Cornelius 2 Flavor Post-Mix Cold Coffee Dispenser Quest... User manual

QUEST 2000
Service Manual
Release Date:March 18, 2004
Publication Number: 720529901SER
Revision Date: November 23, 2004
Revision: B
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

QUEST 2000
SERVICE 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:
Trademarks and copyrights:
Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olympus,
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 permission from Cornelius.
Printed in U.S.A.
Copyright © 2004, All Rights Reserved, IMI Cornelius Inc.
IMI Cornelius Inc.
Corporate Headquarters
One Cornelius Place
Anoka, MN 55303-6234
U.S.A.
Internet:
www.cornelius.com
Email:
[email protected]
In the U.S.A.:
phone:[phone]
800-238-3600
FAX:[phone]
Outside the U.S.A.:
phone:[phone]
FAX:[phone]

TABLE OF CONTENTS
Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Concentrate Handling & Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Loading Concentrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Changing Concentrate Containers: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Brixing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Checking/Adjusting the Brix Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Planned Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Step 1 - Rinse With Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Step 2 - Sanitize Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Step 3 - Prepare Dispenser for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Semi-Annual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Trouble-Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System Wiring Diagram QST 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Main Electrical Box Wiring Diagram QST 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Quest 2000 Service Manual
© 2004, IMI Cornelius Inc. - 1 - Publication Number: 720529901SER
UNIT SPECIFICATIONS
Nameplate Data: Model QST 2000, 115 VAC, 4.5 amps, 1 phase 60 hertz, 6.25 oz. (177g) R-
134a refrigerant. Test press: High side 400 psi (27.6 bar). Low side 100 psi
(6.9 bar).
Model QST 2000, 230 VAC, 2.25 amps, 1 phase 50 hertz, 6.25 oz. (177g)
R-134a refrigerant. Test press: High side 400 psi (27.6 bar). Low side 100
psi (6.9 bar).
Concentrate Storage: Two 0.8 gallon (3.0 liter) disposable bottles.
Clearance Recommended:12” (30.48 cm) on top and 4” (10.16 cm) required in back for air circulation.
Electrical Connection: 6 ft. long (1.83 m) power cord with 3-prong plug attached to dispenser.
Export models have line cord less plug.
Power Supply: 15 amps at 120 volts dedicated power supply.
20 amps at 230 volts dedicated power supply.
Water Connection: 3/8 in. (0.95 cm) SAE male flare fitting on dispenser.
Water Supply Requirements: 80 psi (5.5 bar) maximum static pressure. 20 psi (1.4 bar) minimum
dynamic pressure; i.e., flowing pressure measured at dispenser water inlet
with 3.0 ounces (88.7 ml) per second water flow.
Ice Bank/Pull Down: Weight 7-8 lbs. (4.1-4.5 kg.). Pull Down: 3 hours at 75°F (24°C)

Quest 2000 Service Manual
Publication Number: 720529901SER - 2 - © 2004, IMI Cornelius Inc.
CONCENTRATE HANDLING & LOADING
It is recommended that the concentrate be thawed in a refrigerated 35°F-40°F (1.6°C-4.4°C)
compartment 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 temper-
ature range, especially below 35°F (1.6°C), will cause an out of brix drink (refer to the Brixing Pro-
cedure section for details).
LOADINGCONCENTRATE
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 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.
CHANGINGCONCENTRATECONTAINERS:
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
concentrate pump system.
5. Load concentrate container (see Loading Concentrate).

Quest 2000 Service Manual
© 2004, IMI Cornelius Inc. - 3 - Publication Number: 720529901SER
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.
SUPPLIES
• 1-Small 12 oz. cup (354.8 ml)
• 1-Large 21 oz. cup (621.1 ml)
• 1-Straw
• Paper Toweling
• 1-Thermometer
• 1-Refractometer
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/ADJUSTINGTHEBRIXSETTING
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.
3. Dispense a 12 oz (354.8 ml) drink sample into a clean, dry cup. Thoroughly stir the sample using a
straw.
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 reference use only. Contact your fro-
zen concentrate supplier for specific brix readings.
Brix Reference Chart
Flavor Ratio Brix
Orange Juice 4+1 11.8
Grapefruit Juice 5+1 10.6
Cranberry Cocktail 4+1 13.5
Apple Juice 5+1 12.0
Grape 5+1 13.0
Lemonade 5+1 10.5
Tropical Punch 5+1 11.8
Sweetened Iced Tea 7+1 6.0
Pineapple Juice 4+1 12.8
Prune Juice 2+1 16.0

Quest 2000 Service Manual
Publication Number: 720529901SER - 4 - © 2004, IMI Cornelius Inc.
5. To change the brix setting, simply readjust the water flow rate.
Located on each of the valve assemblies inside the refrigerated com-
partment 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.
IMPORTANT: When making changes to the water flow control, do not rotate more than 1/4 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.
Lowers Brix by increasingwater
Raises Brix by reducing water

Quest 2000 Service Manual
© 2004, IMI Cornelius Inc. - 5 - Publication Number: 720529901SER
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 seconds
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.
5. Clean Splash Zones & Dispense Nozzles:
6. 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.
7. Remove the dispense nozzles and static mixers by rotat-
ing each 90°and pulling down. Remove the mixing
chambers by pulling straight forward. Wash using a mild
dish soap.
IMPORTANT: DO NOT wash nozzles, static mixers, or
mixing chambers in a dish washer. This will distort the
plastic and damage the o-rings. Additionally, do not soak
them in sanitizing solution 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
dissolving 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. Fill a 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.
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.
R

Quest 2000 Service Manual
Publication Number: 720529901SER - 6 - © 2004, IMI Cornelius Inc.
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.
2. Clean the air inlet grilles located on the rear and top panels of the dispenser.
3. Clean the interior base.
4. Wipe the fan blade clean.
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.
ANNUALLY
Replace Pump Tubing:
A replacement pump tubing kit, part#45098, is
available. The kit consists of one pre-cut length of
pump tubing, two white plastic hose clamps, and
instructions.
Removing Pump Platform(s):
1. Remove the concentrate containers from the dis-
penser and place them in a refrigerator.
2. Remove the cabinet shelf that the concentrate
containers sit on.