INTERNATIONAL CARBONIC PREMIER 2000 User manual

PREMIER 2000 PERISTALTIC
PUMP
C
I
I NTERNATI ONAL CARBONI C I NC.
16630 Koala Rd.
Adelanto, California 92301
800 854-1177
1/04
P-2000-PP
SERVICE AND INSTALLATION MANUAL

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 1
GENERAL DESCRIPTION ..................................................................... 2
SYSTEM DESCRIPTION........................................................................ 2
DESIGN DATA ...................................................................................... 3
THEORY OF OPERATION ..................................................................... 3
P-2000PP EXPLODED VIEW ................................................................. 5
P-2000PPEXPLODED VIEW DESCRIPTION .......................................... 6
P-2000PPEXPLODED VIEW DESCRIPTION Cont. ................................ 7
PFC-II-PP EXPLODED VIEW ................................................................. 8
S-1737 ASSEMBLY EXPLODED VIEW .................................................. 9
S-1743 ASSEMBLY EXPLODED VIEW .................................................. 10
PPM EXPLODED VIEW.......................................................................... 11
PPM ELECTRIC SCHEMATIC ............................................................... 12
CHAPTER II
UNPACKING AND INSPECTION........................................................... 13
SELECTING LOCATION........................................................................ 13
LOCATION RECOMMENDATIONS........................................................ 13
SAMPLE OF POSSIBLE INSTALLATION .............................................. 14
INSTALL WATER FILTER ASSY. .......................................................... 14
INSTALL WATER PRESSURE REGULATOR ......................................... 15
INSTALL DRAIN LINE........................................................................... 15
INSTALL B.I.B. ..................................................................................... 15
CONNECTING WATER INLET............................................................... 16
ELECTRICAL REQUIREMENTS ............................................................ 16
CHAPTER III
PREPARING SYSTEM FOR OPERATION .............................................. 17
PREPARING AND STARTING REFRIGERATION UNIT......................... 17
PURGE DISPENSING VALVE................................................................ 17
ADJUST WATER FLOW RATE .............................................................. 17
ADJUST WATER TO SYRUP RATIO ..................................................... 17
CHAPTER IV
OPERATORS INSTRUCTIONS.............................................................. 18
COOLING UNIT MAINTENANCE .......................................................... 18
CHECKING WATER BATH .................................................................... 18
CHANGING WATER BATH.................................................................... 18
CLEANING NOZZLES ........................................................................... 18
CHAPTER V
SERVICE AND MAINTENANCE ............................................................ 19
PERIODIC INSPECTION AND CLEANING ............................................ 19
PERIODIC CLEANING........................................................................... 19
CLEANING CONDENSER COIL............................................................. 19
CHANGING WATER BATH.................................................................... 20
CHANGING PERISTALTIC PUMP TUBING........................................... 21
CLEANING AND SANITIZING............................................................... 22
BRIX INSTRUCTIONS........................................................................... 24
TROUBLE SHOOTING .......................................................................... 26
NOTES .................................................................................................. 30

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 been located in the Southern
California area since 1952 and have 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 post-mix package, i.e.,
carbonation, refrigeration & the ability to
dispense from one self contained unit. We have
pioneered many such firsts and will continue to
develop advance systems for the future, such as
electronic interrogatable portion controls to
electronic liquid level controls.
We hope you enjoy this product 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

P2000-PP CHAPTER I
GENERAL DESCRIPTION
This chapter gives the description, theory of operation, and design data for the
PREMIER 2000-Peristaltic Pump unit, (P2000-PP), and related components.
SYSTEM DESCRIPTION
The P2000-PP is a complete self-contained Juice unit which when combined with
B.I.B containers, will produce a variety of cooled non-carbonated beverages. The
P2000-PP consists of a water bath, refrigeration system, valves, and modular
peristaltic pump compartment. The cabinet is housed in an attractive black vinyl
and the peristaltic pump module is housed in a rugged stainless steel housing. The
P2000-PP has been designed to eliminate the use of bag in the box pumps and
associated components. The P2000-PP will dispense product with B.I.B.’s at a
distance of 100 feet horizontally or 17 feet vertically. THESE DISTANCES ARE ONLY
POSSIBLE IF THE SUPPLY LINE HAS COMPLETE INTEGRITY. IF EVEN THE
SMALLEST VACUUM LEAK IS ALLOWED THESE DISTANCES ARE NOT POSSIBLE.
The P2000-PP can brix from one to one up to twenty to one by using a state of the art
controller/potentiometer adjustment.
For proper function the P2000-PP must have a water supply, and electrical supply
and drainage. The P2000-PP is designed with a unique lift off drain pan that can be
emptied at any convenient drain outlet.
WARNING: Before shipping or relocating a P2000-PP into a
freezing ambient environment empty plain 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 water coil,
peristaltic pumps, water bath, valve(s), etc.
Water Filter Recommended (Optional) See Manufacturer Specifications for Operating
Conditions
2

DESIGN DATA
Overall Cabinet/P.P. Base Dimensions:
Height: .........................................................................22 ½ inches
Width............................................................................11 ¾ inches
Depth............................................................................17 ½ inches
Weights:
Shipping .......................................................................90 LBS
Dry Weight ...................................................................80 LBS
Operational Weight......................................................111 LBS
Ice Bank.......................................................................6 LBS
Capacities:
Unit Water bath (no ice bank) .....................................2.5 gallons
Refrigerant Requirement (R-134a) ..............................90 grams/3.2 ounces
Ambient Operating Temperature.................................40 F. to 100 F.
Electrical Requirements:
The cooling unit requires 115 VAC, single phase, 60-hertz power circuit.
Circuit Ampacity..........................................................4.0 Amps
Condensing Unit ..........................................................2.2 Amps
Agitator........................................................................ .8 Amps
Peristaltic Pump Assembly .........................................1.0 Amps
Refrigeration 1/9th capillary air-cooled.
Water Filter Recommended but Optional
THEORY OF OPERATION
The P2000-PP was designed to manufacture and dispense non-carbonated
beverages much like your local bottling plant that cans or bottles your favorite
non-carbonated drink.
The water bath must be filled with approximately 2.5 gallons of water. After
all connections are made and activation of the refrigeration a certain amount
of this water will be transformed into ice, approximately 6 pounds. This water
reserve and ice bank will act as a reservoir for refrigeration. This reserve is
utilized during peak periods when the BTU output of the compressor is not
sufficient to meet the demand of the draw.
3

The incoming water is routed through a water coil that is submerged in the
above mentioned water bath. The temperature of the incoming water is at
ambient temperature as it enters the submerged water coil. As the incoming
water passes through the water coil the heat is removed from the water in the
water coil and chilled to a temperature acceptable for a quality drink,
normally a temperature of 33 to 34 degrees is reached. The water is now
directed to a valve where the water and syrup are mixed in proper proportions
to dispense a quality drink. Depending on the ratio of water versus syrup the
temperature will rise and be dispensed at approximately 40 degrees
fahrenheit.
With the incorporation of the peristaltic pump the necessity for an air or CO2
supply is no longer necessary, this includes the low and high-pressure
regulators normally needed for a standard juice unit. The peristaltic pumps
will pull the syrup concentrate from the B.I.B., (bag in the box), and then push
the syrup through syrup cooling coils, (optional), and then to the valve where
the syrup concentrate and water are mixed in a proper ratio to dispense a
quality drink. The syrup enters the P2000-PP through a unique 1/4” X 3/8 S-162
bulkhead fitting at the rear of the unit.
The water source should be regulated, this is normally performed by the use of
an in line water regulator. If the water is not regulated then the water
pressure can vary. This variance of water pressure can affect our dispensed
product.
4

INTERNATI ONAL CARBONIC INC.
ADELANTO, CALIFORNIA
TI TLE
DATE
DRN. BY
CHK. BY
APPR. BY
I
C
I
30
31
28
24
34
37
41
46
45
47
43 44
48
49
29
20
14 15
21
13
10
9
8
5
4
3
1
40
11
19
2
42
22
23
18
17
P- 2000- PP
1/15/04
GLW
29
33
50
27
26
25
33
35
36
38
6
7
16
12
39
32
53
51
52
54
5

PREMIER 2000 PP
SYM
QTY
PART NO.
DESCRIPTION
1 1 S-1544 LID WITH INSULATION
2 1 S-783 UNIT ON/OFF SWITCH
3 1 S-1541 SERVICE PANEL, REAR
4 1 S-1542 SERVICE PANEL, LEFT SIDE
5 1 S-1543 SERVICE PANEL, RIGHT SIDE
6 1 G0016 TY-RAP, LARGE
7 1 . . . . 3/8 CLEAR TUBING, 6"
8 2 S-741 EVAPORATOR COIL RETAINER
9 2 S-1323 EVAPORATOR GUIDE WEDGE
10 2 S-1540 EVAPORATOR COIL SUPPORT BRKT.
11 1 S-833 AGITATOR PUMP
12 2 S-1324 POSITIONING BAR
13 1 S-1533-J WATER COIL
14 1 S-1547 STANDPIPE, 6 3/4", WHITE
15 1 S-1546 OVERFLOW, 7", GRAY
16 2 A0016 6-32 X 1 PH SS SCREW
17 1 S-1304-L ICE BANK CONTROL BULB BRACKET
18 1 S-512-C EIBC PROBE
19 1 S1330 SWITCH LOCK, W/KEYS
20 1 S-1531 BUCKET ASSY., WITH INSULATION
21 1 S-1532 EVAPORATOR COIL ASSEMBLY
22 1 S-509 ACCUMULATOR
23 1 X0121 CAP TUBE, 12' - .031
24 1 S-1539-2 VALVE MOUNTING PLATE
25 1 S-1535 CONDENSATE DRAIN NIPPLE
26 1 S-1554 6" CLEAR TUBING, 1/4 I.D. X 3/8 O.D.
6

PREMIER 2000 PP Cont.
SYM
QTY
PART NO.
DESCRIPTION
27 1 S-1534 CONDENSATE DRAIN ELBOW
28 1 S-1530 FRAME COMPLETE
29 11 S-1325 SQUARE GROMMET NUT
30 2 A0046 5/16 X 18 FLANGE WHIZ LOCK SCREW, 3/4"
31 1 AZA0370YXA COMPRESSOR ONLY
32 1 AZA0370YXAXA CONDENSING UNIT, 1/9 H.P.
33 11 A0014 SCREW, #10 X 1/2" PHILLIPS T.H., SS COMBO
34 2 PFC-II DISPENSING VALVE
35 1 S-1551 DRAIN TUBE HOLD DOWN BRACKET
36 1 A0025 10-24 X 1/2 TH SCREW
37 1 S-743 DRAIN PAN HARDWARE, SET
38 1 S-1552 DRAIN TUBE, 5/16 X 4" S.S. TUBING
39 1 S-1700 TRANSFORMER, 24V, 100VA
40 1 E-141-12 CORD
41 1 S-1549 DRAIN PAN W/CUP REST
42 7 S-1335 TERMINAL BOARD SPACER, NYLON
43 1 S-1537 TERMINAL BOX WITH COVER
44 1 S-7/8 HOLE PLUG
45 1 S-1309 TERMINAL BOARD
46 1 S-513-C ELECTRONIC ICE BANK CONTROL, (EIBC)
47 1 S-1538 TERMINAL BOX COVER ONLY
48 5 S-46 BUSHING UNIVERSAL
49 1 E-664 STRAIN RELIEF BUSHING
50 4 A0020 8-32 X 3/8 TH SCREW, S.S.
51 2 S-1737 PP, PERISTALTIC PUMP ASSEMBLY COMPLETE
52 1 S-1556 BASE COVER
53 1 S-1555 BASE
54 1 S-1318 CUSHIONED FEET, SET OF 4
1 S-765 LEGS, 4", SET OF 4, (OPTIONAL)
7

INTERNATIONAL CARBONIC INC.
ADELANTO, CALIFORNIA
TITLE
DATE
DRN. BY
CHK. BY
APPR. BY
PFC-II-PP
2/ 27/ 01 REVI SED 9/ 27/ 01
GLW
I
C
I
3
7
9
PFC-II-Peristaltic Pump
1
2
4
5
6
8
10
11 12
13
14 15
13
16
19
20
21
23
24
22
17 18
SYM QTY PART NO. DESCRIPTION
11E-623 NUT, SOLENOID
2 1 E-525 COIL, W/SHIELD, SOLENOID, 24 VAC
34E-1005 SCREW, RETAINER
4 1 E-739 FLUX PLATE
5 1 E-527 STEM, SOLENOID VALVE
6 2 E-1004 RETAINER, S.S.
7 1 E-135 METERING PIN
8 1 E-1024-M ADAPTER, FLO WASHER, MODIFIED
9 1 E-134 "O" RING, METERING PIN
10 1E-1013 "O" RING, SYRUP ADAPTOR
11 1E-730 PLUNGER & SPRING ASSEMBLY
12 1E-520 METERING PIN ADAPTOR ASSY, INCLUDES SYM 7,9, & 12
13 2E-531 GASKET, SOLENOID STEM
14 1S-1162-A FLANGE PLUG
15 1E-1008 "O" RING, SODA ADAPTOR
16 1E-580 BODY, PFC-II, TWIST LOCK
17 1E-157 SUBMINIATURE SWITCH
18 1E-188 SPRING AND INSULATOR PAD
19 1E-471-FF SYRUP OUTLET TUBE
20 1E-102 "O" RING, NOZZLE
21 1E-581 NOZZLE, TWIST LOCK
22 1E-690 WIRE ASSEMBLY CONSISTS OF E-691 & E-692
23 1E-691 MALE WIRE ASSEMBLY ONLY
24 1E-692 FEMALE WIRE ASSEMBLY ONLY
PFC-II-PP
8

S-1737 ASSEMBLY
S-1698 - PLASTIC CLAMP
MITYFLEX NOR-6F-250 S-1722
S-1739-C HOUSING/COVER
S-1740 - ROLLER ASSY.
S-1739-H PUMP HOUSING BODY
S-1738 - MOTOR/GEAR BOX ASSY.
S-1699 - POTENTIOMETER
S-1742 - SHEET METAL BASE
S-1741 - CONTROLLER
S-1335 - PLASTIC STANDOFF
6-32 X 3/4 PH S.S.
8-32 X 3/8" PH S.S.
PLASTIC WASHER
8/01 revised 12/05
S-1744 - SHIELD, SHEET METAL
9

S-1743 REPLACEMENT ASSEMBLY
S-1739-C HOUSING/COVER
S-1739-H PUMP HOUSING BODY
S-1738 - MOTOR/GEAR BOX ASSY.
S-1742 - SHEET METAL BASE
S-1335 - PLASTIC STANDOFF
6-32 X 3/4 PH S.S.
S-1740 - ROLLER ASSY.
8-32 X 3/8" PH S.S.
PLASTIC WASHER
MITYFLEX NOR-6F-250 S-1722
8/01
10

C
II
INTERNATI ONAL CARBONI C INC.
ADELANTO, CALIFORNIA
TITLE
DATE
DRN BY
CHK BY
APPR. BY
Peristaltic
Module
8/14/00
GLW
12
3
59
4
11
12
SYM QTY PART NO. DESCRIPTION
12 ** S-1698 PLASTIC CLAMP
2 1 S-1700 TRANSFORMER
31 ** S-1743 P.P. ASSEMBLY, INCLUDES S-1742, S-1699
4 * S-162 BULK HEAD FITTING
51 ** S-1699 POTENTIOMETER
61 ** S-1741 CONTROLLER
74 ** S-1335 PLASTIC STANDOFF
81*** *** BASE, MODULE
91 ** S-286-A NUT, SS, LOCKING, 1/2" X 20 (USEW//S-162)
10 1 ** S-1742 BASE, PUMP
11 1 ** S-1325 SQUARE GROMMET NUT
12 1 ** A-14 SCREW #10 X 1/2" PHILLIPS HD S.S.
13 1*** *** COVER, MODULE BASE
** = ONE PER FLAVOR, SPECIFY
*** = SPECIFY NUMBER/MODEL TYPE
* ONE PER FLAVOR PLUS WATER SPECIFY NUMBER
PPM
11

INTERNATI ONAL CARBONIC I NC.
ADELANTO, CALI FORNIA
TI TLE
DATE
DRN. BY
CHK. BY
APPR. BY
PPM
ELECTRICAL
SCHEMATI C
12/7/00
G. L. WHEELER
I
C
I
C
NO
NC
COLORED
BLACK
WATER
110 VOLT
WHI TE
BLACK
THREE PIN CONNECTOR
TO VALVE
FROM VAL VE
POTENTIOMETER
KEY SWITCH
ON/ OFF SWITCH
RIBBED
NON- RIBBE D
BLACK FROM COIL
BLACK FROM COIL
TRANSFORMER
24 VAC
31
C
S R
M
S
1
FAN MOTOR
COMPRESSOR
1 2 3 4 5 6
6
65
5
54
4
4
3
3
3
2
2
2
1
1
1
6
A
B
C
D
COMPRESSOR
COMPRESSOR RIBBED
AGI TATOR MOTOR
GROUND
SCREW
TERMINALS
ON ROW C
MUST BE
COMMONLY
GROUNDED
TO CABINET
ICE BANK CONTROL
ORANGE
BLUE
WHI TE
TRANSFORMER
110 VAC
RIBBED
NON-RIBBED
BLACK
WHI TE
BROWN
BLUE
RIBBED
NON-RIBBED
COLORED
WHI TE
COLORED
12

ELECTRICAL
CHAPTER II
INSTALLATION
P2000-PP
This chapter covers unpacking and inspection, selecting location, installing P2000-
PP and related components, and electrical requirements.
UNPACKING AND INSPECTION
Upon receiving unit, immediately remove P2000-PP from shipping carton and inspect
for shipping damage.
NOTE: Before leaving the factory the P2000-PP unit was carefully inspected
and the carrier has accepted and signed for it. Any damage or
irregularities should be noted at the time of delivery and immediately
reported to delivering carrier. Request a written inspection report
from claims inspector to substantiate any necessary claim. File claim
with delivering agency, not International Carbonic Inc!
SELECTING LOCATION
IMPORTANT: Ambient temperature for cooling unit should not exceed
100 degrees “F". Operation of cooling unit in ambient
above 100 degrees “F" can and will contribute to early
failure of condensing unit and poor quality of finished
product.
LOCATION RECOMMENDATIONS FOR LIL FELLA MID SIZE JUICE PERISTALTIC PUMP
unit, P2000-PP
1. Position unit as close as possible to proper electrical source, 115V 6OHz.
2. Position unit with a minimum of 2" space between bulkhead and cabinet for
sufficient space for ventilation. Allow enough space between ceiling and unit
for lid removal.
3. Position unit as close as possible to floor drain.
4. Position unit as close as possible to B.I.B. racks.
5. Position unit as close as possible to water source. Half-inch gate valve
recommended for water connection.
6. THE P2000-PP IS DESIGNED FOR INDOOR APPLICATIONS ONLY.
13

TABLE 2-1
LOOSE - SHIPPED PARTS
Item Part
No. No. Name Qty
1 Installation/Service Manual 1
2 S-1549 Drain pan/with cup rest 1
3 ----- Product Decals 1 per flavor
4* Water filter 1
5* S-208A Water Pressure Regulator 1
* Optional
FIGURE 2 SAMPLE OF POSSIBLE INSTALLATION.
INSTALLATION
INSTALL WATER FILTER ASSY. (OPTIONAL)
1. Install water filter assembly on wall or other supporting structure.
2. Connect water filter assembly to inlet of valve on water supply line using
minimum 3/8" I.D. water line.
3. Connect water filter assembly outlet to P2000-PP water inlet fitting using
minimum 3/8" I.D. water line. See CONNECTING WATER INLET.
When a water filter is used, it is important to thoroughly flush out water filter
and line prior to making unit connections.
14

INSTALL WATER PRESSURE REGULATOR (OPTIONAL)
If water pressure varies, a water pressure regulator or water pressure-
reducing valve should be installed in the water supply line. The water
regulator must have an orifice of at least 3/16” so as not to restrict the water
flow through the valve. Valves that are built with 1/2" pipe thread connection
usually have a sufficient orifice opening.
WATER REGULATOR
Wat er Filt er
1/2" Gat e Valve
FIGURE 2-4. SUGGESTED WATER FLOW INSTALLATION
INSTALL DRAIN LINE
1. Connect drain line on P2000-PP unit with drain using 1/2” I.D. clear
plastic tubing to nearest outlet.
2. Do not reduce drain connection from cabinet outlet.
3. Be sure all connections are watertight.
INSTALL B.I.B. (bag in the box)
Place B.I.B. as close as possible to P2000-PP unit, preferably no farther than 15 feet.
The P2000-PP will dispense product with the B.I.B.’s at a distance of 100 feet
horizontally or 17 feet vertically. THESE DISTANCES ARE ONLY POSSIBLE IF THE
SUPPLY LINE HAS COMPLETE INTEGRITY. IF EVEN THE SMALLEST VACUUM LEAK
IS ALLOWED THESE DISTANCES ARE NOT POSSIBLE.
1. Lay out syrup lines from unit to B.I.B.
2. Connect lines from B.I.B. to inlet on P2000-PP.
3. Activate Q.C.D.
4. Check all connections for leaks, (see Chapter IV).
15

CONNECTING WATER INLET
WATER PIPE CONNECTIONS AND FIXTURES DIRECTLY CONNECTED TO
POTABLE WATER SUPPLY SHALL BE SIZED, INSTALLED AND MAINTAINED
ACCORDING TO FEDERAL, STATE, AND LOCAL LAWS.
The water connection on the P2000-PP is made to a flexible water line by
means of a 3/8”, hose or barb connection.
After all primary water lines are made up, but prior to connecting water supply
to cabinet, be sure to thoroughly flush all incoming water lines to remove all
scale and any impurities that may be in the lines. It is imperative that the
fresh water-conduit has not less than 3/8” I.D. passageway for any distance
greater than ten feet from the P2000-PP. It can be reduced to 3/8” O.D. copper
tubing and connected to the water inlet connection with-in ten feet of the
P2000-PP. All water inlet connections are clearly tagged.
ELECTRICAL REQUIREMENTS:
The P2000-PP requires a 120 VAC, single phase, 60-Hertz power circuit, and
must be wired in accordance with N.E.C. or local ordinance.
NOTE: Check CHAPTER I for running amperage and connect to
appropriate electrical circuit.
16

CHAPTER III
P2000-PP
PREPARATION
All steps in previous chapters should be understood and carried out before
proceeding.
PREPARING SYSTEM FOR OPERATION
Be sure that electrical power is unplugged, valve on water supply line is closed.
PREPARING AND STARTING REFRIGERATION UNIT
1. P2000-PP refrigeration is pre-set at factory and ready to operate.
2. Remove lid.
3. Fill water bath with clean water until water runs out of condensate drain
outlet, (S-1547), (approximately ½” from top of water bath). DO NOT USE
DISTILLED WATER.
4. Open water inlet supply line.
5. Plug P2000-PP power cord into electrical receptacle box, turn power
switch to the "ON" position. Make sure compressor, condenser fan motor,
agitator motor start. The process of cooling the water bath will commence
after filling water bath. With ambient and water temperature of 75 degree “F”
initial pull down or formation of complete ice bank will take approximately 3.5
hrs. When full ice bank has been formed, compressor and condenser fan
motor will stop. Agitator will continue to operate, circulating water in water
bath.
PURGE DISPENSING VALVES
Dispense water from dispensing valves until all air is purged from water lines.
ADJUST WATER FLOW RATE
Adjust dispensing valves water flow rate to approximately 6 oz. in 5 seconds.
ADJUST WATER-TO-SYRUP "RATIO"
Adjust dispensing valves for Water-to-syrup "Ratio". Contact supplier of syrup
concentrate for recommended ratio.
17