beverage system troubleshooting guide

beverage system troubleshooting guide
BEVERAGE SYSTEM
TROUBLESHOOTING INDEX
Problem
Page
Nothing happens when beverage valve is activated ............ 2
Syrup only is dispensed from all beverage valves .............. 3
Water only is dispensed at all beverage valves ................. 5
Water only is dispensed at one or two valves ................... 7
Poor carbonation .............................................................. 8
Beverage tastes weak ...................................................... 10
Beverage tastes sweet ..................................................... 11
Beverage has an off-taste ................................................. 12
Beverage valve does not maintain brix .............................. 14
Unusual amount of foaming on finished product ................ 15
The beverage valve continues to operate after release ....... 17
Dispensed beverage is over 40o F ..................................... 18
Carbonator does not operate ............................................ 20
B-I-B pump will not start ................................................... 22
B-I-B pump runs constantly .............................................. 23
B-I-B pump operates but does not pump syrup ................. 24
B-I-B pump does not supply enough syrup ....................... 25
B-I-B pump rate of delivery is inconsistent ........................ 26
BEVERAGE
SYSTEM
MANUAL
1
TROUBLE SHOOTING
Problem:
Nothing happens
when the beverage
valve is activated
2
Question:
Possible Solution:
Is the key switch
lock turned on?
Turn switch on
Is the dispenser
cord plugged in?
Plug dispenser into
wall receptacle
Is power to the
electrical outlet?
Restore power to
receptacle
Is the valve
transformer OK?
Replace the valve
transformer
Is the valve switch
defective?
Check and replace the
valve switch
Is the valve properly
connected?
Is the power wires to
the switch connected?
Is product to the
beverage valve?
Turn on the valve back
block shut off
BEVERAGE
SYSTEM
MANUAL
TROUBLE SHOOTING
Problem:
Question:
Syrup only is
dispensed from
all beverage
valves
BEVERAGE
Possible Solution:
Is the carbonator
plugged in?
Carbonator must be
plugged in
Is the water supply
turned on?
The minimum water
supply must be
provided.
Is the CO2 supply
turned on?
Check CO2 supply for
availability. Replace
or refill
Is the water line
frozen?
Allow water line to
thaw out. Repair
cause of frozen line.
Discontinue use of
“super cooled” ice for
cold plate cooling
Do you hear a sound
from the water side
of the valve?
Lack of a sound at
this test indicates
frozen water line. A
sound indicates
carbonator problems.
Are the CO2
pressures set
correctly?
The CO2 pressures
may be too high.
Check and set all
system pressures to
the correct settings.
SYSTEM
MANUAL
3
TROUBLE SHOOTING
Problem:
Syrup only is
dispensed from all
beverage valves
4
Question:
Possible Solution:
See also carbonator
trouble shooting
section
See also carbonator
trouble shooting
section
Is an obstruction in
the water line with
the lines connected
to the correct stub?
If the water system is
obstructed or not
connected correctly,
reconnect the lines to
the proper tubing stubs
or remove the
obstruction to allow
water flow
BEVERAGE
SYSTEM
MANUAL
TROUBLE SHOOTING
Question:
Problem:
Water only is
dispensed at all
beverage valves
BEVERAGE
Possible Solution:
Do you have enough
CO2 gas in the tank?
Replace or refill the
CO2 supply
Do you have any
syrup?
Check and replace any
empty syrup
containers
Are the syrup
connectors clean?
Clean and reinstall the
connectors
Are system
pressures set
correctly?
Adjust and reset
pressures to their
proper settings
Are the syrup
connectors properly
connected?
Remove the
connectors and
properly reinstall the
connectors
Is the syrup line
frozen?
Allow the syrup line to
thaw out. Repair
cause of frozen line
SYSTEM
MANUAL
5
TROUBLE SHOOTING
Problem:
Question:
Possible Solution:
Water only is
dispensed at one
or two valves?
Is an obstruction in
the water line with
the lines connected
to the correct stub?
If the water system is
obstructed or not
connected correctly,
reconnect the lines to
the proper tubing stubs
or remove the
obstruction to allow
water flow.
Is the water line
frozen?
Allow water line to
thaw out. Repair
cause of frozen line
Is the back block
shut off valve
closed?
Check the back block
shut off valve. If it is
closed, open the valve
Is electric getting
through the valve
solenoid when
energized?
Repair or replace the
wiring or solenoid coil
Are the connectors
to the syrup clean
and properly
attached?
Clean the syrup
connector & correctly
attach the connector to
the syrup connector
Is the syrup system
obstructed or lines
installed improperly?
6
Reconnect the lines to
the proper tubing stubs
or remove the
obstruction to allow
syrup flow
BEVERAGE SYSTEM MANUAL
TROUBLE SHOOTING
Possible Solution:
Problem:
Question:
Water only is
dispensed at one
or two valves?
Do you have a full
syrup container
connected?
Replace if necessary
Are valves in the
syrup system
open?
Make sure all
connections with shut
offs are made good
and tight
Check the back block
shut off valve. If it is
closed, open the valve
BEVERAGE
Are the B-I-B
pumps (if used)
operating?
See B-I-B pump
trouble shooting
section
Is electric getting
through the valve
solenoid when
energized?
Repair or replace
Is the syrup line
frozen?
If the syrup line is
frozen, allow syrup line
to thaw out. Repair
cause of frozen line.
Is the syrup flow
control of the
beverage valve
sticking?
Disassemble and
clean or replace
SYSTEM
MANUAL
7
TROUBLE SHOOTING
Problem:
Poor
Carbonation
8
Question:
Possible Solution:
Is CO2 pressure
to the carbonator
properly set?
Reset CO2 pressure to
100-110 PSI
Is the carbonator
air locked (all
CO2 and no water
in the tank)?
Turn off carbonator and
CO2. Release vent on
the tank until water
comes out. Turn
carbonator and CO2 on
Is the inlet water
pressure to the
carbonator above
the minimum?
Minimum inlet water
pressure is 20 PSI
Is the carbonator
inlet water
temperature too
high?
Inlet temperature of the
water to the carbonator
should be no more
than 100o F
BEVERAGE
SYSTEM
MANUAL
TROUBLE SHOOTING
Question:
Problem:
Poor
Carbonation
BEVERAGE
Possible Solution:
Do you have CO2
Gas?
Replace or refill CO2
tank
Is the CO2
pressure a
minimum of 100
PSI to the
carbonator?
Reset pressure
regulator to the proper
pressure
Is the carbonator
tank air locked?
Open carbonator vent
check until water
streams out
Is the water
pressure to the
carbonator higher
than the CO2
pressure?
Reduce carbonator
inlet water pressure to
10# below CO2
pressure
Is the dispensed
beverage
temperature
above 40o F?
Lower beverage
temperature to 36o F to
40o F
Is supply water
pressure to
carbonator 20 to
75 PSI?
Install regulator or
booster pump to
maintain proper
pressures
SYSTEM
MANUAL
9
TROUBLE SHOOTING
Problem:
Beverage tastes
weak
10
Question:
Possible Solution:
Do you have
enough CO2?
Replace or refill your
CO2 supply
Are your system
pressures set
correctly?
Check & correctly set
all system pressures
Do you have a
sufficient supply of
syrup?
Replace empty syrup
containers
Is the syrup flow
control of beverage
valve sticking?
Disassemble and
clean or replace
Has the syrup
supply been
obstructed?
Repair or replace the
obstructed item
Is the water flow
control set
improperly?
Set the volume of
water through the
beverage valve at the
flow rate prescribed by
the valve manufacturer
then brix the valve.
Is the brix of the
valve properly set?
Brix all valves
Are nozzles and
diffusers dirty?
Remove & clean all
nozzles & diffusers
BEVERAGE
SYSTEM
MANUAL
TROUBLE SHOOTING
Problem:
Question:
Possible Solution:
Beverage tastes
sweet
Are your system
pressures set
correctly?
Check & correctly set
all system pressures
Can your
carbonator
handle the
volume of drinks
you are
dispensing?
Check the carbonator
manufacturer’s
specifications
Is an obstruction
in the water
supply line?
Are nozzles and
diffusers dirty?
Is the brix of the
valve set
correctly?
BEVERAGE
SYSTEM
MANUAL
Repair or replace the
obstructed item
Remove and clean all
nozzles and diffusers
Brix all beverage
valves
11
TROUBLE SHOOTING
Problem:
Beverage has
an off-taste
12
Question:
Possible Solution:
Do you notice the
taste on every (most)
beverage(s) in the
dispenser?
Isolate the taste in
the common ater line
before the dispenser.
Repair or replace
components as
necessary. Install
taste removal water
filter in the water line
to carbonator
Do you notice the
taste on one or two
valves on the water
component of the
beverage?
Isolate problem, flush
and sanitize lines
with beverage valves
removed
Do you notice the
taste on one valve on
the syrup component
of the beverage?
Check the beverage
taste at the bulk
container. If it is
good, flush and
sanitize the syrup
lines. If syrup is bad,
flush and sanitize
syrup lines and
replace syrup.
Is the carbonator inlet
check valve holding
carbonated water out
of the regular water
system?
Replace check valve
if leaking through
BEVERAGE
SYSTEM
MANUAL
TROUBLE SHOOTING
Question:
Problem:
Beverage has
an off-taste
Possible Solution:
Are the beverage lines Isolate the lines
running through
through the water.
standing water?
Remove the standing
water, reroute the
lines, or replace the
lines with non
permeable tubing
Does each syrup
container feed the
correct syrup line?
Check each syrup line
for proper syrup supply
Are nozzles and
diffusers dirty?
Remove and clean all
nozzles and diffusers
Is the brix of the valve Brix all beverage
set correctly?
valves.
Is the syrup supply
fresh?
BEVERAGE
SYSTEM
MANUAL
Most syrups should be
used within 75 days of
manufacture.
13
TROUBLE SHOOTING
Problem:
Beverage valve
does not
maintain brix
14
Question:
Possible Solution:
Are the system
pressures correct?
Check and adjust any
pressures and
inconsistent regulators
Is air in the syrup
delivery system?
Bleed air from the syrup
delivery system
Are the flow
controls in the
beverage valve
sticking?
Clean or replace the
beverage valve flow
controls
Is the B-I-B pump
holding pressure?
Repair or replace B-I-B
pump
Are incoming water
pressures
constant?
Add water booster
pump or pressure
regulator to maintain
BEVERAGE
SYSTEM
MANUAL
TROUBLE SHOOTING
Question:
Problem:
Unusual amount
of foaming on
finished product
BEVERAGE
Possible Solution:
Is drink being drawn
correctly?
Make sure cup is tilted
with product flowing
down the inside of the
cup
Is the dispensing
nozzle or valve dirty?
Clean dispensing
components
Is too much CO2 being
added to the available
water?
Check system CO2 and
water pressures &
available water
Is the ice super
cooled?
Ice should be at room
temperature for at least
30 minutes before
using
Is the reusable glass
dirty or have soap
film?
Clean utensils and
thoroughly rinse
Is soft water being
supplied to the
system?
Do not use
commercially softened
water for beverage
systems
Are the individual
beverage components
at the proper
temperature?
All individual
components should be
more than 40o F each
SYSTEM
MANUAL
15
TROUBLE SHOOTING
Problem:
Unusual amount
of foaming on
finished product
Question:
Are the system
pressures too high?
Possible Solution:
Reduce pressures to
the recommended
settings
Is the drink too warm? Dispensed beverage
must be between 36o F
to 40o F
16
Are nozzles or
diffusers dirty?
Remove and clean
nozzles and diffusers
Is the water for the
postmix beverage
being supplied through
a water softener?
The post mix beverage
water supply must be
taken before the water
softener
BEVERAGE
SYSTEM
MANUAL
TROUBLE SHOOTING
Problem:
The beverage
valve continues
to operate after
release
Question:
Possible Solution:
Is the valve lever (if
equipped) sticking?
Replace or adjust the
beverage valve lever to
correct
Is the push button
actuator sticking?
Replace or adjust the
beverage valve
actuator
Is the electric
microswitch sticking?
Clean or replace the
microswitch
Is there something
caught under the
beverage valve pallet?
Clean or replace the
beverage valve pallet
and/or pallet seat
Is the beverage valve
pallet damaged?
Replace beverage
valve pallet
Is the electric solenoid Clean or replace
plunger sticking?
solenoid
BEVERAGE
SYSTEM
MANUAL
17
TROUBLE SHOOTING
Problem:
Dispensed
beverage is over
40o F
18
Question:
Possible Solution:
Is there ice on the
cold plate (if
equipped)?
Be sure ice covers
the entire cold plate.
Give the cold plate
time to cool
Has ice bridged over
the cold plate (if
equipped)?
Push ice down to
ensure ice covers and
contacts the entire
cold plate
Is standing water
covering the cold
plate (if equipped)?
Clean or unstop drain
to the dispenser
Has algae or other
insulator covered
the cold plate (if
equipped) to prevent
heat transfer?
Scrub and clean cold
plate to remove
insulators
Does the system
beverage
temperature
increase
significantly
between cooling
point and
dispensing point?
Locate source of heat
gain. Repair or
replace the cause of
this added heat.
BEVERAGE
SYSTEM
MANUAL
TROUBLE SHOOTING
Problem:
Question:
dispensed
beverage is over
40o F
BEVERAGE
Possible Solution:
Is the refrigeration
system (if equipped)
plugged in or turned
on?
Plug (or turn on) the
refrigeration system if
necessary
Is electric power
supplied to the
receptacle or
refrigeration system?
Restore power to the
receptacle or
refrigeration system
Is the refrigeration
system (if equipped)
operating properly?
Repair or replace the
cooling system
Is the condenser of
the refrigeration
system (if equipped)
clean?
Clean the refrigeration
system, especially
the condenser
If this is an ice bank
type system, has an
ice bank formed?
Allow ice bank to
form or repair
refrigeration system
If this is an ice bank
system, is the
agitator operating?
Locate the reason the
agitator motor is not
operating and repair
SYSTEM
MANUAL
19
TROUBLE SHOOTING
Problem:
Carbonator
does not
operate
Question:
Possible Solution:
Is the water turned on Restore water supply
and the flow pressure within proper limits
is between 20 and 75
PSI?
Is CO2 turned on and Restore CO2 supply to
pressures between 100 the carbonator within
proper limits
and 110 PSI?
Is electric power
supplied to the
carbonator?
Restore electric to the
outlet that supplies the
carbonator with power
Does the motor
operate without the
pump?
Remove the pump from
the motor. Manually
override carbonator
controls to check
operation of motor only.
Replace pump or motor
if necessary
Lower the CO2 pressure
Does the motor
operate but not pump to the pump. If operates
with lowered pressure,
water?
replace pump
Is the water level
control of the
carbonator operating
properly?
20
BEVERAGE
Repair or replace
according to
instructions provided by
the carbonator
manufacturer.
SYSTEM
MANUAL
TROUBLE SHOOTING
Problem:
Carbonator
does not
operate
BEVERAGE
Question:
Possible Solution:
Is the carbonator
level?
Reset carbonator so
the base is level and
flat
SYSTEM
MANUAL
21
TROUBLE SHOOTING
Problem:
B-I-B pump will
not start
Question:
Do you have syrup
connected to the inlet
hose of the pump?
Possible Solution:
Replace syrup
container
Is the connector to the Remove and properly
Bag-in-Box properly
reconnect the B-I-B
connected?
connector
22
CO2 (or compressed
air) supply interrupted
Check CO2 (or
compressed air)
supply. Replace, refill,
or turn on if necessary
Is the gas pressure to
the pump correctly
set?
Adjust gas pressure to
the recommended
setting for the product
BEVERAGE
SYSTEM
MANUAL
TROUBLE SHOOTING
Problem:
B-I-B pump
constantly runs
BEVERAGE
Question:
Possible Solution:
Is air in the syrup
delivery system?
Bleed air from the
syrup delivery system
Syrup leak on pump
discharge line
Locate leak. Repair or
replace leaking
component
Is B-I-B pump
defective?
Replace the B-I-B
syrup pump
Is there air in the B-I-B
bag?
Replace the B-I-B bag
Is there a hole in the
B-I-B bag?
Replace the B-I-B bag
SYSTEM
MANUAL
23
TROUBLE SHOOTING
Problem:
B-I-B Pump
operates but
does not pump
syrup
24
Question:
Possible Solution:
Is a beverage
dispensing valve
open?
Open beverage valve to
allow syrup to flow
through the system
Is the B-I-B pump air
locked?
Make sure B-I-B
pumps are installed
with the outlet port on
top
Is the syrup
container coupling
properly connected?
Remove and correctly
reconnect the coupling
to the Bag-in-box
container
Is there a hole in the
B-I-B container?
Remove and replace
the leaking syrup
container
Is the tubing from the
B-I-B container to the
pump full flow and
not kinked?
Remove or repair kink,
or replace hose
BEVERAGE
SYSTEM
MANUAL
TROUBLE SHOOTING
Problem:
Question:
B-I-B pump
does not supply
enough syrup
BEVERAGE
Possible Solution:
Are the gas or air
pressures supplied to
the pump correct?
Check and correct
any incorrect gas or
air pressures
Are the number of
beverage valves served
by the B-I-B pump
within the B-I-B pump
manufacturer’s
specifications?
Reduce the number of
valves being served
by the pump or
replace the B-I-B
pump
Is the tubing in the
syrup system sized
properly for the line
length?
Replace the syrup
tubing with a larger
diameter tubing
SYSTEM
MANUAL
25
TROUBLE SHOOTING
Problem:
B-I-B pump rate
of delivery is
inconsistent
26
Question:
Possible Solution:
Is air in the syrup
delivery system?
Bleed air from the
syrup delivery system
Does the check
valve at the outlet of
the B-I-B pump
prevent back flow to
the pump?
Replace the B-I-B
pump
BEVERAGE
SYSTEM
MANUAL
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