensing probe Cabinet fan is inoperative result ing in warm concentrate water continues to cool overload Compressor starts but hums and trips overload Defective compressor overload or start capacitor Compressor starts but does not Compressor short cycles on switch off of start winding e Refrigerant leak Contact an electrician Fill ice bath to proper water level Replace sure due to restricted condenser or inoperative condenser fan motor Seized or shorted compressor replace e Test replace Excessively high discharge pres Relay or compressor is defective Test and replace faulty item Repair leak evacuate and recharge system No water dispensed concentrate only No water to dispenser
27. ion from Cornelius Printed in U S A Copyright 2004 All Rights Reserved IMI Cornelius Inc eines Quest Juice Training Manual TABLE OF CONTENTS OVerI VIO W Liss gt dca a cM aoe Nea aS LEM ILI MU LE M LI LM ME MR 1 Product sss dre IUe n EU Ed AES SE S d 1 Dimensions 8 Capacities 2 en HQ 2 Quest TWO uie 2 Quest Foll Flavor uus alee aden ues Geta xr 2 PONOS 515615 eee dcs des Hae 2 ice Bain Canacil ae toss a Ime doces edo awe tenes oe 2 System 1061318 ete eS eee eee 3 tee E ated 3 VV Aer CUNY wart stava ete Be TE ee 3 Eu wE RC TTL 3 0105110 FIOW Rates EX Vb twr d barks amie aries 3 sisiy d Ak hey Soe he aw aua L E E 3 SettiBg the BIX sc S bo fede E eene SUE a 3 INTFOGUCTION 12 25 4 Preview dat o
28. ionally the portion control has full memory retention in case of a power failure Cancel Pour Button To pour a drink without using a pre programmed portion control size simply push and hold the Cancel Pour button Release when the glass is full Publication Number TP00968 8 2004 IMI Cornelius Inc Quest Juice Training Manual PLANNED MAINTENANCE SCHEDULE DAILY Flush System 1 Move Dispense Flush levers located on the platform assembly in the refrigerated cabinet to the Flush position Place an empty cup on the drip tray below each dispense nozzle 2 Close the door and depress each dispense button for 2 3 sec onds or until clear water flows from each dispense nozzle 3 Return the Dispense Flush levers to the Dispense position 4 Press each dispense button for 1 2 seconds to release the water pressure present in the concentrate pump system Clean Splash Zones amp Dispense Nozzles 1 On a daily basis clean the external cabinet and splash areas using a clean damp cloth Remove and wash the cup rest and drip tray using a mild dish soap 2 Remove the dispense nozzles and static mixers by rotating each 90 and pulling down Remove MIXING CHAMBER the mixing chambers by pulling straight forward Wash using a mild dish soap STATIC MIXER DISPENSE NOZZLE IMPORTANT DO NOT wash nozzles static mixers or mixing chambers in a dish washer This will distort the plastic and damage the o rin
29. lenoid s replace parts as necessary refer to the Planned Concentrate warm water cold Publication Number TP00968 platform not shutting off tightly e Cabinet fan inoperable e Agitator motor pump inoperable or restricted Loss of refrigerant charge due to leak in system 96 Maintenance Section Check replace fan Check replace agitator motor e Repair leak and recharge system 2004 IMI Cornelius Inc Gimus Quest Juice Training Manual PROBLEM PROBABLE CAUSE REMEDY Brix Problem e Water supply pressure too low 55 than 20 psi 1 4 bar flowing water pressure fluctuates sharply e Water flow control binding or spring is defective e Improperly thawed concentrate Brix changes as the concentrate temperature changes concen trate becomes thinner as temper ature rises Correct water supply problem to ensure a constant 50 psi 3 5 bar flowing to the dispenser Clean and or replace parts as nec essary Concentrate should be 35 40 F 1 7 4 5 C prior to loading Pump Inoperative e Pump motor defective e No power to transformer or 28VAC output from transformer e Defective voltage regulator board VRB located inside front electri cal box e Defective dispense control board Push button or portion control 28VDC should be present at pump motor during dispense If voltage is present and motor does not start replace pump motor Confirm transformer has line vo
30. line and is only activated when 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 DooR SWITCH 72 B SERIAL NUMBER The door switch on the 72B serial number units Switch 4720202009 is a combination of a door latch and switch The Cam Lock primary function of the door switch is to inter rupt the 26 VAC coming into the VRB board I when refilling the concentrate By cutting this voltage the refill lights are reset automatically NOTE WHEN THE 15 OPEN THE 015 PENSE CIRCUIT IS INOPERABLE DO NOT ATTEMPT TO DEFEAT THIS WITH ANY THING BUT THE CAM LOCK FOUND ON THE DOOR A SPECIAL TOOL IS AVAIL ABLE FOR THIS PURPOSE 2004 IMI Cornelius Inc 29 Publication Number 968 Quest Juice Training Manual eines D Door SWITCH 72 E SERIAL NUMBER On or before April 1 2004 the door switch con figuration will be changed to separate the reset Reset Switch in Top of Door switch from the catch The serial number for this will have a prefix of 72 D for Quest 4 flavor and 72C for Quest 2 flavor Kit 720911146 is available to convert field units to this configuration The sold out feature however will be inoperable with the use of this kit
31. ltage present on primary side If no 28VAC output from the secondary replace transformer 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 Test and replace if necessary Machine continues to e Push button or portion control pad dispense after dis stuck in on position pense button is released or dis penses without opera tor input e Relay on voltage regulator board VRB stuck on Disconnect the wire harness from the rear of the portion control and close the door If unit does not dis pense on its own the dispense con trol board is bad stuck on Disconnect the 4 wire harness from the lower right corner of the VRB If the unit continues to dispense on its own the VRB is defective relay stuck on 2004 IMI Cornelius Inc 37 Publication Number TP00968 Quest Juice Training Manual eines D NOTES Publication Number TP00968 38 2004 IMI Cornelius Inc www cornelius com
32. n 5 Reinstall the right side panel turn on the water supply and plug the dispenser into the power recep tacle Check and Top Off Water Ice Bath 1 Remove the drip tray and lower splash panel 2 If the Ice bath level is below the Full indicator top it off with water Refer to the Filling the Ice Bath procedure in the Installation section of this manual 2 SS V We MN 0 mv 8 01 se Te 9 47 Ad Publication Number 968 10 2004 IMI Cornelius Inc Quest Juice Training Manual ANNUALLY Replace Pump Tubing A replacement pump tubing kit part 45098 is available The kit consists of one pre cut WATER _ INLET QUICK CONNECTOR HOSE length of pump tubing two white plastic JUICE INLET TA CLAMP hose clamps and instructions Removing Pump Platform s 1 THUMB SCREWS DISPENSE FLUSH LEVERS Remove the concentrate containers from the dispenser and place them ina LOCK ING refrigerator Pore on Remove the cabinet shelf that the con SESS centrate containers sit on Flush the system prior to removing the WAT MANIFOLD pump platform refer to the Daily sec tion located at the beginning of the Planned Maintenance Schedule Remove the dispense nozzles and static mixers Unplug the water line quick disconnect
33. n not dispense drinks with the door open SUPPLIES e 1 Small 12 oz 354 8 ml 1 Large 21 oz 621 1 ml 7 E e 1 Straw L Paper Towel te YEO 1 Thermometer Wy 1 Refractometer Concentrate Separator 720601323 Your will also need a flat blade screwdriver to turn a screw if brix adjustments are required NOTE The refractometer shown above P N 511004000 is available through your local Cornelius Distributor CHECKING ADJUSTING THE SETTING The following instructions are for use with a refractometer 1 Dispense approximately 8 oz 236 ml of drink and discard Now draw a second 8 oz drink 2 Check drink temperature with a reliable thermometer 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 using a straw Adjustments should be made in 1 8 to 1 4 turn increments 4 Using a straw transfer a small sample of finished drink to the refractometer lens refer to operating instructions supplied with your refractometer Check the brix reading against the brix chart below NOTE The following brix chart is generic and intended for refer
34. o prevent twisting of the copper tube inside the unit and or possible damage to the water strainer solenoid A water shut off outside the unit is recommended PRIMING FLUSHING WATER SYSTEM To properly prime the unit with water and remove air pockets in the system open the cabinet door and make sure that all the valve levers are in the Dispense position Dispense Flush Lever Close the door and press the dispense button for a few seconds Repeat until a steady flow of water is observed flowing from all dis pense valves NOTE Water splashing may occur during this purge cycle 2004 IMI Cornelius Inc 5 Publication Number TP00968 Quest Juice Training Manual eines D CONCENTRATE HANDLING amp LOADING It is recommended that the concentrate be thawed in a refrigerated 35 F 40 F 1 6 C 4 4 C compart ment for a minimum of 48 hours prior to loading into the Quest Juice Dispenser WARNING Concentrate must be completely thawed and within the temperature range of 35 F 40 F 1 6 C 4 4 C prior to loading Failing to supply concentrate inside the recommended tem perature range especially below 35 F 1 6 C will cause an out of brix drink refer to the Brixing Procedure section for details LOADING CONCENTRATE The Quest Juice Dispenser is designed to use either disposable juice concentrate containers or the optional Cornelius generic refillable container sold separately 1 Thoroughly shake thawed
35. 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 Fan Label When reinstalling the panel it will be necessary to pull back through the wire lead connected to the fan 2004 IMI Cornelius Inc 17 Publication Number TP00968 Quest Juice Training Manual REMOVAL OF PANELS 1 Loosen the 2 screws from the 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 revere L lini 2004 IMI Cornelius Inc Publication Number TP00968 Quest Juice Training Manual 7 Remove the side panels A Right Panel The 2 screws and switch backing plate must be removed before the right panel can be 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
36. raining Manual eines D Step 2 Sanitize Pump System 1 Fill a clean concentrate container with 2 quarts 1 9L of fresh sanitizing solution 2 Place handles in the dispense position and close the door 3 Press and hold the dispense button for 90 seconds then stop Allow sanitizing solution to remain in the lines for 5 minutes 4 After 5 minutes dispense the remaining sanitizing solution Step 3 Prepare Dispenser for Use 1 Replace sanitizing solution container with a concentrate container and close the door 2 Press and hold the dispense button until juice appears from the nozzle Next dispense and discard at least two 8 oz 236 6ML cups of juice in order to prime the system and prepare it for operation SEMI ANNUAL 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 stainless steel water strainer Clean Chassis Interior 1 Clean the condenser cooling fins WATER STRAINER ACCESS 2 Clean the air inlet grilles located on the rear and top panels of the dis 5108 GF DISPENSER penser 3 Clean the interior base Wipe the fan blade clea
37. turn per adjustment Additionally prior to taking your next brix reading tap the corresponding dis pense button several times prior to drawing a sample This will clear remnant drink from the dis pense nozzle AND help move the flow control 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 the Portion Control Module until the Refill light starts blinking Release the switches The blinking Refill GB B light indicates the programming mode is active 2 Place the cup under the dispense nozzle and push the selected size button small medium R large or extra large Hold the button in until the cup fills to the desired portion then release the button Repeat the above procedure for the remaining sizes 3 After programming all the drink sizes press and release the cancel pour switch to return the Portion Control to the operational mode The blinking REFILL light will go out V 4 If at a future date it is decided to change the portion size of the drinks the individual sizes can be adjusted by the above procedure It is not necessary to reprogram every size Addit
38. y Grommets When installing the grommets be sure that each one is sealed below the lead in taper on the top of the bottle adaptor TIP Press the entire tray down evenly to seat Run finger around the edge to seal 2004 IMI Cornelius Inc 31 Publication Number TP00968 Quest Juice Training Manual Bottle Adaptor Flush Mode THE FLUSH MODE IS FOR FLUSHING THE PUMP SYSTEM OF CONCENTRATE ONLY Dispensing water in the flush mode over long periods 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 replaced Publication Number TP00968 32 2004 IMI Cornelius Inc Quest Juice Training Manual WIRING DIAGRAM P gt gt gt gt 3 0080502 N d 1 e Tf s 0 09318 a EIEIZIT PIEZ FERI FELI TE TTV 4 I 939 NOT WNOIS X07009 4 YOLISNNOD WHITE FEMALE CONNECTOR CVNOIS CAS 0007 153 0 WvH9VIQ W31SAS HO
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