Cornelius QLT180/1000-1 Supplement

INSTALLATION & SERVICE MANUAL
MODEL QLT180/1000-1, 1002-1, & 1001-1
IMI CORNELIUS INC.
One Cornelius Place
Anoka,
MN 55303
Tel: [phone]
Fax: [phone]
Part No. 85312001
Revision- C
July 22,2002

Installation & Service Manual
SEMI-ANNUAL "
CAUTION: The following procedures require removal of the dispenser side
panel
(8). Disconnectthe power cord from the receptacleprior to proceed-
A ing.
0 Clean Water InletStrainer:
1. Removethe left side side panelfrom the dispense.
2. Turn off the water supply to the dispenser.
3. Removethe access portfrom the "Y" shaped solenoid
locatedon the water inletinthe lower rear portion
of the
dispenser.
4. Cleanand reinstallthe stainlesssteelwater strainer.
0 CleanChassis Interior:
1. Cleanthe condenser coolingfins.
2. Cleanthe air inletgrille locatedat the base of the dispenser.
3. Cleanthe interior base.
4. Wipe the fan bladeclean.
5. Reinstallthe leftside panel, turn on the water supply, and plugthe dispenser intothe power
receptacle.
8531
2001
10

Installation & ServiceManual
TROU BLE-SHOOTING GUIDE
The followingpagescontaintrouble-shooting information intendedto aidan experiencedservice
personin diagnosingany operationalproblemsthat may occur.
If you are unableto resolvethe
problemafter several attempts,contactthe IMICornelius
/ Wilshire Inc.Technical Servicesde-
partmentat 1-800-238-3600 (763-421-6120 outside the UnitedStates)betweenthe hoursof
8:OO AM and
300 PMCentralStandardTime. You must have the modelandserialnumber (lo-
catedonthe rightsideof the dispenser)priorto calling.
PROBLEM PROBABLE CAUSE REMEDY
due to trippedcircuit
breaker.
Totally Inoperative
No powerto dispenser 0 Reset circuitbreaker.
Confirmthat breakeris
correctsize and no other
equipmentsi operatingon
the same circuit.
Also
confirmthat supplyvolt-
age is
f 10%of name-
platespecifications.
0 Looseor broken power 0 Repair connection.
supply connection inside
dispenser.
Yo Cooling Line voltage isnot within
f 10% of nameplate
specificationscausing
compressor overload to
trip.
Boththermostats in
OFF 0
position.
0
Defectivecompressor 0
overloador start capaci-
tor.
Defectivestart relay
lo- 0
catedon upper rear shelf
insidedispenser.
Compressor startsbut
0
humsand tripsoverload.
Compressor startsbut
0
does notswitch off of start
winding.
Compressorshort cycles
0
on overload.
Contactan electrician.
Turn
ON thermostatsand
recalibratethe tempera-
tures to
40°F f 5 (45°C).
Replace.
Thereshould
be linevolt-
age onthe blackwireof
the relaywhenthere is
linevoltage present
on the
orange
OR yellowwire.
Replacerelay
if itfails this
test.
Seizedor shortedcom-
pressor, replace.
Relay or compressoris
defective. Test and re-
placefaulty item.
Excessivelyhighdis-
charge pressuredueto
restrictedcondenseror
in-
operativecondenserfan
motor.
11 85312001

Installation & Service Manual
No Cooling(Cont'd)
0 Refrigerantleak. 0 Repairleak, evacuate and
rechargesystem.
Yo water dispensed, concen- 0
trate only.
0
0
No watertodispenser. 0
Water supply line inside 0
refrigeratedcabinet dis-
connectedfrom pump
platform.
Water solenoid locatedon
0
pump platformclogged or
defective.
Mainwater solenoid 0
strainer locatedat baseof
dispenser isclogged,
bindingor defective.
No water dispensed,con- 0
centrateonly.
Water supply pressureis
0
greater than 100 psi (7
bar)
Freeze-up of water coilor
0
concentratechamber.
Restorewater.
Reconnect.
Disassemble and clean
solenoid. Replace
if nec-
essary.
Remove and cleanstrain-
er. Confirm28VDC is
presentat solenoidduring
dispense. Confirmsole-
noidcoil is not open. Dis-
assemble andclean sole-
noid.
Add external regulator
and lower pressureto
50
psi (3.5 bar).
Unplugdispenserand al-
low 2-4hoursto thaw.
Water or concentratether-
mostat set too low, recali-
brateto 40"F
f 5 (4.5"C).
Defectivewater or con-
centrate thermostat, re-
place.Refrigerantsolenoid
stuck openor not closing
fully. Evacuatesystem,
replacesolenoidvalve
and recharge.
No water and no concentrate, 0 Serviceswitch locatedun- 0 Turn on switch.
refrigerationisworking. der driptray in OFF posi-
tion.
0 Door switch open. 0 Door switch must be
closed
in orderto operate
pump. Check switchop-
erationand replace
if nec-
essary.
0 6.25 amp fuse insidefront 0 Replacewith 6.25 amp,
25OVAC
slow blow fuse
and test.
0 No output from transform- 0 Confirmtransformer out-
er locatedon rear upper put by measuringfor
shelf. 26VAC atfuse. Replace
transformer
if necessarv.
electrical
box blown.
85312001
12

Installation & ServiceManual
No water andnoconcentrate, 0 Defective voltage regula- 0 Measure acrossthe blue
refrigerationisworking and blackwire locatedin
(Cont'd). insidefront electricalbox. the upper leftcornerof
the board. There should
be28VDC presentwhen
the dispensebuttonis
pressed. ReplaceVRB
if
necessary.
0 Defective portioncontrol 0 Disconnectwire harness
from rear of portioncon-
trol, close door switchand
short the orange and
blackwirestogetheron
the harness.
If unit dis-
pensesportioncontrol
board
is defective. If it
does notdispensethe
voltage regulatorboardis
defective.
tor board(VRB)located
board.
No concentratedispensed,
0 Dispensetube notfully 0 Refer to Concentrate
water only. engaged intoreceptacle
Loading sectionof this
on concentratepouch. manual.
nectedfrom mixingcham-
ber. manual.
open position.
0 Dispensetube discon- 0 Refer to Concentrate
Loadingsectionof this
0 Slide blockon pump in 0 Close and lock the slide
block. Refer to Concen-
trate Loadingsectionof
this manual.
' Switch on pumpplatform 0 Moveswitchto RUN posi-
0 Concentratetoo cold, no 0 Concentrateshouldbe
in FLUSH position. tion.
properlythawed. 3540°F (1.74.5"C) prior
to loading.
I 0 Defectivepumpmotor. 0 Replacepump motor.
Excessiveremnant left in
0 Concentrate pouchim-
0 Concentrateshouldbe
empty concentratepouch. properlythawed. 3540°F (1.7-4.5"C) prior
to loading.
Loading sectionof this
0 Concentrate pouchand/or 0 Refer to Concentrate
dispense tube improperly
installed. manual.
Concentraterefilllightcomes
0 Concentrate pouchim-
0 Concentrateshould be
onprematurely. properlythawed. 3540°F(1.7-4.5"C) prior
to loading.
Loading sectionof this
0 Concentrate pouchandlor 0 Refer to Concentrate
dispense tube improperly
installed. manual.
_____
13 85312001

Installation & ServicgManual
Concentraterefilllightcomes
0 Loose wiring. 0 Check wiringconnections
on prematurely(Cont'd). betweenthe pumpmotor
and the VRB board.
0 BadVRB board. 0 ReplaceVRB board.
I 0 Badpump motor. 0 Replacepump motor. I
Concentraterefilllightdoes 0 Pump improperly locked 0 Closeand lock pump.
not come on at all. or pumpisopen.
FLUSH position. position.
0 Run/flushswitchis inthe 0 Move switchto the RUN
0 Improperlyloadedtube. 0 Refer to concentrateload-
ingsection of this manual.
0 Bad VRB board. 0 ReplaceVRB board.
0 Badportioncontrol. 0 Replaceportioncontrol.
Warm Drink
0 Incomingwater supply too 0 Optimumperformanceis
warm. achievedwhen the dis-
penserutilizeswater from
a pre-cooler.
0 Ambient air too warm. 0 Relocatedispenser.
0 Excessive demandon dis- 0 Add water pre-cooleror
penser. seconddispenser.
0 Dirtycondenser coil. 0 Cleancondensercoil.
I
I
0 Inoperativecondenser 0 Replacecondenserfan
0 Defectivewater thermo- 0 Replacethermostat.
0 Lossof refrigerantcharge 0 Repairleakandrecharge
fan. motor.
stat.
due to leakinsystem. system.
Water continuouslydripsfrom
0 Mainwater solenoidat 0 Cleansolenoid(s),replace
nozzlewhen inOFF mode. baseof unit or water sole-
noidon pump platformnot
shutting
off tightly.
partsas necessary.
No FlushCycle 0 Run/Flush switchon 0 Moveswitchto Flush
pump platform
in Run position.
mode.
switchon pump platform switch.
(concentratecontinuesto
dispensewhile in Flush
mode).
0 DefectiveRun/Flush 0 ReplaceRun/Flush
Concentratewarm, water cold
0 Concentratethermostatis 0 Calibrateto be3540°F
turned
off or notcalibrated
properly. (1-7-4.5"C).
85312001 14

Installation & ServiceManual
Concentrate warm, water cold
0 Concentrate thermostat 0 Replacethermostatand
(Cont'd). defective(stuckopen). calibrateto 3540°F
(1.7-4.5"C).
0 Defectivestart relay lo- 0 Thereshouldbe linevolt-
catedon upper rear shelf
insidedispenser. age on the blackwire of
the relaywhen there is
linevoltage present on the
orange OR yellow wire.
Replacerelay
if itfails this
test.
0 Lossof refrigerantcharge 0 Repair leak and recharge
system.due to leak insystem.
Brix Problem
0 Water supply pressure too 0 Correctwater supply
problemto ensure a
constant
40 psi(2.8 bar)
flowingto the dispenser.
parts as necessary.
3540°F (1.74.5"C) prior
low, lessthan40 psi (2.8
bar)flowingor water pres-
sure fluctuatessharply.
or springis defective.
centrate. Brix changes as
the concentratetempera- to loading.
ture changes (concentrate
becomesthinneras tem-
peraturerises).
0 Water flow controlbinding 0 Clean and/or replace
0 Improperly thawedcon- 0 Concentrateshould be
Pump Inoperative
0 Pump motor defective. 28VDC should be present
0 No power to transformer
or no28VAC outputfrom
transformer.
0 Defectivevoltage regula-
tor board(VRB) located
insidefront electricalbox.
at pump motorduring dis-
pense.
If voltage is pres-
ent and motor does not
start, replacepump motor.
Confirmtransformer has
linevoltagepresenton
primaryside. If no28VAC
outputfrom the secondary
replacetransformer.
Measureacrossthe blue
andblackwire located
in
the upper left corner of
the board. Thereshould
be28VDC presentwhen
the dispensebuttonis
pressed. ReplaceVRB
if
necessary.
15 85312001

Installation & Service Manual
Pump Inoperative(Cont’d).
0 Defectiveportioncontrol 0 Disconnectwire harness
from rear of portioncon-
trol, closedoor switch and
short the orange and
black wires together on
the harness.
If unit dis-
penses portioncontrol
boardis defective.
If it
does not dispense the
voltage regulatorboardis
defective.
board.
Machinecontinues to dis-
0 Portioncontrolpadstuck 0 Disconnectthe wire har-
penseafter dispense buttonis nessfrom the rear of the
releasedor dispenseswithout portioncontroland close
operator input. the door. If unit does not
dispense on itsown the
portioncontrol is bad
(stuck on).
0 Relay on voltage regulator 0 Disconnectthe &wire
harnessfrom the lower
right corner of the VRB.
If
the unitcontinues to dis-
penseonits own the VRB
isdefective (relay stuck
on).
in on position.
board (VRB) stuck on.
8531 2001 16

Installation & Service Manual
System Wiring Diagram
17
8531 2001

Installation & ServiceManual
0
0
0
0
0
0
0
0
0
Main Electrical Box Wiring Diagram
86312001 18

Installation & Service Manual
45551
455381
00
455091 000
45155001
Final Assembly
P/N 45100401.(115VAC)
P/N 45100402 (23OVAC)
Pouch Holder, Plastic
Shelf, Plastic
Platform
Assembly, QLT 180 w/Sold Out Feature
Grill, Drip Pan
I 1
45152
49157
I Item Number
Bracket, Drip Pan
Bushing
- Upper Hinge
I 6
Part Number I Description I
45129001 I DripPan I
I
49155 I ShoulderBolt - 1/4-20 X 13/16S.S.
1
I
49154 I Upper Hinge Plate I
.. -
45087 I Hinge - Top Cover I
45088 I Hinge - BottomCover
I
19 85312001

Installation & Service Manual
TABLE OF CONTENTS
Installation ...............................................
Receiving .........................................................
Unpacking ..........................................................
Counter Location ...................................................
ConnectingWater Supply ............................................
Electrical ..........................................................
FillingWater/Flushing System .. ......................................
Programmingthe Portion Control ......................................
CanceVPour Button ...................................................
Concentrate Loading ...... , ..
............ , ......... , .....
..
Concentrate Empty Indicator ............................................
"8
Unit Specifications ......................................... 3
Brixing Procedure ...........................................
Supplies ..........................................................
Checking/Adjustingthe Brix Settihg ....................................
Planned Maintenance Schedule ............................
Daily ..............................................................
Weekly ............................................................
Semi-Annual ......................................................
Troubleshooting Guide ...................................
Warranty .................................................
Certificate of Warranty ..............................................
Wilshire QLTl80/1000-1.1002.1 ....................................
4
4
4
4
4
5
5
5
5
5
6
7
7
7
9
9
9
10
11
34
34
34
8531
2001
2

Installation & ServicgManual
Item Number
13
14
15
16
I 17
Part Number Description
96561 DoorSupport Plate
45123 Static Mixer
31 525037 &Ring, MixingNozzle
48808001 DispenseNozzle
45159
SplashPanel
I 18 I07061001 I Screw, #lo Type "F" HHWF, 318 Long 1
19
20
21
22
23
46546
Arm Assembly
45749001 Wiring DiagramLabel
46422 Shock HazardLabel
45107 ElectricalBox Cover
0704001
Screw, #8-32 Type "F, 318" Long
24
25
26
27
28
I 29 I 45165 I Water CoilAssembly 1
45028 Transformer, 11 5VAC
45028001 Transformer,23OVAC
451 09 Rear ElectricalBox
45187 FramehnnerLiner Bracket
45151 Water Coil Bracket
37958 Adjustable Leg
I
30 I 45199 f Top Panel 1
I 1
31
32
33
45125
RearPanel
0704101
7245444
LeftSide Panel
Screw, #832 X 3/8 Long, THM
34
35
85312001
7245443
RightSide Panel
470725 HolePlug
20

Installation & ServiceManual
Part Number
289521
30041001
I 1
Description
Screw, #8-32 X 3/8” Type “F HHS, Zinc
Bulkhead Fitting
I
638004442
0704001
45091001
08467
08474
I 2 Solenoid Spacer
Screw, #&32
X 3/8” Type “F BH
Water SolenoidValve
Compressor MountingGrommet
Spring Clip
I
7221320
45105
I 3
StrainRelief Bushing, 0.695 Dia.
FrameWeldment
I
03824001
45104002
E
Jam Nut, 7/8 - 14Hex
ElectricalBox Assembly
I
4501 0 (seenote)
45010001
45010002
45010003
I 8
Compressor, R-l34a, 115VAC, 60Hz.
CompressorOverload, 115VAC, 60Hz.
Compressor Relay, 115VAC, 60HZ.
Compressor StartCapacitor, 115VAC, 60Hz.
I
13
14
I-%-
2124713 I Union - Half, 0.38MFT X 0.38MP
I
I
0702609 I Screw, #8-32 X 3/4” BHMS I
45054 I Compressor, R-l34a, 23OVAC, 50Hz. I
45054001 I ComPressorOverload. 23OVAC. 50Hz. I
21 85312001

Installation & Service Manual
I Item Number I Part Number I Description i
*
16
17
*
18
19
Compressor Relay, 23OVAC, 50Hz.45054002
45054803
44913289 Compressor DischargeTube
44926224 Compressor ChargeTube
45073 FilterDryer
45169
45128
Compressor Start Capacitor, 23OVAC, 50Hz.
Switch & MountingBracketAssembly
HeatExchanne Assembly, 11WAC, 60Hz.
I I 45128001
20 46384
46384001
I I45373020
*
*
23
24
45
1 75001
45175002
0726802
45149
I 25 I48004
27
28
I I 48013
41757 Washer
96285001 Screw, #8-32
X 3/8” Type “T”, HH, Slotted
HeatExchange Assembly, 23OVAC, 50Hz.
1
Power CordAssembly, 11WAC, 60Hz.
Power CordAssembly, 23OVAC, 50Hz.
RefrigerantSolenoidValve, 11WAC, 60Hz.
RefrigerantSolenoidValve, 23OVAC,
50Hz.
1 Fan Motor Assembly, 115VAC (includesitems23-29)
I
1 Fan Motor Assembly, 22OVAC (includesitems23-29) I
~ ~~~~
lfinnarman Nut
Fan Motor Bracket
Fan Motor, 115VAC, 60Hz.
Fan Motor, 23OVAC, 50Hz.
I 26 (45168 I FanBlade 1
I I
29 I45163 I Condenser Assembly
1
Not Shown
NOTE:
Start components are supplied with the compressor.
85312001 22

Installation & Service Manual
Item Number Part Number
1 45167
2 45141
3 45142
4 45051
5 45119
6 0734801
7 45027001
8 07041 05
9 0704106
10 638004441
Description
Inner Liner Assembly - Foamed
FrontWrapper
FrontWrapper
Bottom
LatchStud, #lo-32 THRD S.S.
Liner Gasket
Rivet,
0.125 X 0.375 X 0.26
NozzleBushing
Screw,
8-32 X 1/2" THMS S.S.
Screw, 8-32 X 1/4" THMS
Lower Spacer
85312001
23

Item Number
11
I 12 146366 I Bushing
Part Number Description
0702609 Screw, 8-32
X 3/4” BHMS
I
14
15
*
I 13 I 45132 I Platform Connector Bracket I
0704001
47121
11761 Door Wire HarnessAssembly
Screw, 8-32
X 3/8Type “F” BH
Door Magnet - soldinbulk, 56.6 (143.5cm) requiredperunit
- ~~
* Not Shown
85312001 24

Installation & Service Manual
45048
45049
I Item Number
Washer, #2
Rivet, 3/8" Dia.
HD S.S.
I 9
10
11
12
Platform Assembly
PIN 45509100
I
45283 Rubber Bushing w/Nut Insert
45432 Sealed Rocker Switch
455081
00 Valve Block Assembly
Part Number
07032001
0704001
0704105
11 858
11 877
45046
45047
Description
Screw, #8-32
X 7/16"Type "25" HHWF S.S.
Screw, #8-32 X 3/8" Type "F BD HD
Screw, #8-32
X 1/2" THMS S.S.
Wire Assembly, Blue
Wire Assembly, Red
Latch
- #2 Medium S.S.
LatchGuide, #2 Medium I
25 85312001

Item Number
13
14
15
16
17
Part Number Description
4551 0 Pump Bracket
45514100 Pump Assembly
45516 Platform
45
45541 Run/Flush Label
MixingChamber Assembly (includesO-Ring p/n3152M03)
I
20 I45568 I Label, Hydrometer Holder
18
19
I I
21 I0710901 I Pop Rivet,Close End
45723001 Tube Assembly
0730404 #8LockWasher, ExternalTooth
I I
22 I45567 I Hydrometer Holder
*
45197
11886100
*
Hydrometer
PlatformWire Harness Assemblv
* Not Shown
.
85312001 26
i

Installation & Service Manual
Item Number
1
Part Number
455061 00
5
6
7
8
9
7215323
7215321
18367
31525020
19695001
10
11
12
13
14
18070
4551
8
07032001
16779003
48520001
16
17
18
19
20
60281001
60280002
31525060
48978
48258005
ro
Valve Block Assembly
P/N 45508100 ,,
Description
Valve Block
I I7222081
I
2
HoldDownWasher I
I 3 I 49612
Water Valve Port I
I 4 I 18071
Water Armature Seat
Armature
Retainingring, 0.242 ID
CoilSpring
0-Ring,
5/16 O.D. X 0.176 I.D.
Guide I
RubberGasket, 1.055” Dia.
Valve Block Bracket
Screw,
#&18 X 7/16 Type “25” HHWF S.S.
I
_.
Solenoid “CY Frame I
24VDC Coil I
1 15 10720406
Nut, #lo-32 KEPS
Ceramic Sleeve
Ceramic Piston I
O-Ring, 0.539” X 0.459” X 0.875” O.D.
t
Flow Control/BonnetAssembly I
SDrina I
27 85312001