ICI TOPPER Manual

TOPPER
INSTALLATION AND SERVICE MANUAL
INTERNATIONAL CARBONIC INC.
16630 KOALA ROAD
ADELANTO, CALIFORNIA 92301
800 854-1177
CI
I

IMPORTANT: This manual is a 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
installation of this equipment.

TABLE OF CONTENTS
PAGE
PREFACE ................................................................................................................... 1
CHAPTER I GENERAL DESCRIPTION.................................................................... 1-1
SYSTEM DESCRIPTION............................................................................... 1-1
THEORY OF OPERATION............................................................................ 1-10
CHAPTER II INSTALLATION ..................................................................................... 2-1
UNPACKING AND INSPECTION.................................................................. 2-1
SELECTING LOCATION ............................................................................... 2-1
LOCATION RECOMMENDATIONS FOR TOPPER......................................2-2
INSTALLATION.............................................................................................. 2-2
INSTALL HIGH-PRESSURE CO2 REGULATOR, CO2 CYLINDER
AND LINES .................................................................................................... 2-3
INSTALL LOW-PRESSURE REGULATOR AND LINES............................... 2-3
INSTALL WATER FILTER ASSEMBLY, (OPTIONAL).................................. 2-4
INSTALL WATER PRESSURE REGULATOR, (OPTIONAL) .......................2-4
INSTALL WATER HOLDING TANK, (OPTIONAL)........................................2-4
INSTALL DRAIN LINE ................................................................................... 2-5
INSTALL B.I.B. OR SYRUP TANKS AND ACCESSORIES.......................... 2-5
CONNECTING WATER INLET...................................................................... 2-5
ELECTRICAL REQUIREMENTS................................................................... 2-5
CHAPTER III, PREPARATION.................................................................................. 3-1
PREPARING SYSTEM FOR OPERATION................................................... 3-1
PREPARING AND STARTING REFRIGERATION UNIT.............................. 3-1
PURGE DISPENSING VALVES.................................................................... 3-1
ACTIVATE HIGH-PRESSURE CO2 SYSTEM.............................................. 3-1
ACTIVATE LOW-PRESSURE CO2 GAS AND SYRUP SYSTEMS..............3-2
ADJUST WATER FLOW RATE..................................................................... 3-2
ADJUST WATER-TO-SYRUP “RATIO”......................................................... 3-2
ADJUST SIZE OF DRINK DISPENSED........................................................ 3-2
CHAPTER IV OPERATORS INSTRUCTIONS.......................................................... 4-1
DAILY PRE-OPERATION CHECK................................................................ 4-1
REPLENISHING CO2 SUPPLY..................................................................... 4-1
REPLENISHING SYRUP SUPPLY................................................................ 4-1
COOLING UNIT MAINTENANCE.................................................................. 4-1
CHECKING WATER BATH............................................................................4-2
CHANGING WATER BATH...........................................................................4-2
ADJUSTMENTS............................................................................................. 4-2
ADJUSTING WATER FLOW RATE............................................................... 4-2
ADJUSTING WATER-TO-SYRUP “RATIO” OF DISPENSED PRODUCT ... 4-2
ADJUSTING SIZE OF DRINK DISPENSED.................................................. 4-2
TESTING FOR LEAKS .................................................................................. 4-2
CHAPTER V SERVICE AND MAINTENANCE.......................................................... 5-1
PERIODIC INSPECTION AND CLEANING................................................... 5-1
TOPPER CABINET MAINTENANCE ............................................................ 5-2
CLEANING CONDENSER COIL................................................................... 5-2
CHECKING/CHANGING WATER BATH....................................................... 5-2
WATER PUMP MAINTENANCE ................................................................... 5-3
CARBONATOR MAINTENANCE .................................................................. 5-4
LUBRICATION............................................................................................... 5-5
SERVICING CHECK VALVES....................................................................... 5-5
REPLENISHING CO2 SUPPLY..................................................................... 5-7

TABLE OF CONTENTS (cont’d) PAGE
SYRUP FLAVOR CHANGE........................................................................... 5-7
CHANGING WATER FILTER CARTRIDGE (OPTIONAL)............................ 5-7
ADJUSTMENTS............................................................................................. 5-7
HIGH-PRESSURE CO2 REGULATOR............................................ 5-7
LOW-PRESSURE CO2 REGULATOR............................................. 5-8
DIET SYRUP TANK CO2 REGULATOR.......................................... 5-8
BRIX INSTRUCTION........................................................................ 5-9
CLEANING AND SANITIZING....................................................................... 5-11
CHAPTER VI TROULBESHOOTING......................................................................... 6-1
COOLING UNIT ............................................................................................. 6-1
WATER PUMP MOTOR WILL NOT OPERATE............................... 6-1
WATER PUMP MOTOR WILL NOT SHUT OFF.............................. 6-1
WATER PUMP WILL NOT SHUT OFF AND PRESSURE
RELIEF ENGAGED........................................................................... 6-1
SHORT CYCLING OF WATER PUMP MOTOR .............................. 6-1
WATER PUMP CAPACITY TOO LOW............................................. 6-1
WATER PUMP OPERATES BUT WATER PUMP DOES
NOT PUMP....................................................................................... 6-2
FROZEN WATER BATH................................................................... 6-2
COOLING OR CONDENSING UNIT NOT OPERATIONAL............. 6-2
AGITATOR MOTOR NOT OPERATING .......................................... 6-2
COMPRESSOR DOES NOT OPERATE..........................................6-2
COMPRESSOR WORKS CONTINUOUSLY BUT DOES
NOT FORM SUFFICIENT ICE BANK............................................... 6-2
COMPRESSOR WILL NOT STOP AFTER SUFFICIENT
ICE BANK IS PRODUCED............................................................... 6-3
CONDENSER FAN MOTOR NOT OPERATING ............................. 6-3
DISPENSING VALVES.................................................................................. 6-3
WATER OR SYRUP LEAKING FROM NOZZLE AFTER
ACTUATION ..................................................................................... 6-3
NO WATER, NO SYRUP BEING DISPENSED FROM VALVE....... 6-4
NO SYRUP BEING DISPENSED ..................................................... 6-4
NO WATER BEING DISPENSED..................................................... 6-4
DISPENSED PRODUCT CARBONATED TO LOW......................... 6-4
DISPENSED PRODUCT MAKES FOAM AS IT LEAVES
NOZZLE............................................................................................ 6-4
DISPENSED PRODUCT COMES OUT CLEAR BUT FOAMS
WHEN IT TOUCHES CUP OR GLASS............................................ 6-4
WATER-TO-SYRUP “RATIO” TOO LOW OR TOO HIGH ............... 6-5
ADJUSTMENT OF SYRUP METERING PIN DOES NOT
PRODUCE DESIRED WATER-TO-SYRUP “RATIO”....................... 6-5
CARBONATION TROUBLESHOOTING FLOW CHART #1 ......................... 6-6
CARBONATION TROUBLESHOOTING FLOW CHART #2 ......................... 6-7
CARBONATION TROUBLESHOOTING FLOW CHART #3 ......................... 6-8
NOTE SECTION.........................................................................................................6-9
LIST OF FIGURES
Figure Title
1-1 EXPLODED VIEW OF TOPPER ......................................................1-3
1-2 ILLUSTRATED PARTS BREAKDOWN OF TOPPER...................... 1-4
1-3 EXPLODED VIEW OF TOPPER-J ................................................... 1-6
1-4 ILLUSTRATED PARTS BREAKDOWN OF TOPPER-J................... 1-7

TABLE OF CONTENTS (CONT’D)
Figure Title PAGE
1-5 ELECTRICAL SCHEMATIC 110V....................................................1-8
1-6 ELECTRICAL SCHEMATIC S-1309 JUICE ..................................... 1-9
1-7 ELECTRICAL SCHEMATIC 24V......................................................1-10
2-1 SAMPLE OF A POSSIBLE INSTALLATION .................................... 2-2
2-2 HIGH-PRESSURE CO2 REGULATOR, (S-101).............................. 2-3
2-3 LOW-PRESSURE CO2 REGULATOR, (S-121)............................... 2-3
2-4 SUGGESTED WATER FLOW INSTALLATION............................... 2-4
5-1 WATER PUMP, “Y” STRAINER & SCREEN....................................5-5
5-2 CHECK VALVES............................................................................... 5-6
5-3 COMPOSITE EXPLODED VIEW OF CHECK VALVES AND
RELIEF VALVE................................................................................. 5-7
LIST OF TABLE
1-1 DESIGN DATA.................................................................................. 1-1
2-1 LOOSE-SHIPPED PARTS................................................................ 2-1

PREFACE
INTERNATIONAL CARBONIC INC. has enjoyed over 53 years of
manufacturing excellence in the field of carbonation and 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 II 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 that 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

CHAPTER I
GENERAL DESCRIPTION
This chapter gives the description, theory of operation, and design data for the TOPPER,
TOPPER-J, and related components.
SYSTEM DESCRIPTION
The TOPPER is a complete is a complete self-contained remote cooling/carbonation unit
which when combined with related components, will produce a variety of cooled
carbonated and non-carbonated beverages.
The TOPPER 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 TOPPER must have a water supply, and electrical supply and
drainage. The TOPPER 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 regulator, Low-
pressure regulator, connecting lines, quick couplers, or disconnects and C02.
WARNING: Before shipping or relocating a TOPPER 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.
TABLE I - I
DESIGN DATA
COOLING UNIT
Overall cabinet dimensions: TOPPER TOPPER-J
Height ...........................30”.................... .........................30”
Width.............................13 1/4”.............. .........................13 1/4”
Depth.............................19 1/2”.............. .........................19 1/2”
Weights:
Shipping........................140 LBS. .......... .........................113 LBS.
Dry weight.....................111 LBS. .......... ........................88 LBS.
Operational Weight .......153 LBS. .......... .........................130 LBS.
Ice Bank........................12 LBS. ............ .........................12 LBS.
Capacities: Unit water bath (no ice bank)..... .........................5 gallons
Refrigerant requirement (R-134-A)......... ......................... .........................155 grams
Ambient operating temperature .............. ......................... .........................40 F to 100 F.
1-1

Electrical Requirements: The cooling unit requires a 115 VAC, single phase, 60 Hertz
power circuit.
Topper Topper-J
Circuit Ampacity............10.5 Amps........ .........................3.8 Amps
Condensing Unit............2.5 Amps.......... .........................2.5 Amps
Water Pump Motor........6.2 Amps.......... .........................NA
Transformer....................5 Amps.......... ..........................5 Amps
Agitator...........................8 amps .......... ..........................8 amps
Water Filter Recommended (Optional) See Manufacturer Specifications for Operating Conditions
Pressure
Incoming Water Pressure Regulator (Optional)..........................................25 – 40
C02 High-pressure Regulator (Carbonated units only) PSI........................70 – 75
C02 Low-pressure Regulator (Carbonated/Flavored units only)................BIB Approx. 40 PSI
C02 Low-pressure Regulator (Carbonated/Flavored units only)................FIGAL Approx. 30 PSI
C02 Low-pressure Regulator (Optional).....................................................FIGAL Approx. 30 PSI
C02 Diet Drink Pressure Regulator (if required).........................................6 - 10 PSI
DISPENSING VALVES Ambient Operating Temperature..........................40 F to 100 F
Electrical Requirements: Operating Voltage..........................24VAC, 6Ohz
1-2

INTERNATIONAL CARBONIC INC.
ADELANTO, CALIFORNIA
TITLE
DATE
DRN. BY
CHK. BY
APPR. BY
TOPPER
1/4/05
GLW
ICI
16
37
18
20 21 22
23 24 25 26 30
31
35
53
1
6
5
7
9
12
8
10
11
14 15
13
19
3
4
17
32
36
39
38
45
46
48
40
47
44
52 54
43
42
49
51
50
2
28
29
27
41
33
34
GLW
GLW
FIGURE 1-1
1-3

TOPPER
SYM QTY PART NO. DESCRIPTION
1 1 S0777 NYLON FASTENER
2 1 S0776-G TOP GRID
3 1 S0776-V REAR VENT
4 1 S0775 COVER ONLY
S0774 ITEMS 1,2,3, AND 4, (COMPLETE COVER)
5 1 S0103 PUMP PROTECTOR
6 1 S0785 WATER LINE, COPPER
7 1 S0104 PUMP PROTECTOR BRACKET
8 1 S0170 HALF UNION BRASS, 3/8 MF X 3/8 MP
9 1 S0200 PUMP, CARBONATOR
10 1 S0176 HALF UNION, BRASS, 3/8 M.P. X 1/4 M.F.
11 1 S0650 STRAINER, BRASS
12 1 S0199 MOTOR SHIELD
13 1 S0106 CLAMP, V BAND
14 1 S0096 MOTOR, CARBONATOR
15 2 A0045 5/16 X 18 FLANGE WHIZ LOCK SCREW, 1/2"
16 1 S0513-A ICE BANK CONTROL
17 2 A0046 5/16 X 18 FLANGE WHIZ LOCK SCREW, 3/4"
18 1 E0276 TRANSFORMER, 40 VA
19 1 E0664 STRAIN RELIEF
20 1 S0068-B LIQUID LEVEL CONTROL, (LLC)
21 4 S1335 TERMINAL BOARD SPACER, NYLON, 3/8"
22 1 S-7/8 HOLE PLUG
23 5 A0020 8-32 X 3/8 T.H., S.S. SCREW
24 1 S1310 CONTROL BOX COVER
25 1 S1308 CONTROL BOX WITH COVER
26 5 S0046 BUSHING
FIGURE 1-2
1-4