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MR. ZIPPY’S ICE & WATER MACHINE
Mr. Zippy’s
Ice & Water Machine
Jim Coleman Company
Page 1 of 5
Installation/Operations Manual
Rev. 2 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Introduction to Model Z10000 Mr. Zippy’s Ice and Water Machine
The Mr. Zippy’s Ice and Water Vending Machine is a state-of-the-art, freestanding, self-service
kiosk-type vending machine for the purpose of retail bulk ice and water sales at various outdoor
locations. It has been designed and built with the customer and the operator in mind.
There are many features of this machine the operator needs to be familiar with in order to
successfully operate it. Please read and understand this manual fully before attempting to make
any repairs or adjustments. If there are any areas of repair, adjustment, or maintenance you do
not understand, please contact your local distributor or the main office located in Houston, TX
(800-999-9878) and a service technician will be happy to assist you. Great care must be
exercised when making field adjustments or repairs. Again, if you do not understand what to do,
PLEASE CALL AND WE WILL HELP YOU.
This machine utilizes several processes to produce high-purity, safe, clear, affordable ice and
drinking water. Each process in this machine has been carefully designed and engineered to
work in junction with each other. Please do not make any changes or alterations without
approval of the parent company. Doing this may alter the quality of the product and will void the
NAMA certification.
As the operator, you will be required to keep this machine in a clean and well-maintained
condition.
Keep in mind at all times that this is a place where people come to buy a food product. A dirty or
poorly maintained machine will deter people from using it, and they will go elsewhere. Once a
customer is lost, they don’t return. Keep the machine as clean as you would like to see it if you
were a first time customer.
Jim Coleman Company
Page 2 of 5
Installation/Operations Manual
Rev. 2 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Copyrights and Disclaimers
Mr. Zippy’s Ice and Water Vending Machine is completely developed and designed by Jim
Coleman Company. Any un-authorized use of it is strictly forbidden without written permission
from Jim Coleman Company. No alteration of its systems or operating procedures is allowed. For
more information concerning this system contact:
Jim Coleman Company
5842 West 34th
Houston, Texas 77092
Tel: (713) 683-9878
Toll Free: (800) 999-9878
Fax: (713) 683-9624
E-Mail:[email protected]
Website: www.jcolemanco.com
Patents:
Mr. Zippy’s is covered under the following patents:
Patents
Number
Issue date
Contaminated proof Purified Water Dispenser
Contaminated proof Purified Water Dispenser and method
Ice Dispenser with an Air Cooled bin
Modular Water Vending system and Dispenser
5,881,913
5,911,884
6,093,312
RM255-001
3/16/1999
6/15/1999
7/25/2000
Pending
Jim Coleman Company
Page 3 of 5
Installation/Operations Manual
Rev. 2 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
NAMA Letters of Compliance
Jim Coleman Company
Page 4 of 5
Installation/Operations Manual
Rev. 2 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Jim Coleman Company
Page 5 of 5
Installation/Operations Manual
Rev. 2 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Water Purification for Ice and Water Machines Operation
The ice and water machines use city tap water and process it into high purity ice and drinking
water on site. There are several separate systems incorporated into these machines to produce
and vend the products. We will go through each step starting with the incoming water to the final
vend of ice and water. Afterwards, you will have a general knowledge of the process.
City water comes into the machine through the main inlet valve.
The water goes through a carbon bed tank that removes the chlorine found in
municipal tap water.
The water then goes to the ion exchange water softener to remove calcium and
other hardness minerals.
The water then passes through a 5 five micron secondary filter to catch any loose
carbon particles and to act as a safeguard against any remaining foreign material
that could be in the system.
The water has now completed the pre-treatment phase of the purification process
and is ready for the Reverse Osmosis process of the water.
When the tank level system senses that the storage tank needs to be refilled, the
RO system is activated and RO water is put into the storage tank.
Water pressure is maintained in the system by the system re-pressurization
pump. This keeps a positive 60 psi on the lines to the ice machine and/or water
machine.
The final polishing filter is a charcoal filter used to remove any remaining
impurities or taste of the water.
The water is now ready for the vend stages.
Jim Coleman Company
Page 1 of 5
The Systems
Rev. 10/05/10
MR. ZIPPY’S ICE & WATER MACHINE
1. Ice Vending System Operation
A. When a customer wants to buy ice, they have to the opportunity to purchase a BAG of
ice or ICE IN BULK. The bag will hold approximately 10# of ice and the bulk will
dispense approximately 20# of ice.
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The customer will begin by depositing coins and/or bills ($1, $5, or $10 bills) in any
combination to satisfy the purchase price of the ice they have decided to buy.
After money has been deposited, the deposited amount will show on the display
screen as “x.xx credit”.
Credit will continue to display on the screen followed by a beep indicating to the
customer that they need to do something.
The customer will then make their selection of either bag or bulk ice purchase.
Jim Coleman Company
Page 2 of 5
The Systems
Rev. 10/05/10
MR. ZIPPY’S ICE & WATER MACHINE
Bag Ice – upon selecting the bag ice option, and if the purchase amount for bag
ice is satisfied, instructions will follow. The customer will take the bag, hang on
the hooks, and press the ice button.
Bulk Ice - upon selecting the bulk ice option, and if the purchase amount for bulk
ice is satisfied, instructions will follow for the customer to take and place their
container under the hooks and press the ice button. Once the customer has
placed their container and pressed the ice button, ice will be dispensed into their
container.
•
Refund/Change – if the customer has deposited greater than the required price for
their selection or presses the refund button, their change will be dispensed to them
into the change cup.
B. Inside the machine many operations take place to successfully initiate and complete the
ice vend:
1.
2.
3.
4.
5.
The purified water in the holding tank goes to the ice machine reservoir.
The water is circulated across the cooling coils to form the ice cubes.
Once the ice is formed (approx. 15 min per drop), it drops into the ice tank.
The ice tanks hold the ice waiting for ice vend request.
Every hour the ice is rotated to keep it from freezing together.
Jim Coleman Company
Page 3 of 5
The Systems
Rev. 10/05/10
MR. ZIPPY’S ICE & WATER MACHINE
6. Once a customer pays for ice, the ice shearing gate is opened and approx. 10# of ice
is dropped into the ice delivery bucket (this action is repeated for 20# bulk ice
purchase).
7. The ice delivery bucket delivers the ice to the ice delivery hopper.
8. The ice delivery conveyor lifts the ice delivery hopper up and dumps into the ice
funnel for delivery to the customer.
C. There are many safe guards to the system to ensure a quality delivery of ice to the
customer:
D Ice bucket eyes monitor the level of ice to ensure the customer gets a full purchase
of ice.
D The ice funnel eyes monitor the condition of the ice to ensure the delivery is
accomplished with assistance, if needed.
D The agitator prox ensures the ice is broken up and ready for delivery.
D The coin level is monitored in the coin hopper to ensure customers can be funded
their change/refund upon demand.
D If low coins are monitored, the display shows a message to use correct change.
D If a system failure occurs during the ice purchase process and the machine cannot
recover, the machine goes out of order, the customer is refunded their money, and
the display shows the machine “out of service.”
2. Water Vending System Operation
A. When a customer wants to buy water, they deposit coins and/or one-dollar bills in any
combination up to $5.00.
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The LED display on the control panel will show the amount of money that has been
deposited.
Customers then place their bottles under either vend spout or both if more than one
vend are desired.
By pressing the preferred button on the control panel, 1gal, 3gal, or 5gal vending is
initiated.
After each completed vend, the LED display shows the amount of remaining credit.
After the containers are full, if there is any remaining credit, the customer pushes the
coin return button to receive exact change.
B. Inside the machine, many operations take place to successfully initiate and complete a
vend:
1. The water that is routed to the vend nozzle from the storage tank passes through a
polishing filter to remove any off tastes from the storage tank, then through an
ultraviolet sterilization device to kill any bacteria that could be potentially present in
the product water.
2. When the customer presses a vend button, a signal is sent to the controller, and the
process starts.
3. The controller sends a signal to the shutter control valve, which opens the filler
shutter and lowers the nozzle into position.
4. Once the shutter has opened, and the vend nozzle has lowered into place, a signal is
sent from the filler back to the controller verifying that the nozzle is in place, and the
filling of the bottle can begin.
Jim Coleman Company
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The Systems
Rev. 10/05/10
MR. ZIPPY’S ICE & WATER MACHINE
5. An electric signal is sent to the vend control valve, and water begins to flow into the
customer’s bottle.
6. A flow meter in the vend system sends pulse signals to the controller which counts
these impulses until a set point is reached.
7. At that time, the controller shuts off the vend control valve and closes the shutter,
completing the vend cycle.
C. There are safeguards in the system with which you must be familiar:
D If the total dissolved solids in the product water increases above the set point for any
reason, the TDS controller will de-activate the coin acceptor and the “Sold Out” light
will come on.
D If the ultraviolet sterilizer fails, that particular vend window will become inoperable.
This prevents the customer from buying poor quality water or receiving potentially
bacteria contaminated water.
D If either of these conditions exists, it is imperative that the problem be corrected
immediately before the machine can come back in service.
Jim Coleman Company
Page 5 of 5
The Systems
Rev. 10/05/10
MR. ZIPPY’S ICE & WATER MACHINE
1. Specifications
•
Water line required ¾”
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Drain line 4”
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Must be connected to an approved water source
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Electrical required:
o
208/240 volt single phase-100 amp service - actual draw is 61 amps
o
Alternate electrical specs for 3 phase service
o
208/240 volt 3 phase – 100 amps service - actual draw 50 amps
o
If a second ice production unit is added then the electrical draw will be 30 amps
higher.
Water Production
•
Mr. Zippy’s uses an 8 stage water filtration system to ensure the production of pure
quality great tasting drinking water.
•
RO production approximately 2000 gallons per day
•
RO production will vary depending on water temperature.
•
RO storage approximately 160 gallons
•
Pure water delivery system - 2 separate vending windows
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Dispenses 1 gallon, 3 gallon or 5 gallon based upon customer selection.
•
Accepts nickels, dimes quarters, tokens, $1.00 bills and $5.00 bills
Ice Production
•
Mr. Zippy’s ice production uses purified water to insure a clean great tasting ice. Our
units produce a ¾” square cube.
•
Approximately 2000 lbs of ice production per day standard.
•
Production of ice will vary based upon air and water temperature.
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Ice maker is rated based upon manufacturer specifications.
•
Another 2000 lbs of ice production available to increase capacity to 4000 lbs per day.
•
Approximately 1900 lbs ice storage
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Dispenses - 10 lb bag ice or bulk ice depending on customer selection.
•
Accepts Quarters, Tokens, $1.00 bills, $5.00 bills, $10.00 bills.
•
Dispenses change in quarters
Jim Coleman Company
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Specifications
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
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Jim Coleman Company
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Specifications
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MR. ZIPPY’S ICE & WATER MACHINE
Safety
1. Important Safety Instructions
Extreme caution should be exercised when working
with high voltage and the operation of this equipment.
Do not throw away these important safety instructions. The instructions pertain to risk of
fire, electrical shock, and or injury to persons.
•
Read all instructions before using this product.
•
STAY ALERT- Always gives complete attention to your actions.
•
Do not operate this product when fatigued or under the influence of alcohol or drugs.
•
Keep operation area clear of all persons.
•
Do not attempt to reach over equipment or stand on any unstable support. Keep
good footing and balance at all times.
•
Disconnect all power before installing or servicing this equipment. If the power
disconnects are out of sight, lock it in the open position and tag it to prevent
unexpected application of power. Failure to do so could result in fatal electrical
shock.
•
A qualified electrician should install all wiring according to local, state, and federal
electrical codes.
2. Unpacking the Equipment
Before any operation can be carried out there must be a time of planning. This is no
different for the installation of Mr. Zippy’s Ice and Water Machine. Carefully plan the layout
and setup before starting the installation process.
Thoroughly inspect each component for visible damage. Uncrate the equipment only if
there is no damage.
† NOTE: Carefully inspect and evaluate the freight upon
arrival. If there is damage to any boxes or crates
immediately report it to the freight carrier.
Jim Coleman Company
Page 1 of 2
Safety
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MR. ZIPPY’S ICE & WATER MACHINE
3. Using Suggested Installation Procedures
This manual contains a suggested installation procedure. Located in the back are
electrical schematic and layout drawings. These drawings should be used in assistance of
equipment hook-up.
Completely read this manual prior to beginning installation. This will ensure a proper
understanding of the machine and its installation procedures.
The installation of this equipment involves high
and low voltage electrical connections. Only
qualified and trained personnel should be used
in its hook-up.
This equipment’s circuit protection is located in
the main electrical panel of the building
supplying power to this device. Ensure that this
protection is in place and rated according to the
guidelines set forth on the equipment not to
exceed 15 amps.
Jim Coleman Company
Page 2 of 2
Safety
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Installation
1. Distributor Responsibilities (delivery, install, start up, and training of the new
owner.)
A. The distributor will get the site ready for Mr. Zippy’s by having the construction ready
before the machine arrives on the truck. This will include having the proper permits for
the machine before it arrives. He will have the Water and drain stubbed up in the correct
place and also the Electrician to have the electrical service available.
B. Mr. Zippy’s Express Ice and Water machine will be delivered on a truck and trailer. The
local distributor will unload the machine with a forklift. The machine weighs 9,500 lbs.
and can be unloaded with a 12,000 lbs. heavy-duty forklift with 9’ long forks.
C. Once the unit is set on a foundation, it will need to be fastened down using anchor bolts.
Please see the engineered drawings for correct placement of the anchor bolts. If the
machine is on level ground a ½” by 5” anchor bolt is recommended.
D. The unit will need to be sealed to the foundation to prevent insects or rodents from being
able to get under the machine. You can use a concrete grout to seal machine to the
foundation.
E. The local distributor will then install the mansard fascia on the roof of the building.
1.
2.
3.
4.
5.
Lift the three long mansard frames to the roof and fasten them down.
Fasten the six small frames to the roof pointing out to the sides of the building.
Lift the condenser frame up and fasten the condenser frame to the mansard frame.
Lift the condensers with the forklift and set them into the frame.
Now you can either send the forklift back to the place you rented it from or continue
to use it for the mansard.
6. Raise the round fiberglass corners to the front of the building and fasten them in
place.
7. Take the long front flat panel and slide it in between the two round corners.
8. Take the side panels and fasten them to the side frames.
9. Fasten the two back panels to the mansard frame on the back of the building.
10. Install the corners on the back
11. Fasten the soffit between the building and mansard.
F. The distributor will need to work with the electrician and plumber to make sure they
perform their work properly.
G. Once the electrical and plumbing work is complete, the distributor will need to start up
the machine. Please refer to the start up procedure.
H. Contact the local Manitowoc icemaker distributor to connect the condensers to the ice
makers. The local distributor will charge for this service. Do not call Manitowoc before
you have water and electricity connected to the ice makers and condensers.
I.
Once power, water, and drain are connected, the local distributor will start up the unit
and begin operation. Once the ice makers are started up, it will take 24 hours to fill the
ice tank. The whole installation process should take about five (5) working days to
complete. Once complete, the distributor will need to spend one day training the new
owner on the proper operation of the machine, including reviewing the sanitizing
procedures.
Jim Coleman Company
Page 1 of 3
Installation
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
2. Electrical Work
An Electrician will need to perform the following work:
A. Contact the local power company and arrange for the proper size electrical service to be
installed. This might require the power company to install electrical power transformers
on the pole. Please arrange for this several weeks before the scheduled delivery of Mr.
Zippy’s Ice machine.
B. Pull the necessary electrical permits to allow Mr. Zippy’s to be installed.
C. Bring in the electrical service from the power company to Mr. Zippy’s (normally 100 amp
3 phase service.) Single-phase units are available. The electrical service can be an
overhead service or an underground service (based upon local site conditions.) All
electrical work must meet the National Electrical Code.
D. The electric meter and electrical service can be mounted on the back of Mr. Zippy’s
building. Bring the wiring into the electrical breaker box mounted inside Mr. Zippy’s.
E. The electrician will need to install the lights inside the round holes in the fiberglass round
corners. The electrician can run the electrical circuit from the inside electrical breaker
panel to the lights on the roof. The electrician will need to control the lights by installing a
photo electric cell on the roof. The electrician cannot drill a hole through the roof of Mr.
Zippy’s. The circuits must be run through the wall and then through the soffit of the
building.
F. The electrician will need to run electrical circuits from the breaker panel to the
condensers on the roof. All electrical work must meet the National Electrical Code.
G. Once all the electrical work is complete, the electrician will need to call for inspections
and have the power company turn on the electrical service.
“This machine is intended for connection to Inspected, Approved Water Systems.”
WARNING: All Modular Kiosk Systems must be
connected to an approved ground.
Such grounding must be in accordance with all applicable codes and be checked for
continuity.
3. Plumbing Work
A. Obtain the necessary plumbing permits to allow Mr. Zippy’s to be installed.
B. The plumber will need to bring in a ¾” water line and a 2” sewer line. Most local
municipalities will allow the drain on Mr. Zippy’s to be connected to a storm sewer line.
C. The plumber will need to connect the ¾” water line into the backflow preventer located
inside the building. Once the connection is made, the plumber will need to flush out the
lines to make sure no debris enters into the back flow preventer.
D. The plumber will need to provide a 2” drain line behind the building (see plans for exact
location.) The drain line will need a 4” bell reducer so that all of the drain lines will drain
into the sewer line. All drain lines must have a 2” air gap between the drain line and the
Jim Coleman Company
Page 2 of 3
Installation
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MR. ZIPPY’S ICE & WATER MACHINE
sewer line. This ensures no backing up of water into the Ice and water machine (see the
drawings.)
E. Once complete, the plumber will need to call for inspections and have the water turned
on or the meter set.
F. Once the power, water, and drain are connected, the local distributor will start up the unit
and begin operation. The whole installation process should take about five (5) working
days to complete.
Jim Coleman Company
Page 3 of 3
Installation
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
System Start Up
The following list will assist you in ensuring all steps are taken to have your Mr. Zippy’s Ice and
Water machine ready for service. Place a 9 in the box beside each step when it is completed.
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Flush All Water Lines
Drain Water Tank
Flush Charcoal Filter
Remove Debris In Water Tank, Ice Tank, Ice Chute, And Ice Hopper
Spray All Service Areas With Sanitation Solution Of Clorox And Water
Fill Salt Container With Two Bags Of Salt
Check For Water Hardness
Check Motor Rotation On Condenser
Check Motor Rotation On Ice Agitator On Bottom Of Tank
Check For Water Leaks
Check Valve Readings On R.O.
Water Tank Is Filled To At Least Half Full
Ice Dropped Within 20 Minutes
Ice Machine Runs For At Least 4 Hours
Test Ice And Water Doors For Proper Operation (Electronics, Bag
Dispenser, Etc.)
Jim Coleman Company
Page 1 of 11
System Start Up
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
1. System Start Up (Water)
A. Flush all lines
• This will empty the water lines of any debris that has collected in the installation, such as
pvc shavings, glue, dirt, etc. This will keep the filters and solenoids from collecting extra
material that will shorten their usage time.
• Turn incoming water off at valve inside building
• Take hose loose from incoming side of carbon tank
• Turn water on slowly
• Open valve and let run for 5 minutes to drain
• Shut off valve
• Wait 5 more minutes
• Open valve and let run for additional 5 minutes
• Turn off valve and replace hose on carbon tank
• Turn incoming water back on at valve inside building
B. Setup Water Softener
• See manual in appendix
• Test incoming water hardness and adjust softener accordingly based on incoming water
hardness
C. Flush Charcoal System
• Remove outgoing line from the charcoal filter
• Either run a hose from valve fitting to outside, or let water run out on floor
• Allow water to run for five minutes slowly and shut off
• After a few minutes, turn valve on again and allow to run for another five or until water
coming from charcoal filter is clear
• Replace hose
• Secure all hoses and lines and turn water back on
• Check for leaks
D. Fill Softener with Salt
•
Put at least 2 bags of salt into brine tank
E. Turn R.O. on at Breaker Box
• Turn the RO switch from Normal to Test
• The RO will now start producing RO water
• Watch the two flow valves for reading approx. . . .9 gpm product, 1.49gpm reject
• Allow to run until the holding tank is over half full.
• When the tank gets over half full turn the RO switch from Test to Normal
• RO water will now fill the tank, shutting off when product water has filled the tank.
F. Water Deliver Pressure
• When facing the RO system observe two pumps on the bottom of the unit
• Left hand Procon pump is for production of RO water the larger Grundfoss pump on right
is for water delivery.
• Once water has filled the tank turn on the large valve located on the bottom of the tank
• Push the switch on the top of the Grundfoss pump 1 time to turn on the re-pressurization
• Observe that at least 60 psi is being read on gauge J (water pressure at door)
• Turn water valve on located near gauge J
Jim Coleman Company
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System Start Up
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MR. ZIPPY’S ICE & WATER MACHINE
G. Water Delivery Sanitization
• For complete sanitization procedure see Maintenance and Cleaning section
• Use sanitization mixture of 1/2 oz. Clorox to 1 gallon water
• Spray sanitization liquid on delivery nozzles and bottle area of water machine
Water is now ready to be delivered to the customer.
2. System Start Up (Ice)
A. Remove debris in the following:
• Ice tank
• Ice chute
• Ice bucket/hopper
B. Disinfect tank
• Disinfectant Ratio: 1/2 oz. Clorox to 1 gallon water
• Spray the mixture on all surfaces inside tank, tank walls, ice chute, ice hopper, delivery
hopper, outside of both water and ice doors. In short, sanitize anything that comes in
contact with ice and water!
Caution: Allow the sanitization mixture to
naturally dry! Do not wipe dry!
C. Turn on Ice Machine water supply
• Turn water valve on located near gauge J
D. Turn electricity on to Control Panel
• Insure both ice machines are plugged into the breaker controlled duplex plug located to
the left of the ice holding tank
• Turn on ice machine breaker at breaker panel
• Turn on 3-phase breaker for condenser
E. Changing the harvest sequence water purge
• Reprogram the water purge on the Manitowoc to save water and increase production of
ice. See the Manitowoc operations manual for detailed instructions, pages 3-7
F. Check orientation of compressor motors
• Observe and listen to compressors on top of building
• If the compressors exhibit a loud sound – rotation is backwards on condenser and
rotation will need to be reversed. Smooth running compressors are normal rotation
G. Reversing rotation of compressor motors
The installation of this equipment involves high
and low voltage electrical connections. Only
qualified and trained personnel should be used
in its hook-up.
Jim Coleman Company
Page 3 of 11
System Start Up
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
•
•
•
•
•
Unplug ice machines
Remove cover from electrical panel
Locate 3 pole breaker for condenser
Move the top leg to the middle leg and place the middle leg where the top leg was
Retest the motor rotation by observing and listening for a smooth running compressor
unit
• If everything is correct:
• Replace cover from electrical panel
• Plug ice machines in
NOTE: If you have two ice machines, you will have to
perform these procedures on both machines.
H. Ice Drops
• Change the dump cycle on the Manitowoc ice maker to zero
• Within 20 minutes you should hear ice drop from ice machine into ice tank
• If no ice has dropped within 30 minutes verify that the units have water supply and
electricity
• Check rotation of ice agitator blades clockwise when viewing from top of tank
CAUTION: The ice dropped during the first
four hours of testing is NOT consumable! Use
only to test the bag delivery system and bulk
dispensing. When finished, dispose in a
proper place for melting.
•
•
•
Continue to run ice for at least four hours
Vend the ice to ensure the coin and cash mechanisms work and the ice level is lowering
in the ice tank.
At least 10 inches of ice should be vended out the ice machine to insure that the ice is
ready for consuming by the customer.
I. Vending Operations and Testing (Ice and Water)
• Water – The unit should come to you already set up with your vended prices, calibrated
and ready to vend to the customer. The water door should show that correct change
should be used. Purchase at least $10 in quarters, $4 in nickels, and $5 in dimes and fill
the changer located on the back of the water door.
• Water – Test the 1,3, and 5 gal vend by purchasing water through the vending
mechanism using a mix of coins and bills insuring that the proper purchase is made and
correct change is given.
• Ice – Locate the bag dispensing unit located to the right of the ice storage tank. Install 1
wicket of bags by placing over the bars coming from the bag storage area. While the
unit is making ice it will not vend until enough ice is in the tank and the tank sensor
detects it. The unit will display “Out of Service” while in this state. Once enough ice is in
the tank the display will show “Use Correct Change”.
• Fill the coin hopper with 400 quarters. The sensor will detect that the hopper now has
enough coins to dispense change and the display will now show “Deposit Money”. The
ice machine is now ready to dispense ice in bags or bulk.
Jim Coleman Company
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System Start Up
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MR. ZIPPY’S ICE & WATER MACHINE
J. Check Orientation of Ice Agitator in Tank
• Lift tank cover and observe the rotation of the ice agitator blades in the bottom of the ice
tank. The blades should be going in a clockwise manner when the agitator is running.
o Observing rotation
ƒ On the Red Lion press F7 to access the “Force Outputs” page
ƒ Scroll through the outputs until you see the “agitator forward” page.
ƒ Force the output on
ƒ After observation force the output off
•
If the agitator blades are backwards they will be turning in a counterclockwise manner
and will need to be reversed.
K. Reversing rotation of agitator blades – Variable Frequency Drives (vfd)
The installation of this equipment involves high
and low voltage electrical connections. Only
qualified and trained personnel should be used
in its hook-up.
• Locate the breakers in the breaker panel to the ice control panel and turn off
• Open the ice control panel door
• Caution: Observe lights on plc and vfd drives and insure they are off, this will insure that
not power is in the control panel
• Locate the large vfd on the upper right of the control panel
• Locate the 3 motor wires on the bottom of the drive
• Reverse the 2 left wires
• Close the control panel
• Turn on the circuit breakers in the breaker panel
• Retest the agitation blades by observing the rotation as listed above
3. How to Program the Water Door Controller
1. Service Mode:
A. Entering Service Mode
• The service mode is entered by pressing the yellow MODE switch located on the far
right corner of the logic board. Pressing the MODE switch once will place the controller
into service mode. Successive presses of the MODE switch will cause the controller to
toggle in and out of service mode.
B. Indications of service mode
• To access the various modes, it is necessary to press the Exit button on the outside
panel once. This will bypass the Locked ACCt function.
C. Exiting Service Mode
• Service Mode can be exited in three different ways. The first method is to press the
MODE switch a second time. This will cause the controller to abort service mode and
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MR. ZIPPY’S ICE & WATER MACHINE
return to sales mode. If you were in the process of changing a parameter, such as the
vend time out, this change will be aborted and the previous setting will remain
unchanged. Parameter changes are only recorded if they are terminated using the
“Enter” key. More on this and other keys later.
•
The second method of exiting service mode is to press the “Exit” key. Pressing the exit
key is similar to pressing the MODE key, except that using the Exit key will abort service
mode one level at a time and it might take a few presses to exit service mode
completely. As in the case with the MODE switch, the Exit key will abort changes in
progress unless the Enter key is pressed first.
•
Lastly, service mode can or will be exited automatically by allowing an inactivity timer to
time out. The inactivity timer is always running when the controller is in service mode. If
a key is pressed, the timer is restored to its maximum value. If no keys are pressed for a
period of about 3 minutes, the inactivity timer will expire and the controller will return to
sales mode.
D. Navigating your way through the service mode
• Service mode operation is influenced by the action of the four front panel selection
switches. These switches serve a dual purpose, which is related to the mode that the
controller is in. In sales mode, the front panel selection switches are used by the
customer to select a product to be vended (1 gallon, 3 gallon and 5 gallons). In service
mode, these same switches change function and allow the service person to navigate
between service mode functions and change various parameters on the controller. The
sales mode and service mode key functions are as defined below:
Mode
Sales Mode
Service Mode
Key #1
1 gal, side A
ENTER
Key #2
5 gal, side A
Exit
Key #3
1 gal, side B
scroll UP
Key #4
5 gal, side B
scroll DOWN
Side A is on the left and Side B is on the right.
2. Service Mode key assignments
A. The UP key
• In service mode, the “UP” key is used to increment functions or numbers. It can be used
to move forward through the menu of functions, or increase the value of a setting or
parameter from within a function.
B. The DOWN key
• In service mode the “DOWN” key is used to decrement functions or numbers. It can be
used to move backwards through the menu of functions, or to decrease the value of a
setting or parameter from within a function.
C. The UP and DOWN keys
• These keys can also be used in conjunction with one another to successfully locate a
function or number. For instance, if you were attempting to set the 1 gallon vend price to
0.25, and you were using the UP key to increment the price and you accidentally
overshot and ended up at 0.35. You could use the DOWN key to decrement the price
back down to 0.25. You can also use the same principal to return a menu item that you
were looking for but had mistakenly passed by.
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MR. ZIPPY’S ICE & WATER MACHINE
D. The EXIT key
• In service mode the “Exit” key is used to exit a function or to recover from an inadvertent
parameter change before it is recorded. The Exit key allows you to abort changes in
progress and, if pushed successively, can also terminate the current service mode
function and eventually leave service mode all together.
•
For example, if you were in service mode and were changing the 1 gallon vend price,
the first press of the Exit key would terminate the 1 gallon price modifications and
would return the controller to the set price mode. At this point you are still within the
set price function. If you were to press the ENTER key now, you would return to
editing the 1 gallon vend price. If you were to press the Exit key again, you will be
removed from the set price function and placed in the main service mode feature
menu. A third depression of the Exit button would place the controller out of service
mode and back into sales mode.
E. The ENTER key
• The ENTER key is used to activate a service mode function or to affirm and record a
parameter change. All changes must be followed by the pressing of the ENTER key or
they will not be recorded.
3. Service mode functions and options
The table below summarizes the service mode functions and options that are available in
service mode. These functions are described in detail later in this document. The listing shown
proceeds in the order of occurrence as the features appear in the service mode if the UP key is
pushed several times.
Service mode function or option
“ACCt”- accounting
“PriC”- price setting
“POUr”- vend quantity
“tESt”- test vend
“Opt”- vend options
Function or option description
Allows resettable cash and vend counters to be read and/or reset
Allows vend price to be set for 1 and 5 gallons
Allows adjustment of vend counts and maximum vend time
Allows test vending without altering MIS totals
Allows enabling or disabling of options
• ACCt – Accounting data retrieval mode
Accounting data is not accessible by anyone other than the person collecting the money.
• PriC – Price setting mode
The PriC function allows the prices of both, one, three and five gallon vends to be
adjusted and the maximum credit acceptance level to be set. The vend price can be set
to any price over the range of $0.00 (free vend) to $99.95, subject to the minimum price
increment
The maximum credit acceptance level is the maximum amount of coins and bills that can
be deposited before the coin mech. and bill validator will automatically stop accepting
further credit. The maximum credit acceptance level using bills is also influenced by the
number of coins in the coin mech. tubes.
The controller can override the service mode setting for the maximum credit when there
is a low change condition. The controller has been programmed to accept no more credit
than can be paid out by the coin mech. if the customer presses the escrow lever. In
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MR. ZIPPY’S ICE & WATER MACHINE
other words, the controller will disable the bill validator and coin mech. when the level of
credit accrued has reached the value of coins being held in the tubes of the coin mech.
• To set the one gallon price
To enter price mode, enter service mode as described earlier and press the UP key until
front panel display shows the message “PriC”. Now press the ENTER key and you will
be in set price mode. The display should now show the message “Pr-1” alternating with
the current vend price for one gallon of water. If you wish to change this price, press the
ENTER key. You should now see the one gallon vend price holding on the display and
the “Pr-1” message should not return.
If you wish to increase the vend price, press the UP key. The price should increase. If
you wish to lower the displayed price, press the Down key and the price should
decrease. Pressing and holding the UP or DOWN key for more than five seconds will
cause the number to change in high speed mode. If you overshoot the desired vend
price, use the UP or DOWN key to move the number to the desired value. Once you
have finished pricing the selection press the ENTER key and the new vend price will be
locked in. if you wish to terminate 1 gallon pricing without changing the previous price,
use the Exit key.
• To set the three gallon price
To enter price mode, enter service mode as described earlier and press the UP key until
front panel display shows the message “PriC”. Now press the ENTER key and you will
be in set price mode. Press the UP key once. The display should now show the
message “Pr-3” alternating with the current vend price for three gallon of water. If you
wish to change this price, press the ENTER key. You should now see the three gallon
vend price holding on the display and the “Pr-3” message should not return.
If you wish to increase the vend price, press the UP key. The price should increase. If
you wish to lower the displayed price, press the Down key and the price should
decrease. Pressing and holding the UP or DOWN key for more than five seconds will
cause the number to change in high-speed mode. If you overshoot the desired vend
price, use the UP or DOWN key to move the number to the desired value. Once you
have finished pricing the selection press the ENTER key and the new vend price will be
locked in. if you wish to terminate 3 gallon pricing without changing the previous price,
use the Exit key.
• To set the five gallon price
To set the five gallon vend price, enter price mode as described above. Then press the
UP key until the message “Pr-5” appears on the display alternating with the current vend
price for the five gallons of water. If you wish to change this price, press the ENTER key.
You should now see the five gallon vend price freeze on the display and the “Pr-5”
message should not return. Follow the one gallon price setting instructions above for
setting the five gallon price. Be sure to press the ENTER key or the price changes will
not be recorded.
• To set the maximum credit level
To set the maximum credit level, enter price mode as described above. Press the UP
key until the message “Hi” appears in the display alternating with the current setting for
maximum credit. If you wish to change the displayed number press the ENTER key. The
maximum credit number will freeze on the display and the “Hi” message will not return.
Use the UP or DOWN keys to set the maximum credit level. When finished press the
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MR. ZIPPY’S ICE & WATER MACHINE
ENTER key to lock in the changes. If you do not wish to save the changes, press the
Exit key and the changes will be aborted.
•
POUr – Dispense parameter mode
The POUr function allows the flow meter counts to be adjusted for the volume of water to
be dispensed or “poured” during a one or five gallon vend. The maximum allowable vend
time can also be adjusted.
To enter POUr mode, enter the service mode as described earlier and press the UP key
until the message “POUr” appears on the front panel display. Now press the ENTER key
and you should now see the message “FL-1” alternating with the current flow meter
count corresponding to a one gallon dispense.
•
Changing the one gallon dispenses flow meter count
If you wish to change the flow meter count for the one gallon dispense, enter POUr
mode as described above. Press the UP key until the message “F1-1” is shown in the
display alternating with the current flow meter count for the one gallon dispense. Press
the ENTER key and the one gallon flow meter count should freeze in the display and the
“F1-1” should not return.
NOTE: The “F1-1” display indicates adjustments may be made to side A (left side), one gallon
flow meter count and “F2-1” indicates side B (right side), one gallon flow meter count.
F1-1
F2-1
Side A (left side), one gallon flow meter
Side B (right side), one gallon flow meter
Adjustments to one gallon dispensing volumes are typically done using 10 to 30 count
adjustments.
You can use the UP or DOWN keys to change the flow meter count up or down. Be sure to lock
in your changes by pressing the ENTER key before exiting service mode. As with the other
features, if you have changed the flow meter count and do not wish to save the changes, press
the Exit key and your changes will be ignored.
•
Changing the three-gallon dispenses flow meter count
If you wish to change the flow meter count for the three gallon dispense, enter POUr
mode as described above. Press the UP key until the message “F1-3” is shown in the
display alternating with the current flow meter count for the three gallon dispense. Press
the ENTER key and the three gallon flow meter count should freeze in the display and
the “F1-3” should not return.
NOTE: The “F1-3” display indicates adjustments may be made to side A (left side), three gallon
flow meter count and “F2-3” indicates side B (right side), three gallon flow meter count.
F1-3
F2-3
Side A (left side), three gallon flow meter
Side B (right side), three gallon flow meter
Adjustments to three gallon dispensing volumes are typically done using 10 to 30 count
adjustments.
You can use the UP or DOWN keys to change the flow meter count up or down. Be sure to lock
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MR. ZIPPY’S ICE & WATER MACHINE
in your changes by pressing the ENTER key before exiting service mode. As with the other
features, if you have changed the flow meter count and do not wish to save the changes, press
the Exit key and your changes will be ignored.
Changing the five gallon dispenses flow meter count
If you wish to change the flow meter count for the five gallon dispense, enter POUr mode as
described above. Press the UP key until the message “F1-5” is shown in the display alternating
with the current flow meter count for the five gallon dispense. Press the ENTER key and the five
gallon flow meter count should freeze in the display and the “F1-5” should not return.
NOTE: The “F1-5” display indicates adjustments may be made to side A (left side), five gallon
flow meter count and “F2-5” indicates side B (right side), five gallon flow meter count.
F1-5
F2-5
Side A (left side), five gallon flow meter
Side B (right side), five gallon flow meter
Adjustments to five gallon dispensing volumes are typically done using 50 to 100 count
adjustments.
Change the count using the same methods as described above in section on changing the one
gallon dispense flow meter count.
•
Changing the maximum vend time
If you wish to change the maximum allowable one gallon vend time, enter POUr mode
as described above and press the UP key until the message “SECS” is displayed
alternating with the current maximum vend time. Press the ENTER key and the
maximum dispense time should freeze in the display and the “SECS” message should
not return.
At this point you can use the UP and DOWN keys to change the maximum vend time up
or down. The one gallon maximum vend time will be multiplied by five gallon vend
timing. Be sure to save your changes by pressing the ENTER key when you are done.
The preset vend time of sixty seconds should be adequate for all vending applications. If
you feel you need to change this setting, contact your supervisor or the home office at 1800-297-5839 prior to making any adjustment.
•
tESt - Test vend mode
Test vend mode is used to test the proper operation for the mechanical and electronic
dispensing system without influencing MIS and accounting totals. Test vend mode can
also be used to confirm the proper setting of the flow meter counts that were set in the
POUr mode. To enter the tESt mode, enter service mode as explained earlier and press
the UP key until the message “tESt” appears on the display. Press the ENTER key and
you should see the message “t1-1” on the display.
•
To test vend a selection
To test vend a selection use the UP or DOWN keys to select the vend port and quantity
of water you wish to test. The sequence on the display should be as follows: “t1-1”
(pour1, 1 gallon) “, “t1-3 (pour, 3 gallons), “t1-5” (pour 1, 5 gallons), “t2-1” (pour 2, 1
gallon), “t2-3 (pour, 3 gallons), and finally “t2-5g” (pour 2, 5gallons). When you have
finished with your selection, press the ENTER key to start the test. The quantity of water
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Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
you selected should now be dispensed from the vend nozzle you selected.
The actual quantity of water dispensed will be a function of the flow meter count you
have set up in POUr mode. As the water is being dispensed, the flow meter count will be
displayed on the front panel display. You can use the correct size water container to
measure the quantity of water dispensed during the test. You can use this information to
calibrate the flow meters by adjusting the flow meter counts in the POUr function.
•
Opt – Vending options mode
The Opt mode is used to select how the controller should behave during a specific set of
vending circumstances. There are three vending options you can selectively enable or
disable. Both options are disabled by default and must be enabled if you wish to use
them. The options are described as below.
Option “Nch”: No Cheat, this option prevents the machine from cheating the customer by
disallowing vends that would otherwise occur when the changer can not pay back the
proper amount of change due after a vend. It should be understood that the customer is
always warned about the potential for being cheated when the “exact change” light is
illuminated.
Option “Fvnd”: Forced vend, this option requires that any money the customer places in
the machine be used to acquire a product, unless the machine has sold out. This
prevents a customer from using the machine as a dollar bill changer rather than as a
vending machine.
Option “ShOt”: Shake off time, this option allows the adjustment of the amount of time
the vend nozzle stays in the “Down” position before retracting to allow the water
remaining in the nozzle to drain. This option should always be set at 4.
•
Changing vend options
To change the vend options you must first enter into Opt mode. To do this, place the
controller in to service mode as described above and press the UP key until the
message “Opt” is displayed on the front panel. Press the ENTER key and the display
should now show the message “Nch” alternating with the word “ON” or “OFF”
(depending on whether option is enabled or disabled). If you press the ENTER key
again, the ON or OFF should freeze in the display and the “Nch” should no longer be
visible. At this point you can use the UP or DOWN keys to toggle the ON or OFF state
of the no cheat option. Be sure to lock in changes by pressing the ENTER key. This
same method of changing states applies to the forced vend option.
Jim Coleman Company
Page 11 of 11
System Start Up
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Maintenance Schedule
1. Maintenance Requirements
Daily:
−
−
−
−
−
−
−
−
−
Clean both ice and water vend window
Sanitize the ice delivery hopper, funnel, and ice gate
Sanitize the water delivery nozzles
Run ice delivery test for bag and bulk
Add ice bags
Run one test gallon from each vend nozzle
Removes scuffs, mud, etc. from exterior
Remove graffiti
Clean litter and trash from around building and parking lot
Weekly:
− Check chlorine level and hardness levels
− Check for leaks
− Visually check UV sterilizers and Ozone generator
− Check and record all pressure readings
− Check and record RO flow meters for correct flows
− Check and record TDS meter
− Record gallon meters
− Add softener salt to salt tank if needed
− Drain air system
Monthly:
− Replace carbon polishing filter
Quarterly
− Take required bacteria samples of water and submit to the lab
Semi-Annually:
− Change UV bulbs
Annually:
− Sanitize the ice storage tank
− Empty the ice storage tank and check all the bolts and key way on stirring blades
As Necessary:
− Pressure wash entire unit and signage
− Visually inspect signage and make sure all lights are functioning
− Replace Big Blue and five-micron filters
− Adjust fill rate and amount
− Back flush or replace carbon tank(s)
− Adjust RO system
Jim Coleman Company
Page 1 of 6
Maintenance Schedule
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
2. Mr. Zippy’s Maintenance Log Sheet
Location: ____________________________________
Unit #: _________________
Month: _________________
Week 1
Date:
Chlorine
Hardness
Gauge A
Gauge B
Gauge A-Gauge B
Gauge J
Gauge E
Gauge C
Gauge D
Gauge F
Gauge G
Gauge H
Gauge I
TDS Meter K
Ozone Present?
Drain Air Tank
Heavy Cleaning
Coin Hopper Coins
1 Gal Test Vend A
1 Gal Test Vend B
10# Bag Ice Vend
20# Bulk Ice Vend
Add Salt
Light Check
RO Test Switch
Add Bags
Ice Sales
Water Sales
Machine Sanitizing
Replace Filter (Big Blue)
Replace RO Pre Filter
Replace Final Polish Filter4
Week 2
Date:
Week 3
Date:
Date: ____________________
Tech: ____________________
Time: ____________________
Week 4
Date:
Week 5
Date:
Running <.5ppm
Running <3 grains
Running min 20 psi
Running
<10 psi diff 1
Water being del. 2
Running <195 psi
Running .073
Running 1.43
>50 psi
5 psi
.5 cfm.
.5 cfm.
Yes/no
Yes/no
Yes/no
Ok/no
Water Press
5 Micron
Block Char Filter
RO Production
Product
Reject
Air Pressure
Ozone Pressure
Ozone Door
Ozone Tank
RO Door
Fresh Smell
Normal
Notes/Comments:
1
Gauge A is the incoming water pressure. If gauge B’s reading differential is greater than 10 psi difference then gauge
A then change the 5 Micron filter in the Blue filter housing on the RO. 2 Gauge J is the delivery water pressure. 3 Gauge
3
C is the RO product water and Gauge D is the RO reject water, gauge C should ½ of the reading on gauge D.
4
Reference the RO manual for settings and troubleshooting techniques. Change charcoal filter monthly.
Jim Coleman Company
Page 2 of 6
Maintenance Schedule
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Mr. Zippy’s Maintenance Log Sheet
Location: ____________________________________
Unit #: _________________
Month: _________________
Week 1
Date:
Chlorine
Hardness
Gauge A
Gauge B
Gauge A-Gauge B
Gauge J
Gauge E
Gauge C
Gauge D
Gauge F
Gauge G
Gauge H
Gauge I
TDS Meter K
Ozone Present?
Drain Air Tank
Heavy Cleaning
Coin Hopper Coins
1 Gal Test Vend A
1 Gal Test Vend B
10# Bag Ice Vend
20# Bulk Ice Vend
Add Salt
Light Check
RO Test Switch
Add Bags
Ice Sales
Water Sales
Machine Sanitizing
Replace Filter (Big Blue)
Replace RO Pre Filter
Replace Final Polish Filter4
Week 2
Date:
Week 3
Date:
Date: ____________________
Tech: ____________________
Time: ____________________
Week 4
Date:
Week 5
Date:
Running <.5ppm
Running <3 grains
Running min 20 psi
Running
<10 psi diff 1
Water being del. 2
Running <195 psi
Running .073
Running 1.43
>50 psi
5 psi
.5 cfm.
.5 cfm.
Yes/no
Yes/no
Yes/no
Ok/no
Water Press
5 Micron
Block Char Filter
RO Production
Product
Reject
Air Pressure
Ozone Pressure
Ozone Door
Ozone Tank
RO Door
Fresh Smell
Normal
Notes/Comments:
1
Gauge A is the incoming water pressure. If gauge B’s reading differential is greater than 10 psi difference then gauge
A then change the 5 Micron filter in the Blue filter housing on the RO. 2 Gauge J is the delivery water pressure. 3 Gauge
3
C is the RO product water and Gauge D is the RO reject water, gauge C should ½ of the reading on gauge D.
4
Reference the RO manual for settings and troubleshooting techniques. Change charcoal filter monthly.
Jim Coleman Company
Page 3 of 6
Maintenance Schedule
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Mr. Zippy’s Maintenance Log Sheet
Location: ____________________________________
Unit #: _________________
Month: _________________
Week 1
Date:
Chlorine
Hardness
Gauge A
Gauge B
Gauge A-Gauge B
Gauge J
Gauge E
Gauge C
Gauge D
Gauge F
Gauge G
Gauge H
Gauge I
TDS Meter K
Ozone Present?
Drain Air Tank
Heavy Cleaning
Coin Hopper Coins
1 Gal Test Vend A
1 Gal Test Vend B
10# Bag Ice Vend
20# Bulk Ice Vend
Add Salt
Light Check
RO Test Switch
Add Bags
Ice Sales
Water Sales
Machine Sanitizing
Replace Filter (Big Blue)
Replace RO Pre Filter
Replace Final Polish Filter4
Week 2
Date:
Week 3
Date:
Date: ____________________
Tech: ____________________
Time: ____________________
Week 4
Date:
Week 5
Date:
Running <.5ppm
Running <3 grains
Running min 20 psi
Running
<10 psi diff 1
Water being del. 2
Running <195 psi
Running .073
Running 1.43
>50 psi
5 psi
.5 cfm.
.5 cfm.
Yes/no
Yes/no
Yes/no
Ok/no
Water Press
5 Micron
Block Char Filter
RO Production
Product
Reject
Air Pressure
Ozone Pressure
Ozone Door
Ozone Tank
RO Door
Fresh Smell
Normal
Notes/Comments:
1
Gauge A is the incoming water pressure. If gauge B’s reading differential is greater than 10 psi difference then gauge
A then change the 5 Micron filter in the Blue filter housing on the RO. 2 Gauge J is the delivery water pressure. 3 Gauge
3
C is the RO product water and Gauge D is the RO reject water, gauge C should ½ of the reading on gauge D.
4
Reference the RO manual for settings and troubleshooting techniques. Change charcoal filter monthly.
Jim Coleman Company
Page 4 of 6
Maintenance Schedule
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Mr. Zippy’s Maintenance Log Sheet
Location: ____________________________________
Unit #: _________________
Month: _________________
Week 1
Date:
Chlorine
Hardness
Gauge A
Gauge B
Gauge A-Gauge B
Gauge J
Gauge E
Gauge C
Gauge D
Gauge F
Gauge G
Gauge H
Gauge I
TDS Meter K
Ozone Present?
Drain Air Tank
Heavy Cleaning
Coin Hopper Coins
1 Gal Test Vend A
1 Gal Test Vend B
10# Bag Ice Vend
20# Bulk Ice Vend
Add Salt
Light Check
RO Test Switch
Add Bags
Ice Sales
Water Sales
Machine Sanitizing
Replace Filter (Big Blue)
Replace RO Pre Filter
Replace Final Polish Filter4
Week 2
Date:
Week 3
Date:
Date: ____________________
Tech: ____________________
Time: ____________________
Week 4
Date:
Week 5
Date:
Running <.5ppm
Running <3 grains
Running min 20 psi
Running
<10 psi diff 1
Water being del. 2
Running <195 psi
Running .073
Running 1.43
>50 psi
5 psi
.5 cfm.
.5 cfm.
Yes/no
Yes/no
Yes/no
Ok/no
Water Press
5 Micron
Block Char Filter
RO Production
Product
Reject
Air Pressure
Ozone Pressure
Ozone Door
Ozone Tank
RO Door
Fresh Smell
Normal
Notes/Comments:
1
Gauge A is the incoming water pressure. If gauge B’s reading differential is greater than 10 psi difference then gauge
A then change the 5 Micron filter in the Blue filter housing on the RO. 2 Gauge J is the delivery water pressure. 3 Gauge
3
C is the RO product water and Gauge D is the RO reject water, gauge C should ½ of the reading on gauge D.
4
Reference the RO manual for settings and troubleshooting techniques. Change charcoal filter monthly.
Jim Coleman Company
Page 5 of 6
Maintenance Schedule
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Mr. Zippy’s Maintenance Log Sheet
Location: ____________________________________
Unit #: _________________
Month: _________________
Week 1
Date:
Chlorine
Hardness
Gauge A
Gauge B
Gauge A-Gauge B
Gauge J
Gauge E
Gauge C
Gauge D
Gauge F
Gauge G
Gauge H
Gauge I
TDS Meter K
Ozone Present?
Drain Air Tank
Heavy Cleaning
Coin Hopper Coins
1 Gal Test Vend A
1 Gal Test Vend B
10# Bag Ice Vend
20# Bulk Ice Vend
Add Salt
Light Check
RO Test Switch
Add Bags
Ice Sales
Water Sales
Machine Sanitizing
Replace Filter (Big Blue)
Replace RO Pre Filter
Replace Final Polish Filter4
Week 2
Date:
Week 3
Date:
Date: ____________________
Tech: ____________________
Time: ____________________
Week 4
Date:
Week 5
Date:
Running <.5ppm
Running <3 grains
Running min 20 psi
Running
<10 psi diff 1
Water being del. 2
Running <195 psi
Running .073
Running 1.43
>50 psi
5 psi
.5 cfm.
.5 cfm.
Yes/no
Yes/no
Yes/no
Ok/no
Water Press
5 Micron
Block Char Filter
RO Production
Product
Reject
Air Pressure
Ozone Pressure
Ozone Door
Ozone Tank
RO Door
Fresh Smell
Normal
Notes/Comments:
1
Gauge A is the incoming water pressure. If gauge B’s reading differential is greater than 10 psi difference then gauge
A then change the 5 Micron filter in the Blue filter housing on the RO. 2 Gauge J is the delivery water pressure. 3 Gauge
3
C is the RO product water and Gauge D is the RO reject water, gauge C should ½ of the reading on gauge D.
4
Reference the RO manual for settings and troubleshooting techniques. Change charcoal filter monthly.
Jim Coleman Company
Page 6 of 6
Maintenance Schedule
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Maintenance Procedure
Sanitization
This machine utilizes several processes to produce high-purity, safe, clear, affordable ice and
drinking water. Each process in this machine has been carefully designed and engineered to
work in junction with each other. Please do not make any changes or alterations without
approval of the parent company. To do this may alter the quality of the product and will void the
NAMA certification.
As the operator, you will be required to keep this machine in a clean and well-maintained
condition. Keep in mind at all times that this is a place where people come to buy a food
product. A dirty or poorly maintained machine will deter people from using it, and they will go
elsewhere. Once a customer is lost, they don’t return. Keep the machine as clean as you would
like to see it if you were a first time customer.
1. Cleaning and Maintenance – In Place
A. Sanitizing Procedures
1. The Mr. Zippy’s Z10000 Ice and Water vending machine should be thoroughly sanitized
after installation prior to opening for use by the general public. It should likewise be
sanitized anytime work is performed on the purification or storage system.
2. Recommended sanitizing agent is regular unscented household bleach (Clorox or
equivalent). It is available at any grocery store.
3. Mix ½ oz. bleach to one (1) gallon of water for general cleaning and sanitizing purposes.
4. How to sanitize entire water production system:
a.
b.
c.
d.
e.
Turn off City Water
Remove RO membrane and close drain adjustment valve. Remove RO pre filter
Fill filter housing with sanitizer
Apply city water pressure and flush sanitizer into storage tank for 5 minutes
Reinstall RO membrane and pre filter. Adjust flows and continue flushing until
storage tank is full
f. Shut off the RO system
g. Remove final polishing filter
h. In test mode, run a minimum of 30 seconds through each dispensing nozzle
i. Attach a hose to the outside hose connection, and open valve. Run until the tank is
empty
j. Reinstall membranes and filters. Run and adjust RO to specifications and allow
machine to fill
k. Repeat steps H through J with water only to flush
Jim Coleman Company
Page 1 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
B. Water Side Sanitizing (Exterior)
1. Remove grates from the water delivery area
2. Use any stainless steel cleaner/polish and thoroughly spray the area
3. Use a clean cloth to polish the stainless paying close attention to not so obvious areas
4. Clear any gathered debris from the drains and strainers
5. Replace grates
6. Use a light detergent to clean the front decal of the vending area
7. Rinse away any soap or cleanser build up on the system from cleaning.
8. Take sanitizing solution and saturate any and all areas that will dispense or store water.
9. Spray dispensing nozzles and plastic nozzle protectors
10. Allow sanitizing solution to dry for 2 minutes.
C. Ice Side Sanitizing (Interior)
1. Ice Tank
o Remove any debris that may be in the ice tank
o Inspect tank closure lids for dirt, dust , debris
o Verify blades (movable and stationary) are clean
o Verify that ice shearing gate is clean
2. Ice Bucket
o Inspect interior of ice bucket for dirt and debris
o Verify that ice bucket travel chute is clean
3. Ice delivery hopper
o Inspect and insure that ice delivery hopper is clean on all sides and perforated
bottom
4. Ice hopper and ice gate
o Inspect all sides of the ice hopper
o Insure ice gate is clean and clear of debris
5. Disinfecting Interior components
o Spray the sanitizing mixture liberally on all surfaces inside tank, tank walls, ice
chute, ice hopper, delivery hopper, and ice gate. In short, sanitize anything that
comes in contact with ice and water!
6. Allow sanitizing solution to dry for 2 minutes.
D. Ice Side Sanitizing (Exterior)
1.
2.
3.
4.
5.
6.
7.
Remove grates from the ice delivery area
Use any stainless steel cleaner/polish and thoroughly spray the area
Use a clean cloth to polish the stainless paying close attention to not so obvious areas
Clear any gathered debris from the drains and strainers
Replace grates
Use a light detergent to clean the front decal of the vending area
Rinse away any soap or cleanser build up on the system from cleaning.
Jim Coleman Company
Page 2 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
8. Take sanitizing solution and saturate any and all areas that will dispense ice.
9. Spray ice gate
10. Allow sanitizing solution to dry for 2 minutes.
E. Routine Cleaning
1. It is imperative that the unit be maintained in a clean and attractive state at all times. The
exterior vend area should be cleaned and polished daily. The interior, surfaces, signs
and outer surface of the unit should be thoroughly cleaned weekly – more often in rainy
or windy weather.
2. For cleaning the stainless steel vend areas, use a good quality stainless steel
cleaner/polish. For the vend nozzle guides use sanitizing liquid mix as mentioned above.
A good, general household cleaner such as Formula 409 is preferred for the exterior
surfaces and signs. Be sure to thoroughly rinse all cleaner off all surfaces to prevent
spotting and buildup. These products are available locally at grocery stores in the
household cleaner department.
F. Filter replacement and replenishment schedule
1. The gauges mounted directly on top of the filter housings monitor the Blue filter. When
you see a 10-pound per square inch differential between the A and B gauges, it is
necessary to change that filter.
2. Shut off the incoming water valve and relieve the line pressure before removing the filter
housing. Replace with only the correct, approved filter. Under no circumstances
substitute any other filter. Failure to do so may result in damage to the system and/or
reduced water quality.
G. Reverse Osmosis Membrane
1. The reverse osmosis membrane should last for several years. However, if you
experience lower pure water flow, or increased TDS (total dissolved solids), the
membrane may be in need of cleaning or replacement.
2. If you experience this difficulty, please refer back to the troubleshooting guide later in the
manual.
2. Cleaning and Maintenance – Exterior
We cannot stress the importance of a clean sanitary unit enough. It should be your top priority
as the operator or maintenance person. The success or failure of this machine rests largely
upon your attention to this issue.
Exterior cleaning and maintenance:
1. Daily / Clean both windows of the water and ice machine with stainless steel cleaner
or other quality cleaner, paying close attention to all surfaces including the control
panels, fold down shelves, vend area, and signs. DO NOT use Comet or other
abrasive type cleaners, as this will scratch the surfaces!! Use clean paper towels or
freshly laundered towels only.
Jim Coleman Company
Page 3 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
2. Daily / Ice Machine—Sanitize ice gate and bag hooks with a disinfectant spray 1, and
rinse liberally with a spray bottle full of fresh product water 2.
3. Daily / Water Machine—Sanitize the nozzle guides, ice gate, and bag hooks with a
disinfectant spray 1, and rinse liberally with a spray bottle full of fresh product water 2.
4. Daily / Ice Machine—Run 1 test bag of ice looking for ice quality and integrity. Ice
should be dry, loose, and not frozen together in blocks.
5. Daily / Water Machine—Run one test gallon from each vend nozzle to test for correct
operation. Fill calibrations should be checked weekly or as needed.
6. Daily—Inspect exterior of building for trash, cigarette butts. Dispose of properly.
7. Daily—Remove any scuffs, mud, marks, from building with a stiff bristle brush and a
spray cleaner such as “409”.
8. Weekly—Visually inspect the signage for dirt, bugs. Clean as necessary with
Windex.
9. Weekly or as necessary—Sweep and/or hose parking lot to remove road grime,
scrape used chewing gum off of parking lots.
10. If the machine has been sprayed with graffiti, remove at once! Never leave graffiti
overnight, as research proves that the best way to combat this problem is to never let
it stay on, and eventually they will go elsewhere. Spray paint can be removed from
stainless steel parts with paint thinner or Goof Off.
11. The bacteriological quality of the product water must be tested by an EPA or State
Health Department approved laboratory once monthly or as required by state law, or
at least semi-annually.
12. Weekly—Fill out the weekly log sheet for each machine at the time you do the
weekly maintenance (see sample log sheet on the next page). Be sure to fill out this
log sheet accurately and completely every week. This gives a method of tracking
maintenance problems as well as the functional history of each machine. The sample
log sheet on the next page has been provided to give an example of a correctly filled
out form for a typical week.
1
2
Disinfectant spray is a mixture of 1 gal of water and ½ ounce of household bleach.
Fresh product water should be RO water or distilled purified water.
3. Cleaning and Maintenance – Interior
1. Daily—Check for leaks. Repair leaks as they are found.
2. Weekly—Visually check both UV sterilizers for light and the ozone generator for
ozone scent.
3. Weekly—Manually start RO by turning the test switch on the front of the RO unit to
test. Check gauge A and B pressures, gauge B and C pressures, product flow
(gauges G and H), reject water (Gauge I), and pump gauge (Gauge F) pressures.
Record data on log sheet. Adjust if necessary, replace filters as needed. Note: Test
Jim Coleman Company
Page 4 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
switch bypasses all shut off components in the system and will continue to run until
it is put back into the “Normal” position.
4. Weekly—Check TDS meter and record on log sheet. Reading should be less than 3
ppm. If reading is greater than 3 ppm refer to troubleshooting section for suggested
solutions.
5. Weekly—Record ice and water sales by observing the readings on the user
interface (Red Lion) on the front of the control panel. Compare the weekly reading
to ensure that activity has occurred since the previous reading.
6. Weekly—Drain moisture from the air tank by opening the drain valve located on the
bottom of the tank above the water vend door. Failure to drain the tank will lead to
premature failure of the solenoid valves that operate the filler mechanism as well as
other systems.
7. Weekly – Check air/water separators. CAUTION!! Shut off air supply and relieve air
pressure before attempting to service any pneumatic component. Drain water from
separators and recharge the system by turning the air back on.
8. Weekly—Check chlorine level. The chlorine test is done using the chlorine test kit
provided. If chlorine reading is high, immediate attention must be given to the
charcoal filter after the water softener, see the charcoal filter flush procedure in this
manual. If after the flush the chlorine reading continues to be high, then the
charcoal must be replaced. Failure to address this problem will result in permanent
damage to the RO membrane. Contact the factory for charcoal replacement.
9. As Necessary—Sweep and mop the floor of the building.
10. As Necessary – Visually check and clean entire interior including walls, floors,
equipment, etc.
11.
Weekly – Check salt level in softener brine tank and replenish as needed.
12.
Weekly – Sanitize the ice bucket components using the sanitization solution
a. Pressing the sanitize button on the Red Lion or F5.
b. Extend the ice transfer bucket
c. Liberally spray the inside of the ice transfer bucket
d.
e.
f.
g.
h.
i.
Retract ice transfer bucket
Spray the ice transfer bucket shelf
Spray the ice transfer hopper
Spray the ice delivery hopper
Spray the ice delivery gate
Allow to set for 2 minutes, then put machine back in service
Jim Coleman Company
Page 5 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
4. Filter Replacement
The carbon polishing filters should be changed once monthly, and the Big Blue and five-micron
filter should be changed when the pressure differential between the test gauges becomes too
great. Use the following procedures for changing these filters.
To change Blue or RO Pre-treatment Filter, use the following procedures:
A. Shut off the incoming water valve.
B. Start and stop the RO system. This will relieve the pressure in the RO system or press
the pressure relief valve located on the top of the blue housing.
C. Using the correct filter wrench, turn the filter housing counter-clockwise to remove filter
housing.
D. Remove used filter and pour out remaining water.
E. Verify that the O ring inside the housing is seated properly in the retaining groove.
F. Insert correct replacement filter (Part No Z66040-16) into the housing, making sure it is
fitted properly in the bottom.
G. Replace housing, making sure the top of the filter fits properly in the adapter housing.
H. Tighten filter housing until the O-ring contacts the housing adapter, then tighten
approximately one-quarter turn. DO NOT OVER TIGHTEN!!
I.
Turn on incoming water then check for leaks.
J. Start RO by putting the test/normal switch located on the front of the RO Service Panel
to the “test” position. Check for leaks and note pressure differentials. Return the
test/normal switch back to the “normal” position.
K. Using a service report form, record which filters were changed, and the date of the
change.
To replace the carbon-polishing filter, use the following procedure:
Note: The carbon polishing filters at the vend windows will never plug due to the pure nature of
the water; however, it is very important to change these once monthly. Failure to do so will
cause an algae growth around this filter and compromise the quality of the water sold to your
customer.
A. Close the ball valve handle located to the right of the polishing filter.
B. Press the pressure relief valve located on the top of the filter housing. Gauge J should
go to 0 psi.
C. Using the filter wrench, turn the filter housing counter-clockwise to gain access to the
filter.
D. Discard the used filter, and pour out remaining water.
Jim Coleman Company
Page 6 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
E. Verify that the O-ring inside the housing is seated properly in the bottom.
F. Insert correct replacement filter (Part No. Z890206) into the housing, making sure it is
fitted properly in the bottom.
G. Replace housing, making sure the top of the filter fits properly in the adapter housing.
H. Tighten filter housing until the O-ring contacts the housing adapter, and then tighten
approximately one-quarter turn. DO NOT OVER TIGHTEN!!
I.
Open the ball valve located next to the polishing filter. You should see the gauge now
reading pressure.
J. After changing filters, vend at least five (5) gallons of water from each vend nozzle to
flush the new filters. This is VERY important because the first few gallons will taste like
the filter.
K. Using a service report form, record which filters were changed, and the date of the
change.
L. Taste test the water from the nozzles.
Filter Replacement Chart
Part #
Z66040-16
Z890206
Filter Description
Single R.O. Pre-treatment
Single Carbon Polishing
1 Case R.O. Pre-treatment
1 Case Carbon Polishing
Filter Wrench
5. Carbon Tank Care, Testing, and Replacement
The carbon tank in the machine serves a very important purpose. It removes the chlorine the
municipality puts in the water, as well as various pesticides, if they are present. Chlorine is very
detrimental to the reverse osmosis membrane material. Consequently, it is critical to test the
chlorine level of the water after it leaves the carbon tank. Using the chlorine tester supplied to
you (Part No. Z62175), test for chlorine at least once per week. The maximum reading for
chlorine should never exceed .5 ppm - parts per million.
6. How to Test for Chlorine
•
Test for chlorine at the test valve located on the RO pre-filter following the
manufacturer’s instructions on the test kit.
NOTE: The RO must be running when taking the sample.
When finished, record this reading.
Jim Coleman Company
Page 7 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
7. How to Back Flush a Carbon Tank
•
•
•
Shut off the incoming water valve.
Start RO system to relieve pressure.
After all the pressure is out of the system, disconnect the 2 fittings on the filter.
NOTE: Mark the hoses before you disconnect them since
they need to be reconnected the way they came off.
•
•
•
•
•
•
•
Connect an adapter hose from the inlet hose to the outlet of the carbon tank.
Connect a drain hose to inlet side of carbon tank. Place open end in the floor or door
drain.
Open the inlet valve and let the water flow through the filter and run to drain for fifteen
(15) minutes at approximately 5 gallons per minute.
Shut off the inlet valve and reconnect the carbon tank as it originally was.
Turn on the inlet valve, check for leaks, and manually restart the RO system.
Record action on service report.
Retest the chlorine level the following week. If the level is still high, the carbon tank must
be replaced.
8. How to Replace a Carbon Tank
•
•
•
Shut off the incoming water valve.
Start RO system to relieve pressure.
After all the pressure is out of the system, disconnect the two fittings on the filter.
NOTE: Mark the hoses before you disconnect them since
they need to be reconnected the way they came off.
•
•
•
•
Carefully take the carbon tank out of the unit.
Put the replacement tank in.
Connect an adapter hose from the inlet hose to the outlet of the small carbon tank.
Connect a drain hose to inlet side of the carbon tank. Place the open end in the drain
tank (see instructions on back flushing a carbon tank previously discussed) and back
flush as per instructions.
CAUTION: Failure to back flush a new carbon
tank will contaminate the pretreatment system
with carbon fines (dust) and do considerable
damage!!!
•
•
•
Reconnect carbon tank in the normal operating mode.
Turn on the incoming water valve.
Manually start the RO system.
Jim Coleman Company
Page 8 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
•
•
•
Check for leaks.
Record action on service report form.
Check the pressure differentials the following day and replace the RO pre filter, if
necessary, due to carbon fines buildup that could occur from changing the carbon tank.
9. Cleaning and Maintenance – Ultraviolet Sterilizers
The ultraviolet sterilizers in the Z10000 Mr. Zippy’s Ice and Water machines are designed to kill
bacteria and sterilize the product water just prior to vending. UV sterilization relies on complete
light penetration to all of the water that passes through the sterilizers. Consequently, it is
imperative that the UV bulbs and the quartz sleeves in the sterilizers be kept spotlessly clean.
A. Cleaning the UV Lamp and Quartz Sleeve
Avoid touching any of the surfaces of the bulb and handle the quartz sleeve by the ends only.
Use only clear water and clean dry towels to clean these parts. DO NOT use Windex or other
cleaning agents. These parts must be spotlessly clean with no fingerprints left on them.
1. UV Lamp-Bulb
a. In order for disinfection to remain effective, the UV lamp must be checked and
replaced on a regular basis. Bacteria that may have survived the filtration process is
killed by the UV light when exposed to a specific wavelength of UV light (13,000
μWS/cm2 at 254 nm). As the UV lamp ages, the intensity output weakens. Therefore,
it is important to check the UV lamp a minimum or every six (6) months and replace it
every twelve (12) months. Alternately the lamp may be replaced every six (6)
months.
b. Replacement of the UV lamp is required every six months. This ensures the correct
wavelength ultraviolet light and eliminates the need for testing of the UV lamp.
c. To change the UV bulb:
To replace the lamp, there is NO need to disconnect the system from the water
supply, nor drain the water from the system. Lamp replacement is a quick and simple
procedure requiring no special tools.
•
Disconnect the power source to the unit.
•
Remove the lamp connector by sliding the metal retaining ring away from the
body of the connector.
•
Remove connecter and lamp from the reactor chamber.
•
Separate the lamp from the connector. Do not twist the lamp from the
connector; simply slide the two apart. Avoid touching the lamp on the glass
portion. Handling the lamp on ceramic ends is acceptable. If you must touch
the lamp glass, please use a soft, clean cloth.
•
Fully remove the lamp from the reactor chamber being careful not to angle
the lamp as it is being removed from the chamber. If the lamp is removed at
an angle, pressure will be applied on the inside of the quartz sleeve, causing
the sleeve to fracture.
Jim Coleman Company
Page 9 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
•
To install the new lamp, first remove the lamp from its protective packaging;
again, be careful not to touch the glass lamp itself.
•
Carefully insert the lamp into the reactor vessel (actually inside the quartz
sleeve).
•
Insert the lamp fully into the chamber leaving about two inches protruding
from the chamber.
•
Attach the connector to the UV lamp. The connector is “keyed” and will only
allow correct installation in one position.
•
Ensure the connector is fully seated onto the UV lamp.
•
Once the lamp is seated connector, slide the connector over the aluminum
retaining nut.
•
Make sure the metal retaining ring on the connector is pulled away from the
body of the connector in order that the connector may slide fully over the
retaining nut.
•
Once the connector is located fully over the retaining nut, slide the metal ring
back in to lock the connector in place.
•
As this connector is keyed to the reactor chamber, make sure the depression
on the connector is located over the ground lug located on the reactor
chamber.
WARNING! In order to maintain certification and insure
proper operation of this machine, only use replacement
parts authorized by or obtained from Jim Coleman Company
5842 West 34th Street Houston, TX 77092 1-800-999-9878
Jim Coleman Company
Page 10 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Required Supplies List
Following is a list of required supplies to maintain the Z10000 Mr. Zippy’s Ice and Water
Machine. Please be sure that these and any other items you find useful or necessary are
available for routine maintenance.
D Paper towels or clean white towels
D Stainless steel cleaner
D Scrub pads
D Formula 409 or equivalent cleaner
D Clorox bleach or equivalent
D Spray bottle
D Salt—extra coarse softener salt or softener pellets
D Chlorine tester
D Hardness tester
D Broom
D Sanitation Kit
Consumable Parts List
Consumable parts that should be stocked in each service vehicle:
Quantity
Part #
Description
2
Z66040-16
Five-Micron Filter
2
Z890206
Carbon Filter
Jim Coleman Company
Page 11 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
7.2 Pressure Gauges and their Functions
•
Gauge A: the incoming line pressure gauge and is mounted directly on the behind and
top of the five micron filter. This gauge shows the line pressure coming from the
municipal water supply (city water). The amount of pressure it shows will vary as the city
system fluctuates. However, the Model Z10000 Machine requires at least 20 psi at this
gauge to function properly.
•
Gauge B: the Blue RO Prefilter differential gauge. If there is more than 10-psi difference
between A and B with the RO running, the filter needs to be changed. (5 Micron Part
No. Z66040-2)
•
Gauge C: the RO product gauge. This gauge should read .7gpm – 1.1gpm with RO
running
•
Gauge D: the RO reject gauge. This gauge should read 2 times what the product gauge
is reading 1.4gpm – 2.2gpm running
•
Gauge E: the RO pump pressure gauge. It should read between 180 to 200 psi with the
RO running. If this pressure is out of range with the RO running, the RO needs to be
readjusted or repaired.
•
Gauge F: the air pressure gauge. It is the system air pressure gauge it should read 7090 psi
•
Gauges G: the ozone supply pressure gauge. It should read 5 psi.
•
Gauge H: the door ozone supply. It should read .5 cfm.
•
Gauge I: the tank ozone supply. It should read .5 cfm.
•
Gauges J: the water supply delivery pressure. This gauge monitors the delivery
pressure for the water door and the ice machines. It should read 20-60 psi.
Jim Coleman Company
Page 12 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
7.3 Water Sample and Testing Procedure
The product delivered to the customer from a Mr. Zippy’s Ice and Water machine is considered
to be food grade consumables and should be handled accordingly. Periodic testing of the
quality of product should be done based upon your local requirements.
The following description is based on the requirements of the Texas Health Services under the
Department of Health Services Guidelines.
1. Water Sample
a. A water sample must be taken and submitted to a testing laboratory for
“Microbiological” study.
b. Each water sample must be taken not more than 90 days apart.
c. Sample results must be maintained and on premise for a period of 2 years
(Texas). Compliance must be done for your local requirements.
2. Sample Procedure
a. Once a lab has been identified to do the samples, they will provide you with a
pure and sealed water sample bottle for your sample and the necessary forms
needed for the test. (See sample on page ??)
Test Bottle
Thumbnail of Water Test Form
b. You must procure these bottles and the forms from the lab.
c. Remove the seal from the bottle when you are ready to take the sample.
Jim Coleman Company
Page 13 of 20
Maintenance Procedure
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MR. ZIPPY’S ICE & WATER MACHINE
d. Remove lid on sample bottle and deposit money into the water machine.
e. Begin dispensing water through the machine and fill sample bottle to the line or
100ml.
f.
Replace the lid, tightly.
g. Fill out form and deliver to lab for testing. Lab will require a fee to process the
test. Once the fee has been paid, the lab will assign the sample a lab number.
Ensure that the lab report you receive references this lab number.
h. Results will be sent to the designee on the lab report.
Jim Coleman Company
Page 14 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
3. Chain of Custody
a. Some jurisdictions will require a “Chain of Custody” form if the sample is not
delivered by the person taking the sample. See your local requirements. (See
sample on page ??)
Thumbnail of Chain of Custody
NOTE: Water sample must be delivered to lab within
30 hours for valid testing.
Jim Coleman Company
Page 15 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
7.3.1 Sample Water Testing Form
Sample Form
Fill Out Gray Boxes and Deliver
Form Along With Sample
X
Source
Ice and Water
Jim Coleman Company
Page 16 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
7.3.2 Sample Chain of Custody Form
Jim Coleman Company
Page 17 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Jim Coleman Company
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Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Jim Coleman Company
Page 19 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Jim Coleman Company
Page 20 of 20
Maintenance Procedure
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
User Interface (Red Lion)
The Red Lion Operator Interface Panel is mounted on the door of the electrical control panel of
the Mr. Zippy’s Ice and Water Machine. The interface panel is called a human-machine
interface
(HMI). HMI’s are tools for us, as humans, to be able to change settings on the machine, which, in
this case, is the CP1H Programmable Logic Controller (PLC).
Setup data, income levels, alarms, timers, inputs and outputs, etc are stored in the memory of the
PLC inside the control panel. With the Red Lion HMI, you can view data, perform tests, and make
various changes to, timers and other memory locations in the PLC. The Red Lion is not necessary
for the ice and water Machine to function. In fact, if you disconnected the Red Lion, the machine
will continue to operate.
The PLC and Red Lion have their own independent programs stored in their own internal memory.
When it is first powered up the Red Lion will display the following screen in approximately 5 to 6
seconds:
JCC developed the programs for the Red Lion and the CP1H. The two numbers at the bottom of
the screen represent the version numbers of your unit. The first number (HMI x.xx) represents the
current version stored in the Red Lion. The second number (PLC x.xx) represents the current
version stored on the CP1H.
The following screen will familiarize you on the methods used to move throughout the screens
needed to service and adjust your machine.
Jim Coleman Company
Page 1 of 21
Red Lion
Rev. 2 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
1. This is an image of the Red Lion HMI.
Keypad used
For entering
Passwords or
values
Data Screen to
view settings
and data
Set keys used
to lock in or
change value
Enter and
maneuvering
keys
Alarm views,
main menu,
machine reset
FKeys used to
move through
different
functions
Power Lite
Red – Pwr
Yellow – Data
Green - Comm
2. Key Table
Name
Description
Alarms
Mute
Exit
Menu
F1
F2*
F3*
F4
F5
F6
F7
F8*
Pwr
Prev, Next,
Lower, Raise,
Enter
Set Keys
Data Screen
Keypad
*
Use this key to view the different alarms
Not Used
Machine Reset
Display Main Menu with Software versions
Bag Inventory
Timers and Counters
Prices and Revenue
Operations View
Not Used
Not Used
Technicians Menu
Site Settings
Red, Yellow, Green
Maneuvering keys used to move through the HMI
screens.
Used to change or lock in a value
Use to view software versions
Used for entering Passwords or changing values
These items require password to access
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Page 2 of 21
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MR. ZIPPY’S ICE & WATER MACHINE
FKey Table
FKey
F1
Function
Bag Inventory
F2
Timers and
Counters
Options
0-Add Bags>>>>>>>>>>>
0-Change Bags>>>>>>>>
0-Adjust Timers>>>>>>>>
1-Adjust Counters>>>>>>
F3
F4
F5
F6
F7
Prices and Revenue 0-Price Ice>>>>>>>>>>>>
1-Price Water>>>>>>>>>>
2-Price Token>>>>>>>>>
3-$ Day, Month, Year>>>>
4-$ Last 7 Days>>>>>>>>
5-$ Last 12 Months>>>>>
6-Best Day Last Week>>>
7-Best Day Ever>>>>>>>>
8-Best Month Ever>>>>>>
9-Best Year Ever>>>>>>>
Operations View
Operations
Not Used
Not Used
Technicians Menu 0-View PLC Inputs>>>>>>
1-View PLC Outputs>>>>>
2-Force PLC Outputs>>>>
3-Test Bag Dispenser>>>>
4-Test Agitator>>>>>>>>>
5-Clean Ice Bucket>>>>>>
6-Test 10lb Sequence>>>
7-Test 20lb Sequence>>>
8-Calib H20 Side A>>>>>
9-Calib H20 Side B>>>>>
10-Set Time Clock>>>>>>
11-Reset Cash Balance>>
12-Disable Vac Switch>>>
13-Disable Ice Sensor>>>
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Option Subs
100 Bags
Keypad / Raise-Lower
Vac Buildup 1.0
Vac Watchdog 5.0
Agitator Off Delay .2
Ice Transfer .5
Bucket Staging Time 5.0
Agitator Repeat 60min
Water Left Side
1g–18s / 3g–56s / 5g-87s
Water Right Side
1g–18s / 3g–56s / 5g-87s
No Ice Retries 3
No Agitator Motion 3
No Bag Detect 3
No Cylinder Movement 3
Change /10# / 20# /Accept
Change /1g, 3g, 5g/Accept
Change / Accept
Day, Month, Year
Sun – Sat
Jan – Dec
Date
Date
Date
Date
Used to view Operations
PLC Ch 1
Remote Input Ch2008
Remote Input Ch2009
PLC Rack Ch100
PLC Rack Ch101
PLC Rack Ch100
PLC Rack Ch101
Force Outputs Ch100
Force Outputs Ch101
Force Outputs Ch2001
Test
Test
Extend
Test
Test
1Gl, 3Gl, 5Gl
1Gl, 3Gl, 5Gl
MM-DD-YYYY 00:00 A/PM
Reset
Normal/Bypass
Normal/Sensor Disabled
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F8
Site Settings
0-Number of Dumps/Bag>
1-Change Password>>>>>
2-Pager Values>>>>>>>>
One/10# Bg Two/20# Bg
View/Technician/Revenue/Owner
Site No / Send Delay / Answer Delay / Hang Up
Delay / #1, #2, #3
Change, IP Addr, Mask, Gate
3-Enter IP Address
The following section will take each screen from the table above and briefly describe
what is needed to work through that screen for viewing or changing data.
3. Passwords
Passwords are used to control access to the system. These passwords are changeable
according to you. There are 4 levels of passwords available. View(Default #1) – allows only the
viewing of technical data. Technician(Default #2) – allow the technician to reset, calibrate, or test
settings. Revenue(Default #3) – allows the changing of prices and viewing of revenue.
Owner(Default #4) – allows access to all screens and data.
For example press
the Bag Inventory screen will come up.
then press
press
the log in page will come up,
and then
now press
then
and you will go to the Bag Inventory screen. Follow this sequence
each time you select an item that prompts you with the Log In Page.
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Page 4 of 21
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MR. ZIPPY’S ICE & WATER MACHINE
F1 Bag Inventory
This function allows you to change the quantity of bags available to the customer. Bags come on
wickets of 100 each.
Press the arrow below
, this will bring up
. Press the arrow
to add 100 bags, the screen will return to the base screen now
below
reflecting the added 100 bags. To better fine tune the number of bags available press the arrow
below
if prompted for a password, input password according to the Password
procedure. Change bag count by pressing the
advance or lower the count accordingly.
or the
buttons. This will
F2 Timers and Counters
Timers and Counters are system settings used to operate the different components. For instance
the “Ice Transfer Time” is set .5 seconds. This allows the ice transfer bucket to remain over the
ice conveyor bucket for ½ of a second. This insures that the ice has plenty of time to drop before
the ice transfer bucket returns to its home position. These settings are factory set and should not
be changed without consulting technical support on the Mr. Zippy’s units.
WARNING! Making any changes in the Timers and Counters
can greatly affect the way the machine performs. Please
contact Technical Support prior to making changes. Jim
Coleman Company 1-800-999-9878
Jim Coleman Company
Page 5 of 21
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Press
Now press
to display the Timers and Counts screen.
to access the different screens under the Adjust Timers beginning with
vacuum Buildup.
pressing the
You can change the value by
or
buttons to change the value. Use the
button to
advance to the next choice or the
button to return to the previous choice. Below is a
table identifying the options and their default settings:
Option
Vacuum Buildup
Vacuum Watchdog
Agitator Off Delay
Ice Transfer Time
Bucket Staging
Agitator Repeat Cycle
Water Left Side
Water Right Side
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Setting
2.0s
5.0s
.10s
.50s
5.0s
60m
1g – 17s
3g – 56s
5g – 87s
1g – 17s
3g – 56s
5g – 87s
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Press the
to return to the Timers and Counters screen. Press the
to the Adjust Counters screen. Press
Timers setting use the
button to go
button to access the counters screen. Just like the
and
buttons to
change the values and use the
and
buttons to move between the Counter selections. Below is a table
identifying the options and their default settings:
Option
No. of Ice Retries
No. of Agitator Motions
No. of Bags Detected
No. of Cylinder Movements
Setting
3
3
3
3
F3 Prices and Revenue
The Prices and Revenue section allow you to change the price of Ice and/or Water. This step is
to access the Prices and Revenue Screen.
critical to accurate accounting. Press
Press
such as “Price Ice” or press
to choose one of the settings screens
to advance to the next selection.
,
, and
selections change
The
the values and prices of these items. Refer to Fkey Table on page 57 for a flow chart of these
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MR. ZIPPY’S ICE & WATER MACHINE
choices. Press
3 times to get to the Revenue Viewing screens.
Press
to view the data. The Data will be viewed
in several formats beginning with This Day, This Month and This Year. Scroll through the
different views by pressing the
. You can also view
,
,
,
, and
,
.
Please be aware that data is non re-settable. This maintains
the integrity of the data for future reference.
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Page 8 of 21
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F4 Operations View
The Operations Sequencer screen allows the user to view the operations of the machine as they
should appear. There are no changes that can be made here, just viewing. This section will be
used the most when/while troubleshooting a problem with a technician. Press
Operations Sequence Screen.
to view the
F5 Not Used
F6 Not Used
F7 Technicians Menu
The Technicians Menu is used for a multitude of functions. The technician will be able to use
this screen to view Inputs and Outputs, Force Outputs on for testing, test some of the functions
and much more. As many of the screens this screen is password protected and should only be
used by a qualified tech. Press
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Page 9 of 21
to enter the menu.
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MR. ZIPPY’S ICE & WATER MACHINE
Press the
selections available to the technician. Press the
button to advance through the
to
This will allow the tech to view inputs coming on and going off.
If the box on the right of the screen is
means the input is off. If the box on the right is
then this
then this means the input is on. Press the
button to view other inputs not shown on the screen. At the top of the screen is the
location of the inputs being viewed. In this case
channel
100 is being viewed. Refer to the technical drawings to locate this channel. View other channels
by pressing the
button. After viewing the PLC Inputs press the
to the Technician Menu. Press the
button to return
button to advance to the
. The View PLC Outputs work exactly as the View PLC Inputs.
Press
to return to the main Technician Menu. Press the
the
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Page 10 of 21
button to advance to
. The Force PLC Outputs allows the technicians to
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exercise certain operations for testing, formatting, or viewing. Press
option to force, Ice Shear Gate
to bring up the first
below
, press the
the word force, you will now hear the Ice Shear Gate retract to the open position. You will also
to darken. This will indicate that the Ice Shear Gate
observe both boxes on the screen
performed the requested operation. The item that was forced will remain in that position until you
reverse the operation by pressing the
close and the boxes will return to
below the word force. The Ice Shear Gate will
indicating that the Ice Shear Gate has closed and
returned to it’s normal operation. Press the
can be forced on the channels as listed below:
button to advance through the items that
Channel 100
Ice Shear Gate
Ice Xfer Bucket
Swing Arm Bag Position
Swing Arm Dispense
Pickup Extend
Pickup Retract
Dispense Extend
Dispense Retract
Channel 101
Ice Dispense Gate
Bag Dispense Gate
Agitator Fwd
Agitator Rev
Agitator Speed
Conveyor Raise
Conveyor Lower
Vacuum Motor
Channel 2001
Water Vend Control Power
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Spare
Ice Dam Plunger
Token Diverter
Coin Machine Control Power
Bill Machine Control Power
Sonalert Horn
Spare
Display Operating System
Correct Change
Reset Message
Coin Dispense
Pulse Timer
Msg 10 Pound
Msg 20 Pound
Msg Dispense
Each item can be forced on for testing and/or verification that the function if performing as
expected.
Press
button to advance to the
Test Bag
Dispenser Option. This selection allows you to test the functionality of the bag
dispensing mechanism. Press
Upon reaching this screen press the
actions occur:
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.
below the word test. You will see the following
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1.) The Bag Delivery Cylinder Retract
2.) The Vacuum Motor Turns On
3.) The Bag Swing Arm Advances To The Bag Load Position
4.) The Bag Pickup Box Moves Towards The Bags
5.) The Bag Swing Arm Return To The Bag Dispense Position
6.) The Bag Cylinder Extend And Place The Bag In Position
7.) The Vacuum Motor Turns Off
This test allows the technician to adjust and correct any bag dispense problems that may be
occurring.
Press the
Press
button to return to the
to move to the
screen.
screen. When the test
comes up then press the
below the word
screen
Test. This will turn the agitator on for visual inspection of the blades, motor, drive, and gear box.
Press the arrow below test for a second time to turn the agitator off.
Press the
to return to the main menu and press the
button to advance the next
test procedure. The following list will briefly show the functions and their testing or setup
procedure.
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Press the arrow below the word ‘extend’ to extend the
bucket. This will allow the bucket to be visually
inspected or cleaned. Press the button again to retract
the bucket to the home position.
Test 10 Lb Sequence
Press the arrow below the word test to start 1 10# test
sequence. This will allow a test of dispensing a bag,
dropping 10# of ice, and delivery of the ice.
Test 20 Lb Sequence
Press the arrow below the word test to start 1 20# test
sequence. This will allow a test of dispensing a bag,
dropping 20# of ice, and delivery of the ice.
Calibrate H2O Side A / B
Use this function for calibrating the water dispensing for
When facing the machine the A Side revenue capture. Press the arrow below th 1Gal title
is on the left and the B Side is on the and then purchase 1 Gal of water from the water
right.
machine. The fill time will increase as the gal is being
dispensed. Perform the same procedure for 3 Gal and 5
Gal.
Set Time Clock
Press the enter button to enter the set time mode. Use
the Raise and Lower keys to change the month, and
then press the next key to advance to the day using the
same procedure for each setting. When satisfied with
the settings press the save button and then the enter
button to lock the changes in.
Reset Cash Balance
The display on the Ice Machine can be reset by pressing
the arrow below the word reset.
Disable Vac Switch
This function will allow you to bypass the vacuum sensor
switch in the event of a failure of this switch while waiting
on replacement.
Disable Ice Sensor
This allows the machine to operate without ice
Clean Ice Bucket
F8 Site Settings Menu
The Site Setting Menu is used to setup specific settings for each site. The technician will use
these screens to customize the location such as setting up the Internet IP. As most of the
screens it is password protected and only a qualified tech should make changes to the settings.
Press
to enter the Site Settings Menu.
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MR. ZIPPY’S ICE & WATER MACHINE
Press
to advance through the selections
available to the technician. The first setting is
press
press
view the Num Dumps Per Bag setting.
This setting is used to change the amount of ice that will
be dumped when a customer purchases a bag of ice. Press one of the arrows below the
or
the number that is dark is the amount that is chosen.
done if you have purchased 20# bags for your Mr. Zippys Press
Settings menu.
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Page 15 of 21
Caution: This should only be
to return to the Site
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Press
to advance to
Passwords are used to control access to the system. These passwords are changeable
according to you. There are 4 levels of passwords available. View(Default #1) – allows only the
viewing of technical data. Technician(Default #2) – allow the technician to reset, calibrate, or test
settings. Revenue(Default #3) – allows the changing of prices and viewing of revenue.
Owner(Default #4) – allows access to all screens and data. Caution: When/If changing
passwords document what they are and store in a safe place. If they are forgotten or lost your
program will have to be reset.
to access
Press
. From here you will be able to
change the passwords by pressing the
below
. Press
password that is highlighted to change. Change the password by pressing and
or
buttons. Press the
password to change. Press
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Page 16 of 21
or
buttons to advance
on the
holding the
to the next
to return to the Site Settings menu.
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MR. ZIPPY’S ICE & WATER MACHINE
Press
to advance to the
.
The Pager Values Menu allows the customer to set up a paging system that will alert them in the
event that there is a problem at the location. Setup the following:
Site Number 0-999
Pager Delay
Pager Delay 2
Pager Delay 3
Enter Pager Number
The site number is used to identify which location is paging.
Pager delay allows the phone to answer prior to sending error
codes.
This 2nd delay is used for a delay after the phone has answered
prior to sending the message.
The 3rd delay is for how long the connection is made prior to
disconnecting.
There are 3 pagers that can be dialed to send codes to. Use the
previous and next button to advance through the numbers. Press
enter on the number you want to change. Use the raise and lower
buttons to put in your number, use the next and prev buttons to
advance through the number pressing enter at the end to save the
number..
Note: A phone line, modem, and pager service is required for this to work.
The following section should be done by an internet person that can provide IP,
Mask, and Gateway data.
Press
to advance to the
. The Enter IP Address
menu is used to setup the system for Internet viewing. All functions talked
about in this
section can be performed remotely via. Internet, however caution should be used when forcing
functions on and off to avoid damage or harm to the machine or possible person. Press the
arrow below the
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button. You will now see 3 sections that need to be completed.
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MR. ZIPPY’S ICE & WATER MACHINE
IP is assigned by the person configuring the system. The
IP Mask is standard for your Internet provider. The Gateway will be provided by you Internet
to access the highlighted choice, use the Raise and Lower buttons to
provider. Press the
make changes and the Previous and Next buttons to advance through the setting. Press enter to
save the changes and Next to advance to the next setting. When all of the settings have been
completed then press the
button to lock in all of the changes.
Connecting Mr. Zippy’s to the Internet
Connecting Mr. Zippy’s to the internet can prove to be a very useful tool for you. You will be able
to view data such as alarms, income, status, and more from any internet connection in the world.
Note: Contact Jim Coleman Customer Service for assistance in Internet Connection
1-800-999-9878
Remote Access Configuration for Red Lion Controllers
:::DISCLAIMER:::
Configuring remote access to a Mr. Zippy’s site over the Internet has inherent security risks
associated with it. Even when best practices in security are followed there still remains a
possibility that a site could be accessed by unauthorized users. Even small errors in configuration
can increase the vulnerability of a site significantly.
The Jim Coleman Company will not be held liable for unauthorized site access, loss of data, theft
of data or damage they may result from configuring remote access to a site.
This information is provided as a courtesy and reference to site operators and in no way
implies a guarantee of security. A site should only be configured for remote access by an IT
professional.
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Page 18 of 21
Red Lion
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MR. ZIPPY’S ICE & WATER MACHINE
Synopsis:
This paper describes the procedure for configuring remote access over the Internet for the Red
Lion controllers at a Mr. Zippy’s site.
Prerequisites:
- A broadband Internet connection at the car wash site.
- A static IP address provided by the ISP (Internet Service Provider.)
- Internet Security Appliance (firewall/NAT Router) provisioned by IT Professional making the
connectivity.
- Ethernet network patch cables. One cable per Red Lion controller.
*The length of the cable is determined by the distance from the Red Lion to the firewall.
- A desktop or laptop computer on site temporarily to be used for configuring the firewall.
Configuration:
Using an Ethernet cable connect the Red Lion controller to one of the ports labeled LAN/DMZ
on the firewall.
Using an Ethernet cable plug in the incoming broadband service into the port labeled WAN on
the firewall.
Then assign each Red Lion a unique IP address. The first controller should be assigned the
address 192.168.1.10.
The subnet mask is 255.255.255.0
The gateway address is (xxx.xxx.xxx.xxx) provided by ISP.
To set the IP address information on the Red Lion controller press the Site Data button to access
the Site Settings screen. Use the Raise/Lower buttons to scroll through the settings until you
arrive at the Enter IP Address option. Then press the ENTER button.
Then press the arrow button under the Change option on the screen.
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MR. ZIPPY’S ICE & WATER MACHINE
Then use the key pad to enter the appropriate numbers in the fields. Note that all numbers are
three digits so use leading zeros to pad single and double digit numbers. Use the NEXT and
PREV buttons to navigate between the fields. Once the values are entered correctly press the
arrow button under the Accept option on the screen to save the settings.
Then cycle power to the controller to make the settings take effect.
Next the firewall needs to be configured with the IP settings provided by the internet provider.
This includes a static IP address, subnet mask, default gateway and DNS server information.
Consult your ISP documentation for this information. Your IP professional should perform this
duty.
Configuration is now complete. To access the Red Lion interfaces open a web browser and type
the static IP address provided by the internet provider followed by a colon and the number that
identifies the controller. The first controller number is 8000 the second is 8001 and so on.
For example if the static IP of the site was 127.0.0.1 you would type:
http://127.0.0.1:8000 for the first controller
and http://127.0.0.1:8001 for the second and so on.
This will bring up the screen below.
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Red Lion
Rev. 2 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Click the Remote View link and you will see the remote web interface of the Red Lion controller.
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Red Lion
Rev. 2 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Troubleshooting on Mr. Zippy’s Ice and Water
This section of the manual is designed to cover the basic steps of troubleshooting. This section
assumes that you have basic skills in electrical and electronic troubleshooting and a good
knowledge of plumbing. You will need to know how proxes operate and how to test them. You
will also need to know how eyes operate and how to test them. This section does not cover
every possible problem but it should cover most of them. You should read the entire owners
manual first before attempting to repair the machine. You should also know the theory of
operation on how the machine is designed to work before attempting to work on Mr. Zippy’s.
1. Ice Vend
First step is to always check the Red Lion controller and look at the alarms to troubleshoot the
ice vending problems. Most operations of the ice delivery system can be tested through the Red
Lion by going to F7 and scrolling down to the operation to be tested. The alarms will give you
the source of the problem. When the Red Lion shuts down the ice vending side due to a fault it
will turn off the bill and coin acceptor to prevent customers from loosing money.
In the owner’s manual there is a section that explains the theory of operation for ice delivery,
bag delivery, and agitator operation. You need to read this carefully and become familiar with
the theory of operation to be able to identify problems and make the correct repairs.
•
Bill acceptor not accepting bills? Check Red Lion controller to make sure that the unit
is not disabled because of a different problem.
o Is the red light on the back of the bill acceptor turned on or blinking? Read the
code on the back of the bill acceptor for a detailed description of the cause of the
fault. Please refer to the owner’s manual for complete instruction of the bill
acceptor.
o If the light on the bill acceptor is not turned on then you will need to check the
incoming 24v power to the bill acceptor. First check to see if the Red Lion
controller is showing an alarm that would shut down the ice vending section.
•
Coin acceptor not accepting coins? Check Red Lion controller to make sure that the
unit is not disabled because of a different problem. Check for green power light on coin
acceptor. Is the coin acceptor rejecting all coins? If so please disassemble the coin
acceptor and check for foreign objects or bent coins. Also clean the coin path while coin
acceptor is disassembled. If this does not correct the problem then check incoming
power for 24v.
•
Ice tank is empty. There are several reasons that this can happen. One reason is your
sales exceed the production capacity of the ice maker. If this is true, once your ice
maker fills the tank, the machine will go back in service without any outside assistance.
You can check the ice production on your Manitowoc ice maker by simply timing how
long it takes to produce a batch of ice. The Manitowoc should produce a batch of ice
every 12 to 15 minutes. If your ice maker is greatly exceeding this then refer to the
Manitowoc owner’s manual for advanced testing of the ice maker. If your ice maker is
not making any ice please check to make sure you have water going to the ice maker
and that no breakers are tripped. You can unplug the ice maker and reset the computer
to restart the ice maker. Air and Water temperature will affect ice production. The
Manitowoc Owner’s manual covers how much ice can be produced based upon out side
air temperature.
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Page 1 of 12
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
•
Customer claims that they did not receive an ice bag. You will need to test the ice
machine and see if the machine is dispensing bags properly. Most likely the customer
chooses the bulk ice selection and did not realize that you will not receive a bag. The
computer will shut down the ice vending when you run out of bags. Before a customer
can deposit money an ice bag will be loaded and be ready for delivery to the customer.
•
You find ice bags lying on the floor inside the machine. This is normally caused by
the customer purchasing a 10 lb vend of ice and simply not taking the bag when it is
dispensed to him. If the customer does not take the bag then the bag dispenser tries to
load a bag for the next customer and the bag will sometimes fall on the floor inside the
machine. Test the bag dispenser to make sure it is performing properly.
WARNING: If your Mr. Zippy’s has been shut down for several hours and the ice tank is
almost full or full you will need to check the rotation of the agitator blades before
returning the machine back in to service. Look under the tank while you vend a bag of
ice to make sure the chain sprocket turns every time ice is dispensed. If the sprocket does
not turn when ice is dispensed, then empty out the ice tank and check the blades and hub.
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Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Mr. Zippy Alarm Errors
Alarm Description
00
No Alarm
01
Low Water Level
02
Low Coin Dispenser
03
04
Out of Bags
Ice Shearing Gate Open Fault
Test through Red Lion screen F7
05
Ice Shearing Gate Close Fault
Test through Red Lion screen F7
06
Ice Bucket Close Fault
Test through Red Lion screen F7
07
Ice Bucket Open Fault
Test through Red Lion screen F7
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Service
Explanation
No
Yes
The RO water storage tank is empty.
Check the RO system and find the
problem with the RO system. Once water
tank is full the ice side will then return
back to working properly.
No
The coin dispenser is low and needs to
be filled. This disables the bill acceptor.
Yes
Please reload the ice bags.
Yes
The ice shearing gate failed to open.
Check the air pressure on the ice
shearing gate regulator. Minimum
pressure to operate properly is 70 psi.
Yes
The ice shearing gate failed to close.
Check the air pressure on the ice
shearing gate regulator. Minimum
pressure to operate properly is 70 psi.
Check the opening to see if any
obstructions are keeping the gate from
closing. You can remove the front of the
ice transfer bucket to see the bottom of
the tank and see the ice shearing gate.
Yes
Ice bucket failed to extend. The bucket
should extend smoothly and retract
smoothly when manually operated. You
can remove the front of the ice transfer
bucket to see the bottom of the tank and
see the ice shearing gate. This will allow
you to see if there are any obstructions
blocking the ice transfer bucket from
extending.
Yes
Ice bucket failed to retract. The bucket
should extend smoothly and retract
smoothly when manually operated.
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Mr. Zippy Alarm Errors
Alarm Description
Service
Explanation
Yes
Agitator failed to rotate during the vend
08
Agitator Rotation Fault
operation or during the timed sequence.
Test through Red Lion screen F7
Observe the rotation of the sprocket under
the ice storage tank. If the sprocket does
not rotate then check the motor and gear
box for proper operation. If the sprocket
does rotate but the ice does not fall when
the ice shearing gate is open then you will
need to empty the ice tank to observe the
blades turning. You can remove the front of
the Ice transfer bucket to see the bottom of
the tank and see the ice shearing gate.
Check to make sure all the bolts are tight
and that the keyway is in place.
Yes
The bag delivery system failed to deliver a
09
Bag Delivery Fault
bag.
Test through Red Lion screen F7
Yes
The air cylinder failed to extend to pickup
10
Bag Pickup Extend Fault
an ice bag. The air pressure is set too low
Test through Red Lion screen F7
or the prox failed to detect the air cylinder
movement.
Yes
The air cylinder failed to retract to pickup an
11
Bag Pickup Retract Fault
ice bag. The air pressure is set too low or
Test through Red Lion screen F7
the prox failed to detect the air cylinder
movement.
Yes
The air cylinder failed to swing the bag
12
Swing Arm Fault
delivery arm. The air pressure is set too low
Test through Red Lion screen F7
or the prox failed to detect the air cylinder
movement.
Yes
The air cylinder failed to swing the bag
13
Swing Arm Fault
delivery arm. The air pressure is set too low
Test through Red Lion screen F7
or the prox failed to detect the air cylinder
movement.
Yes
The
bag delivery system failed to deliver a
14
Bag Pusher Fault
bag. The air pressure is set too low or the
Test through Red Lion screen F7
prox failed to detect the air cylinder
movement.
No
Check that the ice gate on the ice vending
15
Ice Gate Open Fault
will open and close properly. This can be
Test through Red Lion screen F7
caused by a customer sticking their hand in
the way when the gate is trying to open.
The air pressure is set too low or the prox
failed to detect the air cylinder movement.
No
Check that the ice gate on the ice vending
16
Ice Gate Close Fault
will open and close properly. This can be
Test through Red Lion screen F7
caused by a customer sticking their hand in
the way when the gate is trying to close.
The problem is normally either the air
pressure is set too low or the prox failed to
detect the air cylinder movement.
Jim Coleman Company
Page 4 of 12
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Mr. Zippy Alarm Errors
Alarm Description
Service
Explanation
No
Bag gate failed to open. This can be
17
Bag Gate Open Fault
caused by a customer sticking their hand
Test through Red Lion screen F7
in the way when the gate is trying to
open. The problem is normally either the
air pressure is set too low or the prox
failed to detect the air cylinder movement.
No
Bag gate failed to close. This can be
18
Bag Gate Close Fault
caused by a customer sticking their hand
Test through Red Lion screen F7
in the way when the gate is trying to
close. The problem is normally either the
air pressure is set too low or the prox
failed to detect the air cylinder movement.
No
Check operation of 10 lb push button.
19
10 lb Push Button Stuck
Make sure it operates properly and
replace if it does not.
No
Check operation of 20 lb push button.
20
20 lb Push Button Stuck
Make sure it operates properly and
replace if it does not.
No
Check operation of the ice dispense push
21
Dispense Push Button Stuck
button. Make sure it operates properly
and replace if it does not.
Yes
This alarm shuts down the machine and
22
Machine Out of Service
will need a manual reset. Press the alarm
key to look at the alarm that shows the
root cause of the problem.
Yes
The floor drain is clogged. Please find the
23
Drain High H20 Fault
obstruction and make sure the floor is
drained properly. Please check for
possible water leaks that could cause
machine to fill with water. If the floor is not
flooded then check the float switch for
proper operation. Sanitize the machine
completely if the floor is flooded.
Yes
The bag delivery system failed to deliver
24
Bag Sequence Fault
a bag. Check the bag delivery system.
Test through Red Lion screen F7
Yes
Agitator failed to rotate during the vend
25
Agitator Sequence Fault
operation or during the timed sequence.
Test through Red Lion screen F7
Observe the rotation of the sprocket
under the Ice storage tank. If the sprocket
does not rotate then check the motor and
gear box for proper operation. If the
sprocket does rotate but the ice does not
fall when the ice shearing gate is open
then you will need to empty the ice tank
to observe the blades turning. Check to
make sure all the bolts are tight and that
the keyway is in place.
Jim Coleman Company
Page 5 of 12
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Mr. Zippy Alarm Errors
Alarm Description
26
Coin Dispense Fault
35
Service
Explanation
Yes
The dispenser failed to dispense a coin.
Do not remove coin dispenser or hopper
from the base unless the power has been
turned off. Check the coin dispenser for
foreign objects and clean as necessary.
Yes
Check the ice storage tank for ice. If the
Low Ice Detected
level of ice is less that 12” then this alarm
will shut down the machine. Check the ice
maker to make sure the ice maker is
producing ice. If the ice maker is not
producing ice check the water pressure
and electricity coming into the ice maker.
See the owner’s manual on the ice maker
for trouble shooting.
Yes
Check the air compressor. Also drain the
Low Air Pressure
air compressor tank. You should have a
minimum of 70 psi.
Yes
The bag delivery system failed to deliver
Bag Dispense Alarm
a bag. Check the bag delivery system.
Test through Red Lion screen F7
Yes
The eyes failed to detect ice in the ice
No Ice Transfer Bucket
transfer bucket when the ice shearing
gate opened. Check to see if there is ice
in the tank. Also clean the eyes on the
transfer bucket. Check the operation of
the eyes to make sure they are operating
normally.
Yes
The conveyor failed to reach the top prox
Conveyor Top Fault
within 5 seconds of running. Check the
Test through Red Lion screen F7
keyway on the conveyor motor. Also
check the top prox for proper operation.
Yes
The conveyor failed to reach the bottom
Conveyor Bottom Fault
prox within 5 seconds of running. Check
Test through Red Lion screen F7
the keyway on the conveyor motor. Also
check the bottom prox for proper
operation.
No
Check operation of the ice dispense push
Ice Dispense Push Button
button. Make sure it operates properly
and replace if it does not.
No
This alarm is displayed when the Red
Low Bag Magazine
Lion count shows less than 10 bags in
inventory. Add Ice bags to bag magazine.
Press the button on Red Lion to tell it that
you have added bags.
No
Spare
36
Water Vend Alarm
27
28
29
30
31
32
33
34
Jim Coleman Company
Page 6 of 12
Yes
Water window failed to dispense water for
customer. Check water pressure to vend
window and check for proper operation.
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
2. Water Vend
•
Water Tank over flowing? This is caused by the float switches in the water tank either
being stuck or not operating properly. This can also be caused by the toggle switch on
front of the RO system being turned on. Check operation of float switches and replace if
defective.
•
Customer did not receive the proper amount of water when purchased? If this
happens the computer will refund the money to the customer and shut down that side of
the water vending machine. This is normally caused by a clogged water filter on the
water vending side. Replace clogged filter and test both vending windows at the same
time. You should not see a reduced flow of water when both vending water stations are
operating at the same time.
•
Water Tank is empty. This is caused by the RO system is either not producing any
water or is not producing enough water to keep up with demand. Look at the product
flow meter on the RO system and see how much water the RO system is producing. The
flow meter should show about 1 gpm. If the flow is about 1gpm then the tank should refill
and the unit will go back in service. You will need to manually reset the water vend door
so that it will start selling water again. If the flow meter indicates very low production
such as .2 to.6 gpm then you will need to consult the RO owner’s manual and find the
cause of low production. Low production rates can be caused by hard water, worn out
pumps, clogged membranes, or bad pressure regulators.
•
One water vend window works properly but the other water vend window will not
dispense water. This is caused by the water vend computer shutting down one side
because it did not provide the customer with the proper amount of water when
purchased. The customer did not lose any money because the computer refunded the
money. You will need to reset the computer mounted on the back side of the water vend
door. By resetting the computer this will allow you to test the water vend window to see
what caused the problem.
•
Water Softener is not producing soft water. You need to check the hardness of the
water coming into the softener. Then check the hardness of the water coming out of the
softener. The softener should reduce the water hardness to about 1 grain hardness or
less. Make sure the softener is plugged in and is programmed correctly based upon the
incoming water hardness. The softener will cycle itself based upon the number of gallons
that flows through it. So if the water is very hard and the softener is not programmed
properly it will not cycle itself at the proper time. If the softener was unplugged or did not
have salt in the brine tank you will need to cycle the softener to allow it to start producing
soft water. Please make sure there is adequate salt in the brine tank and then remove
the cover on the softener and turn the knob according to the owners manual to cause
the softener to go through a cycle. Observe the operation of the softener this will take
about 45 -60 minutes to complete a cycle. Refer to the softeners owners’ manual for a
detailed description on all the steps that the softener goes through. After the softener
has gone through a cycle you will need to test the water again for hardness. Since the
softener is a dual tank system you might need to cycle both sets of tanks in order to get
both tanks recharged and ready to make soft water.
•
Charcoal filter not removing chlorine. If the charcoal filter is not removing the chlorine
you have two choices. Your first choice is to replace the entire carbon filter with all new
housing; second choice requires more labor but is less expensive. The second choice is
Jim Coleman Company
Page 7 of 12
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
to remove the filter and just replace the charcoal only. In the owner’s manual are
detailed instructions on how to accomplish this.
•
Ozone generator not producing ozone. Check to see if the ozone generator is getting
power with a volt meter. The ozone generator should be receiving 9-12 v dc. If it is not
receiving the correct power then look to see what wiring may have come loose that
would cause no voltage to the Ozone generator. If the ozone generator is receiving the
correct electricity and it still is not working then you will need to replace the ozone
generator since this is not a repairable item.
•
RO system is producing high TDS (total dissolved solids) water. The RO system
should remove 98-99% of the TDS out of the water. You should first check the incoming
TDS of the water and then test the product water coming out to the RO system. If the
incoming water is 300 ppm TDS then the RO system will reduce this to 3 to 6 ppm of tds.
If your RO system is not producing this quality of water you should check the
membranes on your system. The reason membranes go bad is caused by hard water or
water that has chlorine in it. Some membranes can be cleaned and returned back to
service however a factory trained specialist will need to test the membranes to
determine this.
•
RO system not producing enough water. Your RO system should produce about 1
gpm of product water. If your system is producing about .4 to .6 then you need to check
several things. First check to see if your water is soft going into the system. Also check
the pressure setting on the regulator and how much water is being rejected. The normal
rule is you will reject twice the amount of product water you produce. If you are not
rejecting enough water this will cause the membrane to slowly clog up.
Jim Coleman Company
Page 8 of 12
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Input and Output card listing on Omron CPU
Channel 1 ( Input located on CPU in Control Panel)
Channel
Description
Normal
Explanation
1.00
side a water being filled
Off
Comes on when side A is dispensing
water for income monitoring
1.01
side b water being filled
Off
Come on when side B is dispensing
water for income monitoring
1.02
float switch on floor
Off
Float switch mounted under ice tank to
detect when floor drain is clogged
1.03
air pressure switch
Off
Senses air pressure from air
compressor
1.04
water vending out of service
Turns off when out of service
ON
1.05
agitator VFD drive fault
Off
Signal from VFD to tell CPU there is a
problem
1.06
conveyor drive fault
Off
Signal from VFD to tell CPU there is a
problem
1.07
ice sensor- thermostat to detect ice ON
Thermostat mounted on wall with
remote probe mounted on ice tank wall
Channel 100 ( Output located on CPU in Control Panel)
Channel
Description
Normal
Explanation
100.00
ice shear gate open
Off
Turns on to open ice shear gate
100.01
extend ice transfer bucket
Off
Turns on to extend ice transfer bucket
100.02
move swing arm to bag position
Off
Turns on to move swing arm to pick up
a bag
100.03
move swing arm to dispense
This is on to allow the swing arm
ON
position
cylinder to stay in the dispense position
100.04
extend bag pick up cylinder
This is on to allow the bag pickup
ON
cylinder to stay in the dispense position
100.05
retract bag pick up cylinder
Off
This turns on to retract bag pick up
cylinder
100.06
dispense extend cylinder
Off
This turns on to dispense a bag.
100.07
dispense retract cylinder
Off
This turns on to retract the dispense
cylinder.
Channel 101 (Output located on CPU in Control Panel)
Channel
Description
Normal
Explanation
101.00
open ice dispense gate
off
Turns on to open ice dispense gate
101.01
open bag dispense gate
off
Turns on to open bag gate
101.02
agitator forward direction
off
Turns on to rotate agitator blades
forward.
101.03
agitator reverse direction
off
Turns on to rotate agitator blades
reverse direction.
101.04
agitator speed select bit
off
Turns on to allow the agitator blades to
start slowly.
101.05
raise conveyor bucket
off
Turns on to raise conveyor bucket.
101.06
lower conveyor bucket
off
Turns on to lower conveyor bucket.
101.07
vacuum motor
off
This turns on to start vacuum motor to
pick up ice bag.
Jim Coleman Company
Page 9 of 12
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Channel 2008 (Remote Input card located in Control Panel)
Channel
Description
Normal
Explanation
2008.00 prox on agitator sprocket
Off or
This prox is mounted under the tank to
tell CPU the position of the agitator
ON
blades
2008.01 prox on upper conveyor
Off
This prox is mounted at the top of the
conveyor to tell CPU to stop conveyor
motor
2008.02 prox on lower conveyor
This prox is mounted at the bottom of
ON
the conveyor to tell CPU that bucket is
at home
2008.03 prox on ice transfer bucket extend
Off
This prox tells CPU ice transfer bucket
is extended
2008.04 prox on ice transfer bucket retract
This prox tells CPU Ice transfer bucket
ON
is retracted
2008.05 prox on ice shear gate extend
This prox tells CPU that ice shear gate
ON
(closed)
is closed
2008.06 prox on ice shear gate retract
Off
This prox tells CPU that ice shear gate
(open)
is open
2008.07 eyes on ice transfer bucket detect
These eyes tell CPU that the ice did fall
ON
ice
into the ice transfer bucket
2008.08 water level switch in water tank
This is the low water switch in the RO
ON
tank to detect when tank is empty
2008.09 vacuum switch (bag detect)
Off
This turns on when it detects a vacuum
once it grabs a bag
2008.10 prox on bag dispense cylinder
Off
Prox on bag dispense cylinder to tell
extend
CPU that cylinder is extended
2008.11 prox on bag dispense cylinder
Off
Prox on bag dispense cylinder to tell
retract
CPU that cylinder is retracted
2008.12 prox on bag pickup cylinder extend
Prox on bag pickup cylinder to tell CPU
ON
that cylinder is extended
2008.13 prox on bag pickup cylinder retract
Off
Prox on bag pickup cylinder to tell CPU
that cylinder is retracted
2008.14 prox on swing arm cylinder at bag
Off
Prox on swing arm cylinder to tell CPU
position
that cylinder is at bag pickup position
Prox on swing arm cylinder to tell CPU
2008.15 prox on swing arm cylinder at
ON
that cylinder is at dispense position
dispense position
Jim Coleman Company
Page 10 of 12
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Channel 2009 (Remote Input card located on ice door)
Channel
Description
Normal
Explanation
2009.00 10 or 20lb ice bag switch
Off
This switch tells the CPU that
customer selected a bag of ice
2009.01 20 lb bulk switch
Off
This switch tells CPU customer
selected bulk ice
2009.02 ice dispense switch
Off
This switch tells CPU to open ice
dispense gate and deliver ice
2009.03 refund button
Off
Turns on when refund switch is
pressed
2009.04 coins delivered from hopper signal
Off
Coin hopper sends a signal for
every quarter dispensed
2009.05 prox on bag delivery gate (open)
Off
This prox tells CPU that bag deliver
gate is open
2009.06 prox on bag delivery gate (closed)
This prox tells CPU that bag
ON
delivery gate is closed
2009.07 prox on ice delivery gate (open)
Off
This prox tells CPU that ice delivery
gate is open
2009.08 prox on ice delivery gate (closed)
This prox tells CPU that ice delivery
ON
gate is closed
2009.09 ice funnel eyes
These eyes tell CPU when ice is
ON
inside the funnel
2009.10
Off
2009.11 input from bill acceptor
Off
Flashes once for each bill
accepted.
2009.12 input from token acceptor
Off
Flashes once for each token
accepted
2009.13 input from quarter acceptor
Off
Flashes once for each quarter
accepted
2009.14 coin sensor in coin hopper
This sensor tells CPU that you
ON
have coins in coin hopper
2009.15 high coin sensor in coin hopper
Off
Turns on when you coin hopper is
full
Channel 2001 (Remote Output card located on Ice door)
Channel
Description
Normal
Explanation
2001.00 water vending door 24vac power
Always on to allow water vending
ON
door to operate.
2001.01
Off
2001.02 ice plunger cylinder
Off
Turns on to extend ice plunger
cylinder
2001.03
Off
2001.04 coin acceptor power 24vdc
Provides power to coin acceptor
ON
2001.05 bill acceptor power 24vdc
Provides power to bill acceptor.
ON
2001.06 audible horn
Off
Turns on to sound horn
2001.07
Off
2001.08 display - out of service message
Off
Turns on out of service message
2001.09 display – correct change message
Off
Turns on use correct change
message
Jim Coleman Company
Page 11 of 12
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
2001.10
2001.11
reset message display
dispense quarter from hopper
Off
Off
2001.12
message- increment coin display
Off
2001.13
message- 10lb bag selected
Off
2001.14
message- 20lb bulk selected
Off
2001.15
message – dispense ice
Off
Jim Coleman Company
Page 12 of 12
Turns on to reset message display
Signal to coin hopper to dispense
one quarter
Shows the amount of money
deposited by customer
Turns on to display 10lb bag
selected message on display
Turns on to display 20lb bulk
selected message
Turns on to display dispense ice
message
Troubleshooting
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Reverse Osmosis Manual
System Description
The Reverse Osmosis System is engineered with the best available components on the market to
deliver purified water. Years of trouble free service, with little maintenance, can be expected.
SPARKLE REVERSE OSMOSIS UNIT RATINGS
Typical recovery rates and settings for a Sparkle R.O. System are as follows:
System Size
1500 GPD
System
Product Water
Minimum GPM
.7
Maximum GPM
.9
Reject Water
Minimum GPM
1.4
Maximum GPM
1.5
Never exceed the above listed recovery rates or severe fouling will result and membrane warranty
will be void. It is best and most economical to have a high rate of reject water, than to take a
chance in damaging membranes by pushing the R.O. unit too hard.
If the unit is not producing the anticipated amount of product water, the following factors can
usually be contributing to its failure:
A.TDS (Total Dissolved Solids) above 300 PPM
B.Hard water
If there are any problems, questions, or concerns on setting up this unit contact the company at
1-800-999-9878 or 1-713-683-9878.
Jim Coleman Company
Page 1 of 3
Reverse Osmosis System
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
COMPUTER OPERATION DESCRIPTION
PRODUCTION
Computer receives a signal from upper float switch that tank is low on water. If signal is present
over 10 seconds the computer will turn on water solenoid valve to production pump. After 10
seconds the computer then determines that if the water pressure is above 20 PSI, to turn on the
production pump motor starter. If at any time the computer does not receive a signal from the
pressure switch that water pressure is above 20 PSI, then the computer will turn off the
production pump.
DELIVERY
Water delivery is accomplished using a re-pressurization pump. This pump monitors the
delivery pressure of the water and maintains a constant 60 psi on the system lines. The pump
turns on when the pressure drops below the preset amount. Safe guards are in place in the
event there is no water available. Power and the run light on the Omron computer must be on
for the computer to function properly.
Jim Coleman Company
Page 2 of 3
Reverse Osmosis System
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
Mr. Zippy’s RO Unit
Input/Output Schedule for Troubleshooting the RO system.
NO.
INPUTS
LIGHTS
LIGHT OPERATION
0000
Water Pressure Switch
On
Turns off when pressure is low
0001
Low Water Switch in RO tank
Off
Turns on when Tank Runs Empty
0002
Mid level Switch in RO tank
On
Turns on when Tank needs filling
0003
Upper water Switch in RO tank
Off
Turns off when Tank is full
0004
Air Pressure Switch
Off
Turns on when air pressure is low
0005
RO delivery pressure switch
Off
0006
High TDS input
Off
Turns on when delivery water pressure
drops
Turns on when Hi TDS is detected
0007
Signal from Ice PLC
On
Turns off to shut down water side
OUTPUTS
LIGHTS
LIGHT OPERATION
On
Turns off to stop water operation
1001
Fault signal to water door
(12vdc)
Fault signal to Ice PLC (24vdc)
On
Turns off to shut down ice operation
1002
RO Production Pump
Off
Turns on for RO production
1003
Flush solenoid (24vac)
Off
Turns on when flushing
1004
Incoming water sol. (24vac)
Off
Turns on during RO production
1005
Low RO product press lite
(24vac)
Tank Empty lite (24vac)
Off
Turns on when product press is low
Off
Turns on when tank is empty
Low incoming water pressure
lite (24vac)
Off
Turns on when there is unsufficient
water pressure for production
1000
1006
1007
Jim Coleman Company
Page 3 of 3
Reverse Osmosis System
Rev. 7/21/10
Model 9000/9100/9500
Service Manual
IMPORTANT: Fill in Pertinent Information on Page 3 for Future Reference
Table of Contents
Job Specification Sheet.......................................................................................................................................... 3
Equipment Configuration........................................................................................................................................ 4
General and Commercial Installation Checklist...................................................................................................... 5
Valve to Tank Installation Instructions..................................................................................................................... 7
Regeneration Cycle Program Setting Procedure................................................................................................... 8
Time Brine Refill and Meter Setting Procedure...................................................................................................... 9
9000/9100/9500 Electro Mechanical Timer Assembly.......................................................................................... 12
Power Head Assembly......................................................................................................................................... 14
9000 Control Valve Assembly............................................................................................................................... 16
9100 Control Valve Assembly............................................................................................................................... 18
9500 Control Valve Assembly............................................................................................................................... 20
1600 Brine Valve System (for 9500)..................................................................................................................... 22
1700 Brine Valve System (for 9500)..................................................................................................................... 23
9000 Second Tank Assembly............................................................................................................................... 24
9100 Second Tank Assembly............................................................................................................................... 25
9500 Second Tank Assembly............................................................................................................................... 26
3/4” Meter Assembly............................................................................................................................................. 27
1” Meter Assembly................................................................................................................................................ 28
1 1/2” Meter Assembly.......................................................................................................................................... 29
9000/9100 Bypass Valve Assembly...................................................................................................................... 30
Bypass Valve Assembly........................................................................................................................................ 31
1710 Brine Valve System (for 9500)..................................................................................................................... 32
2300 Safety Brine Valve....................................................................................................................................... 33
2310 Safety Brine Valve....................................................................................................................................... 34
2350 Safety Brine Valve....................................................................................................................................... 35
Troubleshooting.................................................................................................................................................... 36
General Hints for Meter Control........................................................................................................................... 37
9000/9100/9500 Meter Flow Data........................................................................................................................ 38
9000/9100 Injector Flow Data (1600 Series Injectors)......................................................................................... 39
9500 Injector Flow Data (1600 & 1700 Series Injectors)...................................................................................... 40
9000 Control Dimensions..................................................................................................................................... 41
9100 Control Dimensions..................................................................................................................................... 42
9500 Control Dimensions..................................................................................................................................... 43
Water Conditioner Flow Diagrams........................................................................................................................ 44
9000/9500 Wiring Diagram................................................................................................................................... 46
Service Assemblies.............................................................................................................................................. 47
IMPORTANT PLEASE READ:
•
The information, specifications and illustrations in this manual are based on the latest information available at the time of
printing. The manufacturer reserves the right to make changes at any time without notice.
•
This manual is intended as a guide for service of the valve only. System installation requires information from a number of
suppliers not known at the time of manufacture. This product should be installed by a plumbing professional.
•
This unit is designed to be installed on potable water systems only.
•
This product must be installed in compliance with all state and municipal plumbing and electrical codes. Permits may be
required at the time of installation.
•
If daytime operating pressure exceeds 80 psi, nighttime pressures may exceed pressure limits. A pressure reducing valve must
be installed.
•
Do not install the unit where temperatures may drop below 32°F (0°C) or above 125°F (52°C).
•
Do not place the unit in direct sunlight. Black units will absorb radiant heat increasing internal temperatures.
•
Do not strike the valve or any of the components.
•
Warranty of this product extends to manufacturing defects. Misapplication of this product may result in failure to properly
condition water, or damage to product.
•
A prefilter should be used on installations in which free solids are present.
•
In some applications local municipalities treat water with Chloramines. High Chloramine levels may damage valve components.
•
Correct and constant voltage must be supplied to the control valve to maintain proper function.
Job Specification Sheet
Job Number: __________________
Model Number: ________________
Water Test: ___________________
Capacity Per Unit: ______________
Mineral Tank Size: ___________ Diameter: ___________ Height: __________
Brine Tank Size & Salt Setting per Regeneration: __________
9000/9100/9500 Control Valve Specifications:
1. Type of Timer:
A. 82 minute available regeneration time, 1/15 RPM
B. 164 minute available regeneration time, 1/30 RPM
2. Type of Meter:
Mechanical Valves (Gallon Settings)
Meter
Standard Range
3/4”
125 - 2,125
1”
310 - 5,270
1-1/2”
625 - 10,625
Extended Range
625 - 10,625
1,150 - 26,350
3,125 - 53,125
3. Timer Gallon Setting: _______________Gallons
4. Regeneration Program Setting:
A. Backwash: ____________________ Minutes
B. Brine and Slow Rinse: ___________ Minutes
C. Rapid Rinse: __________________ Minutes
D. Brine Tank Refill: _______________ Minutes
5. Drain Line Flow Control: ____________ gpm
6. Brine Refill Rate: __________________ gpm
7. Injector Size: _____________________ Page Equipment Configuration
9000/9100 Equipment Configuration
9500 Equipment Configuration
Page General and Commercial Installation Checklist
1. Place the softener tank where you want to install the unit.
NOTE: Be sure the tank is level and on a firm base.
2. During cold weather it is recommended that the installer warm the valve to room temperature before
operating.
3. Perform all plumbing according to local plumbing codes.
— Use a 1/2” minimum pipe size for the drain.
— Use a 3/4” drain line for backwash flow rates that exceed 7 gpm or length that exceeds 20’ (6 m).
4. Both tanks must be the same height and diameter and filled with equal amounts of media.
5. The distributor tube must be flush with the top of each tank. Cut if necessary. Use only non-aerosol silicone
lubricant.
6. Lubricate the distributor o-ring seal and tank o-ring seal. Place the main control valve on one tank and the
tank adapter on the second tank.
NOTE: If required, solder copper tubing for tank interconnection before assembling on the main control valve
and tank adapter. Maintain a minimum of 1” distance between tanks on final assembly.
7. Solder joints near the drain must be done before connecting the Drain Line Flow Control fitting (DLFC).
Leave at least 6” (152 mm) between the DLFC and solder joints when soldering pipes that are connected on
the DLFC. Failure to do this could cause interior damage to DLFC.
8. Use only Teflon tape on the drain fitting.
9. Be sure the floor under the salt storage tank is clean and level.
10. Place approximately 1” (25 mm) of water above the grid plate. If a grid is not utilized, fill to the top of the air
check in the salt tank. Do not add salt to the brine tank at this time.
11. On units with a bypass, place in Bypass position.
— Turn on the main water supply.
— Open a cold soft water tap nearby and let water run a few minutes or until the system is free of foreign
material (usually solder) resulting from the installation. Close the water tap when water runs clean.
12. Place the bypass In Service position and let water flow into the mineral tank. When water flow stops, slowly
open a cold water tap nearby and let water run until air is purged from the unit. Then close tap.
Electrical
13. Make all electrical connections according to codes. Plug the valve into an approved power source. Do not
insert meter cable into the meter yet.
14. Tank one has control valve and tank two has adapter.
15. Look on the right side of the control valve, it has indicators showing which position the control valve is in
during Regeneration and which tank is In Service.
NOTE: Make sure the meter cable is not inserted in the meter dome. Swing the timer out to expose the
program wheel (to swing timer out) grab onto the lower right corner of timer face and pull outward.
Page General and Commercial Installation Checklist
Control Valve Position Indicators
Timer
Program Wheel
16. Cycle timer into backwash position. Turn manual knob so that the micro switch rides on the first set of pins.
— In this position the tanks switch (lower piston) and the control valve moves to the backwash position
(upper piston).
— Wait until the positioning of upper and lower pistons stops before advancing the timer further. If advanced
too fast the control will not home into the In Service position (it will not advance to any other position). To correct this, rotate the manual knob back to In Service and start again into backwash.
NOTE: Once valve positions itself into the backwash cycle, the homing circuit locks in.
17. With all the air backwashed, slowly cycle the timer to the brine position; rapid rinse; and brine tank refill.
Wait for the control drive motor to position itself in each cycle and stop, before advancing on to the next
position.
18. Once back in the In Service position, cycle the control valve again into the backwash position. The tanks
switch again, and air head backwashes out of the other tank. Cycle the control back to the In Service position.
Leave the timer in the open position. DO NOT insert meter cable yet.
NOTE: Two motors are available.
1/15 RPM has 82 minute regeneration time.
1/30 RPM has 164 minute regeneration time.
Page General and Commercial Installation Checklist
WATER PRESSURE: A minimum of 25 pounds of water pressure is required for regeneration valve to operate
effectively.
ELECTRICAL FACILITIES: A continuous 115 volt, 60 Hertz current supply is required. Make certain the current
supply is always hot and cannot be turned off with another switch.
EXISTING PLUMBING: Condition of existing plumbing should be free from lime and iron buildup. Piping that is
built up heavily with lime and/or iron should be replaced. If piping is clogged with iron, a separate iron filter unit
should be installed ahead of the water softener.
LOCATION OF SOFTENER AND DRAIN: The softener should be located close to a drain.
BY-PASS VALVES: Always provide for the installation of a by-pass valve.
Valve to Tank Installation Instructions
1. Spin the valve onto the tank, ensuring the threads are not cross-threaded..
NOTE: All Fleck® valves are right-hand threads, or clockwise, to install
2. Rotate the valve freely without using force until it comes to a stop (this position is considered zero).
3. Rotate the valve clockwise from zero, between ¼ turn and ½ turn (see the diagram below)..
.
NOTE: If lubricant is required, a silicone compound is strongly recommended. Dow Corning® Silicone
Compound (available from Fleck®), is recommended for best possible results. Dow Corning® 7 Release
Compound is used in the manufacture of Fleck® control valves. The use of other types of lubricants may
attack the control’s plastic or rubber components. Petroleum-based lubricants can cause swelling in rubber
parts, including o-rings and seals. .
Part No.
16174
16586-8
Description
Silicone, 2 oz Tube
Silicone, Dow #7 8 LB
Page Regeneration Cycle Program Setting Procedure
Setting the Regeneration Cycle Program
The Regeneration cycle program on the water conditioner is preset at the factory. However, portions of the cycle
or program time may be lengthened or shortened for local conditions or system design.
1.
2.
3.
Expose cycle program wheel by grasping timer in lower right hand corner and pulling. This releases snap
retainer and swings timer to the left
NOTE: Meter cable must be removed from meter dome before opening timer.
Remove the program wheel by grasping program wheel and squeezing protruding lugs towards center.
Lift program wheel off timer.
— Switch arms may require movement to facilitate removal.
Return timer to closed position by engaging snap retainer in back plate.
— Make certain all electrical wires locate above snap retainer post.
Changing Length of the Backwash Time
Looking at the numbered side of the program wheel, the group of pins starting at zero determines the length of
time the unit backwashes.
Example: If there are six pins in this section, the time of backwash is 12 minutes (2 minutes per pin). To
change the length of backwash time, add or remove pins as required.
— The number of pins multiplied by two equals minutes of backwash.
Changing Length of Brine and Rinse Time
The group of holes between the last pin in the backwash section and the second group of pins determines the
length of time that a unit will brine and rinse (2 minutes per hole).
To change the length of brine and rinse time, add or remove pins in the rapid rinse group of pins to increase or
decrease the number of holes in the brine and rinse section.
— The number of holes multiplied by two equals minutes of brine and rinse.
Changing Length Of Rapid Rinse
The second group of pins on the program wheel determines the length of time the water conditioner rapid rinses
(2 minutes per pin). To change the length of rapid rinse time, add or remove pins at the higher numbered end of
this section as required.
— The number of pins multiplied by two equals minutes of rapid rinse.
NOTE: Program wheels with 0–82 minute cycle times, use one minute per pin or hole to set Regeneration
times. The layout of pins and holes on the program wheel follow the same procedure as on this page.
Changing Length of Brine Tank Refill Time
The second group of holes on the program wheel determines the length of time the water conditioner refills the
brine tank (2 minutes per hole).
To change the length of refill time, move the two pins at the end of the second group of holes as required.
The Regeneration cycle is complete when the two pin set at end of the brine tank refill section trips the outer
micro-switch. The program wheel, however, continues to rotate until the inner micro-switch drops into the notch on
the program wheel.
Programming
1. The control valve is set at the factory for backwash; brine and slow rinse; rapid rinse and brine tank fill times.
Change any of these times by repositioning the pins and holes or adding more pins.
NOTE: Two speed timer motors are available
1/15 RPM has 82 minute Regeneration Time and each pin or hole equals one minute.
1/30 RPM has 164 minute Regeneration Time and each pin or hole equals two minutes.
Page Time Brine Refill and Meter Setting Procedure
2. The control valve has a separate brine tank fill cycle.
— Calculate the desired salt setting using the brine line flow control rate of refill (in gpm) multiplied by the
timer setting. Then, using one gallon of fresh water dissolving approximately 3 lbs salt, calculate the
refill time.
Example: A desired 30 lbs salt setting:
The unit has a 1.0 gpm refill rate so a 10 gallon fill is required.
10 gallons x 3 lbs/gals = 30 lbs salt
Set the timer refill section at 10 minutes.
10 minutes x 1.0 gpm = 10 gallon fill
NOTE: There must always be two pins at the end of a refill time to stop the fill cycle. With the Regeneration
times set, place timer back to its original position, making sure the lower right hand corner snaps back into the
backplate and the meter cable slides through the backplate and does not bind.
3. Setting the gallon wheel.
Knowing the amount of resin in each tank and the salt setting per Regeneration, calculate the gallons available,
using the following capacities as a guide:
(capacity per ft3 x ft3 of resin per tank) = gallons available
compensated hardness of H2O
NOTE: Based on tank size:
More resin increases capacity, less resin decreases capacity.
More salt increases capacity, less salt decreases capacity.
Example:
Tank Diameter
Compensated Hardness
ft3 Resin (based on flow rate)
lbs of Salt
Capacity per ft3
=
=
=
=
=
16”
35 grains per gallon (tested sample)
4
8
24,000
(24,000 x 4 ft3 of resin per tank) = 2,740 gallons available before regeneration
35 grains
DO NOT SET THIS FIGURE - GO TO STEP 4
— Because the control valve regenerates with soft water from the other tank, subtract the water used for regeneration. Take each regeneration cycle and calculate the water used.
Example: Unit is set for a 16” diameter tank with 4 ft3 of resin and salted at 8 lbs. per ft3, 7 gpm backwash,
#3 injector, 1.0 gpm brine refill, and 60 psi and timer set for 10 min. backwash, 60 min. brine and rinse,
10 min. rapid rinse, 10 min. brine tank fill.
Backwash
Brine and Rinse
Rapid Rinse
Brine Tank Fill
10 minutes x 7.0 gpm =
60 minutes x 1.0 gpm =
10 minutes x 7.0 gpm =
10 minutes x 1.0 gpm =
Total Regeneration Water =
70.0 gallons
60.0 gallons
70.0 gallons
10.0 gallons
210.0 gallons
With the 2740 gallons available calculated in Step 3, subtract the Regeneration water used from the total
water available.
2740 gallons available - 210 gallons used = 2530 gallons
(in Regeneration, Step 4)
Page Time Brine Refill and Meter Setting Procedure
4. Set meter wheel at approximately 2530 gallons. Lift the inner dial of the meter program wheel so that you can
rotate it freely. Position the white dot opposite the 2530 gallon setting.
NOTE: There is a slight delay between the time the meter zeros out and the cycle starts. Units using the:
1/15 RPM motor, 82 minute Regeneration Time has a 9 minute delay
1/30 RPM motor, 180 minute Regeneration Time has an 18 minute delay.
NOTE: This delay period is not critical on residential equipment. However, take this factor into consideration.
for commercial applications by subtracting continuous flows for 9 minutes or 18 minutes from water available.
5. Insert meter cable into meter.
6. Check bypass.
7. Plug in unit.
Page 10
Notes
Page 11
9000/9100/9500 (3200 Series)
Electro Mechanical Timer Assembly
For Service Assembly Numbers, See the Back of this Manual
Page 12
9000/9100/9500 (3200 Series)
Electro Mechanical Timer Assembly
Item No.
Quantity
Part No.
Description
1.................... 1..................... 13870-03..................Housing, Timer, 9000
2.................... 1..................... 17870.......................Label, Indicator, 9000 Timer
3.................... 1..................... 15465.......................Label, Caution
4.................... 1..................... 16930.......................Label, Instruction
5.................... 1..................... 15227.......................Plate, Clutch, Actuator
6.................... 1..................... 10300.......................Screw, Slot Hex Wsh, 18-8 x 3/8
7.................... 1..................... 17513.......................Clip, Spring
8.................... 1..................... 15407.......................Washer, Plain, #4
9.................... 1..................... 15228.......................Spring, Return
10.................. 1..................... 16270-10..................Program Wheel Assy, 9000 3/4
16270-50..................Program Wheel Assy, 9000/9500
16270-30..................Program Wheel Assy, 9000, 1” Std
16270-40..................Program Wheel Assy, 9000, 1” Ext
16270-50..................Program Wheel Assy, 9000/9500
16270-60..................Program Wheel Assy, 9500
11.................. 1..................... 13806.......................Retainer, Program Wheel
12.................. 1..................... 13748.......................Screw, Flt Hd St, 6-20 x 1/2
13.................. 2..................... 11999.......................Label, Button
14.................. 1..................... 15223.......................Actuator, Cycle
15.................. 1..................... 13886.......................Know, 3200
16.................. 4..................... 13296.......................Screw, Hex Wsh, 6-20 x 1/2
17.................. 1..................... 17724.......................Program Wheel, Pinion Drive
18.................. 1..................... 17723.......................Clutch, Drive Pinion
19.................. 1..................... 14276.......................Spring, Meter Clutch
20.................. 1..................... 14253.......................Retainer, Clutch Spring
21.................. 3..................... 14087.......................Insulator
22.................. 1..................... 15314.......................Switch, Micro, Modified
23.................. 1..................... 15320.......................Switch, Micro, Timer
24.................. 2..................... 11413.......................Screw, Pan Hd Mach, 4-40 x 1 1/8
25.................. 1..................... 13018.......................Pinion, Idler
26.................. 1..................... 18563.......................Spring, Idler Shaft
27.................. 1..................... 13017.......................Gear, Idler
28.................. 1..................... 13164.......................Gear, Drive
29.................. 1..................... 13887.......................Plate, Motor Mounting
30.................. 1..................... 18743.......................Motor, 120V, 60 Hz 1/30 RPM, 5600
18824-1....................Motor, 230V, 50 Hz 1/30 RPM
19170.......................Motor, 120V 60 Hz 1/15 RPM
18825.......................Motor, 230V, 50 Hz 1/15 RPM Mallory
31.................. 2..................... 13278.......................Screw, Phil Hd Mach, 6-32 x 1/8 Steel Zinc
32.................. 1..................... 14265.......................Clip, Spring
33.................. 1..................... 15055.......................Timer, Main Drive Gear
34.................. 1..................... 19210-02..................Program Wheel Assy, 9000 1/15
19210-05..................Program Wheel Assy, 9000/3230
35.................. 23................... 15493.......................Pin, Spring, 1/16 x 5/8 SS
36.................. 1..................... 15203.......................Harness, 9000/9500, Timer
37.................. 2..................... 40422.......................Nut, Wire, Tan
Not Shown.... 1..................... 60320-02..................Switch Kit, 3200/9000 Timer Auxiliary
For Service Assembly Numbers, See the Back of this Manual
Page 13
Power Head Assembly
For Service Assembly Numbers, See the Back of this Manual
Page 14
Power Head Assembly
Item No.
Quantity
Part No.
Description
1........................2......................... 18728.............................Nut, Tinnerman, U Type, 8-32
2........................1......................... 11838.............................Power Cord, 6’ Fleck
11839.............................Power Cord, 12’ Fleck
40084-12........................Power Cord, 12’ U.S., Round, 120V Sys 5, 6, 7 &
2900/3150/3900 #4
11545-01........................Power Cord Assy, 4’ Black, Euro w/Terminals
14678.............................Power Cord, U.S., 220/60
19303-01........................Power Cord Assy, Australian w/Terminals
40085-12........................Power Cord, 12’ US, Round, 240V
19674.............................Transformer, 24V, 9.6VA Residential Valves
41475.............................Transformer, 24V, 9.6VA, European
3........................1......................... 15202.............................Harness, 9000/9500, Drive
14822.............................Harness, 2900
40041-06........................Harness, Low V, 9000/9500
4........................1......................... 15134.............................Gear Assy, Drive, 1/2” Stroke 9000/9500
5........................1......................... 15135.............................Gear, Drive, 9000
6........................1......................... 14896.............................Wheel, Geneva
7........................2......................... 40422.............................Nut, Wire, Tan
8........................2......................... 19367.............................Screw, Designer Cover, Thumb 8-32 Blank UV Stable Material
9........................1......................... 15175.............................Label, Shaft Position
10......................2......................... 14917.............................Ring, Retaining
11......................1......................... 15199.............................Plate, Ground, 9000/9500
12......................1......................... 14430.............................Screw, Hex Wsh St, 6 x 1/4 Type “B”
13......................2......................... 19160.............................Screw, Phil Pan, Thread 6-32 x 3/8 Type 23 Zinc
14......................1......................... 18737.............................Motor, 24V, 50/60 Hz, 1 RPM
18738.............................Motor, 120V, 50/60 Hz 1 RPM
18739.............................Motor, 220V, 50/60 Hz 1 RPM
15......................1......................... 15131.............................Backplate, 9000
17784-05........................Panel, Control, 9000/9500 ET
16......................2......................... 15172.............................Screw, Flt Hd Mach, 4-40 x 1 3/8 Steel Zinc Plate
17......................2......................... 10340.............................Washer, Lock #4, Zinc
18................................................. 10218.............................Switch, Micro
19......................1......................... 10339.............................Nut, Hex, 4-40 Zinc Plated
20......................1......................... 15331.............................Screw, Hex Wsh Mach, 10-24 x 3/4 410 S.S.
21......................2......................... 15133.............................Gear Assy, Drive, 3/4” Stroke
22......................1......................... 13547.............................Strain Relief, Flat Cord Heyco #30-1
23......................1......................... 15810.............................Ring, Retaining
24......................1......................... 15132.............................Cam, Triple
17331.............................Cam, 9500
17765.............................Cam Assy, Aux Switch, 9500
25......................1......................... 15368.............................Tube, Cable Guide, 2-Tank
17337.............................Tube, Cable Guide, 9500
26......................2......................... 15372.............................Washer, Thrust, 3/8
27......................1......................... 15216.............................Meter Cable Assy, 15.25”
15425.............................Meter Cable, 13.25”
17744.............................Meter Cable Assy, 20.75” 1 1/2” Std
19121-01........................Meter Cable Assy, SE, Paddle 6600/6700
19121-05........................Meter Cable Assy, ET, 28” 2750/3150 Systemax 4-6
19791-01........................Meter Cable Assy, Turbine/SE
28......................2......................... 15692.............................Washer, Plain, 3/8”
29......................1......................... 16433.............................Switch, Miniature
30......................1......................... 10302.............................Insulator, Limit Switch
31......................2......................... 15173.............................Screw, Slot Rd Hd Mach, 5-20 x 3/8
Not Shown
1......................... 60232-110......................Cover, Designer, 1 Pc Black
1......................... 60232-112......................Cover, Designer, 1 Pc Black w/Left Window
1......................... 60320-09........................Switch Assy, 9000, Drive Cam
1......................... 60320-10........................Switch Assy, 9500, Drive Cam
For Service Assembly Numbers, See the Back of this Manual
Page 15
9000 Control Valve Assembly
For Service Assembly Numbers, See the Back of this Manual
Page 16
9000 Control Valve Assembly
Item No.
Quantity
Part No.
Description
1.........................1...........................14861-01......................... Valve Body, 9000, Machined w/O-ring
40688............................... Valve Body, 9100
2.........................1...........................14914............................... Piston, 9000, Upper
3.........................2...........................14309............................... Retainer, Piston Rod
16590............................... Retainer, Piston Rod
4.........................1...........................14919............................... Rod, Piston, Upper
5.........................2...........................13446............................... End Plug Assy, White
13446-01......................... End Plug Assy, White, HW
6.........................12.........................14241............................... Spacer, 5600
14241-01......................... Spacer, Hot Water
7.........................16.........................13242............................... Seal, 5600
18759............................... Seal, 5600 Low Drive Force
8.........................1...........................14920............................... Rod, Piston, Lower, 9000
9.........................1...........................14905............................... Piston, 9000
10.......................1...........................11710............................... O-ring, -215
11........................1...........................12281............................... O-ring, -338
12.......................1...........................11981-01.......................... Ring, Retaining
13.......................1...........................16098............................... Washer, Nylon Brine
14.......................1...........................11973............................... Spring, Brine Valve
15.......................1...........................13165............................... Cap, Brine Valve
16.......................3...........................13302............................... O-ring, -014
17.......................1...........................12550............................... Quad Ring, -009
18.......................1...........................13167............................... Spacer, Brine Valve
19.......................1...........................14925............................... Brine Valve Stem, 9000
20.......................1...........................12626............................... Seat, Brine Valve
21.......................1...........................15215............................... Body, Injector, 9000
22.......................1...........................10914-X........................... Injector Throat - Specify Size
23.......................1...........................10913-X........................... Injector Nozzle - Specify Size
10225-X........................... Injector Nozzle, SS
24.......................1...........................13303............................... O-ring, -021
25.......................1...........................13166............................... Cap, Injector, 5600
26.......................1...........................16595............................... Spacer, 9000
27.......................1...........................13387............................... Screw, Hex Hd Mach, 10-24 x 1 3/4
28.......................1...........................13361............................... Spacer, 4650/9000
29.......................2...........................13301............................... O-ring, -011, Injector
30.......................1...........................13497............................... Disperser, Air, 5600
31.......................1...........................15348............................... O-ring, -563
32.......................1...........................10227............................... Screen, Injector
34.......................1...........................13244............................... Adapter, BLFC
35.......................1................................................................... Button, BLFC - Specify Size
36.......................1...........................13245............................... Retainer, BLFC
12977............................... O-ring, -015
38.......................1................................................................... Button, DLFC - Specify Size
39.......................1...........................13173............................... Retainer, DLFC Button
40.......................1...........................10332............................... Fitting, Insert, 3/8
15415*............................. Fitting, Insert, 1/2” Tube
41.......................1...........................10330............................... Fitting, Sleeve, 3/8 Celcon
16124*............................. Fitting, Sleeve, Delrin
42.......................1...........................10329............................... Fitting, Tube, 3/8 Nut, Brass
16123*............................. Nut, Brass
43.......................1...........................14928............................... Plug, End Stub, 9000
44.......................1...........................14906............................... Plate, End, 9000
45.......................4...........................15137............................... Screw, Hex Wsh Mach 10-24 x 3/8
47.......................1...........................13387............................... Screw, Hex Hd Mach, 10-24 x 1 3/4
13361............................... Spacer, 4650/9000
48.......................1...........................13315............................... Screw, Hex Wsh Hd, 10-24 x 1 3/16
Not Shown..........1...........................16140............................... Fitting, 1/2T x 1/4 NPT
NOTE: For Hot Water delete items 41 & 42 and use 18698 (Nut, 3/8 Tube, w/Sleeve) and 15414 (Nut, 2900, w/Sleeve)
*These parts are used with #4 injector and 2 GPM or larger BLFC (Items 34, 35, and 36 are not used).
For Service Assembly Numbers, See the Back of this Manual
Page 17
9100 Control Valve Assembly
For Service Assembly Numbers, See the Back of this Manual
Page 18
9100 Control Valve Assembly
Item No.
Quantity
Part No.
Description
1....................... 1.........................40688........................... Valve Body Assy, 9100
2....................... 16.......................13242........................... Seal, 5600
3....................... 12.......................14241........................... Spacer, 5600
4....................... 1.........................16595........................... Spacer, 9000
5....................... 1.........................14928........................... Plug, End Stub, 9000
6....................... 1.........................14906........................... Plate, End, 9000
7....................... 4.........................15137........................... Screw, Hex Wsh Mach, 10-24 x 3/8
8....................... 1.........................14914........................... Piston, 9000, Upper
9....................... 2.........................14309........................... Retainer, Piston Rod
10..................... 1.........................14919........................... Rod, Piston, Upper
11..................... 2.........................13243........................... Plug, End, 5600
12..................... 2.........................13008........................... Retainer, End Plug Seal
13..................... 2.........................10209........................... Quad Ring, -010
14..................... 1.........................14921........................... Link, Piston Rod
15..................... 2.........................11335............................ Screw, Slot Phil Hd, 4-40 x 3/16
16..................... 2.........................17020........................... Screw, Slot Ind Hex, 6-20 x 3/8
17..................... 2.........................13363........................... Washer, Plain, .145 ID SS
18..................... 1.........................14905........................... Piston, 9000
19..................... 1.........................14920........................... Rod, Piston, Lower, 9000
20..................... 1.........................15019........................... Link, Piston Rod, 9000/9500
21..................... 1.........................41500........................... O-ring, Drain, 9100
22..................... 1.........................15215........................... Body, Injector, 9000
23..................... 2.........................13301........................... O-ring, -011, Injector
24..................... 1.........................10227........................... Screen, Injector
25..................... 1.........................10913-1........................ Nozzle, Injector, #1, White
26..................... 1.........................10914-1........................ Throat, Injector, #1, White
27..................... 1.........................13166........................... Cap, Injector, 5600
28..................... 1.........................13303........................... O-ring, -021
29..................... 2.........................13387........................... Screw, Hex Hd Wash, 10-24 x 1 3/4
30..................... 1.........................15348........................... O-ring, -563
31..................... 1.........................13173........................... Retainer, DLFC Button
32..................... 1.........................12085........................... Washer, Flow, 1.2 GPM
33..................... 1.........................14925........................... Brine Valve Stem, 9000
34..................... 1.........................12626........................... Seat, Brine Valve
35..................... 1.........................13167........................... Spacer, Brine Valve
36..................... 1.........................13165........................... Cap, Brine Valve
37..................... 1.........................11973............................ Spring, Brine Valve
38..................... 1.........................11981-01...................... Ring, Retaining
39..................... 1.........................16098........................... Washer, Nylon Brine
40..................... 1.........................12977........................... O-ring, -015
41..................... 1.........................13245........................... Retainer, BLFC
42..................... 1.........................129095......................... Washer, Flow, .50 GPM
43..................... 1.........................12550........................... Quad Ring, -009
44..................... 2.........................13302........................... O-ring, -014
45..................... 1.........................13244........................... Adapter, BLFC
46..................... 1.........................13497........................... Disperser, Air, 5600
47..................... 1.........................13361........................... Spacer, 4650/9000/WCC
48..................... 1.........................40538........................... Retainer, 32mm, O-ring Dist, 7000
49..................... 1.........................61419........................... Kit, 1.05” Distributor, Adapter
Not Shown....... 1.........................13333........................... Label, Injector, Blank
Not Shown....... 1.........................10759........................... Label, .5 GPM, 1.5 LBS Salt/Min
For Service Assembly Numbers, See the Back of this Manual
Page 19
9500 Control Valve Assembly
For Service Assembly Numbers, See the Back of this Manual
Page 20
9500 Control Valve Assembly
Item No.
Quantity
Part No.
Description
1....................... 1.........................16919-01...................... Valve Body, 9500 Machd
2....................... 16.......................16101........................... Seal, 2850
3....................... 12.......................16638........................... Spacer, 9500/2850
4....................... 1.........................17110............................ Piston, 9500, Upper
5....................... 2.........................14309........................... Retainer, Piston Rod
6....................... 1.........................16957........................... Rod, Piston, 9500
7....................... 2.........................17212........................... End Plug Assy, White
17212-01...................... End Plug Assy, White, HW, 560CD
8....................... 1.........................17111............................ Piston, 9500, Lower
9....................... 1.........................16956........................... Rod, Piston, Lower
10..................... 1.........................17092........................... Spacer, Disc, 9500
11..................... 1.........................16955........................... Plug, End, 9500
12..................... 3.........................16394........................... O-Ring -029
13..................... 1.........................14906........................... Plate, End, 9000
14..................... 4.........................41875........................... Screw, Phil Oval HD, #10-24 x 3/8 Mchd
41876........................... Screw, Phil Oval HD, Mchd M5 x 0.8 x 10MM
15..................... 4.........................17052........................... Fitting, Pipe, Coupling
16..................... 4.........................17224........................... O-Ring -224
17..................... 1.........................17061........................... Retainer, Coupling
18..................... 8.........................10231........................... Screw, Slot Hex, 1/4 - 20 x 1/2
17659........................... Screw, Hex Hd Mach, M6 x 12
19..................... 2.........................17353........................... Fitting, Elbow, 1 1/2 x .065
20..................... 1.........................16916-01...................... Adapter, 9500, 2nd Tan, Machd w/O-rings
21..................... 2.........................13577........................... O-ring -226
22..................... 2.........................16455........................... O-ring -347
23..................... 1.........................14805........................... Gasket, Injector Body, 1600/1700
24..................... 1.........................*14802.......................... Throat, Injector
25..................... 1.........................17777........................... Body, Injector, 1700
26..................... 1.........................*14801.......................... Nozzle, Injector
27..................... 1.........................10229........................... Gasket, Injector Cap, 1600
28..................... 1.........................11893............................ Cap, Injector, SS
29..................... 2.........................14804........................... Screw, Hex Hd Mach, 10-24 x 2 3/4
17655........................... Screw, Hex Hd, M5 x 70
30..................... 1.........................16221........................... Disperser, Air
31..................... 1.........................17776........................... Injector, 1600
32..................... 1.........................10914-3........................ Throat, Injector, #3, Yellow
33..................... 1.........................10227........................... Screen, Injector
34..................... 1.........................10913-3........................ Nozzle, Injector, #3, Yellow
35..................... 2.........................10692........................... Slot Hex Hd, 10-24 x
17656........................... Screw, Hex Hd, M5 x 40
36..................... 2.........................17558........................... Disc, Spacer, End Plug
Not Shown....... 2.........................19608-15...................... Disperser, Commercial 1 1/2”
Not Shown....... 1.........................11248............................ Pin, Roll 5/32 x 7/8
Not Shown....... 1.........................60366-XX..................... D.L.F.C. NPT - Specify Size
*Injector Throat Injector Nozzle Size Color
14802-03.......................... 14801-03..........................#3C............ Yellow
14802-04.......................... 14801-04..........................#4C............ Green
14802-05.......................... 14801-05..........................#5C............ White
14802-06.......................... 14801-06..........................#6C............ Red
For Service Assembly Numbers, See the Back of this Manual
Page 21
1600 Brine Valve System (for 9500)
Item No.
Quantity
Part No.
Description
1....................... 1.........................16960........................... Tube, Brine Valve
2....................... 1.........................10329........................... Fitting, Tube, 3/8 Nut, Brass
3....................... 1.........................10330........................... Fitting, Sleeve, 3/8 Celcon
4....................... 1.........................10332........................... Fitting, Insert, 3/8
5....................... 1.........................12747........................... Fitting, Flow Control
6....................... 1.........................12550........................... Quad Ring, -009
7....................... 1.........................12626........................... Seat, Brine Valve
8....................... 1.........................16958........................... Brine Valve Stem, 1600 Coated
9....................... 1.........................11982............................ O-ring, -016
10..................... 3.........................15137........................... Screw, Hex Wsh Mach, 10-24 x 3/8
11..................... 3.........................10269........................... Nut, Jam, 3/84 - 16
12..................... 3.........................16922........................... Bracket, Brine Valve Mounting
13..................... 1.........................10250........................... Ring, Retaining
14..................... 1.........................10249........................... Spring, Brine Valve
15..................... 1.........................12748-01...................... Brine Valve Body, 1600
16..................... 2.........................10328........................... Fitting, Elbow, 90 Deg.
For Service Assembly Numbers, See the Back of this Manual
Page 22
1700 Brine Valve System (for 9500)
Item No.
Quantity
Part No.
Description
1....................... 1.........................14792........................... Plug, End, Brine Valve
2....................... 1.........................13201........................... Quad Ring, -020
3....................... 1.........................12550........................... Quad Ring, -009
4....................... 1.........................14785-01...................... Retainer, Flow Control
5....................... 2.........................14811............................ O-ring, -210, 560CD, Brine
6....................... 1.........................14795........................... Piston, Brine Valve
7....................... 1.........................16929........................... Brine Valve Stem, Coated
8....................... 1.........................15415........................... Fitting, Insert, 1/2” Tube
9....................... 1.........................16124........................... Fitting, Sleeve, Delrin
10..................... 1.........................16123........................... Nut, Brass
11..................... 1.........................15137........................... Screw, Hex Wsh Mach, 10-24 x 3/8
12..................... 1.........................10269........................... Nut, Jam, 3/4 - 16
13..................... 1.........................16922........................... Bracket, Brine Valve Mounting
14..................... 2.........................10250........................... Ring, Retaining
15..................... 1.........................15310........................... Spring, Brine Valve
16..................... 2.........................14790........................... Brine Valve Body
17..................... 1.........................14798........................... Spacer, 1700, Brine
18..................... 1.........................15414........................... Nut, 2900, w/Sleeve
19..................... 1.........................15413........................... Fitting, Elbow, Male, 1/2T x 3/8 NPT
20..................... 1.........................16959........................... Tube, Brine 9500/1710, 10.6”
For Service Assembly Numbers, See the Back of this Manual
Page 23
9000 Second Tank Assembly
Item No.
Quantity
Part No.
Description
1.................... 1..................... 14864-01..................Adapter, 9000, 2nd Tank, Machd w/O-rings
2.................... 8..................... 13305.......................O-ring, -119
3.................... 1..................... 11710.......................O-ring, -215
4.................... 1..................... 12281.......................O-ring, -338
5.................... 2..................... 13708-40..................Yoke, 1” Sweat
..................... 1..................... 15823-XX.................Yoke Assy. Specify Tank Size
6.................... 4..................... 13255.......................Clip, Mounting
7.................... 4..................... 14202-01..................Screw, Hex Wsh Mach, 8-32 x 5/16
8.................... 4..................... 15078.......................Adapter, 1” Coupling
For Service Assembly Numbers, See the Back of this Manual
Page 24
9100 Second Tank Assembly
Item No.
Quantity
Part No.
Description
1.....................4...................... 40678........................ Ring, 9100, Yoke Retainer
2.....................4...................... 13287........................ O-ring, -123
3.....................1...................... 14865........................ Adapter Assy, 2nd Tank, 9100
4.....................1...................... 19054........................ O-ring, -124
5.....................1...................... 40538........................ Retainer, 32mm, O-ring Dist, 7000
6.....................1...................... 61419........................ Kit, 1.05” Distributor, Adapter
7.....................1...................... 18303........................ O-ring, -336
8.....................4...................... 13255........................ Clip, Mounting
9.....................4...................... 14202-01................... Screw, Hex Wsh Mach, 8-32 x 5/16
For Service Assembly Numbers, See the Back of this Manual
Page 25
9500 Second Tank Assembly
Item No.
Quantity
Part No.
Description
1.................... 1..................... 13577.......................O-ring, -226
2.................... 1..................... 16455.......................O-ring, -347
3.................... 8..................... 10231.......................Screw, Slot Hex, 1/4 - 20 x 1/2
4.................... 4..................... 17224.......................O-ring, -224
For Service Assembly Numbers, See the Back of this Manual
Page 26
3/4” Meter Assembly
Item No.
Quantity
Part No.
Description
1.................... 1..................... 14613.......................Flow Straightener
2.................... 4..................... 12473.......................Screw, Hex Wsh, 10-24 x 5/8
3.................... 1..................... 14038.......................Meter Cap Assy
4.................... 1..................... 13847.......................O-ring, -137, Std/560CD, Meter
5.................... 1..................... 13509.......................Impeller, Meter
6.................... 4..................... 13314.......................Screw, Slot Ind Hex, 8-18 x .60
7.................... 4..................... 13255.......................Clip, Mounting
8.................... 4..................... 13305.......................O-ring, -119
9.................... 1..................... 15150.......................Meter Cap Assy, Ext
15237.......................Meter Cap Assy, Ext
10.................. 1..................... 13821.......................Body, Meter, 5600
For Service Assembly Numbers, See the Back of this Manual
Page 27
1” Meter Assembly
Item No.
Quantity
Part No.
Description
1.................... 4.................... 12112.......................Screw, Hex Hd Mach 10-24 x 1/2
2.................... 1.................... 15218.......................Meter Cap Assy
15237.......................Meter Cap Assy, EXT
3.................... 1.................... 13847.......................O-Ring, -137, STD/560CD, Meter
4.................... 1.................... 13509.......................Impeller, Meter
13509-01..................Impeller, Celcon
5.................... 1.................... 13882.......................Post, Meter Impeller
6.................... 1.................... 15043.......................Body, Meter, 9000 1”
7.................... 1.................... 14960.......................Flow Straightener, 1”
8.................... 4.................... 13305.......................O-Ring, -119
9.................... .2.................... 15078.......................Adapter, 1” Coupling
10.................. 2.................... 13255.......................Clip, Mounting
11.................. 2.................... 14202-01..................Screw, Hex Wsh Mach, 8-32 x 5/16
12.................. 1..................... 15150.......................Meter Cap Assy, Ext
15237.......................Meter Cap Assy, Ext
For Service Assembly Numbers, See the Back of this Manual
Page 28
1 1/2” Meter Assembly
Item No.
Quantity
Part No.
Description
1.................... 1..................... 17569.......................Body, Meter, 2850/9500
2.................... 1..................... 13882.......................Post, Meter Impeller
3.................... 1..................... 13509.......................Impeller, Meter
4.................... 1..................... 13847.......................O-Ring, -137, Std/560CD, Meter
5.................... 1..................... 15218.......................Meter Cap Assy
6.................... 4..................... 12112.......................Screw, Hex Hd Mach, 10-24 x 1/2 18-8 S.S.
7.................... 1..................... 17542.......................Flow Straightener, 1 1/2”
8.................... 1..................... 12733.......................O-Ring, -132
9.................... 1..................... 17544.......................Fitting, 1 1/2” Quick Connector
10.................. 1..................... 17543.......................Nut, 1 1/2”, Q/C
11.................. 1..................... 15150.......................Meter Cap Assy, Ext
15237.......................Meter Cap Assy, Ext
Not Shown.... 1..................... 17790.......................Sleeve, Meter, 1 1/2” x 1”
For Service Assembly Numbers, See the Back of this Manual
Page 29
9000/9100 Bypass Valve Assembly
Item No. Quantity
Part No.
Description
1...................1.................... 17290.......................By-Pass Body, 3/4”
17290NP..................By-Pass Body, 3/4” NP, 5600
13399.......................By-Pass Body, 1”
13399NP..................By-Pass Body, 1” NP
2...................1.................... 14105.......................Seal, By-Pass, 560CD
3...................1.................... 11972.......................Plug, By-Pass, w/Wax
4...................1.................... 11978.......................Plate, By-Pass, Top
5...................1.................... 13604-01..................Label, By-Pass, Standard Mount
6...................8.................... 15727.......................Screw, Hex Wsh Hd, 10-24 x 1/2
7...................1.................... 11986.......................Plate, By-Pass, Bottom
8...................1.................... 11979.......................Lever, By-Pass
9...................1.................... 11989.......................Screw, Sltd Indent, 1/4 - 14 x 1 1/2
For Service Assembly Numbers, See the Back of this Manual
Page 30
Bypass Valve Assembly
Item No. Quantity
Part No.
Description
1...................2.................... 13305.......................O-ring, -119
2...................2.................... 13255.......................Clip, Mounting
3...................2.................... 13314.......................Screw, Slot Ind Hex, 8-18 x .60
4A................1.................... 18706.......................Yoke, 1”, NPT, Plastic
18706-02..................Yoke, 3/4”, NPT, Plastic
4B................1.................... 41027-01..................Yoke, 3/4”, NPT, Cast, Machd
41026-01..................Yoke, 1”, NPT, Cast, Machd, SS
For Service Assembly Numbers, See the Back of this Manual
Page 31
1710 Brine Valve System (for 9500)
Item No.
Quantity
Part No.
Description
1.................... 1..................... 41202.......................Brine Valve, 1700, Plastic, Top
2.................... 1..................... 14785-01..................Retainer, Flow Control
3.................... 2..................... 14811.......................O-ring, -210, 560CD, Brine
4.................... 1..................... 14798.......................Spacer, 1700, Brine
5.................... 1..................... 14795.......................Piston, Brine Valve
6.................... 1..................... 41429.......................Stem, Brine, 1710, Plastic, 9500
7.................... 1..................... 41201.......................Brine Valve, 1700, Plastic, Bottm
8.................... 1..................... 12550.......................Ring, Quad, -009
9.................... 1..................... 17908.......................Sleeve, Brine Valve Stem
10.................. 1..................... 41547.......................O-ring, 2mm x 35mm
11.................. 1..................... 15310.......................Spring, Brine Valve
12.................. 1..................... 10250.......................Ring, Retaining
13.................. 1..................... 17906-01..................Guide, Brine Valve Stem
14.................. 4..................... 14202-01..................Screw, Hex Wsh, Mach, 8-32 x 5/16”
15.................. 2..................... 41056.......................Nut Assy, 1/2” Plastic
16.................. 1..................... 41493-XX.................Label, BLFC, 1710 (Specify GPM)
17.................. 1......................................................Washer, Flow (Specify GPM)
18.................. 3..................... 15415.......................Fitting, Insert, 1/2”, Tube
19.................. 1..................... 15414.......................Nut, 2900, w/Sleeve
20.................. 1..................... 16959.......................Tube, Brine 9500/1700, 10.6”
For Service Assembly Numbers, See the Back of this Manual
Page 32
2300 Safety Brine Valve
Item No.
Quantity
Part No.
Description
1.................... 1..................... 60027-00..................Safety Brine Valve, 2300, Less Elbow
2.................... 1..................... 10138.......................Ball, 3/8”, Brass
3.................... 1..................... 11566.......................Ball Stop, Slow Fill
4.................... 1..................... 10328.......................Fitting, Elbow, 90 Deg. 1/4 NPT x 3/8T
5.................... 1..................... 10332.......................Fitting, Insert, 3/8
6.................... 1..................... 10330.......................Fitting, Sleeve, 3/8 Celcon
7.................... 1..................... 10329.......................Fitting, Tube, 3/8 Nut, Brass
8.................... 1..................... 10186.......................Nut, Hex, 10-32
9.................... 1..................... 60002.......................Air Check, #500
10.................. 1..................... 10149.......................Rod, Float
11.................. 1..................... 10700.......................Float Assy, Blue/White
12.................. 3..................... 10150.......................Grommet, .30 Dia
For Service Assembly Numbers, See the Back of this Manual
Page 33
2310 Safety Brine Valve
Item No. Quantity
Part No.
Description
1...................1.................... 19645.......................Body, Safety Brine Valve, 2310
2...................1.................... 19803.......................Safety Brine Valve Assy
3...................1.................... 19804.......................Screw, Sckt Hd, Set, 10-24 x .75
4...................1.................... 19805.......................Nut, Hex, 10-24, Nylon Black
5...................1.................... 19652-01..................Poppet Assy, SBV w/O-Ring
6...................1.................... 19649.......................Flow Dispenser
7...................1.................... 11183........................O-Ring, -017
8...................1.................... 19647.......................Elbow, Safety Brine Valve
9...................2.................... 19625.......................Nut Assy, 3/8” Plastic
10.................1.................... 18312.......................Retainer, Drain
11.................1.................... 60014.......................Safety Brine Valve Assy, 2310
12.................2.................... 10150.......................Grommet, .30 Dia
13.................1.................... 60068.......................Float Assy, 2310, w/30” Rod
14.................1.................... 60002.......................Air Check, #500
For Service Assembly Numbers, See the Back of this Manual
Page 34
2350 Safety Brine Valve
Item No.
Quantity
Part No.
Description
1.................... 1..................... 60038.......................Safety Brine Valve, 2350
1A................. 1..................... 61024.......................Actuator Assy, 2350 Brine
2.................... 1..................... 60026-30..................Float Assy, 400A/2350, 30” Red/Wht
3.................... 1..................... 60009-00..................Air Check, #900, Commercial Less Fittings
60009-01..................Air Check, #900, Commercial, HW Less Fittings
Not Shown:
1..................... 18603.......................Fitting Assy, 900 Air Check 2350
For Service Assembly Numbers, See the Back of this Manual
Page 35
Troubleshooting
Problem
Cause
Correction
1. Water conditioner fails to
regenerate.
A. Electrical service to unit has
been interrupted
A. Assure permanent electrical service
(check fuse, plug, pull chain, or switch)
B. Timer is defective.
B. Replace timer.
C. Power failure.
C. Reset time of day.
A. By-pass valve is open.
A. Close by-pass valve.
B. No salt is in brine tank.
B. Add salt to brine tank and maintain
salt level above water level.
C. Injector screen plugged.
C. Clean injector screen.
D. Insufficient water flowing into
brine tank.
D. Check brine tank fill time and clean
brine line flow control if plugged.
E. Hot water tank hardness.
E. Repeated flushings of the hot water
tank is required.
F. Leak at distributor tube.
F. Make sure distributor tube is not
cracked. Check O-ring and tube pilot.
G. Internal valve leak.
G. Replace seals and spacers and/or
piston.
A. Improper salt setting.
A. Check salt usage and salt setting.
B. Excessive water in brine tank.
B. See problem 7.
A. Iron buildup in line to water
conditioner.
A. Clean line to water conditioner.
B. Iron buildup in water conditioner.
B. Clean control and add mineral cleaner
to mineral bed. Increase frequency of
regeneration.
C. Inlet of control plugged due
to foreign material broken loose
from pipes by recent work done on
plumbing system.
C. Remove piston and clean control.
2. Hard water.
3. Unit used too much salt.
4. Loss of water pressure.
5. Loss of mineral through drain A. Air in water system.
line.
A. Assure that well system has proper
air eliminator control. Check for dry well
condition.
B. Improperly sized drain line flow
control.
B. Check for proper drain rate.
6. Iron in conditioned water.
A. Fouled mineral bed.
A. Check backwash, brine draw, and
brine tank fill. Increase frequency of regeneration. Increase backwash time.
7. Excessive water in brine
tank.
A. Plugged drain line flow control.
A. Clean flow control.
B. Plugged injector system.
B. Clean injector and screen.
C. Timer not cycling.
C. Replace timer.
D. Foreign material in brine valve.
D. Replace brine valve seat and clean
valve.
E. Foreign material in brine line
flow control.
E. Clean brine line flow control.
Page 36
Troubleshooting
Problem
Cause
Correction
8. Softener fails to draw brine.
A. Drain line flow control is
plugged.
A. Clean drain line flow control.
B. Injector is plugged.
B. Clean injector
C. Injector screen plugged.
C. Clean screen.
D. Line pressure is too low.
D. Increase line pressure to 20 P.S.I.
E. Internal control leak
E. Change seals, spacers, and piston
assembly.
F. Service adapter did not cycle.
F. Check drive motor and switches.
9. Control cycles continuously.
A. Misadjusted, broken, or shorted
switch.
A. Determine if switch or timer is faulty
and replace it, or replace complete
power head.
10. Drain flows continuously.
A. Valve is not programming correctly.
A. Check timer program and positioning
of control. Replace power head assembly if not positioning properly.
B. Foreign material in control.
B. Remove power head assembly and
inspect bore. Remove foreign material
and check control in various regeneration
positions.
C. Internal control leak.
C. Replace seals and piston assembly.
General Service Hints For Meter Control
Problem: Softener delivers hard water
Reason: Reserve capacity has been exceeded.
Correction: Check salt dosage requirements and reset program wheel to provide additional reserve.
Reason: Meter is not measuring flow.
Correction: Check meter with meter checker.
Reason: Program wheel is not rotating with meter output.
Correction: Pull cable out of meter cover and rotate manually. Program wheel must move without binding
and clutch must give positive clicks when program wheel strikes regeneration stop. If it does not, replace
timer.
Page 37
9000/9100/9500 Meter Flow Data
9000 Meter Flow Data
9100 Meter Flow Data
9500 Meter Flow Data
Page 38
9000/9100 Injector Flow Data (1600 Series Injectors)
Page 39
9500 Injector Flow Data (1600 & 1700 Series Injectors)
1600 Series Injectors
1700 Series Injectors
Page 40
9000 Control Dimensions
Page 41
9100 Control Dimensions
Page 42
9500 Control Dimensions
Page 43
Water Conditioner Flow Diagrams
Page 44
In Service Position
Tanks Switching Position
(Meter Initiated Regeneration)
Backwash Position
Brine Draw Position
Water Conditioner Flow Diagrams
Slow Rinse Position
Rapid Rinse Position
Brine Tank Fill Position
In Service Position, Tanks Switched
Page 45
19752_REVB
9000/9500 Wiring Diagram
Page 46
Service Assemblies
Brine Line Flow Controls (9000/9100):
60022-12................... BLFC, .125 GPM, 5000/5600/9000/9100
60022-25................... BLFC, .25 GPM, 5000/5600/9000/9100
60022-50................... BLFC, .50 GPM, 5000/5600/9000/9100
60022-100................. BLFC, 1.0 GPM, 5000/5600/9000/9100
60350........................ Brine Valve Assy, 9000/9100
Brine Line Flow Controls (9500):
60020-25................... BLFC, .25 GPM, 1600
60020-50................... BLFC, .50 GPM, 1600
60020-100................. BLFC, 1.0 GPM, 1600
Brine Valve Assemblies:
60037-610................. Brine Valve, 9500/1600, .25 GPM,
Cold & HW 180°
60037-620................. Brine Valve, 9500/1600, .50 GPM,
Cold & HW 180°
60037-630................. Brine Valve, 9500/1600, 1.0 GPM,
Cold & HW 180°
60350........................ Brine Valve Assy 9000/9100,
Cold & HW 180°
60350-01................... Brine Valve Assy, 9000/9100/Twinfl100,
Cold & HW 180°
1700 Brine Valve Assembies (9500):
60039-XX.................. Brine Valve, 1700/9500, Cold & HW 180°
Bypass Assemblies:
60040SS.................... Bypass Valve, 5600, 3/4” NPT
60041SS.................... Bypass Valve, 5600, 1” NPT
60049........................ Bypass Plastic Assy
Injector Assemblies (9000/9100):
60385-X..................... Injector Assembly (specify size of injector)
Injector
Number DLFC Number BLFC Number
Red #0......... 00............... Blank...... 0.................Blank...... 0
White #1...... 01............... 1.2.......... 1.................0.25........ 1
Blue #2 ....... 02............... 1.5.......... 2.................0.50........ 2
Yellow #3 .... 03............... 2.0.......... 3.................1.00........ 3
Green #4..... 04............... 2.4.......... 4
3.0.......... 5
3.5.......... 6
4.0.......... 7
5.0.......... 8
7.0.......... 9
Injector Assemblies (9500):
60381-03................... Injector Assy, 1700, #3, Cold & HW 150°
60381-04................... Injector Assy, 1700, #4, Cold & HW 150°
60381-05................... Injector Assy, 1700, #5, Cold & HW 150°
60381-06................... Injector Assy, 1700, #6, Cold & HW 150°
60480-01................... Injector Assy, 1600, #1, Plastic,
Cold Water
60480-02................... Injector Assy, 1600, #2, Plastic,
Cold Water
60480-03................... Injector Assy, 1600, #3, Plastic,
Cold Water
60480-04................... Injector Assy, 1600, #4, Plastic,
Cold Water
60481-21................... Injector Assy, 1600, #1, SS, HW 180°
60481-21................... Injector Assy, 1600, #2, SS, HW 180°
60481-21................... Injector Assy, 1600, #3, SS, HW 180°
60481-21................... Injector Assy, 1600, #4, SS, HW 180°
Meter Assemblies (9000/9100):
15078-01................... Adapter, 1” Coupling
60086........................ Meter Assy, 5600/9000/9100,
3/4” Std/Range
60087........................ Meter Assy, 5600/9000/9100, 3/4”, Ext
60389........................ Meter Assy, 9000/9100, 1”
60389NP................... Meter Assy, 9000/9100, 1”, N/P
60389-20................... Meter Assy, 9000/9100, 1”, BSP/Metric
60390........................ Meter Assy, 9000/9100, 1”, Ext
60390NP................... Meter Assy, 9000/9100, 1”, Ext, N/P
60390-20................... Meter Assy, 9000/9100, 1”, Ext/BSP/Metric
60612........................ Meter Assy, 9000/9100, 1”, Std Range,
HW 150°
60612NP................... Meter Assy, 9000/9100, 1”, Std Range,
HW 150°, NP
14038........................ Meter Cap Assy
15150........................ Meter Cap Assy, Ext
15218........................ Meter Cap Assy
15218NP................... Meter Cap Assy, Std, NP
15237........................ Meter Cap Assy, Ext
15237NP................... Meter Cap Assy, Ext, NP
13509........................ Impeller, Meter
13509-01................... Impeller, Celcon, HW 150°
Meter Assemblies (9500):
60610-01................... Meter, 2850/9500, 1 1/2” Std
60610-01HW............. Meter, 2850/9500, 1 1/2” Std, HW 150°
60610-01NP.............. Meter, 2850/9500, 1 - 1/2” Std, N/P
60610-02................... Meter, 2850/9500, 1 - 1/2” Ext
60610-02HW............. Meter, 2850/9500, 1 1/2” Ext, HW 150°
60610-02NP.............. Meter, 2850/9500, 1 - 1/2” Ext, N/P
60610-21................... Meter, 2850/9500, 1 - 1/2” Std/BSP Metric
60610-21NP.............. Meter, 2850/9500, 1 - 1/2” Std/BSP
Metric, Nickel Plated
60610-22................... Meter, 2850/9500, 1 - 1/2” Ext/BSP Metric
60610-22NP.............. Meter, 2850/9500, 1 - 1/2” Ext/BSP
Metric/Nickel Plated
60611-01HW............. Meter, 2850/9500, 1” Sleeve,
1 1/2” Std, HW 150°
60611-01................... Meter, 2850/9500, 1” Sleeve,
1 1/2” Std Meter
60611-01NP............... Meter, 2850/9500, 1” Sleeve, NP
1 1/2” Std Meter
60611-02................... Meter, 2850/9500, 1” Sleeve,
1 1/2” Ext Meter
60611-02NP............... Meter, 2850/9500, 1” Sleeve, NP 1 1/2”
Ext Meter
17790........................ Sleeve, Meter, 1 1/2” x 1” (NOTE: when
reducing a 1-1/2” meter to a 1” meter,
the program wheel and timer settings must
be changed to a 1” meter size)
Page 47
Service Assemblies
Meter Checker Kits:
60460........................ Meter Checker Kit, Std
60461........................ Meter Checket Kit, Ext
Piston Assemblies:
60108........................ Piston Assy, 9500, Upper
60108-01................... Piston Assy, 9500, Upper, HW 180°
60109........................ Piston Assy, 9500, Lower
60109-01................... Piston Assy, 9500, Lower HW, 180°
60400........................ Piston Assy, 9000/9100, Top
60400-01................... Piston Assy, 9000/9100, HW Upper, 180°
60401........................ Piston Assy, 9000/9100, Lower
60401-01................... Piston Assy, 9000/9100 Lower, HW 180°
Seal & Spacer Kits:
60125........................ Seal & Spacer Kit, 5600/9000 Top
60125-20................... Seal & Spacer Kit, Top, 559 PE
Cold and Chloramine
60125HW.................. Seal & Spacer Kit, 9000/9100,
Upper HW 180°
60133........................ Seal & Spacer Kit, 9500, Lower,
Cold & HW 180°
60133-20................... Seal & Spacer Kit, 9500, Lower
60133-30................... Seal & Spacer Kit, 9500, Lower
60134........................ Seal & Spacer Kit, 9500, Upper,
Cold & HW 180°
60134-20................... Seal & Spacer Kit, 9500, Upper
60134-30................... Seal & Spacer Kit, 9500, Upper
60421........................ Seal & Spacer Kit, 9000/9100, Bottom
60421-20................... Seal & Spacer Kit, 9000/9100,
Bottom 559PE
60421HW.................. Seal & Spacer Kit, 9000/9100,
Bottom, HW 180°
Second Tank Assemblies (9000):
14202-01................... Screw, Hex Wsh Mach, 8-32 x 5/16
18-8 S.S.
13255........................ Clip, Mounting
15078-01................... Adapter Assy, 1” Coupling
14864-01................... Adapter, 9000/9100, 2nd Tank,
Machd w/O-rings
14864-01NP.............. Adapter, 9000/9100, 2nd Tank, Machd, NP
15823-06................... Yoke Assy, 6” Tank & 6” Tube
15823-06NP.............. Yoke Assy, 6” Tank, NP 6” Tubes
15823-12................... Yoke Assy, 6” - 12” Tank, 8 1/2 Tube
15823-12NP.............. Yoke Assy, 6” - 12” Tank, NP 8 1/2” Tubes
15823-14................... Yoke Assy, 14” Tank, 10 1/2” Tube
15823-14NP.............. Yoke Assy, 14” Tank, NP 10 1/2” Tube
15823-16................... Yoke Assy, 16” Tank, 12 1/2” Tube
15823-16NP.............. Yoke Assy, 16” Tank, NP 12 1/2” Tube
Second Tank Assemblies (9100):
60425-12................... Tube Assy, 9100, 6-12” Tanks
60425-16................... Tube Assy, 9100, 13-16” Tanks
14865........................ Adapter Assy, 2nd Tank, 9100
61419........................ Kit, 1.05” Distributor Adapter
Page 48
Second Tank Assemblies (9500):
16919-01................... Valve Body, 9500 Machd
16919-01NP.............. Valve Body, 9500 Machd, NP
16919-21................... Valve Body, 9500 BSP, Mtrc, Machd
16919-21NP.............. Valve Body, 9500 BSP, Mtrc, Machd
Nickel Plated
60715-16................... Tube Assy, 9500, 2nd Tank for
14” to 16” Tanks
60715-16NP.............. Tube Assy, 9500, 2nd Tank, NP for
14” to 16” Tanks
60715-20................... Tube Assy, 9500, 2nd Tank for 20” Tanks
60715-24................... Tube Assy, 9500, 2nd Tank for 20” and
24” Tanks
60715-24NP.............. Tube Assy, 9500, 2nd Tank, Nickel
for 20-24” Tanks
Tools:
12763........................ Stuffer Tool Assy, 5600/9000
13061........................ Puller Assy, Port Ring
13759........................ Tool, DLFC Retainer
Valve Body Assembly (9100):
40688........................ Valve Body Assy, 9100
18303........................ O-ring, -336
18569........................ Retainer, Tank Seal
Notes
Page 49
Notes
Page 50
Cashflow 7512i
Operation & Service Guide
2008©MEI Inc. All Rights Reserved.
The MEI device, MEI CASHFLOW, MEI EASITRAX and SODECO are registered trademarks of MEI in the U.S. and other
countries. Information is subject to change without notice. MEI has made every effort to assure that the information in this
document is accurate. However, we cannot be held responsible for any errors or omissions.
CASHFLOW 7512i Page-1
Technical Support 1-800-345-8172
Part # 794471001 G2
www.meigroup.com
Contents
General Information. ............................................................................................................................... 3
Introduction .................................................................................................................................................................................. 3
Interface. ....................................................................................................................................................................................... 3
Rated Operating Voltage ............................................................................................................................................................... 3
Installing the Coin Manager ................................................................................................................. 4-9
Before you Begin .......................................................................................................................................................................... 4
Alignment ..................................................................................................................................................................................... 4
Connection .................................................................................................................................................................................... 5
Coin Manager with one harness ................................................................................................................................................... 5
Coin Manger with two harnesses ................................................................................................................................................. 5
Initial Power Up ........................................................................................................................................................................... 6
Service Menu ................................................................................................................................................................................ 6
Using the MMI Display ................................................................................................................................................................ 7
Accessing the Service Mode ........................................................................................................................................................ 8
Par ................................................................................................................................................................................................. 8
Par (Float). .................................................................................................................................................................................... 8
Cassette ........................................................................................................................................................................................ 9
Custom Cassettes ......................................................................................................................................................................... 9
Setup Section ...................................................................................................................................... 10-15
Setup options .............................................................................................................................................................................. 10
Messages .................................................................................................................................................................................... 10
Par Options ................................................................................................................................................................................. 11
Change Management .................................................................................................................................................................. 11
Vendor Options. .......................................................................................................................................................................... 11
Coin Configuration ............................................................................................................................................................... 11-13
Audit Configuration. .................................................................................................................................................................. 13
General ....................................................................................................................................................................................... 14
Error Log .................................................................................................................................................................................... 14
Test. ............................................................................................................................................................................................ 14
Language .................................................................................................................................................................................... 14
Setup Menu Map ........................................................................................................................................................................ 15
Auditing the Coin Manager .............................................................................................................. 16-22
How to Section ................................................................................................................................... 23-34
How to remove envelope icon from display .............................................................................................................................. 23
How to delete a token ................................................................................................................................................................. 24
How to understand tube terminology ......................................................................................................................................... 25
How to reset the “Clean me” message ....................................................................................................................................... 26
How to calibrate a coin cassette ................................................................................................................................................. 27
How to float/par the coin manager ............................................................................................................................................. 28
How to set-up auto float/par ....................................................................................................................................................... 29
How to set-up float to value ....................................................................................................................................................... 30
How to use snapshot float .......................................................................................................................................................... 31
How to select a payout algorithm. .............................................................................................................................................. 32
How to audit bill information on an MDB changer. .................................................................................................................. 33
How to setup tokens ................................................................................................................................................................... 34
Frequently Asked Questions (FAQ) ................................................................................................. 35-40
Cashflow 7512i Exploded Views. ...................................................................................................... 41-45
Cashflow 7512i Dimensions ................................................................................................................... 46
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CASHFLOW 7512i Page-2
Part # 794471001 G2
GENERAL INFORMATION
1
Introducing the MEI CASHFLOW™ 7512i coin manager.
Principle components of the coin manager are:
2
1 Reject Lever
2 Acceptor/Separator. Sensors determine the authenticity of a coin or
token. Accepted coins or tokens are routed to one of five tubes or the
cashbox. Rejected coins or tokens are routed to the coin return cup.
4
3
3 LED’s. Red, Amber and Green LEDs are used to indicate the status of
the coin manager.
4 Keypad and message display. This is used to configure the coin
manager, by using a menu.
5 Coin tube cassette. This is used to store and route coins for dispensing
as change, thus enabling bills of high denomination to be accepted.
5
6 Dispenser. This dispenses coins being returned as change.
Interface
MEI CASHFLOW™ 7512i operates in machines that support the MDB
interface*. MDB is a serial communication interface standard that
developed into vending equipment since 1996. It allows for multiple
devices to be added to a single connection on the vending machine
control board, by linking one device to another parallel to the main
MDB harness.
6
Rated Operating Voltage
Voltage: 34v d.c. 12W
The operating voltage of a MEI CASHFLOW™ 7512i coin manager is stated on the label of each product. The label is
located on the left side of the coin manager. It must not be used with any power source other than that indicated.
The features of the Coin Manager include:
„
„
„
„
„
„
„
In field changeable/configurable coin cassette
Five auto-replenishing coin cubes (flexibility)
$1 coin payout
LCD display panel - gives instant status of unit
Patented coin inventory recognition
MDB interface
Ability to manage coin inventory to minimum levels
*Note: MDB (Multi drop bus) interface information can be found on
NAMA’s website located at www.vending.org
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CASHFLOW 7512i Page-3
Part # 794471001 G2
INSTALLATION
Before you begin...
•
Remove the coin manager from the packaging material. Inspect unit for physical
damage that may have occurred during shipping.
Turn OFF the power supply to the vending machine.
Push and hold the yellow button on the top right (below reject lever) of the coin
manager and tilt the acceptor assembly forward. You do not have to remove the
cassette (See Fig 1).
Once open, the mounting holes are accessible. Hang the coin manager on the
mounting studs/screws, ensuring that the changer is mounted on all three studs/
screws (See Fig 2).
Tighten screws (if required) and close the acceptor assembly.
Remove cassette by sliding two fingers in the yellow latch and lift the cassette
outwards and upwards as shown in Fig. 3.
Manually fill cassette with coins. Insure that coins are inserted into the proper tubes.
•
•
•
•
•
•
Fig. 1
1
2
Yellow Latch
Tube
E
Tube
A
Fig. 2
Cassette viewed
from above
3
Fig. 3
Tube
B
Tube
C
Tube
D
Alignment
•Once the coin manager is installed, check that there is a small gap (2-4 mm) between the lever on the vending machine and
the return lever on the coin manager (See Fig 4). Check that when you press the coin return lever on the machine door, it
fully opens the acceptor lid on the coin manager then returns smoothly without holding the lid open.
•Check the alignment of the coin input chute and cashbox chute. Insert some coins to check that they enter the coin manager
properly and exit into the return cup (See Fig 5). Ensure that the coin chute does not rest on or open the flight deck lid.
Most machines allow you to adjust the return lever, coin chute, and the return cup to align with
the coin manager.
Leave a small gap 2-4 mm
Fig. 4
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Fig. 5
CASHFLOW 7512i Page-4
Part # 794471001 G2
Connection
The coin manager will be supplied with one or two harnesses. One connects the coin
manager to the vending machine. The second harness, if present, allows for power and
communication between the coin manager and another MDB device.
Coin manager with one harness...(Main)
• If you have a bill acceptor, connect the MDB harness coming from the coin
manager to the bill acceptor’s “Y” connector.
From Bill
Acceptor
“Y” Connector
To
Machine
To Coin
Mechanism
• If there is no bill acceptor, connect the coin manager harness to the harness coming from the machine’s control
board.
• Switch on power.
Coin manager with two harnesses... (Main and MDB Peripheral)
The purpose of having two harnesses (one male connector, one female socket), is that the 7512i coin manager has the ability
to store bill acceptor audit data. The bill acceptor data can be viewed on the 7512i display. Connecting the bill acceptor to the
coin manager enhances the coin management capabilities and allow you to collect critical business statistics (CBS is defined
on page 19).
6 pin male connector
(connects to vendor)
6 pin female socket
(connects to other MDB device)
• Disconnect the harness connecting the bill acceptor to the machine’s control board. Attach the male connector coming from
the coin manager to the female connector coming from the VMC. Attach the female connector from the coin manager to the
bill acceptor’s male connector.
Note: There will be an unused MDB connector from the bill acceptor.
“Y” Connector
From Bill
Acceptor
To coin manager’s
peripheral harness
Unused
• Tuck any excess length of harnessing inside the machine. Make sure all harnesses are not trapped when the coin return
lever is pressed or when the vending machine door in closed.
•Now you may switch “ON” the power to the vending machine.
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CASHFLOW 7512i Page-5
Part # 794471001 G2
Initial Power Up (First Time Out of Box)
The coin manager will power up and check to see
how many coins are in each tube. If the tubes are
empty the coin manager will alert you which tubes are
low (See figure 6). You should fill the three lowest
coin value tubes with a minimum of five coins per
tube (i.e. On a 5,5,25,10,25 configuration, you would
have to fill tubes ACD).
Once you’ve filled the cassette with coins, the coin
manager will measure the tubes for 5 seconds and
display a happy face, an “OK”, and the total amount
of change in the tubes (See Fig. 7). Dispense some
coins from each tube to check that all coins drop into
the return cup properly.
If no cassette has been defined, the coin manager,
when powered up, will display a warning message
indicating the cassette needs to be defined before
the product will operate (See fig. 8).
Fig. 6
Fig. 7
Fig. 8
The user needs to press the “more” key to proceed.
The user has two options:
•Enter the cassette model located on the front of the
cassette (i.e. AB). The unit may be ordered with one
Fig. 9
of the cassette configurations shown on page 9.
or
•Insert a valid coin, then select the tube location (AE) to which that specific coin is to be routed. Repeat
procedure on all five tubes until all tubes have been
assigned a coin. Press “Next” , followed by “Accept”.
Once you’ve defined the cassette, fill the cassette with coins. The coin manager will check tube capacity, then display a
happy face, an “OK”, and the total amount of change in the tubes ( as shown in Fig. 7).
Service Menu
The yellow button below the ”E” is the mode key.
The mode key provides access to all of the features of
the coin manager.
Fig. 10
When the yellow MODE key is pressed once, the user
interface will enter Service Mode where features can
be selected by pressing the keypad (See Fig. 10).
After 5 seconds the screen will change slightly and the “audit” key will become the “Back” key.
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CASHFLOW 7512i Page-6
Part # 794471001 G2
2
Using the MMI Display
1
1 - 3 LEDs - Red, Amber, and Green provide changer status.
2 - Buttons A thru E - When the coin manager is in the idle state,
the blue buttons can be used to dispense coins from the tubes.
3
4
If however, the mode button is pressed before hand, these
5
buttons are used to navigate through the service & set-up menu
options.
3 - Display (LCD) - Displays warnings and menu information
4 - Mode Button - The mode button can be used to access the two configuration modes available. Service Mode and
Set-up mode.
• Service Mode: gives access to the most frequently used product configuration options.
• Set-up Mode: gives access to general product configuration options that are required when setting up your coin
manager.
5 - Service Connector - Allows you to connect a Cashflow programming Module (CPM) to the coin manager.
LED Light Codes
The 3 LEDs fitted on the coin manager provides up to the minute status information.
If all LEDs are off, then the coin changer has no power.. Check that there is power to the host machine and that the harness
is connected properly.
During power up or when reset, the LEDs will cycle 5 times.
If a coin changer ever flashes alternate red and green
, remove the coin changer, and send to a local service center.
Green LED Codes
A solid
means the coin manager is on and working properly.
Blinking
1 blink
means coins are being measured.
means a valid coin was accepted.
2 blinks
means an unknown coin was rejected.
3 blinks
means a valid coin that has been inhibited was rejected. You can program the coin manager or
the vending machine to inhibited a coin.
Slow flashing
Fast flashing
means the coin manager is in Set-up or Service Mode
means the coin manager has a message available for display.
Amber LED Codes
Solid amber
1 flash
means the coin manager is inhibited by the VMC.
means there is a discriminator error
2 flashes
means there is an accept gate error
3 flashes
means there is a separator module top sensor or tube cassette error.
4 flashes
means there is a dispenser module error
5 flashes
means there is a low change alert
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CASHFLOW 7512i Page-7
Part # 794471001 G2
Accessing the Service Mode
A Quick press of the Yellow
(mode) button will take you into the Service Mode menus. The display will change to
show the available option available. (see picture below).
Service Mode Menu
(Options Available)
Available options are:
Par
Cassette
Setup
Audit
Flashing
Quick Press
Mode Button
“Audit” Changes to
“back” in 2 seconds
Par
If you press the A button in service mode, the coin manger will start par. The coin manager will either
dispense excess coins or ask you to insert a specific quantity of coins into each tube to equal the set par
value. (For more information on par options, refer to the set-up mode section).
PAR (Float)
The PAR default setting (comes set from the factory) is “PAR to Level”. PAR to Level allows you set
the level of each individual tube so that once the level is reached, further coins may be sent to the cash
box.
The default PAR Level (from factory) is full tubes.
If you change the PAR setting to “PAR to Value”. The default value is $50.
Par to value looks at the total value of coins in all five tubes.
The PAR (or float) operation has three stages:
•
•
•
Payout of any coins above the PAR
Request insertion of coins that are below PAR
Display Results
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CASHFLOW 7512i Page-8
Part # 794471001 G2
Cassette
If you press the D button in service mode, you enter cassette mode. In Cassette mode, you will need to
enter a cassette code or insert a coin through the acceptor. The cassette mode allow you route coins to
different tubes. You may choose a preprogrammed cassette or custom configure a cassette.
Pre-Programmed USA Cassettes
Key Code
TubeA Tube B Tube C Tube D Tube E
AA
10
5
25
25
5
AB
10
5
25
$1
5
BA
25
5
25
25
25
BB
10
5
10
25
5
CC Custom cassette 1 - defined in factory or by service tool.
CD Custom cassette 2 - define yourself using cassette teach.
DAC
25
5
$1
$1
25
DCA
25
10
25
$1
5
DCB
25
10
$1
$1
5
DCC
25
10
25
25
5
DCD
5
10
10
10
5
DCE
10
10
10
10
5
Tube
E
Tube
A
Cassette viewed
from above
Tube
B
Tube
C
Tube
D
Custom cassettes:
You must always include at least one 5c tube in all custom configured cassettes.
Do not place the $1 tube in position A or B.
Do not place the 25 cent tube in position B.
Do not place the 10 cent tube in position E
Coin Tube Base Color
Max Fill ($)
Manual Fill($)
5c
10c
25c
$1
77 (3.85)
115 (11.50)
84 (21.00)
69 (69.00)
87 (4.35)
127 (12.70)
96 (24.00)
81 (81.00)
Red
White
Black
Blue
Tube Position – OK
A,B,C,D,E,
A,B,C,D,
A,C,D,E,
C,D,E,
Select the cassette option, Insert a nickel into the top of the coin manager. Select all tube locations (AE) where you placed a nickel tube. Follow the same procedure with remaining coins for which a tube
has been assigned in your custom cassette. Once all letters on the display have been replaced by a coin
denomination press the next button. The display will ask you to accept / cancel the change. Once you
accept the change press OK to complete the operation.
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CASHFLOW 7512i Page-9
Part # 794471001 G2
Setting or Changing Options
Setup
If you press the E button in service mode, you enter setup mode. In Setup mode a warning will appear
asking you to press the A- B -C buttons to make sure you want to enter this menu. Once you press these
buttons, you access to the following:
A
B
C
WARNING! Setup
Menu - Press Code
To Enter
Exit
u to select par style (par to auto, par
ar to value).
Messages*
*If a message is available setup mode will begin with this option to view the message.
If no message is available, the setup mode will start with “par options”.
PAR OPTIONS
CHANGE MGMT
VENDOR OPTIONS
COIN CONFG
AUDIT CONFG
GENERAL
ERROR LOG
TEST
LANGUAGE
Allows you to setup tube fill levels and coin payout mix to optimize coin return.
Allows you to setup option that are specific to the Multi Drop Bus (MDB) interface.
Allows you to setup token teach, security, coin setup, channel setup, exchange rate,
and alarm timeout (0 - 1275 seconds).
Allows you to view the machine id and serial number under the setup option, reset
the ir pod password, and set the install date, edit report titles and edit interims in the
printer option.
Allows you to calibrate tubes, change coins being accepted, reset the clean-me level,
save changer setting or restore the last saved settings.
Allows you to view or reset the last 10 error logs recorded by the coin manager.
Allows you to test the coin manager components, connectivity, and coin manager
information.
Allows you to change the language displayed (English, French, Spanish, Italian,
Portugues, etc).
Defining each setup option:
Messages*
Messages are the result of “tube wizard”. Tube wizard is an application that generates
tube and cassette suggestions in any of the par options. These messages suggest
different tube configurations based on the coin managers operation over previous
weeks of constant operation. If coin demand changes or fluctuates over time,
messages will appear suggestion changes.
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CASHFLOW 7512i Page-10
Part # 794471001 G2
Defining each setup option(continued):
PAR OPTIONS
CHANGE MGMT
Par is the level/value of coins that are to be left in the changer after the route person
fills/services the coin manager. Three types of par options are: par levels, par value,
and snapshot par.
Par to level
Tube fill level:
Fill to Max Capacity - means the tubes will fill to capacity. Capacity for each coin are:
5c - 77 coins, 10c - 115 coins, 25c - 84 coins, $1 - 69 coins.
Fill to Par- means that additional coins, that exceed the setup amount, will be routed
to the cashbox.
Large Coins - means “Best for customer” Fewest coins paid out to consumer.
Small Coins - means “Best for operator” Small coins dispensed more often. Less
small coins directed to cashbox.
Change machine - Acts like a bill changer machine. Will give a mix of coins
(i.e.$1=3x25c,2x10c,1x5c).
VENDOR OPTIONS
Optimize change:
Off / On - If “On”, the coin manager decides the best mix of change to dispense.
Levels:
Level - MDB protocol has Level 2 and Level 3 (MDB comms type). Keep always in
Level 3. Consult MEI technical support for more detail regarding this option.
Coin Counts:
As TRC0004 - reports first 3 coins as zero as does the TRC6512.
As CF 1234 - reports all coins in tubes as does the CF690 (Euro).
Par coins:
Hide / Report - When filling, par coins credit is not reported in the hide mode. In
report mode par coins are credited to the machine.
Coin Scaling:
Should be set to 5 for US and Canada. Never change this setting.
Decimal Pnt:
Should be set to 2 for US and Canada. Never change this setting.
Country:
Should be set to 0001 for US and Canada. Never change this setting.
COIN CONFG
Token Teach:
Select a location (1 - 6)
Value token - Enter value, then name then insert 32 samples
Vend token - Enter name, then insert 32 samples
Reject token - Enter name, then insert 32 samples
Slug - Enter name, then insert 32 samples
Security (changes settings for all 32 coin channels):
Hi acceptance - Default setting. Should remain in this mode unless frauds occur
Hi security - Tighter acceptance window. Used if frauds occur.
Coin Setup:
Allows operator to edit values (i.e. US and/or Canadian), enable/disable acceptance
and change coin type (coin, token, slug).
32 coin channels available.
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CASHFLOW 7512i Page-11
Part # 794471001 G2
Defining each setup option(continued):
COIN CONFG
Channel setup:
Channel 1 -32 (enabled / disabled)
Acceptance parameters for an individual channel can be set.( i.e. changing the US.10
cent coin from high acceptance to high security).
Exchange rate:
Set the exchange rate between two currencies (i.e. exchange rate from US$ to CN$ is
set at US$1 to CN$1.5819). The operator must set and maintain the exchange rates as
they fluctuate.
Cleanme level:
Default level @ 59%. A cleanme message will appear if acceptance falls below this
set value. An operator may change the percentage.
# of accepted coins out of the last 64 coins
This percentage is based on: ____________________________________
* 100%
the last 64 coins inserted
Alarm timeout:
Operator may set unit to reject coins in increments of 5 seconds after a fraud is
detected. Default has this feature turned off.
Alarm time x 5 seconds (i.e. if alarm time is set a “2”, coins will be rejected for 10
seconds after a fraud is detected).
The following types of tokens can be taught:
· Vend token – the token is reported as an MDB TOKEN to the machine, which
typically treats it as a free vend token, for more precise information on vend token
handling refer to the vending machine manual.
· Value token – the token is assigned a value (as per a coin) and accepted and
routed to cashbox. As MDB does not distinguish between coin credit and token
credit it will be possible to get change or returned monies having inserted a value
token.
· Reject vend token – the token is reported as an MDB TOKEN to the machine,
which typically treats it as a free vend token, for more precise information on
vend token handling refer to the vending machine manual. However, this token
will always be returned to the customer in the reject chute even though it is
credited as being accepted as a token. A typical application would be using a
token to open a newspaper vendor on a street corner.
· Slug – this allows a fraudulent object to be taught and inhibited, to prevent it
being accepted and credited as a valid coin.
See token diagram on the next page.
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CASHFLOW 7512i Page-12
Part # 794471001 G2
Defining each setup option(continued):
Vend Token
AUDIT CONFG
Value Token
Reject vend token
Slug
Setup:
Reset audit - None, interims, totals + Interims
None - means no reset after collection of audit information
Interims - all interims values are reset after each collection
Totals + Interims - All values (including historical) are rest after collection. Operator
decides on feature’s use.
Machine ID: (default is unit serial number)
Operators may change this number to suit needs. The machine ID will appear in DEX
readings.
IR password (Reset):
This option is for remote IR port. Does not affect the IR port on the changer keypad.
Printer:
The entire printer feature sets printed report parameters if an optional printer is
installed on the changer.
Report type
Basic (print basic report)
Interims (prints basic + interims)
Free Vends (prints all three reports)
Report Languages - English, French, German, Dutch, Spanish
Report Title
Edit as needed.
Install date
Edit as needed.
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CASHFLOW 7512i Page-13
Part # 794471001 G2
Defining each setup option(continued):
GENERAL
ERROR LOG
TEST
LANGUAGE
Accept / pay:
Allows operator to change between coins accepted and coins paid out from tubes.
Calibrate tubes:
Should only be performed by service personnel!
Settings:
Allows operator to set configuration of changer and save. If settings are unknown,
operator can restore to last saved setting.
Save (save new configuration settings)
Restore (restore last saved settings)
View / reset:
Allows operator to view last 10 error records. These are shown from newest to oldest.
Errors in log may be erased (reset).
Auto / Manual / Info:
Auto test - performs an auto test of all components of the coin manager. Upon
completion of a successful test, the changer will display “passed”.
Manual test - Allows you to perform individual test of the components.
The components are:
Coin sensors (coin sensor idles)
Accept gate (checks accept gate sensor)
Gate Sensor
Separator
Cassette
Dispenser
Temperature
Comms
Other
Info:
In the info mode, the following information is provided for servicing purposes.
Software version, Hardware version, Boot loader version, coin manager serial
number, acceptor serial number.
Language is set at factory. Operator can change as needed. The following languages
are available.
English, French (Euro or Canadian), Spanish (Spain or Latin American) , Dutch,
Portuguese, Italian.
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CASHFLOW 7512i Page-14
Part # 794471001 G2
Defining each setup option(continued):
Setup Menu Map
Set-up
Æ
Language
Æ
Test
Æ
Module
Connectivity
Info
Æ
Error Log
Æ
View
Reset
Æ
General
Æ
Accept/Pay
Calibrate tubes
Clean Me
Settings
Æ Coin sensors
Accept gate
Gate sensor
Separator
Cassette
Dispenser
Temperature
Comms
other
Save
Restore
Æ
Æ
Audit Cfg
Æ
Set up
Ir Password
Printer
Report Type
Report
Language
Report Title
Install Date
Æ
Coin Cfg
Æ
Token Teach
Security
Coin Set-up
Channel Set-up
Exchange Rate
Alarm Timeout
Coin 1.. 32
Æ
Vendor Options
Æ
MDB Options
Æ Optimize change
Level
Coin Counts
Par Coins
Coin Scaling
Decimal Pnt
Country
Æ
Change Mgmt
Æ
Tube Fill Level
Payout mix
Æ
par/float Options
Æ
Select Style
Set par/float value
Set Par Level
Snapshot Par Level
Æ
Messages
Æ
View
Reset
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Æ US value
CN value
Coin acceptance
Coin type
CASHFLOW 7512i Page-15
Part # 794471001 G2
Audit
If the yellow Mode Key is pressed twice in quick succession (with cassette in), then the display will
show audit information. Each message will be shown for 3 seconds. The screen can be frozen on the
display by pressing “pause”. The “pause” button will then alter to become a “resume” button . When the
“resume” button is pressed, the screens will continue to show, in sequence, the audit information.
Audit information displayed:
Value of Cash to Cashbox
Annualized Estimates
Value of Cash to Tubes
Sales Lost in Exact Change
*Value of Bills Accepted
Percentage time in Exact Change
Value dispensed as change
Value of Sales in Exact Change
Value of manual dispense
Value of Sales with Change Available
Total Tube value
Number of Sales in Exact Change
Tube A Count
Number of Sales with Change Available
Tube B Count
Average Price with Change Available
Tube C Count
Time In Change
Tube D Count
Time With Change
Tube E Count
Time Disabled by VMC
* “Value of Bills Accepted” will be present in the audit information, only if the bill acceptor is attached
to the coin manager’s optional MDB peripheral harness.
Audit Screens
There are three types of data shown. The first set of screens show historical data (sometimes referred to
as totals or non-resettable values). These values are set to zero when the product is built and then always
increase. The second set of screens show the current status of the tube counts and the third set show
estimates for yearly performance.
Audit Data
Non resettable historical records
Current Tube Status
Estimates
Yearly predictions
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CASHFLOW 7512i Page-16
Part # 794471001 G2
Audit(Cont.)
The first few screens show audit information that has been recorded from actual events. They are a
historical record of what has occurred since the product was first built.
EVA DTS (DEX) reference CA306
Value of Cash To Cash Box Since Initialisation
Value of cash sent to the cashbox. Does not include value of
free vend tokens. Non-Resettable.
EVA DTS (DEX) Reference CA307
Value of Cash To Tubes Since Initialisation
Value of all coins sent to the inventory tubes, including sales
and manual fill modes. Does not include value of free vend
tokens. Non-Resettable.
EVA DTS (DEX) Reference CA308
Value of Bills In Since Initialisation
Total value of all bills (banknotes) accepted. Does not include
value of free vend tokens. Non-Resettable.
NOTE: This screen will only be shown if a bill validator is
currently attached (or has been previously attached) to the MDB
peripheral connector. The changer cannot record audit information
if the bill validator is connected directly to the vending machine.
EVA DTS (DEX) Reference CA403
Value of Cash Dispensed Since Initialisation
Total value paid out as change plus the value manually
dispensed. Non-Resettable.
EVA DTS (DEX) Reference CA404
Value of Cash Manually Dispensed Since Initialisation
Total value dispensed manually. Non-Resettable.
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CASHFLOW 7512i Page-17
Part # 794471001 G2
Audit (Cont.)
Current Tube Information
The next few screens show information that describes the current state of the coin tubes.
Total Tube Value
This is the total currency value of all the coins stored in the
entire cassette.
Tube A Count
This screen shows the number of coins in tube A e.g. 80
The type of coin e.g. 25 cent. The total value of coins in this
tube $20.00 (i.e. 80 x 25c = $20.00)
Tube B Count
This screen shows the number of coins in tube B, the type of
coin and the total value of coins in this tube
Tube C Count
This screen shows the number of coins in tube C, the type of
coin and the total value of coins in this tube
Tube D Count
This screen shows the number of coins in tube D, the type of
coin and the total value of coins in this tube
Tube E Count
This screen shows the number of coins in tube E, the type of
coin and the total value of coins in this tube
Critical Business Statistics (CBS) - Estimates of Yearly Performance
This information provides annualized estimates of product performance and is based on a limited amount
of information. The product collects data up to the last 28 days and makes yearly estimates based on this.
However this information may not be totally accurate for the following reasons a) As the MDB protocol does not give the changer full knowledge of the vend cycle, the CF7XXX has to
make some assumptions on when and what data to collect (i.e. when vends occur and how much they
cost.).
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CASHFLOW 7512i Page-18
Part # 794471001 G2
Audit (Cont.)
Critical Business Statistics (CBS) - Estimates of Yearly Performance
b) The unit will store data for up to the last 28 days and will extrapolate this to give the yearly estimates, 1
full day of information is sufficient to start the process. Therefore predictions based on a small amount of
information (less than 28 days or small number of transactions) may give wildly inaccurate predictions.
This also does not account for any seasonal variation.
c) Exact change is when the changer has less than 5 tube coins of any of the lowest three coin denominations
This may be a different algorithm to that used in the vending machine so the light on the front of the
machine may not reflect what the changer thinks is happening.
d) If a tube is not in use (dispenser jam or tube jam) then the count for that tube is set to 0 and if it is a sole
low denomination tube this will cause the changer to consider it is in exact change for 100% of the time.
e) If bills are used to pay for products and the validator is not connected to the changer MDB peripheral
connector then some of yearly estimates will be wrong.
GUIDANCE NOTE: CBS information is not audit data and must be treated separately. As it is
based on estimations it should really be used as a guide only.
This message is shown for a few seconds as a prompt that the
next few screens of information are estimates for the upcoming
year.
Sales Lost in Exact Change
This value is an estimate of how much sales will have been lost
because customers may have been deterred from using the machine
because the exact change light is on.
This figure is calculated by comparing the daily rate of sales when
the exact change light is on vs. daily rate of sales when exact change
light is off then scaling this figure to be a yearly estimate.
Percentage Time in Exact Change
This is a computation of the % time the changer was low in change
over the monitored period.
This percentage is computed using the actual measured amount of
time in exact change over the monitored period and the duration of
the period.
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CASHFLOW 7512i Page-19
Part # 794471001 G2
Audit (Cont.)
Critical Business Statistics (CBS) - Estimates of Yearly Performance
Value of Sales in Exact Change
This is a yearly estimate of how much product will be sold when the
changer deems it is in exact change.
Computed by averaging the amount of sales in exact change over the
monitored period then scaling it to a yearly figure.
Value of Sales With Change Available
This is a yearly estimate of how much product will be sold when the
changer deems it has change available.
Compute an estimate by averaging the amount of sales when change is
available over the last period
Number of sales in Exact Change
This is a yearly estimate of how many products will be sold when the
changer deems it is in exact change.
Averages the number of sales when in exact change light over the
monitored period then scales it to a yearly figure.
Number of sales with Change Available
This is a yearly estimate of how many products will be sold when the
changer deems there is change available.
Averages the number of sales when not in exact change light over the
monitored period then scaling it to a yearly figure.
Average Price With Change Available
This is computed by dividing total value of sales by the number of
sales to get an average price.
Notes:
This figure may create a value which is not a multiple of valid coins
e.g. 21 cents, this is likely to occur on vending machines that have
more than one price. The value of a sale is not available over MDB
and so the changer has to estimate this based on coins inserted and
paid out. This simple estimation will not be correct if the machine is
in multi vend mode, a bill validator is attached directly to the machine or any other non standard set-up.
Time With Change Available
This is a yearly estimate of how long the changer will be operating
with change available (i.e. exact change light OFF)
This is based on a daily average time with change available scaled
to a yearly figure.
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CASHFLOW 7512i Page-20
Part # 794471001 G2
Audit (Cont.)
Critical Business Statistics (CBS) - Estimates of Yearly Performance
Time Disabled by VMC
This is an estimate of how long in a year the machine will be disabled.
This could be because of machine faults, sold out of product, jams
etc
The average daily time disabled is scaled to make a yearly figure.
Notes
This excludes brief periods (less than 30 seconds) typically when
the product is being vended
The changer does not have a real time clock so only measures time
when it is powered on. If the machine is switched off at night and
operates correctly during the day the changer will measure it as never
being disabled.
End of Audit
This message indicates there are no more screens of information
CBS Yearly Estimate Formula
This section contains more detailed formula used in the computation of the CBS yearly estimates.
The following items are monitored during the monitoring period (which may be upto 28 days long) and are
used as a basis for the estimates:
· Value of Sales
· Number of Sales
· Duration in Exact change
· Value of Sales when in exact change
· Number of Sales when in exact change
· Duration disabled by vending machine
· Elapsed time (time when the changer is powered on)
Sales Lost in Exact Change
SalesValueDuringOK = Sum of sales for last period / number of days in the period
SalesValueDuringEC = Sum of sales for last period / number of days in the period
SalesValueECPerDay = (SalesValueDuringEC * ONE_DAY_IN_MINS) / MinsInECCondition;
SalesValueOkPerDay = (SalesValueDuringOK * ONE_DAY_IN_MINS) / MinsInOKCondition;
Yearly sales lost in exact change = (SalesValueOkPerDay - SalesValueECPerDay) * 365
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CASHFLOW 7512i Page-21
Part # 794471001 G2
Audit (Cont.)
Critical Business Statistics (CBS) - Estimates of Yearly Performance
Percentage Time in Exact Change
Total time in exact change = sum of time in EC for last period
Average time per day in EC = total time in exact change / number of days in the period
Percentage time in exact change = (average time per day in EC/time for 1 day) * 100
Value of Sales in Exact Change
Daily sales in EC = sum of sales when EC ON in last period/ number of days in last period
Yearly sales in EC = daily sales in EC * 365
Values of Sales With Change Available
Daily sales with change available = sum of sales when EC OFF in last period/ number of days in
last period
Yearly sales with change available = daily sales with change available * 365
Number of sales in Exact Change
Volume of daily sales with EC ON = sum of volume of sales when EC ON in last period/ number
of days in last period
Yearly volume of sales with EC ON = volume of daily sales with EC ON * 365
Number of sales with Change Available
Volume of daily sales with EC OFF = sum of volume of sales when EC OFF in last period/ number
of days in last period
Yearly volume of sales with EC OFF = volume of daily sales with EC OFF * 365
Average Price With Change Available
SalesValueDuringOK = sum of value of sales in the last period while EC is OFF
SalesNumberDuringOK; = number of sales in the last period while EC is OFF
average_price = SalesValueDuringOK / SalesNumberDuringOK;
Time With Change Available
SecsInECCondition = sum of time in exact change in last period
Daily average time in EC = SecsInECCondition / number of days in last period
Daily average time with change available = Number of seconds in a day - Daily average time in EC
Yearly Time with change = Daily average time with change available * 365
Time Disabled by VMC
Total time disabled = sum of time disabled in the last period
Average daily time disabled = total time disabled / number of days in the period
Yearly time disabled = average daily time disabled * 265
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CASHFLOW 7512i Page-22
Part # 794471001 G2
How to Section
How to remove envelope icon from display
Symptom:
Envelope icon appears on display
Cause :
SMS message available for reading
Fix:
View, action and delete SMS message
The changer will indicate an SMS message is present
as follows:
·
·
Green LED flashes fast continuously
Envelope icon appears on the display
The system reports the presence of an SMS message
when:
·
·
The operator has left a message for another
operator/user
Tube Wizard is recommending a change to cassette
configuration
To view message(s):
·
·
·
·
·
·
Press Menu
Press Setup
Press abc
Press Select to choose messages
Press Select to view messages
Use Up/Down arrows to access messages
To delete message(s):
·
·
·
·
·
·
·
Press Menu
Press Setup
Press abc
Press Select to choose messages
Press Up Arrow
Press Select
Press Accept to delete all messages
NOTES:
The same Tube Wizard message is not repeated in
consecutive weeks for the same cassette - even if the
recommendation made is still valid. Changing the
cassette model resets the recommendation system.
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CASHFLOW 7512i Page-23
Part # 794471001 G2
How to Section
How to delete a token
Symptom:
Want to remove a previously taught token
Cause :
Token was previously taught and accepted
Fix:
Follow this procedure to delete the token data
Enter token teach by:
·
·
·
·
·
·
·
Press menu then
Press Setup then
Press abc
scroll to the “Coin cfg” menu and
Press Select.
Scroll to “Token Teach” menu
Press Select.
Select the required token by:
· using the up and down keys
· press OK.
Select the type of token as:
· Delete - this will delete data for the existing
token in this slot
A confirmation screen will be displayed:
· Press Accept to delete the token
When a token has been deleted it will
· Delete the data that was used to validate what
object it was
· Delete the type of token
· Delete the token description (text string)
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CASHFLOW 7512i Page-24
Part # 794471001 G2
How to Section
How to understand tube terminology
Flared top section
Top
of tube
Clip on
back of
tube, to
retain tube
in cassette
chassis
% full
markings
Hinge point on front of tube,
engages with cassette chassis
Bottom
of tube
Coloured tube base (blue)
Tube References (Soft Options)
Tube full
Absolute top of the physical tube
(Factory set)
Max fill
Maximum number of coins the changer will
actively route a tube, further coins routed to
cashbox
(Factory set)
Float (par) Adjustable level, set by the customer. The level of
required coins at the end of a float operation (for
level
float to level).
Safe
Minimum number of coins to ensure best
dispense performance
(Factory set)
Empty
No coins in the tube, totally empty
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CASHFLOW 7512i Page-25
Part # 794471001 G2
How to Section
How to reset the “Clean me” message
Symptom:
Changer indicates it requires the deck to be cleaned
Cause :
Dirt build up on the coin flight deck
Fix:
Follow the procedure below to Clean
Changer displays a message indicating it
needs cleaning because it has detected that
recently (in the last 64 insertions) a lot of
coins are not being discriminated as a valid
coins
Open the lid
wipe both surfaces of the coin entry with a
damp cloth
Close the lid
Press menu
Press float on 7900 or par on 7512
Press A (there is no prompt by the A key)
The changer now displays it is OK
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CASHFLOW 7512i Page-26
Part # 794471001 G2
How to Section
How to calibrate a coin cassette
Symptom:
Changer indicates the cassette has not been calibrated
Cause :
The changer has not been previously calibrated with that cassette configuration
Fix:
Follow the procedure below to perform the calibration
If the display indicates a cassette is un-calibrated or you
want to improve the performance of the coin level
sensing system by calibrating the exact cassette that is
fitted to the changer then follow this procedure.
Remove the cassette and check it is empty then refit it.
Press menu then setup then abc
Scroll to the “General” menu then press Select
Scroll to the “Calibrate tubes” menu then press Select.
It will prompt you to check the corresponding cassette
is fitted, if it is then press Calibrate , otherwise press
Back and program the correct cassette code before
restarting this procedure.
The changer will check each tube at least twice so there
will be at least 10 clicks.
It will display a message when it has finished, press
OK.
Press the Back key repeatedly to exit the menu, the main
screen will now be shown with no un-calibrated warning.
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CASHFLOW 7512i Page-27
Part # 794471001 G2
How to Section
How to float/par the changer
Symptom:
Changer has more or less coins that the target float condition
Cause :
Changer has paid out and received coins since last being visited
Fix:
Float the changer as described
The float process involves two stages:
(a) Dispense of excess coins
(b) Addition of insufficient coins
If there is no action to be performed for a stage then it will
automatically move onto the next stage.
To start the float operation:
· Press menu
· Press float
The changer will display a screen indicating it is about to start
the float process. Either
· Wait 2 seconds or/
· Press the Next key
(a) Dispense excess coins
The changer will now dispense any excess coins, that is extra
coins in the tube that are above the float setting. As coins are
dispensed remove them from the coin return on the machine. If
the coin return fills up with coins the dispense process can be
paused (then resumed) by either:
· Press Pause key or/
· Press the reject lever
When all the excess coins have been dispensed the changer will
move to stage 2 and ask the user to insert any additional coins it
requires to achieve the float condition.
(b) Add extra coins
Insert the requested coins into the changer through the validator,
the count of how many coins are required will decrease as coins
are inserted. When sufficient quantity of a coin have been inserted
it will stop prompting for that coin and reject any more of that
type.
When all coins have been inserted it will display a message
indicating that the float condition has been achieved.
It is possible to skip stages and not insert all the required coins, if
this is done a different message will be shown at the end indicating
the float condition was not achieved.
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CASHFLOW 7512i Page-28
Part # 794471001 G2
How to Section
How to set-up auto float/par
Symptom:
Too much money in changer tubes
Cause :
Manually set float/par levels are too high
Fix:
Use auto float/par and set it up as described
What is Auto Float/par?
The aim of this algorithm is to have no settings for the customer to setup or compute and the changer to
operate with the minimum amount of money in the tubes but ensuring the exact change light is rarely lit
and that change is available for vends.
How Does it work?
The algorithm uses probability calculations to reduce the chance of the exact change light coming and
monitors prices and whether bills are used to determine the fewest number of coins with the best optimal
mix.
Will it work immediately?
No, it requires some time to gather information on how the tubes are being used, during this time it will run
the tubes at their maximum level to ensure there is always enough change.
How do you Set-up Auto Float?
Use the keypad and screen to enable this function by:
· Press Menu
· Press Setup
· Press abc
· Scroll to the item "Float options" then press Select
· Scroll to the item "Select style" then press Select
· Press Edit
· Use the up or down keys to alter the setting to "Float to
auto" then press OK
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CASHFLOW 7512i Page-29
Part # 794471001 G2
How to Section
How to set-up float to value
Symptom:
Want to improve coin mix in the tubes but keep same value in the tubes
Cause :
Manually set float to level not working well enough
Fix:
Use float to value to allow changer to compute coin levels
What is Float to value?
The aim of this algorithm is for the customer to have a simple setup and audit process i.e. they want $xx in
the tubes but for the changer to compute and dynamically alter the ratio of coins in the tubes to give the best
mix of coins ready for change.
How Does it work?
The algorithm continually computes coin levels for each tube based upon whether tubes are naturally
replenished or deplenished and how often the tube is used for change. It will always try and have at least 7
coins in any tube to ensure the exact change indication is kept off, then add more coins to the tubes until the
overall value for the entire cassette matches the target value set by the customer.
IN
Total float value = $32.25
Dynamic
levels
Algorithm
OUT
% times this tube used
for change vs. other
tubes
Will it work immediately?
Yes, however the initial mix of coins in
the tubes may be non optimal
How do you set it up?
Use the keypad and screen to enable this function by:
Set the float style
· Press Menu
· Press Setup
· Press abc
· Scroll to the item “Float options” then press Select
· Scroll to the item “Select style” then press Select
· Press Edit
· Use the up or down keys to alter the setting to “Float to
value” then press OK
Set the float value
· Scroll to the item “Float value” then press Select
· Press Edit
· Use the up/down/left/right keys to alter the value
· Press OK
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CASHFLOW 7512i Page-30
Part # 794471001 G2
How to Section
How to use snapshot float
Symptom:
Want to set float levels to current cassette condition
Cause :
Float not setup as required
Fix:
Use snapshot float by following this procedure
The snapshot feature works regardless of the float style (to level or to value, not applicable
to auto). When this function is triggered it takes a “snapshot” of the current cassette and
uses that to setup the float settings.
If required fill the cassette with the required amount of coins.
· This maybe a specific mix of coins e.g. 30 x 5c, 20 x 10c, 10 x 20c
· Or so each tube is filled so the top of all the coins are at the same level
· Or the overall value of the cassette holds €20.00
To take a snapshot follow these steps:
· Press menu
· Press float
· Press snapshot
If operating in “float to level” the screen will show the current levels in the tubes
If you wish to adjust a value then
· press the adj key
· use the up/down keys to select the required tube
· press Edit
· use the up and down keys to alter the value
· press OK
· when all coin tube values have been updated (if required) press Done
·
If the displayed values for float are acceptable then press Accept
If operating in “float to value” the screen will display the total value of coins currently in
the cassette
·
·
This value can be adjusted by pressing the adj key in a similar manner
When the required value is displayed press Accept
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CASHFLOW 7512i Page-31
Part # 794471001 G2
How to Section
How to select a payout algorithm
Symptom:
Changer does not payout coins using required mix
Cause :
Incorrect payout algorithm being used
Fix:
Configure changer to use desired algorithm
There are three payout algorithms in the Cashflow 7000 Series changer
to improve the performance when used for particular tasks.
· Big coins
· Small coins
· Change machine
Big Coins (Best for Customer)
This is the default payout mix, use this if you want the fewest number
of coins paid back to the customer. Hence these will typically be
large value coins. This is sometimes referred to as a least coins
algorithm
Small Coins (Best for Operator)
This simplifies the operation of counting coins in the cashbox for the
routeman/counting room by having less quantity but higher value
coins in the cashbox, as a result the customer may get a few extra
small coins as change. This payout mix aims to leave the changer
with space (10%) in the lowest two coin tubes for coins to be routed
to rather than go to cashbox.
Change Machine
This is intended for applications where a dedicated change machine
that converts bills to coins has been removed from the site and the
remaining vending machines are setup to operate in a replacement
capacity. The changer will try and payout one coin of each type, to
give a mix of coins then pay any remaining value using the big coins
algorithm.
All payout algorithms may be affected by the amount of change coins available, as typically they will
try and stop a tube depleting to very low levels and use non preferred coins for payout instead.
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CASHFLOW 7512i Page-32
Part # 794471001 G2
How to Section
How to audit bill information on an MDB changer
Symptom:
No bill audit information in the changer
Cause :
Bill validator connected between changer and MDB machine
Fix:
Connect the bill validator to the MDB peripheral loom on the changer as described
Connect the changer’s MDB loom to the MDB loom
on the vending machine (shown in red).
If one is not fitted then fit an MDB peripheral loom
to the changer.
Connect the MDB peripheral loom from the changer
to the MDB loom of the bill validator (shown in blue).
Power on the changer. The changer will listen to
messages between the vending machine and the bill
validator and audit any bills that are accepted.
The audit value that records the non resetable value
of bills accepted can be accessed on the display by
pressing the yellow mode key twice in quick
succession (menu then audit). When a validator is
attached then this extra screen of information will be
shown.
The audit data can be collected via the Ir port (or a
DEX terminal if a DEX lead is fitted). Bill data will
be logged in the bold fields in the audit data.
DEX Data Extract
DEX field descriptions
DXS*9252131001*VA*V1/6*1
…
CA3*100*0*0*1*615*100*415*1
…
CA14*100*1*1*1*1
…
DXE*1*1
CA301 = value of cash (coins and bills) in (interim)
CA304 = value of bills accepted (interim)
CA305 = value of cash (coins and bills) in (total)
CA308 = value of bills accepted (total)
CA1401 = bill value e.g. 100 for a $1 bill
CA1402 = number of this bill type accepted (interim)
CA1403 = number of this bill type stacked (interim)
CA1404 = number of this bill type accepted (total)
CA1405 = number of this bill type stacked (total)
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CASHFLOW 7512i Page-33
Part # 794471001 G2
How to Section
How to setup tokens
Symptom:
Doesn’t accept tokens
Cause :
Tokens not taught or setup correctly in the changer
Fix:
Teach and configure tokens as described
CF7512 can have upto 6 tokens taught in the field.
Press menu then setup then abc then scroll to the “Coin cfg”
menu then press select. At the “Token Teach” menu press select.
Slots 27 to 32 are reserved for the 6 tokens that can be taught.
Select the required slot, typically an empty or unused one then
press OK.
Select the type of token you are about to teach:
· Value token - a token that has a value (similar in use to a
coin but tokens are routed to the cashbox only), you will be
prompted later to enter a value for this token.
· Vend token - where the vending machine will typically
give a free vend (this will vary from machine to machine)
· Reject token - this operates exactly like a free vend token
but it is returned directly to the customer
· Slug - a fraudulent object that will be rejected
· Delete - this will delete data for the existing token in this
slot
You can now alter the name that will be displayed when the token
is finally set-up, by default it will be named “T” followed by the
slot number e.g. T26. Use the cursor keys to alter the name then
press OK
You will now be prompted to insert 32 samples of the token.
Although you do not need to drop 32 the changer will perform
significantly better if you drop as many as you can. You should
not drop the same token repeatedly but use a collection of tokens
of the same type.
X 32
When 32 tokens have been dropped a screen will be displayed,
simply press the finish key.
The screen will then go to the beginning ready for another token
type to be taught, if you have no more to teach then press the
back key repeatedly to quit the menu.
5
10
Tok
Finally test that the tokens and all coins are accepted.
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CASHFLOW 7512i Page-34
Part # 794471001 G2
Frequently Asked Questions (FAQs)
How is MEI CASHFLOWTM 7000 different from other coin changers?
Simply put, MEI CASHFLOWTM 7000 is simple to use, yet very sophisticated in how it helps to manage
change and information.
This product is a whole new breed of coin manager with improved features over other models. The
combination of all these features resulted in the creation of a brand new tool that will increase your
profitability and efficiencies, and make your life easier. The true breakthrough is how it will do the work
for you without your constant intervention.
How does MEI CASHFLOWTM 7000 increase the operators’ bottom-line?
By providing a better mix and more available change, better pricing options, bill flexibility, higher reliability
and security, self reporting of lost sales and increasing account retention/customer satisfaction.
Drives Higher Sales:
1.
Virtually eliminates exact change situations
2.
Handles high value bills – $10 and $20 bills
3.
Provides true price flexibility
4.
Less down time – water resistant, jam resistant, more reliable
5.
Reduces service call since drivers can fix most issues
Lowers Costs:
1.
Accountability for all money, even cash in tubes
2.
Provides instant paring
3.
Drivers can resolve all jams, without tools
4.
Virtually no training needed
5.
Stores the least amount change necessary and prevents exact change issues
6.
Reports on how well your team is doing.
7.
Driver can alter the tubes by changing the cassette or the tubes
What does exact change really cost?
Most operators know it’s a problem, believe current prices are correct or perceive the value of lost sales is
insignificant. MEI CASHFLOW series 7000 shows you the true picture by individual vending machine.
MEI CASHFLOW series 7000 measures the selling rate when change is available and the selling rate
when change in either unavailable or low. Then computes the percent of time the problem has occurred
and the annualized value of not having enough change. For the first time management has the data from
their own locations to show if exact change is truly a problem.
How does it eliminate exact change?
Through change optimization, complete and easy tube replenishment and highest tube capacity.
Change Optimization – MEI studied change algorithms and found many in traditional coin acceptors make
poor use of change.
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CASHFLOW 7512i Page-35
Part # 794471001 G2
Frequently Asked Questions (FAQs) - Continued
For example, a 70¢ item purchased with a $1 bill can:
§ payout three dimes
§ quarter/nickel combinations (even when the dime tube is full)
§ If the nickel tube is quickly emptied the machine is unnecessarily put into exact change for all
other combinations.
The MEI CASHFLOW Series 7000 change override computes the coins to be paid and uses all combinations
to stretch the available coins as far as possible. This feature prevents certain prices from starving the
machine of change and allows the machine to have ample change.
Industry’s only Five Tube Changer with Complete Tube Replenishment – Each tube can be replenished
with the coins coming in from consumers. Coins are not diverted to the cashbox if space is available for
that denomination.
Easy Replenishment –The driver can easily refill the change tubes.
§ The three tube openings are the largest available – so the driver can pour in an entire roll of change
without even touching the mechanism.
§ A removable cassette can be refilled at leisure, and has an L-shaped base to prevent toppling.
§ The mechanism has a hook to hold the cassette in a completely accessible position. The driver does
not need a flat surface for the cassette and won’t need to hold open a flap with one hand while
trying to hold the change bag, get out change and put into a narrow slot.
Highest Tube Capacity – MEI CASHFLOW series 7000 tubes hold more that the competition. MEI has
five tubes, each with a height of 6 ¼ inches of coins (159mm). The total capacity of all tubes is 31¼ inches
change. The MEI capacity for one is like having an extra “invisible tube” of capacity compared to
competition.
Compare to the a five-tube competition with 5 3/8ths inches (136mm) tubes for a total of 26¾ inches.
Another four-tube competitor has space for only 5 ¾ inches (148mm) of coins in a tube to its tube full
sensor giving it a total replenishable capacity of less than 23 ½ inches.
What that means is that the MEI CASHFLOW series 7000 holds approximately 17% - 33% more volume
in coins than it competitors’ models.
How does the MEI CASHFLOW Series 7000 provide true price flexibility?
Stronger Location Negotiations – When negotiating to win a location the vend price can be the most
important consideration. But, certain prices cause change problems unless there is a change machine on
the same floor or in the same break room. Isolated machines run into exact change problems when moving
off a quarter multiple. Even dropping the vend price from 75¢ to 70¢ can trigger untenable service calls to
keep the machine’s change replenished. The “exact change prevention” capabilities in MEI CASHFLOW
Series 7000 allow the operator to negotiate without this constraint.
Maximize Specific Price Contracts – Certain customer contracts allowing pricing at or below 95¢. In
many cases, so many consumers are inserting dollars that the available price cannot be used. This means
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CASHFLOW 7512i Page-36
Part # 794471001 G2
Frequently Asked Questions (FAQs) - Continued
a lower price of 75¢ or 85¢ is the highest that can be supported without being buried in service cost to top
off a changer. (Industry average cost of service calls is $50.) The flexible tube configuration, larger
capacity and coin recycling enable better change management to support these price points.
Flexible Tubes to Optimize Payout – The cassette can have its tube reconfigured without using tools. They
are simply unsnapped and the desired new configuration snapped in.
How does it handle high value bills, not just $5 bills but $10 and $20 bills?
The unit allows the largest number of big diameter coins. Up to three, dollar tubes and a nickel tube can be
used. The changer can hold over $320 for making change. The unique L-shape cassette eliminates the
constraint that all tubes must fit in a straight row across the front of the changer. Allowing MEI CASHFLOW
series 7000 to handle truly large bills $10s and $20s that used to need a their own change machine.
What makes it water resistant, jam resistant and more reliable?
The unit meets MEI Gold Standard for Water Resistance. The MEI CASHFLOW series 7000 is designed
to take abuse from vandals squirting water in openings, outdoor machines with leaky seals and drivers
filling machines in the rain. The MEI CASHFLOW series 7000 will stay in service and prevent “jackpotting,”
and shorted boards.
MEI engineers reviewed the existing market base for the problems experienced by operators. Not just
MEI products, but all products. Iffy dispensing, coin jams, clearing out debris, off home dispensers and
dozens of other potential weak points have been researched and solved by eliminating them from the
design. For instance the lid opens wider. And, the dispenser has more than double the old power meaning
sticky and gritty coins are no longer an issue. For example, weak areas have been reinforced making them
tougher.
How does it reduce downtime and service calls?
Now the location staff or the route driver can fix the issues without leaving the machine down until the
repairman can be scheduled. The unit is designed to allow sticky bits of paper, match boxes, etc. to be
easily cleared without tools by the route driver.
Exact change is finally flagged. Exact change frustrates your customers, but on most machines there is no
indication to the driver that there is a problem. It is left for him to “discover” one or more key tubes are
short. Not a clear process for changers with opaque tubes. Finally, exact change triggers a warning, just
like poor acceptance or dirt, with a warning light that is clearly visible.
How does MEI CASHFLOW Series 7000 provide accountability of all money, even cash in tubes?
Sonar zeros in on tube cash. No matter how the tubes are filled to what point, the level sensing sonar
“reads it.” A single number is posted on the LCD display to show the total of all tubes. No eyeball
readings, no hand calculations, just a single number. Less labor, less ambiguity.
All of the money. Bills stacked, coins to cash box, coins in the tubes, all are measured. Again by reporting
a single number. If the tubes are replenished from traditional cash bag (take out a roll of dimes and take
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CASHFLOW 7512i Page-37
Part # 794471001 G2
Frequently Asked Questions (FAQs) - Continued
back five ones) then without special notes or accounting, the money will be tracked. The total in the cash
bag will be the same (like value for like value) and the total net in the mechanism will be the same too.
Less temptation. Maintaining tight accountability with minimal effort also reduces the time spent on
investigating and documenting cash irregularities.
What is the cash capacity of the tubes?
The tubes will hold up to $343 in US coins. A typical set up would hold $305.
How accurate is the sonar technology?
The sonar sensing is accurate +/- 2 coins. In approximately 0.2% (1 in 500), there could be a “fluke” where
accuracy is compromised. But upon the next sonar reading, the accuracy is again at the expected high
level.
How can my drivers attain instant paring?
MEI CASHFLOW series 7000 does all the work. The simplest accountability is to fill the machine with
product (to its planned level) and to replenish the tubes in the changer to their planned levels. Paring the
changer used to involve dumping out surplus coins and refilling the denominations that are not at their
levels.
Now with MEI CASHFLOW series 7000’s advanced processor, the LCD display and the sonar system in
the changer do most of the work. With the push of the par button, surplus coins are automatically dispensed.
(And, if dispensing is too rapid, there is a pause button.) The display lists any denominations that are short
and by how much.
MEI CASHFLOW series 7000 makes paring simpler, faster and more accurate.
Can my drivers manage service calls without tools?
Drivers call fix all jams and save two calls. Having all coin paths accessible without tools, and eliminating
special repair training fix saves the cost of the repair call – typically $50. As mentioned earlier it also
makes money by brining the machine back to operation sooner. That is the second saving.
Driver can alter the tubes by changing the cassette or the tubes. As prices change or machines relocate,
what is an ideal tube configuration may be suddenly be inappropriate. Both options for changing tubes are
available in the MEI CASHFLOW 7000. Swap tubes individually by just snapping them in and out. Or,
change out the entire cassette. In both situations the LCD display walks you through each step.
How much training is required?
Almost no training is needed, operations are very simple.
The “Smart” Display Menu Tells All. Similar to a cell phone, the display presents simple menus that list
what is available and guide the driver though what to do. And, if desired, choose from up to 8 languages
including Spanish and French.
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CASHFLOW 7512i Page-38
Part # 794471001 G2
Frequently Asked Questions (FAQs) - Continued
Service versus Replenish. Should you want to restrict what the drivers can change, the controls are build
in. Paring or changing the tubes is available to everyone. However, changing par levels and changemaking modes are restricted with a password.
How do I eliminate excess change in my tubes?
Every Coin Must Earn Its Keep. With MEI CASHFLOW 7000 only the least amount of change necessary
is stored. The automatic par mode computes how many of each denomination is needed to prevent an
exact change occurrence. This is the number of coins retained, not one extra. Automatic float customizes
the change retained so it is best for that specific location.
Will the changer dispense to zero coin inventory?
Yes.
How can I tell how well my team is managing the equipment?
Last month statistics – provides reports to supervisors on how much time was spent in exact change mode,
the value of lost sales and which tubes were replenished. This information can be used to improve driver
training and provide objective feedback.
How will I restrict access to changer information?
You can set a code on the mechanism such that a supervisor can restrict access to sensitive soft option
features. Drivers will however have access to audit data – as they should.
What is the life of a changer?
MEI CASHFLOW series 7000 has a projected 12-year design life, which is twice that of the competitors.
And, an anticipated 20-year physical life.
Does MEI offer a trade-in upgrade program? - No
Can I get training for my technicians?
While downtime and repairs are minimal, route drivers can manage many required repairs during servicing.
Drivers have true jam detection through the LCD diagnostics. MEI CASHFLOW series 7000 is very
intuitive and requires practically no training. Most drivers who use a cell phone will find the LCD display
very easy to navigate.
How will MEI CASHFLOWTM 7000 be serviced?
Service for MEI CASHFLOW series 7000 will be consistent with other MEI products. You may contact
your MEI Authorized Service Center (ASC), just as you do with your other MEI products.
Do all tubes self fill?
Yes.
Can we just buy “tubes” to change the cassette?
Yes.
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CASHFLOW 7512i Page-39
Part # 794471001 G2
Frequently Asked Questions (FAQs) - Continued
Can we get labels to identify the tubes?
Yes, this is planned to be available for the launch date.
Are there limitations on the tube configurations?
The only restrictions are; no dollar tube in A or B-positions, no quarter tube in B-position, no dime tube in
E-position.
Can you teach the changer in the field?
In the field, you can “teach” tokens and program coins.
What is the warranty on the MEI CASHFLOW series 7000?
The standard warranty period is 2 years, or the same as your current customer agreement.
Who should I contact with questions about MEI products?
Your first line of contact is your MEI sales representative. For additional questions, you may contact the
MEI customer service team, at 1-800-345-8215.
How do I reach the technical support call center?
The technical support number is staff by industry-specific technical field representatives and can be reached
by calling 800-345-8215.
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CASHFLOW 7512i Page-40
Part # 794471001 G2
CF7512i Exploded Views
Acceptor
MMI
Chassis
Acoustics
Cassette
Dispenser
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CASHFLOW 7512i Page-41
Part # 794471001 G2
CF7512i Acceptor
3
4
1
7
5
2
6
8
1 Acceptor Main
Body Latch
2 Acceptor Module
4
3 Acceptor Sensor
Cover
1
4 Reject Lever
2
5 Interface
Control Board
3
6 MMI / LCD
Assembly
7 End Snubber
8 Ramp Snubber
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CASHFLOW 7512i Page-42
Part # 794471001 G2
1 Chassis
2 Acoustic Manifold
3 Upper Control Board Cover
4 Lower Control Board Cover
5 Dispenser Assembly
1
3
2
4
5
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CASHFLOW 7512i Page-43
Part # 794471001 G2
CF7512i Cassette
2
4
3
1
1 Cassette Cover
2 Cassette Release Latch
3 Cassette Skeleton
4 Coin Tubes
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CASHFLOW 7512i Page-44
Part # 794471001 G2
CF7512i Dispenser
DispenserMotor
Upper Gear Housing
Electromagnet
Magnetic Clutch
Lower Gear Housing
Actuator Arm
Baseplate
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CASHFLOW 7512i Page-45
Part # 794471001 G2
CF7512i Dimensions
Front View
Side View
Bottom View
Top View
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CASHFLOW 7512i Page-46
Part # 794471001 G2
MEI
Technical Support 1(800)345-8172
Customer Support 1(800)345-8215
http://www.meigroup.com
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CASHFLOW 7512i Page-47
Part # 794471001 G2
VN2700R Series
with Recycler
Installation Guide
GENERAL INFORMATION
This bill validator is designed to fit into the standard bill acceptor opening provided by
vending machine manufacturers. It mounts on either the existing four mounting studs
located in the machine or on the mounting bracket provided in various mounting kits.
The VNR Recycler stores and provides $1 or $5 bills
as change and accepts $1, $2, $5, $10 and $20 for
transactions. Recycling bills reduces coin usage and
expands vending to higher value bills.
Features of the VN2700R include:
•
$1, $2, $5, $10 and $20 bill acceptance
•
Four Direction bill acceptance
•
Re-programmable Flash Memory (Flashport™)
•
Coupon configuration
•
Enhanced Security
•
Easy access to the bill path, even when mounted
•
2 Character Diagnostic display (see back of unit)
•
Multi-Drop Bus (MDB) vending Interface (24V)
•
Supports free vend and value coupons
•
Supports High Visibility Bezels (HVB) - Optional
•
Lighted Bezel (standard)
•
VNR Recycler (returns bills for change)
INTERFACE
The VN2700R Bill Acceptor operates via a MDB interface: The following harness is
provided to support this interface:
250070096P – 24 VAC Multi-Drop Bus Interface (MDB)
MEI
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12
Note: This harness fits onto the male connectors located on the left side of the Bill
Acceptor and is designed to connect to the machine controller’s and coin changer’s Bill
Acceptor interface harness.
For further information on either interface harnesses or mounting kits, please contact
your supplier or MEI Approved Service Center.
©2009 MEI
www.meigroup.com
Part # 250059384
Revision G2
INSTALLATION INSTRUCTIONS
Configuration Coupon
1. Set Bill Acceptor option switches.
Note: When you receive the product, all switches are off.
This will automatically enable the options as follows:
•
•
•
•
Accept $1 and $5 dollar bills.
Four way accept.
High Security accept.
HVB (Optional) – Denom lights on with blended colors
Important Note: Placing any switch ON will override the
above options, and the Bill Acceptor will operate according
to the switch settings label.
NOTE: The unit may be configured with the attached
coupon rather than using the option switches. For coupon
configuration, turn all option switches OFF and proceed
to Coupon Configuration instructions on page 5.
1,2
3
4-8
SWITCH DESCRIPTION
Combination of these two switches selects
number of enabled bill directions.
Position allows either acceptance or security to be
maximized.
Individual switches enable or disable
corresponding bill denomination.
Electronic copies of this manual
will not have the coupon
included. Please contact MEI if
you need a configuration coupon.
1a. Recycler Factory Default Settings
When the VN2700R is received from the factory, the following
option settings are by default:
•
•
•
•
•
Recycled Bill (rb) =
Interface (IF) =
Capacity (CA)=
Par Level (PL)=
High Visibility Bezel (Hb)=
scrolling)
$1 (1)
Level 3 (L3)
25 notes (25)
12 notes (12)
‘Rainbow’ mode (bLEnd –
Please refer to Section 10 for instructions regarding changing the
recycler option settings.
2. Remove power from the entire machine.
3. Install the VN2700R onto the Bill Acceptor mounting studs and through the
mounting hole of the machine. Secure using the appropriate hardware. If you do not
have a “full face” mounting bracket contact MEI or your MEI distributor and order part
number: 250067030
Note: Several alternate Bezels are available for different vending machine
applications. For further information regarding available Bezels, please contact your
supplier, MEI Approved Service Center or MEI Help Desk.
2
11
NOTES
4. Connect the VN2700R
Locate the main MDB connector from the vending machine. Connect to the mating
connector of the VN2700R. There is an additional cable coming from the VNR which
connects to the coin changer. Please note: The coin changer MUST connect directly
into the VN2700R. Other MDB devices must NEVER be connected between the coin
changer and the VN2700R.
5. Apply power to the machine.
Observe that the MODE / SELECT display on the back of the VN2700R is ON.
During power up, the display shows the VNR Recycler firmware version and then the
VN2700R Bill Validator firmware version. The display then changes to show the
number of bills in the VNR Recycler.
Recycler
Firmware Version Acceptor
Firmware Version Recycler holds
18 bills Unknown number
of bills in Recycler By default, in normal operation, the display always shows the number of bills currently
held in the Recycler available for use as change. If the recycler has lost count of the
number of bills for whatever reason, then a double dash will be displayed. The recycler
will recalculate and display the number momentarily. This could take up to 1.5 minutes.
10
3
6. MODE / SELECT Switches
The MODE switch will cycle between the different set-up modes. The available modes
are Load Recycler, Unload Recycler, Coupon Mode and Setup Mode.
When the MODE switch is pressed and held for 2 seconds, the unit will stop displaying
the bill count and will display the current mode. The text will flash. Each press of the
MODE switch will toggle to the next mode. If a mode is selected and the user takes no
further action for 30 seconds, the bill count display mode will be automatically selected.
17. Trouble shooting VN2700R
Unit Dead (won’t power up)
1. Harness(es) may be loose, not properly connected, or bent pins.
2. Check source voltage to ensure that power is being supplied to the bill
acceptor.
Pressing and holding the mode button does not change the display to the menu.
1. Unit may be in demo mode. Press the mode and select buttons
simultaneously and release to enter the menu mode and change the interface
to L2 or L3.
Error Codes
If an error occurs, the display will alternately flash ‘Er’ followed by an error
code and then the number of bills in the recycler. When multiple errors occur, the
display will cycle through each error in turn.
When a mode is displayed, pressing the SELECT button will enter that mode.
7. Load Recycler Mode
Note: For further information on trouble shooting and error codes for the VN2700R,
please contact your MEI Authorized Service Center, the MEI Tech Support line, or the
VN2700R Operation and Service Guide.
If the Load Recycler mode is selected, the display will stop flashing and alternate with
the current bill count. The user may then insert bills of the type being recycled.
Validation will be performed on the inserted bills. Unrecognized bills will be rejected
and ‘Un’ displayed for 5 seconds or until the user inserts another bill. Bills of the wrong
type will be rejected with a ‘tP’ error message displayed for 5 seconds or until the user
inserts another bill. If the recycler is full, then ‘FL’ will be displayed and bill input is
inhibited. If there is no activity from the user for 30 seconds or the mode button is
pressed, the Load Recycler mode will be exited.
Waiting for inserted bill Bill Inserted Recycler
store full
Unknown
bill
Invalid
bill type
Bill added to recycler store 4
9
13. Open Access Cover
Push up yellow release latch and pull back on Access Cover. This will open
like a clamshell. Finger Disc is revealed (A).
8. Unload Recycler Mode
If the Unload Recycler mode is selected, the display will alternate number of bills and
UL, Each further short press of the select button will move one bill from the recycler to
the cassette. If there is no activity from the user for 30 seconds or the mode button is
pressed, the Unload Recycler mode will exit. If the recycler is empty, then pressing the
select button will have no effect.
If the select button is pressed for more than 2 seconds, the recycler will continuously
move bills from the recycler to the cassette until a pre-determined, programmable
number is reached. This number can be set using the Par Level option in Setup Mode,
section 10, page 6. To unload to zero, the above method must be used to stack one
bill at a time.
Waiting for
Select button
A
Button
Pressed
14. Removing Recycled Bills
1. Powered - The push button (mode) will slowly move the rotor forward for
unloading recycled bills. Please note: After opening the clamshell while
powered up, the display will show ‘Op’.
2. Manual - Rotate finger disc counter clockwise (see “A” above) to remove
recycled bills.
When bill is
stacked, recycler
count is updated
9. Coupon Mode
15. Close Access Cover and Install VNR Recycler
To insert the VNR Recycler, push unit into LED location allowing yellow
latches to snap engage into chassis.
Recycler will now reset itself (could take up to 1 minute), then start counting
the loaded bills. Counting could take up to 1 and 1/2 minutes and depends on
the number of bills loaded on the Recycler. The fewer the bills, the reset will
take longer. This operation is required for the Recycler to function.
16. Cleaning
The VN2700R series will not need cleaning as often as magnetic sensing
Bill Acceptors. If cleaning is required, use a soft cloth moistened with mild,
non-abrasive detergent.
To clean the bill validator bill path remove both the VNR Recycler and
Magazine for full bill path access.
The VNR Recycler does not require cleaning and could be damaged by
aggressive cleaning.
8
9a. Configuration Coupon Input Mode (All option switches set to OFF, see page 2)
If the Coupon Input mode is selected, the recycler will wait 120 seconds for the user to
input a configuration coupon. If no coupon is input, the system will exit configuration
mode and re-display the bill count.
If a configuration coupon is fed into the recycler, the system will attempt to decode the
coupon and then return it. The display will momentarily show CF.
If the configuration is successful, then the front LEDs will flash 10 times. If the
configuration process is not successful, the LEDs will flash a number corresponding to
the section of the configuration coupon that is either not completed or completed
incorrectly. Also, if the coupon is damaged or not the correct size, it will not configure
correctly.
Coupon
Inserted
9b. Free Vend and Value Coupon programming.
If the Coupon Input mode is selected, the recycler will wait 120 seconds for the user to
insert a Free Vend coupon, a $1 Value coupon or a $5 Value coupon. Depending on
the current status of the coupon mode, the inserted coupon will either be accepted
(display momentarily shows En for enabled) or rejected (display momentarily shows DI
for disabled). If the coupon was accepted, then it is now enabled for use. If it was
rejected, it is disabled. This mode toggles between enabling and disabling coupons.
NOTE: Value coupons are treated by the vending machine as cash. Change,
including bills and coins, will be dispensed after a transaction.
5
9. Configuration Coupon Input Mode (continued)
Carefully cut the coupon from this Installation Guide. Copies are usable if made on a
standard, carbon-based, non-color copier, AND if cut to match the size of the attached
coupon. (Coupon is located on page 11.)
Fill out the coupon using a #2 or HB pencil. Fill in one block for each line (except
section 3). Do not mark the back of the coupon.
Section 1 - Bill Direction Enable one or two-way (face-up) or four-way acceptance (all
directions).
Section 2 - Bill Denomination Fill in one block for each denomination. Select High
Accept for maximum bill acceptance. Select High Security for a higher level of
discrimination. Select OFF to reject bills of that denomination.
Section 3 – High Visibility Bezel (HVB) options. (if applicable)
Fill in Denom to enable the denomination lights to operate. Leave blank for
denomination lights to remain off. If color blending is desired, do not fill in any other
box. Refer to Table 1 below for color combinations and fill in the appropriate box(es).
Boxes Filled In – RED, GREEN, BLUE
None (no colors filled in)
Blue only
Green only
Green and Blue
Red only
Red and Blue
Red and Green
Red and Green and Blue
Resulting Colors on Bezel
Blend of all available colors
Blue
Green
Cyan
Red
Magenta
Yellow
White
The Par Level can be set to a value between 0 and 30. It defines the number of bills
left in the Recycler when in unload mode and the Select Button is pressed and held.
The Recycler will add bills up to the capacity setting during normal operation. This
setting should be set to something below the Capacity level.
High Visibility Bezel (HVB) Options allows the operator to choose a primary color on
the HVB or blend colors when the HVB is fitted.
Profile mode allows the operator to calibrate the bill acceptor or the recycler film. It is
recommended that operators do not enter this mode unless proper training has been
received and calibration paper is available.
11. Check operation
•
Insert a recycled bill ($1 or $5) and observe that it is accepted, and stored in the
VNR Recycler.
•
Load the recycler with recycled bills to the Par Level or full setting.
•
Insert a high denomination bill ($5, $10 or $20) and verify that proper credit has
been established.
•
Vend a selection with the largest enabled bill and confirm correct change given.
TO ACCESS BILL PATH
Remove both VNR Recycler and magazine for full bill path access.
Section 4 – Bezel lights flash/ON.
10. Setup Mode
If the Setup Mode is selected, the recycler will cycle between different options. The
available options are Recycled Bill, Interface, Capacity, Par Level, High Visibility Bezel,
and Profile. The mode switch selects between the different options. Press and hold
Select to save the displayed value. Pressing and holding the Mode Button will return to
the Setup Option menu starting with ‘rb’.
Default display 30 sec. return Mode Switch Press Mode Switch Press Mode Switch Press Recycled Bill (Flashing) Interface (Flashing) Mode
Switch Press Mode Switch Press Capacity (Flashing) Par Level
(Flashing) Mode
Switch Press Mode
Switch Press High Vis Bezel
(Flashing) 12. Remove VNR Recycler
To remove the VNR Recycler, pull yellow latch lever releasing latches and pull
out Recycler.
Profile
(Flashing) The Recycled Bill can be set to the value of the bill to be recycled. MEI recommends
$1 or $5 notes for recycling in Vending applications.
The Interface can be set to:
dE – Demo Mode – This will allow unit to store, return and stack notes with power only.
Once in Demo Mode, you must press mode and select simultaneously to get
back to the menu.
Au – To be defined (do not use)
L2 – Level 2 MDB (use this when accepting $20 notes)
L3 – Level 3 MDB (this is the default mode from the factory)
The Capacity defines the number of bills held by the Recycler in operation. Excess
bills get stacked into the Magazine. The Capacity can be set to between 0 and 30.
6
7
9. Configuration Coupon Input Mode (continued)
Carefully cut the coupon from this Installation Guide. Copies are usable if made on a
standard, carbon-based, non-color copier, AND if cut to match the size of the attached
coupon. (Coupon is located on page 11.)
Fill out the coupon using a #2 or HB pencil. Fill in one block for each line (except
section 3). Do not mark the back of the coupon.
Section 1 - Bill Direction Enable one or two-way (face-up) or four-way acceptance (all
directions).
Section 2 - Bill Denomination Fill in one block for each denomination. Select High
Accept for maximum bill acceptance. Select High Security for a higher level of
discrimination. Select OFF to reject bills of that denomination.
Section 3 – High Visibility Bezel (HVB) options. (if applicable)
Fill in Denom to enable the denomination lights to operate. Leave blank for
denomination lights to remain off. If color blending is desired, do not fill in any other
box. Refer to Table 1 below for color combinations and fill in the appropriate box(es).
Boxes Filled In – RED, GREEN, BLUE
None (no colors filled in)
Blue only
Green only
Green and Blue
Red only
Red and Blue
Red and Green
Red and Green and Blue
Resulting Colors on Bezel
Blend of all available colors
Blue
Green
Cyan
Red
Magenta
Yellow
White
The Par Level can be set to a value between 0 and 30. It defines the number of bills
left in the Recycler when in unload mode and the Select Button is pressed and held.
The Recycler will add bills up to the capacity setting during normal operation. This
setting should be set to something below the Capacity level.
High Visibility Bezel (HVB) Options allows the operator to choose a primary color on
the HVB or blend colors when the HVB is fitted.
Profile mode allows the operator to calibrate the bill acceptor or the recycler film. It is
recommended that operators do not enter this mode unless proper training has been
received and calibration paper is available.
11. Check operation
•
Insert a recycled bill ($1 or $5) and observe that it is accepted, and stored in the
VNR Recycler.
•
Load the recycler with recycled bills to the Par Level or full setting.
•
Insert a high denomination bill ($5, $10 or $20) and verify that proper credit has
been established.
•
Vend a selection with the largest enabled bill and confirm correct change given.
TO ACCESS BILL PATH
Remove both VNR Recycler and magazine for full bill path access.
Section 4 – Bezel lights flash/ON.
10. Setup Mode
If the Setup Mode is selected, the recycler will cycle between different options. The
available options are Recycled Bill, Interface, Capacity, Par Level, High Visibility Bezel,
and Profile. The mode switch selects between the different options. Press and hold
Select to save the displayed value. Pressing and holding the Mode Button will return to
the Setup Option menu starting with ‘rb’.
Default display 30 sec. return Mode Switch Press Mode Switch Press Mode Switch Press Recycled Bill (Flashing) Interface (Flashing) Mode
Switch Press Mode Switch Press Capacity (Flashing) Par Level
(Flashing) Mode
Switch Press Mode
Switch Press High Vis Bezel
(Flashing) 12. Remove VNR Recycler
To remove the VNR Recycler, pull yellow latch lever releasing latches and pull
out Recycler.
Profile
(Flashing) The Recycled Bill can be set to the value of the bill to be recycled. MEI recommends
$1 or $5 notes for recycling in Vending applications.
The Interface can be set to:
dE – Demo Mode – This will allow unit to store, return and stack notes with power only.
Once in Demo Mode, you must press mode and select simultaneously to get
back to the menu.
Au – To be defined (do not use)
L2 – Level 2 MDB (use this when accepting $20 notes)
L3 – Level 3 MDB (this is the default mode from the factory)
The Capacity defines the number of bills held by the Recycler in operation. Excess
bills get stacked into the Magazine. The Capacity can be set to between 0 and 30.
6
7
13. Open Access Cover
Push up yellow release latch and pull back on Access Cover. This will open
like a clamshell. Finger Disc is revealed (A).
8. Unload Recycler Mode
If the Unload Recycler mode is selected, the display will alternate number of bills and
UL, Each further short press of the select button will move one bill from the recycler to
the cassette. If there is no activity from the user for 30 seconds or the mode button is
pressed, the Unload Recycler mode will exit. If the recycler is empty, then pressing the
select button will have no effect.
If the select button is pressed for more than 2 seconds, the recycler will continuously
move bills from the recycler to the cassette until a pre-determined, programmable
number is reached. This number can be set using the Par Level option in Setup Mode,
section 10, page 6. To unload to zero, the above method must be used to stack one
bill at a time.
Waiting for
Select button
A
Button
Pressed
14. Removing Recycled Bills
1. Powered - The push button (mode) will slowly move the rotor forward for
unloading recycled bills. Please note: After opening the clamshell while
powered up, the display will show ‘Op’.
2. Manual - Rotate finger disc counter clockwise (see “A” above) to remove
recycled bills.
When bill is
stacked, recycler
count is updated
9. Coupon Mode
15. Close Access Cover and Install VNR Recycler
To insert the VNR Recycler, push unit into LED location allowing yellow
latches to snap engage into chassis.
Recycler will now reset itself (could take up to 1 minute), then start counting
the loaded bills. Counting could take up to 1 and 1/2 minutes and depends on
the number of bills loaded on the Recycler. The fewer the bills, the reset will
take longer. This operation is required for the Recycler to function.
16. Cleaning
The VN2700R series will not need cleaning as often as magnetic sensing
Bill Acceptors. If cleaning is required, use a soft cloth moistened with mild,
non-abrasive detergent.
To clean the bill validator bill path remove both the VNR Recycler and
Magazine for full bill path access.
The VNR Recycler does not require cleaning and could be damaged by
aggressive cleaning.
8
9a. Configuration Coupon Input Mode (All option switches set to OFF, see page 2)
If the Coupon Input mode is selected, the recycler will wait 120 seconds for the user to
input a configuration coupon. If no coupon is input, the system will exit configuration
mode and re-display the bill count.
If a configuration coupon is fed into the recycler, the system will attempt to decode the
coupon and then return it. The display will momentarily show CF.
If the configuration is successful, then the front LEDs will flash 10 times. If the
configuration process is not successful, the LEDs will flash a number corresponding to
the section of the configuration coupon that is either not completed or completed
incorrectly. Also, if the coupon is damaged or not the correct size, it will not configure
correctly.
Coupon
Inserted
9b. Free Vend and Value Coupon programming.
If the Coupon Input mode is selected, the recycler will wait 120 seconds for the user to
insert a Free Vend coupon, a $1 Value coupon or a $5 Value coupon. Depending on
the current status of the coupon mode, the inserted coupon will either be accepted
(display momentarily shows En for enabled) or rejected (display momentarily shows DI
for disabled). If the coupon was accepted, then it is now enabled for use. If it was
rejected, it is disabled. This mode toggles between enabling and disabling coupons.
NOTE: Value coupons are treated by the vending machine as cash. Change,
including bills and coins, will be dispensed after a transaction.
5
6. MODE / SELECT Switches
The MODE switch will cycle between the different set-up modes. The available modes
are Load Recycler, Unload Recycler, Coupon Mode and Setup Mode.
When the MODE switch is pressed and held for 2 seconds, the unit will stop displaying
the bill count and will display the current mode. The text will flash. Each press of the
MODE switch will toggle to the next mode. If a mode is selected and the user takes no
further action for 30 seconds, the bill count display mode will be automatically selected.
17. Trouble shooting VN2700R
Unit Dead (won’t power up)
1. Harness(es) may be loose, not properly connected, or bent pins.
2. Check source voltage to ensure that power is being supplied to the bill
acceptor.
Pressing and holding the mode button does not change the display to the menu.
1. Unit may be in demo mode. Press the mode and select buttons
simultaneously and release to enter the menu mode and change the interface
to L2 or L3.
Error Codes
If an error occurs, the display will alternately flash ‘Er’ followed by an error
code and then the number of bills in the recycler. When multiple errors occur, the
display will cycle through each error in turn.
When a mode is displayed, pressing the SELECT button will enter that mode.
7. Load Recycler Mode
Note: For further information on trouble shooting and error codes for the VN2700R,
please contact your MEI Authorized Service Center, the MEI Tech Support line, or the
VN2700R Operation and Service Guide.
If the Load Recycler mode is selected, the display will stop flashing and alternate with
the current bill count. The user may then insert bills of the type being recycled.
Validation will be performed on the inserted bills. Unrecognized bills will be rejected
and ‘Un’ displayed for 5 seconds or until the user inserts another bill. Bills of the wrong
type will be rejected with a ‘tP’ error message displayed for 5 seconds or until the user
inserts another bill. If the recycler is full, then ‘FL’ will be displayed and bill input is
inhibited. If there is no activity from the user for 30 seconds or the mode button is
pressed, the Load Recycler mode will be exited.
Waiting for inserted bill Bill Inserted Recycler
store full
Unknown
bill
Invalid
bill type
Bill added to recycler store 4
9
Universal Hopper Series Manual
TSP079.doc
Issue 2.6 – June 2004
This document is the copyright of Money Controls Ltd and may not be reproduced in part or in total by any means,
electronic or otherwise, without the written permission of Money Controls Ltd. Money Controls Ltd does not accept
liability for any errors or omissions contained within this document. Money Controls Ltd shall not incur any penalties
arising out of the adherence to, interpretation of, or reliance on, this standard. Money Controls Ltd will provide full
support for this product when used as described within this document. Use in applications not covered or outside the
scope of this document may not be supported. Money Controls Ltd. reserves the right to amend, improve or change
the product referred to within this document or the document itself at any time.
©Money Controls 2004. All rights reserved.
Universal Hopper Series Manual
TSP079.doc
Issue 2.6 – June 2004
Contents
1.
2.
3.
4.
5.
Diary of Changes .................................................................................................................................................. 4
Introduction........................................................................................................................................................... 5
Safety Note - MK4 Hoppers only ......................................................................................................................... 5
General Description ............................................................................................................................................. 6
Options .................................................................................................................................................................. 7
5.1
Connector Position ......................................................................................................................................... 7
5.2
Level Sensing ................................................................................................................................................. 7
5.3
Connector Options.......................................................................................................................................... 8
5.4
Coin Sizes ...................................................................................................................................................... 8
5.5
EMC................................................................................................................................................................ 8
5.6
Passive Overflow ............................................................................................................................................ 8
5.7
Baseplate........................................................................................................................................................ 9
6. Installation........................................................................................................................................................... 10
6.1
Safety ........................................................................................................................................................... 10
7. Mechanical Description...................................................................................................................................... 11
7.1
General......................................................................................................................................................... 11
7.2
Differences Between MKll, MKlll, MK4 and Lite Hoppers ............................................................................. 11
7.3
Track guard Removal and Refitting (MKll and MK Ill only)............................................................................ 11
7.4
Coin Box Removal and Refitting ................................................................................................................... 11
7.5
Track and 12-Pin Plug access ...................................................................................................................... 11
8. Electronic Description........................................................................................................................................ 12
8.1
General Electronic Description ..................................................................................................................... 12
8.2
Operating Mode Selection (Universal Hopper Lite – Mode 1 ONLY) ............................................................ 12
8.2.1
Mode 0 - Direct switching (Not ‘lite’) ..................................................................................................... 12
8.2.2
Mode 1 - Logic Control ......................................................................................................................... 12
8.2.3
Mode 2 - Coin Counting (Not ‘lite’)........................................................................................................ 13
8.2.4
Reset Function (Not ‘lite’) ..................................................................................................................... 13
8.3
Optical Sensors ............................................................................................................................................ 14
8.4
Optical Security Feature ............................................................................................................................... 14
8.5
Motor Operation............................................................................................................................................ 14
8.6
Motor Current Limit ....................................................................................................................................... 14
8.7
Coins With Holes .......................................................................................................................................... 15
8.8
High Security Exit Window (Available for MK4 EMC version ONLY) ............................................................ 16
8.8.1
Timer values ......................................................................................................................................... 16
8.8.2
Opto test ............................................................................................................................................... 16
9. Electrical Specification Power Supply Requirements ..................................................................................... 17
9.1
Power Supply................................................................................................................................................ 17
9.1.1
Suggested Connection ......................................................................................................................... 17
9.1.2
EMC...................................................................................................................................................... 17
10.
Product Compliance’s.................................................................................................................................... 18
10.1
MK3 .............................................................................................................................................................. 18
10.2
MK3 (EMC)................................................................................................................................................... 18
10.3
MK4 .............................................................................................................................................................. 18
10.4
MK4 (EMC)................................................................................................................................................... 18
11.
Applications .................................................................................................................................................... 19
11.1
Output Sensor Interfacing............................................................................................................................. 19
11.2
Motor Switch Off Time .................................................................................................................................. 19
11.3
Security Output (Not ‘Lite’)............................................................................................................................ 20
11.4
Level Sense Plates ....................................................................................................................................... 20
11.5
IN1 to IN3 and Motor Control Inputs ............................................................................................................. 21
11.6
LED Indicators (Not ‘Lite’)............................................................................................................................. 21
©Money Controls 2004. All rights reserved.
Page 2 of 30
Universal Hopper Series Manual
TSP079.doc
Issue 2.6 – June 2004
12.
Technical Specifications................................................................................................................................ 22
12.1
Coin Sizes .................................................................................................................................................... 22
12.2
Capacity........................................................................................................................................................ 22
12.3
Connections.................................................................................................................................................. 22
12.4
Motor Supply – Pin 9 .................................................................................................................................... 23
12.5
Logic Supply (Not ‘Lite’)................................................................................................................................ 23
12.6
Logic Inputs (IN1, IN2, IN3 and Motor Control I/P) ....................................................................................... 23
12.7
Logic Outputs (Sensors, Security) ................................................................................................................ 24
12.8
Important Supply Notes ................................................................................................................................ 24
12.9
Environment ................................................................................................................................................. 24
13.
Hopper Dimensions and Exploded Diagrams .............................................................................................. 25
Tables
Table 1: Approximate Hopper Capacities. ...................................................................................................................... 6
Table 2: Coin Size v Track Type..................................................................................................................................... 8
Table 3: Hopper Differences......................................................................................................................................... 11
Table 4: Mode Selection Logic Input. ........................................................................................................................... 12
Table 5: Guide To Coinage v Jumper Position. ............................................................................................................ 15
Table 6: Connector Pin-outs ......................................................................................................................................... 22
Table 7: Motor Supply Requirements ........................................................................................................................... 23
Table 8: Logic Supply Requirements............................................................................................................................ 23
Table 9: Logic Input Requirements............................................................................................................................... 23
Table 10: Logic Output Parameters.............................................................................................................................. 24
Table 11: Environmental Parameters ........................................................................................................................... 24
Figures
Figure 1: Connector Position Options............................................................................................................................. 7
Figure 2: Sense Plate Position Options .......................................................................................................................... 7
Figure 3: Connector Types ............................................................................................................................................. 8
Figure 4: Passive Overflow Positions ............................................................................................................................. 8
Figure 5: Minimum Timings .......................................................................................................................................... 13
Figure 6: Jumper positions for coins with holes (MKIII Only) ........................................................................................ 15
Figure 7: Recommended Connection Diagram............................................................................................................. 17
Figure 8: Sensor Output Cct. ........................................................................................................................................ 19
Figure 9: Sensor Output Waveforms. ........................................................................................................................... 19
Figure 10: Recommended Security Output Sensor Interfaces...................................................................................... 20
Figure 11: Recommended Level Sense Plate Interfaces.............................................................................................. 20
Figure 12: Recommended INx and Motor Control Inputs. ............................................................................................ 21
Figure 13: Connector Pin-outs...................................................................................................................................... 22
Figure 14: MKII and MKIII Exploded Diagram .............................................................................................................. 25
Figure 15: MKII and MKIII Dimensions ......................................................................................................................... 26
Figure 16: MK4 Exploded Diagram............................................................................................................................... 27
Figure 17: MK4 and ‘Lite’ Dimensions .......................................................................................................................... 28
Figure 18: Baseplate Dimensions................................................................................................................................. 29
©Money Controls 2004. All rights reserved.
Page 3 of 30
Universal Hopper Series Manual
1.
TSP079.doc
Issue 2.6 – June 2004
Diary of Changes
th
Issue 2.0 ......................................................................................................................................................... 15 May 2003
st
¾
1 Issue in new format.
Issue 2.1 ................................................................................................................................................................ July 2003
¾
Added details of High Security Exit Window (Section 8.8).
¾
Updated details in Table 2.
¾
Added Universal Hopper ‘Lite’ details.
th
Issue 2.2 ......................................................................................................................................................... 18 Aug 2003
¾
Changed High level to Top level sense available for UH Lite
th
Issue 2.3 ......................................................................................................................................................... 28 Aug 2003
¾
Added section 10 Product Compliance’s.
th
Issue 2.4 ............................................................................................................................................................8 Feb 2004
¾
Ammended details in Table 2.
th
Issue 2.5 ......................................................................................................................................................10 March 2004
¾
Corrected details in Table 2.
Issue 2.6...................................................................................................................30th June 2004
¾
Changed footer
©Money Controls 2004. All rights reserved.
Page 4 of 30
Universal Hopper Series Manual
2.
TSP079.doc
Issue 2.6 – June 2004
Introduction
Money Controls’ Universal Hoppers were first introduced in 1984. The MKII and MKlll models
proved themselves to be exceptionally reliable, with high count accuracy. The MK4 is the latest
generation of this extremely successful series.
The MK4 Universal Hopper can be used as a direct replacement for MKll and MKlll Hoppers. Any
specific variances are clearly indicated, where appropriate, in this manual. When ordering MK4
Universal Hoppers as a replacement, it is important to specify which version is being replaced.
The Universal Hopper ‘Lite’ is a cost effective solution for standard applications. Unlike the other
Universal Hoppers, the ‘Lite’ has been designed to only work in Mode 1.
3.
Safety Note - MK4 Hoppers only
To meet the requirements for EN 60950 the equipment must be installed according to the
following requirements:¾
¾
¾
The equipment must be protected by a 3A fuse.
The equipment must be supplied from a SELV limited power source.
The equipment must be installed in an enclosure but positioned so that it is external
to any fire enclosure area within the main enclosure.
©Money Controls 2004. All rights reserved.
Page 5 of 30
Universal Hopper Series Manual
4.
TSP079.doc
Issue 2.6 – June 2004
General Description
The Universal Hopper is an “intelligent” large capacity coin and token dispenser ideal for a wide
range of applications including Gaming, Vending and Transportation systems.
MKll and MKlll hoppers will handle most coins in the range 16.25mm - 30mm diameter and 1.25mm
- 3.5mm thick, giving the following approximate capacities:-
Table 1: Approximate Hopper Capacities.
Diameter
Thickness
Approx. Capacity
28.4mm
2.21mm
800
24.25
1.75
1600
The MK4 and ‘Lite’ have extended the range to include 31mm diameter and 1mm thick coins.
The rate of payout, whilst being dependent on the coin dimensions and also the volumes of coins in
the Hopper at any given time, is approximately 3 coins per second.
Precise payout is ensured through optical sensing and verifying of coin dispensing with an
electronic security signal which alerts against coin jams, failed sensors and a bad power supply.
LED indicators are provided for easy visual checking of power supply, security status and coin
sensors.
The Universal Hopper has the in-built facility to operate in 3 modes:Mode 0 (Not available on the ‘Lite’ version)
the direct switching mode.
Mode 1
the hopper is controlled directly by a LOGIC (Motor) CONTROL LINE. When the line is ‘active’, the
motor runs.
Mode 2 (Not available on the ‘Lite’ version)
the hopper is driven by pulses on the control line which allows the hopper to be used in place of a
solenoid payout with no software and few hardware changes.
©Money Controls 2004. All rights reserved.
Page 6 of 30
Universal Hopper Series Manual
5.
TSP079.doc
Issue 2.6 – June 2004
Options
There is a standard Universal Hopper handling coins in the diameter range of 21mm - 30mm, and
the small coin Universal Hopper handling coins in the diameter range of 16.25mm - 20.9mm. Both
of these models can be supplied with a number of options:-
5.1
Connector Position
The 12-pin connector can be in one of two positions, either on the opposite side of the coin exit,
known as the standard position, or on the same side as the coin exit, known as the adjacent
position.
Figure 1: Connector Position Options
5.2
Level Sensing
Universal Hoppers can be supplied with a choice of coin sensing positions, these can be either:High level or Top level.
High Level is NOT available with the Universal Hopper Lite.
All Hoppers are automatically supplied with a low level function to indicate coin starvation.
Figure 2: Sense Plate Position Options
©Money Controls 2004. All rights reserved.
Page 7 of 30
Universal Hopper Series Manual
5.3
TSP079.doc
Issue 2.6 – June 2004
Connector Options
MK4 Universal Hoppers are available with connectors compatible with MKll and MKlll Hopper
installations. It is important, when ordering, MK4 Hoppers as a replacement to specify which
version is being replaced.
Universal Hopper Lite is ONLY available with the ‘Cinch’ plug.
Figure 3: Connector Types
5.4
Coin Sizes
Table 2: Coin Size v Track Type.
5.5
Track Type
Coin Range
Hopper Type
Large coin
30.01 - 31.50 mm x 1.25 - 3.30 mm
MK4, Serial
Standard coin
21.01 - 30.00 mm x 1.25 - 3.30 mm
MKII, MKIII, MK4, Serial
Euro track [Yellow]
(€2, €1, 50c, 20c, 10c, 5c)
19.00 - 26.40 mm x 1.50 - 2.50 mm
MK4, Serial
Euro small coin [Green]
(1c, 2c, 5c, 10c)
16.25 - 20.90 mm x 1.00 - 3.1 mm
previously called the small coin.
MKII, MKIII, MK4, Serial
EMC
See section 9.1.2
5.6
Passive Overflow
Either the top, the bottom, both or neither panel can be specified to be removed.
Figure 4: Passive Overflow Positions
©Money Controls 2004. All rights reserved.
Page 8 of 30
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Baseplate
The baseplate can be ordered with the following options:¾
¾
¾
¾
¾
¾
fitted to the hopper
packed separately
supplied with no connector
connector only (no baseplate)
no baseplate
the connector can be packed separately
All of the above options must be specified when ordering.
©Money Controls 2004. All rights reserved.
Page 9 of 30
Issue 2.6 – June 2004
Universal Hopper Series Manual
6.
TSP079.doc
Issue 2.6 – June 2004
Installation
Important: Power should not be applied until the installation is complete.
1. Secure the baseplate in position, using the six fixing holes. The hole positions are shown in
Figure 18.
2. Wire up the baseplate connector to the host machine - see section 12.3 for connector details,
and sections 8.8 & 10 for interfacing recommendations.
NOTE: The wire to be used should have a maximum length of 3 metres, and must be capable of
handling the maximum currents and voltages specified in section 12.
3. Slide the hopper into the baseplate and ensure that the two halves of the connector are
securely mated.
4. Turn on the power.
6.1
Safety
1. Do not put a hand into the hopper while the motor is running.
2. Static. It is possible for coins paid out to have a static charge on them.
3. Coins should be discharged to earth before being presented to the user.
IMPORTANT:
The hopper should not be installed/removed from baseplate with power connected.
Avoid inhalation of coin dust during any servicing operations.
©Money Controls 2004. All rights reserved.
Page 10 of 30
Universal Hopper Series Manual
7.
7.1
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Issue 2.6 – June 2004
Mechanical Description
General
The hopper is mounted in a machine via the base plate.
Electrical connection to the hopper is made via the 12 pin socket on the baseplate which mates
with the corresponding plug on the hopper body. Coins are stored in the cashbox section of the
hopper and fed onto the elevator belt via a passage in the centre plate. The cut-out in the centre
plate has been designed to regulate the flow of coins onto the belt. The stirrer agitates the coins
in the coin box in order to minimise the occurrence of bridging. The elevator belt is driven by a
motor, gearbox, and idler gear. Coins are picked up at the bottom of the belt and carried up to
the exit window. Optical sensors in the exit window detect the coins as they roll out of the
hopper.
A cable connects the main control board to the 12 way socket and carries all power supplies and
control signals.
7.2
Differences Between MKll, MKlll, MK4 and Lite Hoppers
Table 3: Hopper Differences.
Feature
MKII
MKIII
MK4
Lite
Motor Drive
Belt
Belt
Direct
Direct
Plastic
Plastic
Metal & Plastic
Metal & Plastic
Centre Plate
Centre Plate
Coin Box
Exit Window
PCB
PCB
Exit Window
None
Opto Sensors
2 sets
1 set
3 sets
3 sets
Track Guard
Blue
Green
None
None
Gears
µP PCB Location
LED’s Location
7.3
Track guard Removal and Refitting (MKll and MK Ill only)
See Figure 14.
Firstly, locate cut away slots in Centre plate and End plate at the base of the track guard
opposite the PCB. Push track guard up to reveal a gap between body moulding and the guard.
Insert broad flat bladed screwdriver or equivalent into gap and gently lever out the guard until the
leading edge is above the outside edge of the body mouldings. Now slide the guard down
towards the cut out and gradually withdraw it. Slide back the track guard to refit.
7.4
Coin Box Removal and Refitting
Please refer to the Universal Hopper Service Manual TSP053
7.5
Track and 12-Pin Plug access
Please refer to the Universal Hopper Service Manual TSP053
©Money Controls 2004. All rights reserved.
Page 11 of 30
Universal Hopper Series Manual
8.
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Issue 2.6 – June 2004
Electronic Description
8.1
General Electronic Description
Operation of the hopper is controlled by a 8-bit microprocessor.
The microprocessor allows the choice of 3 different operating modes (except for ‘Lite’ which only
has Mode 1). It also provides the motor control drive via a darlington bridge and an optical
payout detection output.
Separate power supplies are recommended for the motor supply input and the logic supply
input. Note:- The ‘Lite’ version only has one supply input.
8.2
Operating Mode Selection (Universal Hopper Lite – Mode 1 ONLY)
Three modes of operation are available, selected via inputs IN1 and IN2 (pins 4 and 8 of the 12
way connector). Input signals may be controlled by the host machine, or may be hardwired.
Additionally, input IN3 (pin 12) is the logic control line, used in modes 1 and 2. These inputs are
passive pull-up active pull-down. The signals therefore default to logic ‘1’ if left open circuit.
NOTE: It is strongly recommended that if these inputs are to be controlled by the host machine,
then open collector NPN transistors, referenced to logic OV (connector pin 2) be used to set the
input levels to IN1, IN2 and IN3.
With the exception of ‘RESET’ mode which can be applied at any time (with instantaneous
effect), Mode selection is determined at power-up. The hopper allows a 100ms time-out after
power-up, then reads the inputs IN1 and IN2. The hopper will remain in the selected mode until
the power is removed, i.e., any further changes in the levels at IN1 and IN2 will be ignored.
See Table 4.
Refer to section 11.5 for recommendations for driving input signals on pins IN1, IN2 and IN3.
Table 4: Mode Selection Logic Input.
Mode
IN1
IN2
0
1
1
1
0
0
2
1
0
Reset
0
1
8.2.1
MODE 0 - DIRECT SWITCHING (NOT ‘LITE’)
This is the default operating Mode, and is selected when all of the input selectors are left
open circuit. When the 24V line is established, the motor starts in the forward direction and
when the 24V power line is removed, the motor is braked.
8.2.2
MODE 1 - LOGIC CONTROL
In this mode the logic and 24V power supplies can be permanently connected and motor
function is determined via a logic level on the IN3 input.
When IN1 (pin 4) and IN2 (pin 8) are pulled down to OV at power up, mode 1 is selected.
The operation of the motor is now controlled via a logic signal on IN3 (pin 12). With the 24V
supply present, a low level on IN3 starts the motor and a high level on IN3 brakes the motor.
©Money Controls 2004. All rights reserved.
Page 12 of 30
Universal Hopper Series Manual
8.2.3
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Issue 2.6 – June 2004
MODE 2 - COIN COUNTING (NOT ‘LITE’)
In this mode, the hopper will pay out a coin for every pulse it receives on input IN3.
Mode 2 is selected by setting IN1 (pin 4) high and IN2 (pin 8) low at power up. Once
selected, the processor continually scans input IN3. When a pulse is detected on IN3, an
internal register is incremented. When a coin is paid out, it is detected and the register is
decremented.
The motor is started when the internal coin register is non-zero and is stopped when it
returns to zero. The maximum count for the coin register is 4095 coins. Should the 24V line
fail at any point, the motor is braked. When the 24V line re-appears, the payout of coins
continues until the coin register returns to zero. Coin counting on IN3 can take place while
coins are being paid out.
Figure 5: Minimum Timings
A pulse is defined as a falling edge followed by a rising edge.
Pulse edges may be no closer than 5ms (see Figure 5). This is so that the processor has
adequate time to poll the IN3 pin and debounce. This represents a maximum pulse rate of
100Hz.
There is no lower limit. The waveform duty cycle is unimportant.
At power-up in mode 2, IN3 is high. The first falling edge will be recognised as the first pulse
and the hopper motor will start running.
Pulsing on IN3 should not commence earlier than 130ms after the logic supply has been
established. This will allow for the power-up time-out of 100ms and further processing time
prior to running the main program.
8.2.4
RESET FUNCTION (NOT ‘LITE’)
The reset function is available on MKlll and, when specified on the MK4 version. In this
mode the Hopper is reset, i.e. processor reset and motor drive disabled. This function is
provided as added security enabling the host machine to immediately stop the Hopper
irrespective of its mode of operation.
Whilst in this mode connecting IN3 (pin 12) to ground turns the exit window sensor off in
order to test it is operative. Confirmation would be given as a signal output on pin 3 and 11 of
the 12 pin connector.
©Money Controls 2004. All rights reserved.
Page 13 of 30
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8.3
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Issue 2.6 – June 2004
Optical Sensors
Optical sensors are fitted in the exit window to detect coin payout.
The signal on Pin 11 is the ‘Raw’ coin output signal (Not applicable to the ‘Lite’). A de-bounced
coin output is available on Pin 3. When no coins are present at the exit window, the optical
sensors are clear, the output transistors are open circuit, and the LED indicator is off. Coins
passing the optical sensors obstruct the light path causing the output transistors to pull down to
OV and the LED “SENSOR” indicator switches on.
8.4
Optical Security Feature
The output of the optical sensor is monitored by the microprocessor and if the sensor remains
obstructed for more than one second, the motor will be braked and will remain off until either the
sensor is cleared or power down takes place. This action will result if a coin jams in the exit
window or if the optical sensor fails which could be checked by toggling IN3 in Reset mode.
If the security feature should operate, the security output on output pin 5 and the LED
“SECURITY” indicator will be switched off. The optical security feature operates identically in all
3 Modes.
Note: The security feature works the same on the Universal Hopper Lite but there is no output
pin to indicate to the host machine that there is a security issue.
8.5
Motor Operation
The DC motor is controlled by the processor via a transistor bridge. The motor will run provided
that one of the sets of conditions shown below is met. If any single condition fails then the motor
is braked and remains so until all conditions become true, or a power down occurs.
Mode 0 Motor Start Conditions: Security feature true - 24V line true.
Mode 1 Motor Start Conditions: Security feature true - 24V line true - IN3 input low.
Mode 2 Motor Start Conditions: Security line true - 24V line true - internal coin count non-zero.
When braking is initiated and for whatever reason, 50ms braking is carried out even if the fault
condition recovers before that time. This guarantees that the motor is stationary when the
bridge drivers change state, so that no excess current flows in the motor windings.
8.6
Motor Current Limit
The motor current is monitored by the processor. When the motor initially starts a high current
flows generating maximum torque to force the coin belt up to speed. After a short time the motor
current is reduced to a fraction of the initial surge current.
At any time after the initial surge, if the current rises above a pre-set value, then a jam is
deemed to have occurred. The motor is braked for 50ms then reversed for 150ms. After a
further 50ms
braking, the motor is started in the forward direction again. The current is tested after 100ms
and if the jam has not been cleared the reversing cycle will be repeated. This action will
continue until the jam has cleared. This reversing action is effective in clearing soft jams.
One further action is to test the current in the reverse direction during the final 50ms of the
reversing cycle. If during that time period an over current is detected, then the motor will be
braked for 50ms and then disabled for 1 second. This action limits the duty cycle sufficiently in
the case where a jam is solid in order to prevent motor damage.
©Money Controls 2004. All rights reserved.
Page 14 of 30
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8.7
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Issue 2.6 – June 2004
Coins With Holes
The MKll hopper has not been designed to handle coins with holes and cannot be guaranteed to
perform correctly with such coins.
The MKlll hopper can count most coins with holes correctly, but requires a jumper, on the control
board, to be set in the right position for small or standard coins - see below.
Figure 6: Jumper positions for coins with holes (MKIII Only)
If a MKlll hopper is converted from one coin size to the other, the jumper position must also be
altered. This is achieved by removing the track guard, as described in 7.3, placing the jumper in
the required positions, then refitting the track guard.
Table 5: Guide To Coinage v Jumper Position.
Position 2
Small coin
17.5 - 21mm
Coinage
Danish 1 Kroner
Position 1
Standard coin
21 - 30mm
x
Danish 2 Kroner
x
Danish 5 Kroner
x
The MK4 exit window has been designed so that more coins with holes will be counted correctly.
No adjustments are necessary to cope with standard and small coins.
Note:- Jumper position 3 is not used.
©Money Controls 2004. All rights reserved.
Page 15 of 30
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Issue 2.6 – June 2004
High Security Exit Window (Available for MK4 EMC version ONLY)
The high security version of the exit window has been designed to be retro-fittable into existing
MK4 EMC hoppers. Hence, high security hoppers will use the same main control board as the
existing EMC product and will retain the same operating modes.
The high security function will detect any attempts to “blind” the optical sensors by shining an
external light onto them. Such an action could cause the hopper to miscount.
The detection procedure, during normal operation – stationary or paying out – is:i).
ii).
iii).
iv).
The infra-red LED’s will be turned off for a fixed time, Toff;
At the end of the time period, the state of the phototransistors will be examined;
If the phototransistors are in the correct state, i.e. not seeing any light, the LED’s will
be turned on again;
After a defined time, Tint, the test will be repeated.
The detection sequence, in the case of a fault – stationary or paying out – is:i).
ii).
iii).
iv).
v).
The infra-red LED’s will be turned off for a fixed time, Toff;
At the end of the time period, the state of the phototransistors will be examined;
If the phototransistors are switched on, i.e. still seeing light, the LEDs will be left off
and also the phototransistors will be disconnected for a defined time, Tfault. This time
must be greater than 1 second;
When the phototransistors have been disconnected for 1 second, the main control
board will recognise the condition as a blocked opto. The hopper motor will be stopped
and the security output will be turned off. This will alert the host machine to the
problem;
At the end of the time period, Tfault, the optos will be turned on again and testing will
resume.
It is the responsibility of the host machine to monitor the security signal and to take whatever
action is deemed appropriate. All other functions of the hopper, i.e. motor control, jam clearing,
coin counting, etc, are the same as the existing product.
NOTE: During the 1 second period, between the fault being detected and the motor stopping, it
is possible that a few coins may be paid out and not counted.
8.8.1
TIMER VALUES
Toff
Tint
Tfault
8.8.2
-
500 µsecs +/-10%
50 msecs +/-10%
2 secs
+/-10%
OPTO TEST
By holding the hopper in reset and toggling the IN3 line, the optics can be checked for a
blockage prior to paying out.
During Reset, a High on IN3 will cause a low on “Output 1” and “Output 2”. Alternately a Low
on IN3 will cause a high on “Output 1” and “Output 2”.
NOTE:- This is only true if the optics are NOT blocked.
©Money Controls 2004. All rights reserved.
Page 16 of 30
Universal Hopper Series Manual
9.
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Issue 2.6 – June 2004
Electrical Specification Power Supply Requirements
9.1
Power Supply
For ease of use and maximum noise suppression, the 0 volt logic line (pin 2) and the motor 0
volt line (pin 1) are not commoned inside the hopper. This means the outputs from the hopper
(Opto and Security) are noise free.
9.1.1
SUGGESTED CONNECTION
A suggested connection diagram is shown in Figure 7.
A twisted wire pair is recommended for the motor power leads to reduce the radiated noise.
The TIP 126 arrangement shown would only be required for Mode 0 operation where power
line interruption is the method of motor control. In Modes 1 and 2 the power line can be left
permanently on and the TIP 126 and 1K and 4K7 resistors can be omitted.
Figure 7: Recommended Connection Diagram
9.1.2
EMC
The MKlll hopper is EMC hardened. There is a version of the MK4 hopper which is also EMC
hardened. This is to help users to meet the European EMC regulations (EN50081 &
EN50082). Further precautions should be taken with the installation to minimise the effects
of electrical noise, i.e. –
i)
ii)
iii)
Max cable length = 3 metres
All wires to the hopper should be bundled together.
Minimum capacitance between the logic supply rails = 100µF
©Money Controls 2004. All rights reserved.
Page 17 of 30
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Issue 2.6 – June 2004
10. Product Compliance’s
10.1 MK3
This product has been self assessed to EN 60950:1992 + Amdt A1 & A2: 1993 & A3: 1995
Safety.
10.2 MK3 (EMC)
This product has been self assessed to EN 60950:1992 + Amdt A1 & A2: 1993 & A3: 1995
Safety.
10.3 MK4
This product is compliant to EN 60950:1992 + Amdt A1 & A2: 1993 & A3: 1995 Safety.
10.4 MK4 (EMC)
This product is compliant to:EN 50081-1: 1992 Electromagnetic compatibility – Emissions.
EN 50082-1: 1997 Electromagnetic compatibility – Immunity.
This product is compliant to EN 60950:1992 + Amdt A1 & A2: 1993 & A3: 1995 & A4: 1996
Safety.
©Money Controls 2004. All rights reserved.
Page 18 of 30
Universal Hopper Series Manual
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Issue 2.6 – June 2004
11. Applications
11.1 Output Sensor Interfacing
Both sensor outputs are open collector NPN transistors, as shown in Figure 8.
When a coin is paid out, the raw sensor output will switch on, connecting output Pin 11 (Not
connected on the ‘Lite’ version) to OV, the Sensor output on Pin 3 will switch on approximately
5ms later - see Figure 9. Both outputs will stay switched on until the coin has left the exit
window. The open collector outputs are provided for easy interfacing to TTL, CMOS or relay
inputs, see Figure 10.
NOTE: A flywheel diode is required on any output which has an inductive load connected, e.g. a
relay. A 30V maximum can be tolerated on these outputs (positive with respect to 0V).
Figure 8: Sensor Output Cct.
Figure 9: Sensor Output Waveforms.
11.2 Motor Switch Off Time
When using the hopper in mode 0 (see section 8.2.1) the host machine applies power to the
motor and monitors the payout sensors, disconnecting the motor power when it has counted out
the correct quantity of coins. The motor power should be removed within 30ms of the leading
edge of the output. Similarly, to avoid erroneous payout in mode 1, IN3 should be taken high
within 30ms of the leading edge of the opto SENSOR output (pin 3).
©Money Controls 2004. All rights reserved.
Page 19 of 30
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Issue 2.6 – June 2004
11.3 Security Output (Not ‘Lite’)
The security output is an open collector NPN transistor which should be connected as shown
in Figure 8. In normal operation the transistor will be switched on, i.e. the output pin will be
connected to 0V. The transistor will switch off if a fault is detected – see section 8.4.
Figure 10: Recommended Security Output Sensor Interfaces.
11.4 Level Sense Plates
Brass plates are used for level sensing. One plate is connected to the logic 0 volts and the other
plates are wired to the 12 way connector - pin 7 for low level; pin 6 for either high or top level.
See Figure 11. The signal levels on these pins will be determined by the presence or absence
of an electrical contact, via the coins, between the 0 volt plate and the other plates.
Note:- High Level is not available with the Universal Hopper Lite.
Figure 11: Recommended Level Sense Plate Interfaces.
Tip:- When the hopper motor is running, coins will be moving across the level plates. This could
cause incorrect level signals. It is recommended that the level sense outputs are read when the
hopper motor is switched off.
©Money Controls 2004. All rights reserved.
Page 20 of 30
Universal Hopper Series Manual
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Issue 2.6 – June 2004
11.5 IN1 to IN3 and Motor Control Inputs
These are the control signals from the host to the hopper which determine the Mode of
operation. These are input to the hopper microprocessor via a resistor as shown in Figure 12.
IN3, if used, should always be driven via an open collector transistor referred to logic OV. IN1
and IN2 can also be driven via open collector transistors (see Figure 12) or if no change of mode
is required, then strapped to logic OV or left floating (internal pull-up) depending on the mode
required.
Figure 12: Recommended INx and Motor Control Inputs.
11.6 LED Indicators (Not ‘Lite’)
Three LED indicators are fitted on the hopper. On MKll and MKlll hoppers they are visible under
the track guard at the top corner, at the side of the coin exit. MK4 hoppers have the LED’s
mounted in the coin exit area.
See Figure 6 for details. The LED designations/positions are the same for all universal hoppers.
©Money Controls 2004. All rights reserved.
Page 21 of 30
Universal Hopper Series Manual
TSP079.doc
Issue 2.6 – June 2004
12. Technical Specifications
12.1 Coin Sizes
Please refer to Table 2.
The MK4 hopper however has extended this range to include 31mm diameter coins. Coins
falling outside of the above ranges may be used but would require special qualification.
For more information contact Money Controls Technical Services Department.
12.2 Capacity
Approximate, (±10%), coin capacities can be estimated by applying the following formula.
Alternatively a calculator program can be obtained from the Money Controls Technical Services
Department.
12.3 Connections
Table 6: Connector Pin-outs
Figure 13: Connector Pin-outs
Pin
Note:- Shown from back of
connector on baseplate.
Description
‘Lite’
1
Motor supply 0 volt
Motor supply 0 volt
2
Logic 0 volt
Logic 0 volt
3
uP Sensor Output
uP Sensor Output
4
IN1
N.C.
5
Security output
N.C.
6
High or top level
sense output
Top level sense
output
7
Low level sense
output
Low level sense
output
8
IN2
N.C.
9
Motor supply
+24V Supply
10
Logic supply
N.C.
11
Raw Sensor Output
N.C.
12
IN3
Motor Control I/P
©Money Controls 2004. All rights reserved.
Page 22 of 30
Universal Hopper Series Manual
TSP079.doc
12.4 Motor Supply – Pin 9
Table 7: Motor Supply Requirements
Current consumption at 24V DC:Nominal running current
0.5A
Nominal reverse current
1.0A
Nominal cut-out current during a reverse
1.5A
Nominal start-up current
2.0A
Power supply requirement
24V DC at 2 Amps
Supply Voltage:Nominal voltage
24V DC
Absolute minimum voltage
18V DC
Absolute maximum voltage
27V DC
Maximum rise/fall time
50ms
Absolute worst case ripple at 24V
+3V/-6V
12.5 Logic Supply (Not ‘Lite’)
Table 8: Logic Supply Requirements
Description
Value
Nominal Supply
12V DC at l00mA
Absolute minimum voltage
11V DC
Absolute maximum voltage
27V DC
Maximum rise/fall time
100ms
Absolute worst case ripple
+/-1V
12.6 Logic Inputs (IN1, IN2, IN3 and Motor Control I/P)
Table 9: Logic Input Requirements
Description
Value (Vin)
Absolute maximum logic 0 input
<= 0.6V
Absolute minimum logic 1 input
=> 2.4V
©Money Controls 2004. All rights reserved.
Page 23 of 30
Issue 2.6 – June 2004
Universal Hopper Series Manual
TSP079.doc
Issue 2.6 – June 2004
12.7 Logic Outputs (Sensors, Security)
Table 10: Logic Output Parameters
Description
Value
Absolute maximum ‘true’ output Vout
<= 0.3V at 50mA
Absolute maximum sink current
100mA
Absolute maximum Voff
30 Volts
Sensor output typical pulse width
MKll/lll 50 - 100ms
MK4
70 - 120ms
12.8 Important Supply Notes
1.
2.
3.
4.
The specified maximum motor and logic +ve voltages must not be exceeded, otherwise
damage/injury could result.
Hopper speed (and payout rate) varies with applied motor voltage
The power supply fall time is critical if the hopper is being used in mode 0. When the
host machine has counted out the required number of coins, it must disable the +24 Volt
supply. The motor is not disabled until the power line falls below a pre-set level of 18
volts DC, therefore there is a danger of extra coins being paid out if the power supply fall
time is greater than 5ms. A power supply switching device such as a transistor,
darlington or MOSFET is therefore recommended.
The standby current is the current drawn when the motor is disabled, e.g. if the coin
register is zero in mode 2 or if IN3 is high in mode 1.
12.9 Environment
Table 11: Environmental Parameters
Description
Value
Operating temp
0 to 60°C
Storage temp
-20 to 60°C
Life
Up to 3 million coins
Mounting
±3° of vertical in any direction
NOTE: DO NOT use the hopper in an explosive atmosphere.
©Money Controls 2004. All rights reserved.
Page 24 of 30
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TSP079.doc
13. Hopper Dimensions and Exploded Diagrams
Figure 14: MKII and MKIII Exploded Diagram
©Money Controls 2004. All rights reserved.
Page 25 of 30
Issue 2.6 – June 2004
Universal Hopper Series Manual
TSP079.doc
Figure 15: MKII and MKIII Dimensions
©Money Controls 2004. All rights reserved.
Page 26 of 30
Issue 2.6 – June 2004
Universal Hopper Series Manual
TSP079.doc
Figure 16: MK4 Exploded Diagram
©Money Controls 2004. All rights reserved.
Page 27 of 30
Issue 2.6 – June 2004
Universal Hopper Series Manual
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Figure 17: MK4 and ‘Lite’ Dimensions
©Money Controls 2004. All rights reserved.
Page 28 of 30
Issue 2.6 – June 2004
Universal Hopper Series Manual
TSP079.doc
Figure 18: Baseplate Dimensions
©Money Controls 2004. All rights reserved.
Page 29 of 30
Issue 2.6 – June 2004
Universal Hopper Series Manual
TSP079.doc
Issue 2.6 – June 2004
This manual is intended only to assist the reader in the use of this product and therefore
Money Controls shall not be liable for any loss or damage whatsoever arising form the
use of any information or particulars in, or any incorrect use of the product. Money
Controls reserve the right to change product specifications on any item without prior
notice.
©Money Controls 2004. All rights reserved.
Page 30 of 30
S Model & Ice Beverage
QuietQube® Ice Machines
with CVD® Technology
Installation,
Use and Care Manual
Thank you for selecting a Manitowoc Ice Machine, the dependability leader in ice making equipment and related products.
With proper installation, care and maintenance, your new Manitowoc Ice Machine will provide you with many years of
reliable and economical performance.
This manual is updated as new information and models
are released. Visit our website for the latest manual.
www.manitowocice.com
Part Number 000002477
10/2007
Safety Notices
Procedural Notices
As you work on a QuietQube®-Series Ice Machine, be
sure to pay close attention to the safety notices in this
manual. Disregarding the notices may lead to serious
injury and/or damage to the ice machine.
As you work on a QuietQube®-Series Ice Machine, be
sure to read the procedural notices in this manual.
These notices supply helpful information which may
assist you as you work.
Throughout this manual, you will see the following types
of safety notices:
Throughout this manual, you will see the following types
of procedural notices:
! Warning
PERSONNEL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
! Warning
Text in a Warning box alerts you to a potential
personal injury situation. Be sure to read the
Warning statement before proceeding, and work
carefully.
Important
Text in an Important box provides you with
information that may help you perform a procedure
more efficiently. Disregarding this information will
not cause damage or injury, but it may slow you
down as you work.
NOTE: Text set off as a Note provides you with simple,
but useful, extra information about the procedure you
are performing.
Read These Before Proceeding:
! Caution
! Caution
Text in a Caution box alerts you to a situation in
which you could damage the ice machine. Be sure
to read the Caution statement before proceeding,
and work carefully.
Proper installation, care and maintenance are
essential for maximum ice production and troublefree operation of you Manitowoc Ice Machine.
Read and understand this manual. It contains
valuable care and maintenance information. If you
encounter problems not covered by this manual, do
not proceed, contact Manitowoc Ice, Inc. We will be
happy to provide assistance.
Important
Routine adjustments and maintenance procedures
outlined in this manual are not covered by the
warranty.
We reserve the right to make product improvements at any time.
Specifications and design are subject to change without notice.
Table of Contents
Section 1
General Information
Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Read a Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Bagger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Bin Thermostat Kit - K00364 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CVD1486 Water Cooled Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . .
Stacking Two Ice Machines on a Single Dispenser . . . . . . . . . . . . . . . . . .
Arctic Pure Water Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manitowoc Cleaner and Sanitizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guardian Sachet Packets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aucs® Automatic Cleaning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model/Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Owner Warranty Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commercial Ice Machine Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . .
Residential Ice Machine Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-4
1-4
1-4
1-4
1-4
Section 2
Installation Instructions
Ice Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stacking Two Ice Machines on a Single Storage Bin . . . . . . . . . . . . . . . . . . .
Ice Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IB0600C Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IB0800C Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IB1000C Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CVD Condensing Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CVD0675/CVD0885/CVD1085/CVD1285/CVD1485 . . . . . . . . . . . . . . . . .
CVD1885/CVD2075 Air-Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Storage Bin Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 inch (76cm) Ice Storage Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S970 Ice Storage Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Large Capacity Ice Storage Bin Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . .
30 Inch (76 cm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 Inch (122 cm) & 60 Inch (152 cm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Machine Installation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CVD1486 Condenser Water Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Machine Head Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Machine Head Section Installation Requirements . . . . . . . . . . . . . . . . . .
S600C/S850C/S1000C/S1200C/S1470C/S1870C/S2070C . . . . . . . . . . . .
IB0600C/IB0800C/IB1000C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Number 000002477
2-1
2-1
2-2
2-2
2-2
2-2
2-3
2-3
2-3
2-4
2-4
2-4
2-4
2-4
2-4
2-5
2-5
2-5
2-6
2-6
2-6
1
Table of Contents (continued)
Ice Machine Head Section Clearance Requirements . . . . . . . . . . . . . . . . . . .
S600C/S850C/S1000C/S1200C/S1470C/S1870C/S2070C . . . . . . . . . . . .
IB0600C/IB0800C/IB1000C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location of CVD Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensing Unit Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .
CVD675/CVD885/CVD1085/CVD2075 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CVD1285/CVD1485/CVD1885 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CVD1486 ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bin Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leveling the Ice Storage Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S1470C/S1870C/S2070C Installation on a Manitowoc Bin . . . . . . . . . . . . .
Dispenser Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IB0600C/IB0800C/IB1000C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Ice Beverage on a Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Circuit Ampacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Fault Circuit Interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
QuietQube® Ice Machine Head Section Electrical Wiring Connections . . . .
QuietQube® Ice Machine Head Section
115/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
230/1/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For United Kingdom Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensing Unit Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CVD Condensing Unit
208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
208-230/3/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
230/1/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Machine Head Section Water Supply and Drains . . . . . . . . . . . . . . . . . . .
Potable Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potable Water Inlet Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Tower Applications (Water-Cooled Models) . . . . . . . . . . . . . . . . . . .
Water Cooled Condenser Water Supply and Drains . . . . . . . . . . . . . . . . . . . .
Condenser Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Cooled Condenser Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensing Unit Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Supply and Drain Line Sizing/Connections . . . . . . . . . . . . . . . . . . . .
Refrigeration System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration Line Set Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Line Set Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Line Set Rise or Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Suction Line Oil Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Bin Thermostat Instructions IB600C/IB800C/IB1000C Only . . . . .
Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Starting the Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AuCS® Automatic Cleaning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2-6
2-6
2-6
2-7
2-7
2-7
2-7
2-7
2-8
2-8
2-8
2-9
2-9
2-10
2-11
2-11
2-11
2-11
2-11
2-11
2-12
2-14
2-14
2-14
2-14
2-15
2-15
2-15
2-15
2-16
2-16
2-16
2-16
2-16
2-17
2-17
2-17
2-17
2-18
2-19
2-20
2-20
2-20
2-20
2-21
2-30
2-30
2-31
2-32
2-32
Part Number 000002477
Table of Contents (continued)
Section 3
Ice Machine Operation
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Machine Head Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Making Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . .
Freeze Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Harvest Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Thickness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Harvest Sequence Water Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
3-3
3-4
3-4
3-4
3-5
3-5
3-6
3-6
3-6
3-6
3-7
Interior Cleaning and Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Removal for Cleaning/Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Component Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water-Cooled Condenser and Water Regulating Valve CVD1486 Only . . . .
Ice Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guardian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guardian Sachet Replacement Frequency . . . . . . . . . . . . . . . . . . . . . . . . .
Sachet Installation/Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . .
Clean Up Procedure for Damaged Sachet Packet . . . . . . . . . . . . . . . . . . .
Removal from Service/Winterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CVD 1486 Water Cooled Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-1
4-2
4-10
4-12
4-12
4-12
4-12
4-13
4-13
4-13
4-13
4-14
4-14
4-14
Section 4
Maintenance
Section 5
Before Calling For Service
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Limit Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Number 000002477
5-1
5-2
3
Table of Contents (continued)
THIS PAGE INTENTIONALLY LEFT BLANK
4
Part Number 000002477
Section 1
General Information
Section 1
General Information
Model Numbers
How to Read a Model Number
This manual covers the following models:
Ice Machine Head Section
SD0672C
SY0674C
IB0624YC
IB0622DC
SD0872C
SY0874C
IB0824YC
IB0822DC
SD1072C
SY1074C
SD1272C
SY1274C
IB1024YC
IB1022DC
SD1472C
SY1474C
SD1872C
SY1874C
SD2072C
SY2074C
CVD® Condensing Unit*
9 REMOTE
AIR-COOLED
CVD0675
# CUBE SIZE
CONDENSER TYPE
2
3
4
5
AIR-COOLED
WATER-COOLED
AIR-COOLED
WATER-COOLED
DICE
DICE
HALF-DICE
HALF-DICE
S Y 1074 C
CVD0885
CVD1085
ICE MACHINE
MODEL
ICE MACHINE
SERIES
ICE CUBE SIZE
D DICE
Y HALF DICE
CVD1285
CONDENSER TYPE
A
W
N
C
SELF-CONTAINEDAIR-COOLED
SELF-CONTAINEDWATER-COOLED
REMOTE AIR-COOLED
CVD REMOTE AIR-COOLED
SV3106
Remote Condensing Unit
CVD1485
CVD1486
5
6
CVD1885
AIR-COOLED
WATER-COOLED
CVD 1485 3
CVD2075
CONDENSING
UNIT MODEL
For 3 phase electrical option: add the number “3” to the
end of model number (CVD10853).
CONDENSING
UNIT SERIES
3 PHASE
SV3107
! Warning
PERSONNEL INJURY POTENTIAL
Ice Cube Sizes
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified from
that of original manufactured specifications.
! Warning
When installed on a bin an ice deflector is required.
Prior to using a non-Manitowoc ice storage system with
Manitowoc ice machines, contact the manufacturer to
assure their ice deflector is compatible with Manitowoc ice
machines.
SV3105
Dice
Half Dice
7/8" x 7/8" x 7/8"
3/8" x 1-1/8" x 7/8"
2.22 x 2.22 x 2.22 cm 0.95 x 2.86 x 2.22 cm
! Warning
S1470C/S1870C/S2070C ice machines are not approved
for use on Manitowoc B570 series bins.
Part Number 000002477
1-1
General Information
Section 1
Accessories
ARCTIC PURE WATER FILTER SYSTEM
Contact your Manitowoc distributor for these optional
accessories:
Engineered specifically for Manitowoc ice machines,
This water filter is an efficient, dependable, and
affordable method of inhibiting scale formation, filtering
sediment, and removing chlorine taste and odor.
ICE BAGGER
Maximize profits from bagged ice sales with this
convenient accessory. This sturdy unit rests on the bin
door frame, and adapts for left or right side filling.
ICE DEFLECTOR
An ice deflector is required when the ice machine is
installed on a bin. An ice deflector is not required when
the ice machine is installed on a dispenser.
! Warning
Manitowoc QuietQube® ice machines require a
deflector when installed on an ice storage bin.
Prior to using a non-Manitowoc ice storage system
with Manitowoc ice machines, contact the
manufacturer to assure their ice deflector is
compatible with Manitowoc ice machines.
MANITOWOC CLEANER AND SANITIZER
Manitowoc Ice Machine Cleaner and Sanitizer are
available in convenient 16 oz. (473 ml) and 1 gal (3.78 l)
bottles. These are the only cleaner and sanitizer
approved for use with Manitowoc products.
Cleaner Part Number
AuCS®-SO - 94-0546-3
AuCS®-SI - 40-1326-3
Sanitizer Part Number
AuCS®-SO - 94-0565-3
AuCS®-SI - 40-1327-3
GUARDIAN SACHET PACKETS
Guardian sachet packets release chlorine dioxide on a
controlled basis to inhibit the growth of bacteria and
slime.
Guardian sachet packets are available through your
local Manitowoc Ice Machine dealer.
ELECTRONIC BIN THERMOSTAT KIT - K00364
DISPENSER
This kit reduces overfill and condensation issues and
can be used on any Manitowoc ice machine installed on
an ice dispenser. The kit includes a universal mounting
bracket which attaches over the dispenser side wall.
A counter-top dispenser is ideal for cafeterias and many
types of self-service facilities. Manitowoc auto-fill, floorstanding ice dispensers meet the strict sanitary
requirements of the food service, lodging and health
care industries.
Important
Ice/Beverage Ice Machines require the installation
of a thermostat to maintain the dispenser ice level.
The thermostat ships with the ice machine.
AUCS® AUTOMATIC CLEANING SYSTEM
This accessory reduces equipment cleaning expense.
The AuCS® accessory monitors ice making cycles and
initiates cleaning procedures automatically.
CVD1486 WATER COOLED CONDENSING UNIT
(With High Pressure Water Regulating Valve)
A special order condensing unit is available that allows
condenser water inlet pressure up to 350 psig
(24.13 bar).
STACKING TWO ICE MACHINES ON A SINGLE
DISPENSER
Ice/Beverage Ice Machines cannot be stacked.
S QuietQube ice machines cannot be stacked. However
an adapter is available that allows two S QuietQube ice
machines to be placed side by side on 60” Manitowoc
F & B style bins. This requires an installation kit that is
necessary to allow access to the shut-off valves during
installation and will improve access during future
service. Refer to sales literature to determine the proper
installation kit for you application.
1-2
Part Number 000002477
Section 1
General Information
Model/Serial Number Location
Record the model and serial number of your ice machine
and bin or dispenser in the space provided below.
These numbers are required when requesting
information from your local Manitowoc distributor,
service representative, or Manitowoc Ice, Inc.
The model and serial number are listed on the OWNER
WARRANTY REGISTRATION CARD. They are also
listed on the MODEL/SERIAL NUMBER DECAL affixed
to the ice machine head section and condensing unit.
Both model/serial numbers must be referenced to obtain
warranty or service information.
Ice Machine Head Section
Condensing Unit
MODEL /
SERIAL
NUMBERS
DECAL
(ICE
MACHINE)
SV1746
MODEL / SERIAL NUMBERS DECAL
(CVD CONDENSING UNIT)
MODEL /
SERIAL
NUMBERS
DECAL
(BIN)
SV3143
CVD1486 Condensing Unit
MODEL / SERIAL
NUMBERS DECAL
(CVD CONDENSING
UNIT)
SV3077
SV3147
INSIDE FRONT COVER
(ICE MACHINE HEAD SECTION)
FRONT OF CONTROL BOX OR
SIDE OF CONTROL BOX
Model/Serial Number Location
Ice Machine
Bin or Dispenser
CVD Condensing Unit
AuCS Accessory
Model Number
Serial Number
Part Number 000002477
1-3
General Information
Owner Warranty Registration Card
GENERAL
The packet containing this manual also includes
warranty information. Warranty coverage begins the day
the ice machine is installed.
Important
Complete and mail the OWNER WARRANTY
REGISTRATION CARD as soon as possible to
validate the installation date.
If the OWNER WARRANTY REGISTRATION CARD is
not returned, Manitowoc will use the date of sale to the
Manitowoc Distributor as the first day of warranty
coverage for your new ice machine.
Warranty Coverage
COMMERCIAL ICE MACHINE LIMITED WARRANTY
The following Warranty outline is provided for your
convenience. For a detailed explanation, read the
warranty bond shipped with each product.
Contact your local Manitowoc Distributor or Manitowoc
Ice, Inc. if you need further warranty information.
PARTS
1. Manitowoc warrants the ice machine against defects
in materials and workmanship, under normal use
and service for three (3) years from the date of
original installation.
2. The evaporator and compressor are covered by an
additional two (2) year (five years total) warranty
beginning on the date of the original installation.
LABOR
1. Labor required to repair or replace defective
components is covered for three (3) years from the
date of original installation.
2. The evaporator is covered by an additional two (2)
year (five years total) labor warranty beginning on
the date of the original installation.
1-4
Section 1
EXCLUSIONS
The following items are not included in the ice machine’s
warranty coverage:
1. Normal maintenance, adjustments and cleaning as
outlined in this manual.
2. Repairs due to unauthorized modifications to the ice
machine or use of non-standard parts without prior
written approval from Manitowoc Ice, Inc.
3. Damage caused by improper installation of the ice
machine, electrical supply, water supply or drainage,
or damage caused by floods, storms, or other acts of
God.
4. Premium labor rates due to holidays, overtime,
etc.; travel time; flat rate service call charges;
mileage and miscellaneous tools and material
charges not listed on the payment schedule.
Additional labor charges resulting from the
inaccessibility of equipment are also excluded.
5. Parts or assemblies subjected to misuse, abuse,
neglect or accidents.
6. Damage or problems caused by installation,
cleaning and/or maintenance procedures
inconsistent with the technical instructions provided
in this manual.
AUTHORIZED WARRANTY SERVICE
To comply with the provisions of the warranty, a
refrigeration service company qualified and authorized
by a Manitowoc distributor, or a Contracted Service
Representative must perform the warranty repair.
NOTE: If the dealer you purchased the ice machine from
is not authorized to perform warranty service; contact
your Manitowoc distributor or Manitowoc Ice, Inc. for the
name of the nearest authorized service representative.
SERVICE CALLS
Normal maintenance, adjustments and cleaning as
outlined in this manual are not covered by the warranty.
If you have followed the procedures listed in this manual,
and the ice machine still does not perform properly, call
your Deasler, Local Distributor or the Service
Department at Manitowoc Ice, Inc.
Part Number 000002477
Section 1
General Information
RESIDENTIAL ICE MACHINE LIMITED WARRANTY
WHAT DOES THIS LIMITED WARRANTY COVER?
Subject to the exclusions and limitations below,
Manitowoc Ice, Inc. (“Manitowoc”) warrants to the
original consumer that any new ice machine
manufactured by Manitowoc (the “Product”) shall be
free of defects in material or workmanship for the
warranty period outlined below under normal use and
maintenance, and upon proper installation and start-up
in accordance with the instruction manual supplied with
the Product.
HOW LONG DOES THIS LIMITED WARRANTY
LAST?
Product Covered
Warranty Period
Ice Machine
Twelve (12) months
from the sale date
WHO IS COVERED BY THIS LIMITED WARRANTY?
This limited warranty only applies to the original
consumer of the Product and is not transferable.
WHAT ARE MANITOWOC ICE’S OBLIGATIONS
UNDER THIS LIMITED WARRANTY?
If a defect arises and Manitowoc receives a valid
warranty claim prior to the expiration of the warranty
period, Manitowoc shall, at its option: (1) repair the
Product at Manitowoc’s cost, including standard straight
time labor charges, (2) replace the Product with one that
is new or at least as functionally equivalent as the
original, or (3) refund the purchase price for the Product.
Replacement parts are warranted for 90 days or the
balance of the original warranty period, whichever is
longer. The foregoing constitutes Manitowoc’s sole
obligation and the consumer’s exclusive remedy for any
breach of this limited warranty. Manitowoc’s liability
under this limited warranty is limited to the purchase
price of Product. Additional expenses including, without
limitation, service travel time, overtime or premium labor
charges, accessing or removing the Product, or
shipping are the responsibility of the consumer.
HOW TO OBTAIN WARRANTY SERVICE
To obtain warranty service or information regarding your
Product, please contact us at:
MANITOWOC ICE, INC.
2110 So. 26th St.
P.O. Box 1720,
Manitowoc, WI 54221-1720
Telephone: 920-682-0161 Fax: 920-683-7585
www.manitowocice.com
Part Number 000002477
WHAT IS NOT COVERED?
This limited warranty does not cover, and you are solely
responsible for the costs of: (1) periodic or routine
maintenance, (2) repair or replacement of the Product
or parts due to normal wear and tear, (3) defects or
damage to the Product or parts resulting from misuse,
abuse, neglect, or accidents, (4) defects or damage to
the Product or parts resulting from improper or
unauthorized alterations, modifications, or changes; and
(5) defects or damage to any Product that has not been
installed and/or maintained in accordance with the
instruction manual or technical instructions provided by
Manitowoc. To the extent that warranty exclusions are
not permitted under some state laws, these exclusions
may not apply to you.
EXCEPT AS STATED IN THE FOLLOWING SENTENCE, THIS
LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE
WARRANTY OF MANITOWOC WITH REGARD TO THE
PRODUCT. ALL IMPLIED WARRANTIES ARE STRICTLY
LIMITED TO THE DURATION OF THE LIMITED WARRANTY
APPLICABLE TO THE PRODUCTS AS STATED ABOVE,
INCLUDING BUT NOT LIMITED TO, ANY WARRANTY OF
MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.
Some states do not allow limitations on how long an
implied warranty lasts, so the above limitation may not
apply to you.
IN NO EVENT SHALL MANITOWOC OR ANY OF ITS
AFFILIATES BE LIABLE TO THE CONSUMER OR ANY OTHER
PERSON FOR ANY INCIDENTAL, CONSEQUENTIAL OR
SPECIAL DAMAGES OF ANY KIND (INCLUDING, WITHOUT
LIMITATION, LOSS PROFITS, REVENUE OR BUSINESS)
ARISING FROM OR IN ANY MANNER CONNECTED WITH THE
PRODUCT, ANY BREACH OF THIS LIMITED WARRANTY, OR
ANY OTHER CAUSE WHATSOEVER, WHETHER BASED ON
CONTRACT, TORT OR ANY OTHER THEORY OF LIABILITY.
Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
HOW STATE LAW APPLIES
This limited warranty gives you specific legal rights, and
you may also have rights that vary from state to state or
from one jurisdiction to another.
REGISTRATION CARD
To secure prompt and continuing warranty service, this
warranty registration card must be completed and sent
to Manitowoc within thirty (30) days from the sale date.
Complete the following registration card and send it to
Manitowoc.
1-5
General Information
Section 1
THIS PAGE INTENTIONALLY LEFT BLANK
1-6
Part Number 000002477
Section 2
Installation Instructions
Section 2
Installation Instructions
Ice Machine Dimensions
Important
Failure to follow these installation guidelines may
affect warranty coverage.
S0600C/S0850C/S1000C/S1200C ICE MACHINES
D
W
14.88" (37.80cm)
5.36" (13.61cm)
Liquid
Line
Suction
Line
H
Water Inlet
3/8” FPT
17.14" (43.53cm)
Electrical
Drain
1/2”
FTP
5.00" (12.70cm)
Base Drain
AuCS
Knockout
5.75" (14.6cm)
8.41" (21.36cm)
8.50" (21.59cm)
10.61" (26.94cm)
Ice
Machine
S0600C
S0850C
S1000C
S1200C
Dimension D
Dimension W
Dimension H
24.5 in
(62.2 cm)
24.5 in
(62.2 cm)
24.5 in
(62.2 cm)
24.5 in
(62.2 cm)
30 in
(76.2 cm)
30 in
(76.2 cm)
30 in
(76.2 cm)
30 in
(76.2 cm)
21.5 in
(54.6 cm)
26.5 in
(67.3 cm)
29.5 in
(74.9 cm)
29.5 in
(74.9 cm)
Part Number 000002477
Stacking Two Ice Machines on a Single Storage Bin
S QuietQube ice machines cannot be stacked. However
an adapter is available that allows two S QuietQube ice
machines to be placed side by side on 60” Manitowoc
F & B style bins.
2-1
Installation Instructions
Section 2
S1470C ICE MACHINES
24.5”
(62.23 cm)
30”
(76.2 cm)
6.87”
(17.45 cm)
3.24”
(8.23 cm)
25”
(63 cm)
Electrical
Suction
Line
Water Inlet
3/8” FPT
14.77”
(37.52 cm)
Liquid
Line
5.5”
(14.0 cm)
20.96”
(53.24 cm)
AuCS
Knockout
21.5”
(54.6 cm)
2.02”
(5.13 cm)
Base
Drain
Drain
1/2”
FTP
Base Drain
S1870C/S2070C ICE MACHINES
25”
(63.5cm)
30”
(76.2cm)
Suction
Line
Electrical
Liquid
Line
30”
(76.2cm)
26.5”
(67.3cm)
20.5”
(52cm)
Drain
1/2”
NPTF
Water Inlet
3/8” FPT
5.5”
(14cm)
6.0”
(15.2cm)
Base Drains
! Warning
S1470C/S1870C/S2070C ice machines are not approved
for use on Manitowoc B570 series bins.
2-2
Part Number 000002477
Section 2
Installation Instructions
Ice Machine Dimensions
IB0600C ICE MACHINE
IB1000C ICE MACHINE
22”
(55.8 CM)
22”
(55.8 CM)
3”
(7.62 CM)
21”
(54.6 CM)
19.5”
(48.9 CM)
5.5”
(14 CM)
3”
(7.62 CM)
3”
(7.62 CM)
30.5”
(77.47 CM)
26”
(66 CM)
5.5”
(14 CM)
3”
(7.62 CM)
10”
(25.4 CM)
5.9”
(15 CM)
8.25”
(21 CM)
17.25”
(243.81 CM)
5.9”
(15 CM)
SV3093
14”
(35.56 CM)
8.25”
(21 CM)
SV3093
14”
(35.56 CM)
Important
IB0800C ICE MACHINE
Failure to follow these installation guidelines may
affect warranty coverage.
22”
(55.8 CM)
3”
(7.62 CM)
26.5”
(67.31 CM)
21.8”
(55.4 CM)
5.5”
(14 CM)
3”
(7.62 CM)
12.7”
(32.26 CM)
5.9”
(15 CM)
8.25”
(21 CM)
SV3093
14”
(35.56 CM)
Part Number 000002477
2-3
Installation Instructions
Section 2
CVD Condensing Unit Dimensions
CVD0675/CVD0885/CVD1085/
CVD1185/CVD1285/CVD1485
CVD1486
24.13”
(53.7 CM)
34”
(86.4 CM)
21.87”
(55.5 CM)
24.53”
(62.3 CM)
25.75”
(65.4 CM)
20.64”
(52.4 CM)
14.5”
(36.8 CM)
FRONT VIEW
4.26”
(10.8 CM)
14.5”
(36.8 CM)
12.6”
(32 CM)
9.5”
(24.1 CM)
10.75”
(27.3 CM)
8.54”
(21.6 CM)
8.70”
(22.1 CM)
SV3076
SV1758
CVD1885/CVD2075 Air-Cooled
26”
(66.04 CM)
52.5”
(133.35 CM)
11.5”
(28.58 CM)
6.5”
(16.5 CM)
26”
(66.04 CM)
10.25”
(26.04 CM)
FRONT VIEW
13.5”
(34.3 CM)
14.5”
(36.8 CM)
8”
(20.32 CM)
10”
(25.4 CM)
5”
(12.7 CM)
9”
10”
5.25”
(13.34 CM)
2-4
PT1307
Part Number 000002477
Section 2
Installation Instructions
Ice Storage Bin Dimensions
Large Capacity Ice Storage Bin Dimensions
30 INCH (76CM) ICE STORAGE BIN
30 INCH (76 CM)
A
34” (86.4 cm)
B
25.25”
(64.1 cm)
43.6”
(110.81 cm)
Bin Model
B570
Dimension A
34.0 in (86.3 cm)
Dimension B
44.0 in (111.7 cm)
6”
(15.2 cm)
! Warning
Manitowoc QuietQube ice machines require the ice
storage bin to incorporate an ice deflector.
Prior to using a non-Manitowoc ice storage system
with other Manitowoc ice machines, contact the
manufacturer to assure their ice deflector is
compatible with Manitowoc ice machines.
Dimension B
(Height)
B750
30 in. (76.2 cm.)
58 in. (147.3 cm.)
B1050
30 in. (76.2 cm.)
78 in. (198.1 cm.)
The bin drain is exactly in the center of the bin.
Bin Model
Dimension A (Width)
48 INCH (122 CM) & 60 INCH (152 CM)
S970 ICE STORAGE BIN
A
34” (86.4 cm)
B
25.25”
(64.1 cm)
43.6”
(110.81 cm)
6”
(15.2 cm)
! Caution
30” large capacity bins must be attached to the wall
with the bracket provided with the bin.
Part Number 000002477
Dimension A
Dimension B
(Width)
(Height)
B1100
48 in. (121.9 cm.)
55.0 in. (139.7 cm.)
B1400
60 in. (152.4 cm.)
55.0 in. (139.7 cm.)
The bin drain is exactly in the center of the bin.
Bin Model
2-5
Installation Instructions
Section 2
General
These instructions are provided to assist the qualified
installer. Check your local Yellow Pages for the name of
the nearest Manitowoc distributor, or call Manitowoc Ice,
Inc. for information regarding installation and start-up
services.
S1470C
TUBING CAN BE
ROUTED OUT TOP
Important
Failure to follow these installation guidelines may
affect warranty coverage.
TUBING CAN BE
ROUTED OUT
BACK OF THE ICE
MACHINE WITH
PROVIDED 90°
ELL’S
TRIM TOP PANEL WHEN
EXITING TOP
! Warning
PERSONAL INJURY POTENTIAL
Remove all ice machine panels before lifting and
installing.
Ice Machine Installation Options
CVD1486 CONDENSER WATER PRESSURE
Water pressure at the condenser cannot exceed 150
psig (10.34 bar) with the standard water-regulating
valve. Contact your distributor if your water pressure is
greater than 150 psig (10.34 bar). A special order
condensing unit is available that allows water pressure
up to 350 psig (24.13 bar).
ICE MACHINE HEAD SECTIONS
The ice machine head can be installed with the electrical
inlet, water supply inlet and refrigeration tubing entering
from the back or top of the ice machine.
The ice machine water drain must exit the back of the
ice machine.
TUBING CAN BE ROUTED
OUT BACK OR TOP
TRIM TOP COVER
IN THIS AREA
Cut the top cover for top routing of electrical inlet, water
supply inlet or refrigeration lines.
1. Prior to cutting, mount top cover onto ice machine.
2. Use ice machine back panel recessed area as a
template to mark the underside of the top cover.
Do not cut up to or past this line!
3. Using an aviator snips, cut top cover as needed:
A. Do not cut out entire area! Cut up to 1/8 inch to
marked line.
B. Cut out only what is needed. (If routing only
refrigeration lines out the top, cut just enough to
route these lines.)
SV1752
2-6
C. Do not cut out the entire corner area.
Part Number 000002477
Section 2
Installation Instructions
Ice Machine Head Section Installation
Requirements
Ice Machine Head Section Clearance
Requirements
S600C/S850C/S1000C/S1200C/S1470C/S1870C/S2070C
S600C/S850C/S1000C/S1200C/S1470C/S1870C/S2070C
The location selected for the ice machine must meet the
following criteria. If any of these criteria are not met,
select another location.
Top 5” (12.7 cm) is recommended for efficient operation
and removal of top cover/servicing.
Sides 5” (12.7 cm) is recommended for efficient
operation and servicing. There is no minimum clearance
required.
Back 3” (7.6 cm) required when routing electrical inlet,
water inlet and refrigeration tubing out of the top of the
unit.
5” (12.7 cm) required when routing all connections out
the back.
•
The location must be free of airborne and other
contaminants.
•
The air temperature must be at least 35°F (1.6°C),
but must not exceed 110°F (43.4°C).
•
The location must not be near heat-generating
equipment or in direct sunlight.
•
The location must not obstruct airflow through or
around the ice machine. Refer to ice machine head
section clearance requirements.
IB0600C/IB0800C/IB1000C
•
Ice/Beverage Ice Machines require the installation of
a thermostat to maintain dispenser ice level. The
thermostat ships with the ice machine.
•
The ice machine head is installed with the electrical
inlet, water supply inlet, refrigeration tubing and
water drain entering from the back of the ice
machine.
•
The ice machine head section contains a service
loop that must remain installed between the ice
machine head section and line set. Sufficient tubing
length must be available to allow 180° rotation of the
ice machine.
•
Maintain a 3” space between the back of the ice
machine and the back of the dispenser to allow room
for the refrigeration line set service loop.
•
The water inlet and electrical connection must
contain a service loop to allow future service and
maintenance access.
•
The drain line must contain a union or other suitable
means of disconnection at the ice machine head
section.
•
The location must be free of airborne and other
contaminants.
•
The air temperature must be at least 35°F (1.6°C),
but must not exceed 110°F (43.4°C).
•
The location must not be near heat-generating
equipment or in direct sunlight.
•
The location must not obstruct airflow through or
around the ice machine. Refer to ice machine head
section clearance requirements.
Part Number 000002477
IB0600C/IB0800C/IB1000C
Top 2” (5.1 cm) required clearance for cleaning
procedures and servicing.
Back 5” (12.7 cm) required when routing all connections
out the back.
Sides 8” (20.3 cm) required for servicing.
! Caution
The ice machine head section must be protected if it
will be subjected to temperatures below 32°F (0°C).
Failure caused by exposure to freezing
temperatures is not covered by the warranty. See
“Removal from Service/Winterization”.
2-7
Installation Instructions
Section 2
Location of CVD Condensing Unit
Condensing Unit Clearance Requirements
The location selected for the CVD Condensing Unit must
meet the following criteria. If any of these criteria are not
met, select another location.
CVD675/CVD885/CVD1085/CVD2075
•
The air temperature must be at least -20°F (-28.9°C)
but must not exceed 130°F (54.4°C).
•
CVD675/CVD2075 Only - The air temperature must
be at least -20°F (-28.9°C) but must not exceed
120°F (48.9°C).
•
CVD1486 Only- The air temperature must be at least
50°F (10°C) but must not exceed 110°F (43°C).
•
The location must not allow exhaust fan heat and/or
grease to enter the condenser.
•
The location must not obstruct airflow through or
around the condensing unit. See below for clearance
requirements.
Top/Sides
There is no minimum clearance required, although 6”
(15.2 cm) is recommended for efficient operation and
servicing only.
Front/Back
48” (122 cm)
CVD1285/CVD1485/CVD1885
Top/Sides
There is no minimum clearance required, although 6”
(15.2 cm) is recommended for efficient operation and
servicing only.
Front
24” (61 cm)
Back
48” (122 cm)
CVD1486 ONLY
Top - 5” (12.7 cm) is required for efficient operation and
servicing.
Front/Back/Sides - 12” (30.5 cm)
2-8
Part Number 000002477
Section 2
Installation Instructions
Bin Installation
All ice machines installed on a bin require an ice
deflector. Manitowoc bins have a built in deflector that
requires no modifications when used with a forward
facing evaporator. Ice machines with multiple
evaporators require a deflector kit.
Bin adapters or custom bin tops are available to allow
installation of a 30” ice machine on a 48” or 60” bin.
Refer to ice machine price list for options.
! Warning
S1470C/S1870C/S2070C INSTALLATION ON A
MANITOWOC BIN
! Warning
S1470C/S1870C/S2070C ice machines are not approved
for use on Manitowoc S570 series bins.
An ice deflector kit is required for installation. Order
appropriate kit (30” or 48”) for your bin.
Step 1 Remove the stock ice deflector.
Manitowoc QuietQube ice machines require the ice
storage bin to incorporate an ice deflector.
Prior to using a non-Manitowoc ice storage system
with other Manitowoc ice machines, contact the
manufacturer to assure their ice deflector is
compatible with Manitowoc ice machines.
LEVELING THE ICE STORAGE BIN
A. Remove the left and right side cover screws
B. Remove the cover to expose four screws, which
secure the plastic deflector.
C. Remove fours screws and plastic deflector
D. Install polymer spacer on each side and secure
with the four screws.
E. Reinstall cover and screws.
1. Screw the leveling legs onto the bottom of the bin.
2. Screw the foot of each leg in as far as possible.
RE-INSTALL TOP
COVER
! Caution
The legs must be screwed in tightly to prevent them
from bending.
3. Move the bin into its final position.
REMOVE
DEFLECTOR
REMOVE 1
SCREW ON
EACH SIDE
REMOVE 2
SCREWS
ON EACH
SIDE
4. Level the bin to assure that the bin door closes and
seals properly. Use a level on top of the bin. Turn
each foot as necessary to level the bin.
THREAD LEVELING
LEG INTO BASE AS
FAR AS POSSIBLE
ADJUST LEGS TO
LEVEL BIN
SV1606
Leveling Leg and Foot
Part Number 000002477
2-9
Installation Instructions
Step 2 Install front support and filler panels.
A. Remove foam tape from front support location.
B. Set front support in place and install foam tape.
C. Position filler panels (align with front support),
drill and secure.
D. Install foam tape on front and back. Seal all
foam tape edges.
Step 3 Install ice deflector.
A. Locate center of ice machine drop zone (center
is 11” from left edge of ice machine to left edge
of bracket).
Section 2
Dispenser Installation
No deflector is needed for machines that match the size
of the dispenser (30” head section on a 30” dispenser)
unless required by the dispenser manufacturer.
Adapters are required when a smaller ice machine is
going on a larger dispenser (22” machine on a 30”
dispenser).
IB0600C/IB0800C/IB1000C
Securing the Ice Machine to the Dispenser
Important
Manitowoc Ice/Beverage Ice Machines require an
adapter for mounting. Adapters are not included
with the ice machine, dispenser or bin and must be
ordered separately. When a non-Manitowoc adapter
is used, verify the adapter is compatible with
Manitowoc Ice/Beverage Ice Machines prior to
installation.
B. Cut and remove foam tape on the front and the
back of the bin where the deflector will be
located.
C. Remove any residual adhesive; areas must be
clean and dry.
D. Remove protective covering from double sided
tape on bottom of deflector bracket.
E. Install deflector bracket; Distribute equally to the
front and back and locate pin to the rear.
F. Apply foam tape over bracket and seal joints
with silicone sealant.
G. Refer to illustration and install deflector in
mounting bracket.
The ice machine and adapter plate must be secured to
the dispenser to prevent tipping.
•
Two holes are located in the front bottom rail of the
ice machine, to allow attachment to the adapter
plate.
•
The adapter cover must be secured to the dispenser
to prevent ice from dislodging the cover during
agitation.
! Warning
2. LOCK IN PLACE WITH PIN
The ice machine and adapter plate must be secured
to the dispenser to prevent tipping.
1. SLIDE FORWARD
2-10
Part Number 000002477
Section 2
Installation Instructions
TYPICAL ICE BEVERAGE ON A DISPENSER
Important
DO NOT REMOVE the label on bin adapters. The
retainer clips and brackets must be used.
1. Install bin level thermostat bracket.
2. Set adapter on dispenser. Position the adapter so
that the front flange of the adapter will be up against
the front lip of the dispenser. Adapter may have to
be moved towards the back of the dispenser.
3. Using the slotted holes in the adapter as a template,
drill four (4) 9/64” diameter holes at the bottom of the
slots. Note: Do not drill deeper than 1/4” past the
sheet metal. Use a drill stop!
4. Fasten the adaptor to dispenser using the four (4) #8
screws supplied with the adaptor kit.
5. Set the ice machine on top of the adapter. Align
holes in ice machine front angle with threaded
bosses on the adapter.
BIN
COVER
6. Secure the ice machine to the adaptor with two (2)
#8-32 screws supplied with the kit.
7. Set the bin cover on the adapter, move backwards
until the cover hits the stop, and lower the plastic
cover insuring that the latch locks.
8. To remove the bin cover, twist the knob, lift up, and
pull forward.
PLACE A LARGE FILLET OF
FOOD GRADE RTV INSIDE
EDGE ALONG BOTH SIDES
WHERE ADAPTER
TOUCHES BIN
SV3121
ADAPTER
SCREWS
DEFLECTOR MUST
STAY IN PLACE
SV3120
SV3122
Part Number 000002477
2-11
Installation Instructions
Section 2
Electrical Service
FUSE/CIRCUIT BREAKER
GENERAL
The ice machine head section and condensing unit are
wired independently from each other.
! Warning
All wiring must conform to local, state and national
codes.
Ice Machine Head Section
The ice machine head section does not require a
dedicated circuit breaker.
CVD® Condensing Unit
VOLTAGE
For both the Ice Machine Head Section and the CVD®
Condensing Unit, the maximum allowable voltage
variation is ±10% of the rated voltage at ice machine
start-up (when the electrical load is highest).
! Warning
The ice machine and condensing unit must be
grounded in accordance with national and local
electrical codes.
All electrical work, including wire routing and grounding,
must conform to local, state and national electrical
codes. The following precautions must be observed:
•
The ice machine must be grounded.
•
A separate fuse/circuit breaker must be provided for
each condensing unit.
•
A qualified electrician must determine proper wire
size dependent upon location, materials used and
length of run (minimum circuit ampacity can be used
to help select the wire size).
•
The maximum allowable voltage variation is +/-10 of
the rated voltage at ice machine start-up (when the
electrical load is highest).
•
Check all green ground screws in the control box and
verify they are tight before starting the ice machine.
A separate fuse/circuit breaker must be provided for
each condensing unit. Circuit breakers must be H.A.C.R.
rated (does not apply in Canada).
MINIMUM CIRCUIT AMPACITY
The minimum circuit ampacity is used to help select the
wire size of the electrical supply. (Minimum circuit
ampacity is not the ice machine’s running amp load.)
The wire size (or gauge) is also dependent upon
location, materials used, length of run, etc., so it must be
determined by a qualified electrician. Manitowoc Ice
requires minimum #8 AWG for S2070C condensing unit
applications.
GROUND FAULT CIRCUIT INTERRUPTER
Ground Fault Circuit Interrupter (GFCI/GFI) protection is
a system that shuts down the electric circuit (opens it)
when it senses an unexpected loss of power,
presumably to ground. Manitowoc Ice, Inc. does not
recommend the use of a GFCI/GFI circuit protection with
our equipment. If code requires the use of a GFCI/GFI
then you must follow the local code. The circuit must be
dedicated, sized properly and there must be a panel
GFCI/GFI breaker. We do not recommend GFCI/GFI
outlets as they are known for more intermittent nuisance
trips than panel breakers.
Important
Observe correct polarity of incoming line voltage.
Incorrect polarity can lead to erratic ice machine
operation and a safety issue. This is especially critical on
230 volt / 50 cycle ice machines.
2-12
Part Number 000002477
Section 2
Installation Instructions
Electrical Requirements
QuietQube® Ice Machine Head Section
Important
Due to continuous improvements, this information is
for reference only. Please refer to the ice machine
serial number tag to verify electrical data. Serial tag
information overrides information listed on this page.
Local or state electrical code, length of wire run or materials used, can increase the minimum wire or breaker
size requirement. A qualified electrician must determine the wire and breaker size, although the minimum
wire size must meet or exceed the specifications in these charts.
Ice Machine
S0600C
S0850C
IB0620C
IB0820C
IB1020C
Voltage
Phase
Cycle
115/1/60
230/1/50
115/1/60
230/1/50
Maximum
Fuse/Circuit
Breaker
15 amp
15 amp
15 amp
15 amp
115/1/60
230/1/50
115/1/60
230/1/50
115/1/60
S1200C
230/1/50
115/1/60
S1470C
208-230/1/60
S1870C
230/1/50*
S2070C
* Not available on S2070C models.
** All conductors must be solid copper wire
S1000C
Part Number 000002477
1.1
0.6
1.1
1.5
#14 Solid Copper
Conductor
#14 Solid Copper
Conductor
Minimum Breaker
Size Required by
Manitowoc
15 amp
15 amp
15 amp
15 amp
15 amp
15 amp
1.4
0.8
#14 Solid Copper
Conductor
15 amp
15 amp
15 amp
15 amp
15 amp
15 amp
15 amp
15 amp
15 amp
2.5
1.5
2.5
1.5
1.1
0.6
0.6
#14 Solid Copper
Conductor
15 amp
15 amp
15 amp
15 amp
15 amp
15 amp
15 amp
Total Amps
**Minimum Wire Size
Required by Manitowoc
#14 Solid Copper
Conductor
#14 Solid Copper
Conductor
2-13
Installation Instructions
Section 2
CVD® Condensing Unit
Important
Due to continuous improvements, this information is
for reference only. Please refer to the condensing
unit serial number tag to verify electrical data. Serial
tag information overrides information listed on this
page.
Local or state electrical code, length of wire run or materials used, can increase the minimum wire or breaker
size requirement. A qualified electrician must determine the wire and breaker size, although the minimum
wire size must meet or exceed the specifications in these charts.
Condensing
Unit
CVD0675
CVD0885
CVD1085
CVD1285
CVD1485
CVD1486
CVD1885
CVD2075
Voltage/Phase/Cycle
Maximum Fuse/
Circuit Breaker
Minimum
Circuit Amps
**Minimum Wire Size
Required by Manitowoc
208-230/1/60
208-230/3/60
230/1/50
208-230/1/60
208-230/3/60
230/1/50
208-230/1/60
208-230/3/60
230/1/50
208-230/1/60
208-230/3/60
230/1/50
208-230/1/60
208-230/3/60
230/1/50
208-230/1/60
208-230/3/60
230/1/50
208-230/1/60
208-230/3/60
230/1/50
208-230/1/60
208-230/3/60
15 amp
15 amp
15 amp
20 amp
15 amp
20 amp
20 amp
15 amp
20 amp
25 amp
20 amp
20 amp
20 amp
15 amp
30 amp
20 amp
15 amp
20 amp
40 amp
25 amp
30 amp
50 amp
40 amp
9.6
7.3
9.0
11.8
9.1
10.0
12.5
9.4
10.9
14.7
10.6
11.7
20.0
15.0
20
20.0
15.0
20.0
25.0
20.0
20.0
40.0
30.0
#14 Solid Copper Conductor
#14 Solid Copper Conductor
#14 Solid Copper Conductor
#12 Solid Copper Conductor
#14 Solid Copper Conductor
#12 Solid Copper Conductor
#12 Solid Copper Conductor
#14 Solid Copper Conductor
#12 Solid Copper Conductor
#10 Solid Copper Conductor
#12 Solid Copper Conductor
#12 Solid Copper Conductor
#8 Solid Copper Conductor
#10 Solid Copper Conductor
#8 Solid Copper Conductor
#10 Solid Copper Conductor
#12 Solid Copper Conductor
#12 Solid Copper Conductor
#8 Solid Copper Conductor
#10 Solid Copper Conductor
#8 Solid Copper Conductor
#10 Solid Copper Conductor
#10 Solid Copper Conductor
Minimum
Breaker Size
Required by
Manitowoc
15 amp
15 amp
15 amp
20 amp
15 amp
20 amp
20 amp
15 amp
20 amp
25 amp
20 amp
20 amp
20 amp
15 amp
30 amp
20 amp
15 amp
20 amp
40 amp
25 amp
30 amp
50 amp
40 amp
NOTE: The QuietQube® Ice Machine Head Section and CVD Condensing Unit are wired independently from each other.
! Warning
CVD2075 ONLY
Connect power supply wiring directly to L1 & L2 on the
contactor. Torque screws to the torque value
specification on the contactor label. Follow all local,
state and national electrical codes.
2-14
Part Number 000002477
Section 2
Installation Instructions
QuietQube® Ice Machine Head Section Electrical Wiring Connections
! Warning
These diagrams are not intended to show proper
wire routing, wire sizing, disconnects, etc., only the
correct wire connections.
All electrical work, including wire routing and
grounding, must conform to local, state and national
electrical codes.
Though wire nuts are shown in the drawings, the ice
machine field wiring connections may use either
wire nuts or screw terminals.
QUIETQUBE® ICE MACHINE HEAD SECTION
115/1/60
QUIETQUBE® ICE MACHINE HEAD SECTION
230/1/50
L1
L1
N
N
GROUND
GROUND
L1
L1
N=115V
OR
L2=208-230V
GROUND
ICE MACHINE
CONNECTIONS
TO SEPARATE
FUSE/BREAKER.
DISCONNECT ALL
POLES.
SV1191
GROUND
ICE MACHINE
CONNECTIONS
SV1258
FOR UNITED KINGDOM ONLY
As the colors of the wires in the mains lead of the appliance may not correspond with the colored markings
identifying the terminals in your plug, proceed as follows:
•
The wire which is colored green and yellow must be connected to the terminal in the plug which is marked with
the letter E or by the earth ground symbol
or colored green or green and yellow.
•
The wire colored blue must be connected to the terminal which is marked with the letter N or colored black.
•
The wire colored brown must be connected to the terminal which is marked with the letter L or colored red.
Part Number 000002477
2-15
Installation Instructions
Section 2
Condensing Unit Wiring Connections
CVD CONDENSING UNIT
208-230/3/60
! Warning
L1
L1
L2
L2
L3
L3
These diagrams are not intended to show proper
wire routing, wire sizing, disconnects, etc., only the
correct wire connections.
All electrical work, including wire routing and
grounding, must conform to local, state and national
electrical codes.
Though wire nuts are shown in the drawings, the ice
machine field wiring connections may use either
wire nuts or screw terminals.
GROUND
CONDENSING
UNIT
CONNECTIONS
CVD CONDENSING UNIT
208-230/1/60
TO SEPARATE
FUSE/BREAKER
CVD2075 ONLY
CONDENSING UNIT CONNECTIONS
L1
L1
GROUND
L1
CONTACTOR
L1
L2
L2
GROUND
L2
GROUND
L3
CONDENSING UNIT
CONNECTIONS
L3
TO SEPARATE
FUSE/BREAKER
GROUND
SV1258
GROUND
CVD2075 ONLY
CONDENSING UNIT CONNECTIONS
TO SEPARATE
FUSE/BREAKER
SV1190a
CONTACTOR
T1
L1
T2
L2
CVD CONDENSING UNIT
230/1/50
L1
L1
GROUND
N
N
GROUND
TO SEPARATE
FUSE/BREAKER
GROUND
SV1258a
CONDENSING UNIT
CONNECTIONS
2-16
GROUND
TO SEPARATE
FUSE/BREAKER.
DISCONNECT ALL
POLES.
Part Number 000002477
Section 2
Installation Instructions
Ice Machine Head Section Water Supply and Drains
POTABLE WATER SUPPLY
Local water conditions may require treatment of the
water to inhibit scale formation, filter sediment, and
remove chlorine odor and taste.
Important
If you are installing a Manitowoc water filter system,
refer to the Installation Instructions supplied with the
filter system for ice making water inlet connections.
POTABLE WATER INLET LINES
Follow these guidelines to install water inlet lines:
•
•
Do not connect the ice machine to a hot water
supply. Be sure all hot water restrictors installed for
other equipment are working. (Check valves on sink
faucets, dishwashers, etc.)
If water pressure exceeds the maximum
recommended pressure of 80 psig (5.52 bar), obtain
a water pressure regulator from your Manitowoc
distributor.
•
Install a water shut-off valve for ice making potable
water.
•
Insulate water inlet lines to prevent condensation.
•
A 3’ service loop or disconnect (union) must be
installed at the ice machine head section.
Cooling Tower Applications
(Water-Cooled Models)
A water cooling tower installation does not require
modification of the ice machine. The water regulator
valve for the condenser continues to control the
refrigeration discharge pressure.
It is necessary to know the amount of heat rejection, and
the pressure drop through the condenser and water
valves (inlet and outlet) when using a cooling tower on
an ice machine.
•
Water entering the condenser must not exceed 90°F
(32.2°C).
•
Water flow through the condenser must not exceed 5
gallons (19 liters) per minute.
•
Allow for a pressure drop of 7 psi (48 kPA) between
the condenser water inlet and the outlet of the ice
machine.
•
Water exiting the condenser must not exceed 110°F
(43.3°C).
IMPORTANT
The Commonwealth of Massachusetts requires that all
water-cooled models must be connected only to a closed
loop, cooling tower system.
DRAIN CONNECTIONS
Follow these guidelines when installing drain lines to
prevent drain water from flowing back into the ice
machine and storage bin:
•
Drain lines must have a 1.5 inch drop per 5 feet of
run (2.5 cm per meter), and must not create traps.
•
The floor drain must be large enough to
accommodate drainage from all drains.
•
Run separate bin and ice machine drain lines.
Insulate them to prevent condensation.
•
Vent the bin and ice machine drain to the
atmosphere. The ice machine drain requires an 18”
vent.
•
Drains must have a union or other suitable means to
allow in place disconnection from the ice machine
when servicing is required.
Part Number 000002477
2-17
Installation Instructions
Section 2
Water Cooled Condenser Water Supply and Drains
CONDENSER WATER SUPPLY
Local water conditions may require treatment of the
water to inhibit scale formation, filter sediment, and
remove chlorine odor and taste.
WATER COOLED CONDENSER LINES
Follow these guidelines to install water lines:
•
Contact your distributor if your water pressure is
greater than 150 psig (1034 kPA). A special order
condensing unit is available that allows water
pressure up to 350 psig (2413 kPA).
•
Install a shutoff valve (inlet and outlet on cooling
tower or closed loop circuits) to allow isolation of the
water system.
•
Water entering the condenser must not exceed 90°F
(32.2°C).
•
Water flow through the condenser must not exceed 5
gallons (19 liters) per minute.
•
Allow for a pressure drop of 8 psig (55 kPA) between
the condenser water inlet and outlet.
•
Water exiting the condenser must not exceed 110°F
(43.3°C).
•
Do not connect to the potable water filter system.
CONDENSING UNIT DRAIN CONNECTIONS
The condensing unit drain is provided to remove any
condensate produced by the suction accumulator.
Condensate amounts will vary depending on
temperature and humidity.
•
The condensing unit must be level front to back and
side to side to allow the condensate to drain.
•
Drain lines must have a 1.5-inch drop per 5 feet of
run (2.5 cm per meter), and must not create traps.
•
Drain termination must meet applicable costs.
2-18
Part Number 000002477
Section 2
Installation Instructions
WATER SUPPLY AND DRAIN LINE SIZING/CONNECTIONS
! Caution
Plumbing must conform to state and local codes.
Location
Water Temperature
Water Pressure
Ice Machine Fitting
Ice Making
Water Inlet
35°F (1.6°C) Min.
90°F (32.2°C) Max.
3/8” Female Pipe
Thread
Water Cooled
Condenser
35°F (1.6°C) Min.
90°F (32.2°C) Max.
1/2” Female Pipe
Thread
1/2” (12.7 mm) min. inside
diameter
Ice Making
Water Drain
---
20 psi (1.4 bar) Min.
80 psi (5.5 bar) Max.
Standard
20 psi (1.4 bar) Min.
150 psi (10.3 bar) Max.
High Pressure Option
20 psi (1.4 bar) Min.
350 psi (24.1 bar) Max.
---
Tubing Size Up to Ice
Machine Fitting
3/8” (9.5 mm) min. inside
diameter
---
---
1/2” Female Pipe
Thread
3/4” Female Pipe
Thread
---
---
1/2” (12.7 mm) min. inside
diameter
3/4” (19.1 mm) min.
inside diameter
1” (25.4 mm) min.
inside diameter
Bin Drain
Large Capacity
Bin Drain
1” Female Pipe Thread
Refer to “Ice Machine Dimensions” at the beginning of Section 2 for the exact locations of inlets and drains for the model you are working on.
18.00” VENT
(45.70 cm)
ICE MAKING WATER
DRAIN FITTING
1/2” F.P.T. (1.27 cm)
BIN DRAIN TUBING
3/4”MIN. I.D. (1.91 cm)
INCORRECT
DO NOT TRAP
MUST HAVE
AIR-GAP
AIR GAP
OPEN, TRAPPED OR
VENTED DRAIN
Typical Water Supply Drain Installation
Part Number 000002477
2-19
Installation Instructions
Section 2
Refrigeration System Installation
QuietQube®
Ice Machine
S0600C
IB620C
S0850C
IB820C
S1000C
S1200C
IB1020C
S1470C
S1870C
S2070C
Remote Single
Circuit
Condenser
CVD675
CVD885
! Caution
Line Set*
RC-21
RC-31
RC-51
CVD1085
CVD1285
CVD1485
CVD1486
CVD1885
CVD2075
*Line Set
Suction
Line
Liquid
Line
RC 21/31/51
5/8 inch
(15.9 mm)
3/8 inch
(9.5 mm)
RC 20/30/50**
3/4 inch
(19.1 mm)
1/2 inch
(12.7 mm)
Factory Equipment Refrigeration Amounts
RC-20
RC-30
RC-50
Insulation
Thickness
1/2”(13mm)
Suction Line
1/4” (7mm)
Liquid Line
1/2”(13mm)
Suction Line
1/4” (7mm)
Liquid Line
**NOTE: The CVD2075 has a suction line fitting of
7/8” and a liquid line fitting of 5/8”. Since the line set
is sized differently, please use the provided
bushings to properly connect the line set to the CVD
Condensing Unit.
Important
Manitowoc remote systems are only approved and
warranted as a complete new package. Warranty on
the refrigeration system will be void if a new ice
machine head section is connected to pre-existing
(used) tubing or condensing units or vice versa.
USAGE WITH NON-MANITOWOC
CONDENSING UNITS
Manitowoc CVD® Condensing Units are specifically
designed for usage with a QuietQube® Ice Machine
Head Section. Standard condensing units and NonManitowoc condensing units will not operate a
QuietQube® Ice Machine Head Section.
2-20
The refrigeration system warranty will not apply if the
Manitowoc Ice Machine and Manitowoc CVD
Condensing Unit are not installed according to
specifications. This warranty also will not apply if the
refrigeration system is modified with a condenser,
heat reclaim device, or other parts or assemblies not
manufactured by Manitowoc Ice, Inc.
ICE MACHINE HEAD SECTION
Each ice machine head section ships from the factory
with a R-404A refrigerant charge appropriate for the
entire system operation. The serial tag on the ice
machine indicates the refrigerant charge. The refrigerant
charge is sufficient to operate the ice machine in
ambient temperatures between -20°F & 130°F (-29°C &
54°C)*. With line set lengths of up to 100 feet (30.5 m).
*CVD675/CVD2075 = -20°F to 120°F (-29°C to 49°C)
CVD1486 = 50°F to 110°F (10°C to 43°C)
! Warning
Potential Personal Injury Situation
The ice machine head section contains the refrigerant
charge. Installation and brazing of the line sets must be
performed by a properly trained and EPA certified
refrigeration technician aware of the dangers of dealing
with refrigerant charged equipment.
! Caution
Never add more than nameplate charge to the
refrigeration system for any application.
CVD® CONDENSING UNIT
Each condensing unit ships from the factory pressurized
with 50/50 nitrogen helium mixture that must be
removed during the installation process (approximately
20 psig).
REFRIGERATION LINE SETS/TRAP KIT
Refrigeration Rated Tubing and Trap Kits are shipped
capped with atmospheric pressure.
! Warning
Installation of a QuietQube® Condensing Unit may require
the use of special equipment for placement. Trained and
qualified personnel are required for proper rigging and
lifting. Holes are provided on the corners of the condensing
unit to allow the use of lifting shackles.
Part Number 000002477
Section 2
Installation Instructions
Refrigeration Line Set Installation
A. LINE SET LENGTH
GENERAL
100 feet (30.5 m) Length: The maximum measured
length the line set can be.
The receiver is designed to hold a charge sufficient to
operate the ice machine in ambient temperatures
between -20°F (-28.9°C) and 130°F (54.4°C)*, with line
set lengths of up to 100 feet (30.5 m).
*CVD675/CVD2075 = -20°F to 120°F (-29°C to 49°C)
CVD1486 = 50°F to 110°F (10°C to 43°C). The
maximum amount of lineset which can be exposed on
the rooftop is 25% of the total length of the lineset.
Refrigeration line set installations consist of vertical and
horizontal line set distances between the ice machine
and the condensing unit. The following guidelines,
drawings and calculation methods must be followed to
assure proper oil return and CVD® condensing unit/ice
machine operation.
The refrigeration line set installer must be USA
Government-Environmental Protection Agency (EPA)
certified in proper refrigerant handling and servicing
procedures.
! Warning
The ice machine head section contains refrigerant
charge. The ice machine head section contains three
(3) refrigeration valves that must remain closed until
proper installation of the line sets is completed.
Important
QuietQube® ice machines will not function with line
sets greater than 100 feet (30.5 m). Do not attempt to
go beyond this distance and add refrigerant charge to
compensate!
B. LINE SET RISE OR DROP
! Warning
Disconnect electrical power to the ice machine head
section and CVD® condensing unit before
proceeding.
Step 1 Verify Ice Machine and CVD® Condensing
Unit Locations Are Within Guidelines.
Prior to installation of the ice machine head section and
CVD® condensing unit be sure that the distance
between then is within the line set routing guidelines
outlined in this manual.
Roof/Wall Penetration
If required, cut a 3-inch (76.2 mm) circular hole in the
wall or roof for routing of refrigeration tubing. A qualified
person must perform all roof penetrations.
Step 2 Route Refrigeration Tubing
35’ (10.7 M)
MAX.
DISTANCE
SV1751
35 feet (10.7 m) Rise: The maximum distance the
CVD® condensing unit can be above the ice machine.
Properly route refrigeration tubing between the ice
machine head section and the CVD® condensing unit.
15’ (4.5 M)
MAX.
DISTANCE
SV1750
15 feet (4.5 m) Drop: The maximum distance the CVD®
condensing unit can be below the ice machine.
Part Number 000002477
2-21
Installation Instructions
Section 2
C. SUCTION LINE OIL TRAPS
! Caution
Do not form unwanted traps in refrigeration lines.
Never coil excess refrigeration tubing.
0 to 20 feet (0 to 6.1 m) Rise: The ice machine head
section has one oil trap built in which allows for a
maximum condenser rise of 20 feet (6.1 m) without
additional traps in the suction line.
21 to 35 feet (6.4 to 10.7 m) Rise: The suction line
requires an additional Oil Trap (“S” type) to be installed.
Install the trap as close as possible to midpoint between
the ice machine head section and CVD condensing unit.
S-Trap Kits are available from Manitowoc (refer to chart).
Service Loop
A service loop in the line set permits easy access to the
ice machine for cleaning and service.
•
The supplied service loop (on Ice Beverage ice
machines) is an installation requirement. Excess
tubing length must be sufficient to allow 180°
rotation of the ice machine.
•
A service loop is not considered an oil trap.
•
The service loop is not included when calculating
length, rise or drop of the tubing run.
•
Do not use hard rigid copper for the service loop.
! Caution
If a line set has a rise followed by a drop, another rise
cannot be made. Likewise, if a line set has a drop
followed by a rise, another drop cannot be made.
Step 3 Lengthening or Reducing Line Set Lengths
! Caution
21’ OR MORE
RISE
ADDITIONAL
TRAP KIT
REQUIRED
Do not form unwanted traps in refrigeration lines.
Never coil excess refrigeration tubing.
When the line set required shortening or lengthening, do
so before connecting the line set to the ice machine
head section or the CVD condensing unit.
SV1751
SV1760
Manitowoc S-Trap Kit
Model
S-Trap Kit
Number
Tubing Size
S600C S850C
S1000C
K00172
5/8 inch
(15.9 mm)
S1200C
S1470C
S1870C
S2070C
K00166
3/4 inch
(19.1 mm)
2-22
Part Number 000002477
Section 2
Installation Instructions
Connect The Line Set To The CVD Condensing Unit
Step 4 Connecting the line set.
To prevent oxidation of the copper, purge line set and
condensing unit with dry nitrogen while brazing.
! Warning
The condensing unit ships from the factory
pressurized with a 50/50 mixture of nitrogen/helium.
Bleed off pressure from both suction and liquid line
access ports prior to cutting into refrigeration lines.
Connect The Line Set To The Ice Machine Head
Section
! Warning
The ice machine head section contains refrigerant
charge. The ice machine head section contains three
(3) refrigeration valves that must remain closed until
proper installation of the line sets is completed.
The line set can be routed for entry through the top or
rear of the ice machine head section.
•
Top routing requires the cover to be trimmed.
•
Rear routing requires the use of the supplied 90°
elbows.
The line set shut off valves at the back of the ice
machine must remain closed and be protected from heat
during the brazing process. Wrap the valves in a wet rag
or other type of heat sink prior to brazing. Cool braze
joint with water immediately after brazing to prevent heat
migration to the valve.
The compressor oil rapidly absorbs moisture. Be
prepared to complete line set installation and start your
evacuation process in order to minimize the time the
compressor is exposed to the atmosphere. (Maximum
amount of time the system can be exposed to the
atmosphere is 15 minutes). The line set can be routed
for entry through the front or left side of the condensing
unit.
•
Remove knockout for preferred location.
•
Insert supplied plastic bushings in knockout holes to
prevent tubing from contacting sheet metal.
•
Use the supplied 90° elbows to route tubing.
•
Cut the tubing ends of the suction and liquid lines
and braze the line sets to the condensing unit.
SUCTION
FILTER
SUCTION
LINE
MINIMIZE THE TIME THE REFRIGERATION
SYSTEM IS EXPOSED TO THE ATMOSPHERE
(15 MINUTES MAXIMUM)
VALVES MUST REMAIN
CLOSED AND BE
PROTECTED FROM
HEAT WHEN BRAZING
(WRAP WITH WET RAG)
SV2085
SV1757
! Warning
The condensing unit ships from the factory
pressurized with a 50/50 mixture of nitrogen/helium.
Bleed off pressure from both suction and liquid line
access ports prior to cutting into refrigeration lines.
LIQUID
LINE
SUCTION
LINE
SV3077
Part Number 000002477
2-23
Installation Instructions
Section 2
Step 5 Pressure Test and Evacuate The Line Set
and CVD Condensing Unit
Schrader valve core removal tools that allow for removal
and installation of the valve cores without removing
manifold gauge set hoses are recommended to
decrease the evacuation time.
Leave the line set shut off valves closed (front seated).
Pressure test the line sets and CVD condensing unit
with 150 psig of dry nitrogen. Add nitrogen at the line set
shut off valves located at the back of the ice machine.
Complete the pressure test, verify no leaks are present
and remove the nitrogen from the system before
connecting the vacuum pump. Connect a vacuum pump
to both of the line set shut off valves located at the back
of the ice machine head section. Evacuate to 500
microns (or less). To completely evacuate the CVD
condensing unit, continue the evacuation for 30 minutes
after reaching the 500 micron point.
If required, the line set and condensing unit can be
evacuated from the schrader valves located in the CVD
condensing unit. Schrader valve core removal tools (that
allow for putting the cores back in without removing
vacuum pump hoses) must be used if evacuating from
the condensing unit side.
Isolate the vacuum pump from the line set shut off
valves and/or condensing unit access ports prior to
proceeding. Open refrigeration system shut off valves.
The suction line, liquid line and receiver service valves
are closed during shipment and installation.
CONNECT
VACUUM PUMP TO
LINE SET SHUT
OFF VALVES
ALTERNATE CONNECTIONS AT
CONDENSING UNIT SCHRADER VALVES
SV1757
CVD1485 CONDENSING UNIT SCHRADER
VALVES
SV2085
SV1757
CONNECT
VACUUM PUMP TO
LINE SET SHUT
OFF VALVES
CVD1486
CONDENSING UNIT
SCHRADER VALVES
SV1769b
SV3081
2-24
Part Number 000002477
Section 2
Installation Instructions
Step 6 Open The Valves Prior To Starting The Ice
Machine.
A. Slowly backseat (open-turn counterclockwise)
the suction line shut off valve.
USE ALLEN WRENCH
TO OPEN (TURN
COUNTERCLOCKWISE)
LIQUID AND SUCTION
LINE SHUT OFF
VALVES
B. Slowly backseat (open-turn counterclockwise)
the liquid line shut off valve.
C. Slowly backseat (open-turn counterclockwise)
the receiver service valve.
NOTE: You will not hear refrigerant flow when the valves
are opened. Refrigerant will not flow until the toggle
switch is placed in the ice position and the solenoid
valve opens.
OPEN SUCTION AND LIQUID LINE SHUT OFF VALVES
S1470C/S1870C/S2070C
! Caution
USE ALLEN WRENCH TO OPEN
(TURN COUNTERCLOCKWISE)
LIQUID AND SUCTION LINE
SHUT OFF VALVES
SV1762
OPEN SUCTION AND LIQUID LINE SHUT OFF VALVES
S0600C/S0850C/S1000C/S1200C
After opening suction, discharge and receiver service
valves, refrigerant pressure will not be detected until
the toggle switch is placed in the ice position and the
harvest solenoid valve energizes.
Important
.
All refrigeration valve caps must be reinstalled to
prevent future refrigeration leaks.
Verify O-ring in schrader valve caps are intact and
reinstall on shut off valves to prevent refrigerant leakage.
Replace shut off valve access caps and torque to the
following specifications.
Torque Value’s
USE ALLEN WRENCH
TO OPEN (TURN
COUNTERCLOCKWISE)
LIQUID AND SUCTION
LINE SHUT OFF
VALVES
Stem
18-20 ft. lbs.
Caps
12-15 ft. lbs.
Schrader Core
1.5-3 in. lbs.
SV3051
OPEN SUCTION AND LIQUID LINE SHUT OFF VALVES
IB0600C/IB0800C/IB1000C
Part Number 000002477
2-25
Installation Instructions
Section 2
Replace cap on receiver service valve and tighten.
To prevent condensation the entire suction line including
the shut-off valve must be insulated. All insulation must
be airtight and sealed at both ends.
The following insulation requirements prevent
condensation at 90°F (32.2°C) ambient 90% Relative
Humidity. If higher humidity is expected, increase
insulation thickness.
The entire suction line set, including the suction service
valve located on the back of the ice machine requires:
TURN
COUNTERCLOCKWISE
RECEIVER SERVICE VALVE CAP
(TURN COUNTERCLOCKWISE
TO REMOVE)
Step 8 Insulation Requirements
Suction Line
Liquid Line
Min. Insulation
Thickness
3/4 inch
(19.1 mm)
1/2 inch
(12.7 mm)
5/8 inch
(15.9 mm)
3/8 inch
(9.5 mm)
1/2”(13mm)
Suction Line
1/4” (7mm)
Liquid Line
7/8 inch
(22.2 mm)
5/8 inch
(15.9 mm)
SV1756
Open Receiver Service Valve
There is a liquid line solenoid valve at the outlet of the
receiver; refrigerant will not flow to the condensing unit
until the ice machine head section is started. Connect
power to both the ice machine head section and the
CVD condensing unit. Place the ICE/OFF/CLEAN toggle
switch into the ICE position, this will allow refrigerant to
enter the line set and condensing unit.
3/4” (19mm)
Suction Line
1/4” (7mm)
Liquid Line
Step 7 Leak Check The Refrigeration System
Leak check the new line set connections at the ice
machine head section, condensing unit and S trap as
well as all factory joints throughout the entire system.
Disconnect power to the CVD condensing unit. Place the
ICE/OFF/CLEAN toggle switch into the ICE position.
This allows the low side and high side pressures to
equalize. Place the ICE/OFF/CLEAN toggle switch in the
OFF position. Connect power to the CVD condensing
unit and allow system to pump down.
2-26
Important
To prevent condensation the entire suction line
including the shut off valve must be insulated. All
insulation must be airtight and sealed at both ends.
The minimum requirements are for conditions at or
below 90% humidity and 90°F (32.2°C) ambient.
When higher humidity will be experienced, insulation
wall thickness will need to be increased.
Part Number 000002477
Section 2
Installation Instructions
Suction Shut Off Valve Insulation
The pre-formed suction shut-off valve insulation is
located in the plastic bag taped to the water curtain.
A. Verify valve and schrader caps are tightened to
specifications (see Step 6).
PRE-FORMED
INSULATION
TIGHTEN VALVE CAPS
TO SPECIFICATIONS
SV3084
B. Place insulation over schrader valve cap and left
side of valve. Position the tab between the
mounting bracket and rear panel.
PLACE TAB BETWEEN
VALVE BODY AND PANEL
SV3085
C. Fold insulation and hold against right hand side
of valve while securing with electrical tape. Seal
the line set insulation to the shut off valve
insulation with electrical tape.
FOLD INSULATION OVER
RIGHT SIDE OF VALVE AND
SECURE WITH
ELECTRICAL TAPE
SV3086
Part Number 000002477
2-27
Installation Instructions
Section 2
CVD CONDENSING
UNIT
ELECTRICAL
DISCONNECT
SUCTION
LINE
LIQUID
LINE
ELECTRICAL
DISCONNECT
ICE MACHINE
HEAD SECTION
SUCTION
REFRIGERANT
SHUT-OFF VALVE
ELECTRICAL
SUPPLY
LIQUID
REFRIGERANT
SHUT-OFF VALVE
BIN
SV1759
Typical QuietQube® System Installation - S600C/S850C/S1000C/S1200C
2-28
Part Number 000002477
Section 2
Installation Instructions
CVD CONDENSING
UNIT
ELECTRICAL
DISCONNECT
SUCTION
LINE
LIQUID
LINE
LIQUID
REFRIGERANT
SHUT-OFF VALVE
SUCTION
REFRIGERANT
SHUT-OFF VALVE
ICE MACHINE
HEAD SECTION
ELECTRICAL
SUPPLY
POTABLE WATER
INLET
ELECTRICAL
DISCONNECT
BIN
SV1768c
Typical QuietQube® System Installation - S1470C/S1870C/S2070C
Part Number 000002477
2-29
Installation Instructions
Section 2
CVD CONDENSING
UNIT
ELECTRICAL
DISCONNECT
LIQUID
LINE
ICE MACHINE
HEAD SECTION
SUCTION AND LIQUID
REFRIGERANT
SHUT-OFF VALVE
LOCATED INSIDE
SUCTION
LINE
ELECTRICAL
CORD ENTRANCE
POTABLE WATER
INLET
REFRIGERATION
LINE SET SERVICE
LOOP
WATER DRAIN
FITTING
SV1759A
Typical Ice/Beverage System Installation - IB600C/IB800C/IB1000C
2-30
Part Number 000002477
Section 2
Installation Instructions
Electronic Bin Thermostat Instructions
IB600C/IB800C/IB1000C Only
POSITIONING
1. Remove water trough.
2. Remove sensor probe from the water trough.
3. Remove 2 screws - see illustration below.
4. Position sensor probe into dispenser and secure
with screws.
5. Re-install water trough.
6. The control is preset and does not require
programming.
FINAL
POSITION
SHIPS IN THE
WATER
TROUGH
REMOVE 2
SCREWS
Bin Thermostat Location
CONTROL
LOCATION
Control Location
Part Number 000002477
2-31
Installation Instructions
Section 2
Installation Checklist
Is the Ice Machine level?
Has the ice machine receiver service valve been
opened 100%?
Has all of the internal packing been removed?
Does the condenser fan motor operate properly
after start-up?
Have all of the electrical and water connections
been made?
Have all the refrigeration fittings and joints been
leak checked?
Has the supply voltage been tested and checked
against the rating on the nameplate?
Is the line set routed properly?
Is there proper clearance around the ice machine
for air circulation?
Has the ice machine been installed where
ambient temperatures will remain in the range of
35° - 110°F (2° - 43°C)?
Has the ice machine been installed where the
incoming water temperature will remain in the
range of 35° - 90°F (2° - 32°C)?
Are the ice machine and bin drains separately
vented?
Are all electrical leads free from contact with
refrigeration lines and moving equipment?
Has the owner/operator been instructed regarding
maintenance and the use of Manitowoc Cleaner
and Sanitizer?
Has the warranty registration card been sent to
the factory?
Has the ice machine and bin been sanitized?
Is a refrigeration oil trap (S-trap) installed if the
condenser is installed 21 to 35 feet (6 to 11m)
above the ice machine head?
Has the CVD® condensing unit been installed to
prevent any roofing damage?
Have the refrigeration lines been insulated and
secured properly to prevent vibration?
Has the remote condensing unit been located
where ambient temperatures will remain in the
range of -20° to 130°F (-29° to 54°C)?
CVD675/CVD2075 Only - The air temperature
must be at least -20°F (-29°C) but must not
exceed 120°F (49°C).
Are the plastic bushings installed on the CVD®
condensing unit to prevent refrigeration tubing
from contacting the sheet metal panel?
CVD1486 Only - Is the drain installed on the
condensing unit?
Is the condensing unit level?
IB Only - Has the thermostat kit been installed
and tested?
IB Only - Is the adapter secured to the
dispenser?
2-32
Part Number 000002477
Section 2
Installation Instructions
Before Starting the Ice Machine
AuCS® Automatic Cleaning System
All Manitowoc ice machines are factory-operated and
adjusted before shipment. Normally, new installations do
not require any adjustment.
To ensure proper operation, follow the Operational
Checks in Section 3 of this manual. Starting the ice
machine and completing the Operational Checks are the
responsibilities of the owner/operator.
Adjustments and maintenance procedures outlined in
this manual are not covered by the warranty.
This optional accessory monitors ice making cycles and
initiates cleaning procedures automatically. The AuCS®
accessory can be set to automatically clean or sanitize
the ice machine every 2, 4 or 12 weeks.
! Warning
Potential Personal Injury Situation
Do not operate equipment that has been misused.
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
Part Number 000002477
2-33
Installation Instructions
Section 2
THIS PAGE INTENTIONALLY LEFT BLANK
2-34
Part Number 000002477
Section 3
Ice Machine Operation
Section 3
Ice Machine Operation
Component Identification
ICE MACHINE HEAD SECTION
S600C/S850C/S1000C/S1200C
EVAPORATOR
DISTRIBUTION
TUBE
ICE/OFF/CLEAN
SWITCH
ICE THICKNESS
PROBE
WATER INLET
VALVE
(LOCATED IN
REFRIGERATION
COMPARTMENT)
WATER LEVEL
PROBE
DUMP VALVE
WATER CURTAIN
WATER INLET
LOCATION
WATER PUMP
WATER TROUGH
SV3149
SV3150
S1470C/S1870C/S2070C
ICE
THICKNESS DISTRIBUTION
TUBE
AIR
PROBE
PUMP
EVAPORATOR
LEFT SIDE
AIR
PUMP
SPLASH
SHIELD
TXV SENSING
BULB
BOOT
BIN
SWITCH
DRIER
HARVEST
VALVE
WATER
TROUGH
SHIELD
LIQUID LINE
SOLENOID
VALVE
ICE DAMPER
WATER
TROUGH
WATER
PUMP
ICE/OFF/CLEAN
SWITCH
Part Number 000002477
DUMP
VALVE
WATER
LEVEL
PROBE
RECEIVER
WATER INLET
VALVE
EXPANSION
VALVE
3-1
Ice Machine Operation
Section 3
IB0600C/IB0800C/IB1000C
ELECTRICAL
COMPARTMENT
ELECTRICAL
COMPARTMENT
ICE/OFF/CLEAN
TOGGLE
SWITCH
WATER
DISTRIBUTION TUBE
SHUT OFF
VALVES
RECEIVER
SERVICE
VALVE
DISCHARGE
LINE
CHECK
VALVE
ICE
THICKNESS
PROBE
WATER
INLET
VALVE
LIQUID
LINE
DRYER
DUMP
VALVE
WATER
CURTAIN
LIQUID LINE
SOLENOID
VALVE
WATER
TROUGH
RECEIVERS
3-2
COOL
VAPOR
VALVE
Part Number 000002477
Section 3
Ice Machine Operation
CONDENSING UNITS
CVD0675/CVD0875/CVD0885/CVD1085/
CVD1486
CVD1185/CVD1285/CVD1485
ACCESS
VALVES
CONDENSER
FAN MOTOR
AIR
CONDENSER
ELECTRICAL
COMPARTMENT
LIQUID LINE
AND
SUCTION LINE
CONNECTION
POINTS
HEAD PRESSURE
CONTROL VALVE
ELECTRICAL
COMPARTMENT
HEAD
PRESSURE
CONTROL
VALVE
LIQUID LINE AND
SUCTION LINE
CONNECTION
POINTS
SUCTION
ACCUMULATOR
WATER
REGULATING
VALVE
SUCTION
ACCUMULATOR
COMPRESSOR
SV2085
WATER
COOLED
CONDENSER
COMPRESSOR
PT1382
CVD1885/CVD2075
ACCESS
VALVES
CONDENSER
FAN MOTOR
AIR
CONDENSER
ELECTRICAL
COMPARTMENT
HEAD PRESSURE
CONTROL VALVE
LIQUID LINE
AND
SUCTION LINE
CONNECTION
POINTS
SUCTION
ACCUMULATOR
COMPRESSOR
PT1306A
Part Number 000002477
3-3
Ice Machine Operation
Section 3
Ice Making Sequence of Operation
INITIAL START-UP OR START-UP AFTER
AUTOMATIC SHUT-OFF
1. Water Purge
Before the compressor starts, the water pump and water
dump solenoid are energized for 45 seconds, to
completely purge the ice machine of old water. This
feature ensures that the ice making cycle starts with
fresh water.
The harvest valve and air compressor (when used) are
also energized during water purge, although they stay
on for an additional 5 seconds (50 seconds total on time)
during the initial refrigeration system start-up.
2. Refrigeration System Start-Up
Ice Machine Head Section: The liquid line solenoid
valve energizes after the 45 second water purge, and
remains on throughout the entire Freeze and Harvest
Sequences. The harvest valve and air compressor
(when used) remains on for 5 seconds during initial
compressor start-up and then shuts off.
The water fill valve is energized at the same time as the
liquid line solenoid valve.
FREEZE SEQUENCE
3. Prechill
The compressor is on for 30 seconds (60 seconds initial
cycle) prior to water flow, to prechill the evaporator. The
water fill valve remains on until the water level probe is
satisfied.
4. Freeze
The water pump restarts after the prechill. An even flow
of water is directed across the evaporator and into each
cube cell, where it freezes. The water fill valve will cycle
on and then off one more time to refill the water trough.
When sufficient ice has formed, the water flow (not the
ice) contacts the ice thickness probe. After
approximately 10 seconds of continual water contact,
the harvest sequence is initiated. The ice machine
cannot initiate a harvest sequence until a 6 minute
freeze lock has been surpassed.
Continued on next page …
CVD Condensing Unit: When the refrigerant pressure
is high enough to close the low-pressure control, (after
the harvest valve energizes in step 1) the contactor coil
is energized and the compressor starts. The compressor
and fan cycling control* are supplied with power
throughout the entire Freeze and Harvest Sequences.
When the refrigerant pressure is high enough to close
the fan cycling pressure control the condenser fan motor
starts.
*The IB0600C & S0600C ice machines do not use a
fan cycling control. The compressor and the
condenser fan motor are wired through the contactor.
Any time the contactor coil is energized, these
components are supplied with power.
3-4
Part Number 000002477
Section 3
Ice Machine Operation
HARVEST SEQUENCE
AUTOMATIC SHUT-OFF
5. Water Purge
7. Automatic Shut-Off
The air compressor (when used) and the harvest
valve(s) open at the beginning of the water purge to
divert refrigerant gas into the evaporator. The water
pump continues to run, and the water dump valve
energizes for 45 seconds to purge the water in the sump
trough. The water fill valve energizes for the last 15
seconds of the 45-second water purge.
Ice Machine Section: Shuts off when:
After the 45 second water purge, the water fill valve,
water pump and dump valve de-energize. (Refer to
“Water Purge Adjustment” for details.)
After the water curtain or ice damper are held open for
30 seconds, the ice machine shuts off. The ice machine
remains off for 3 minutes before it can automatically
restart.
When the refrigerant pressure is low enough to open the
fan cycling pressure control the condenser fan motor
stops.
* The IB0600C & S0600C ice machines do not use a
fan cycle control, therefore the condenser fan motor
will continue to run in the harvest cycle.
6. Harvest
The air compressor (when used) remains energized and
the harvest valve(s) remain open. The refrigerant gas
warms the evaporator causing the cubes to slide, as a
sheet, off the evaporator and into the storage bin. The
sliding sheet of cubes swings the water curtain out or ice
damper down, opening the bin switch.
The momentary opening and re-closing of the bin switch
terminates the harvest sequence and returns the ice
machine to the freeze sequence (steps 3-4).
Part Number 000002477
•
The storage bin is full at the end of a harvest
sequence.
•
The sheet of cubes fails to clear the water curtain
and hold it open.
•
Ice damper is held down.
CVD Condensing Unit: The liquid line solenoid valve
closes, allowing the refrigeration system to pump down.
When the refrigerant pressure is low enough to open the
fan cycling pressure control the condenser fan motor
stops. When the refrigerant pressure is low enough to
open the low pressure control, the contactor coil is deenergized and the compressor stops.
The ice machine remains off until enough ice has been
removed from the storage bin to allow the ice to fall clear
of the water curtain or ice damper. As the water curtain
or ice damper swings back to the operating position, the
bin switch re-closes and the ice machine restarts (steps
1 - 2), provided the 3 minute delay period is complete.
* The IB0600C & S0600C ice machines do not use a
fan cycle control, therefore the condenser fan motor
will energize and de-energize with the compressor.
3-5
Ice Machine Operation
Section 3
Operational Checks
ICE THICKNESS CHECK
GENERAL
After a harvest cycle, inspect the ice cubes in the ice
storage bin. The ice thickness probe is factory-set to
maintain the ice bridge thickness at 1/8" (3.2 mm).
Manitowoc ice machines are factory-operated and
adjusted before shipment. Normally, a newly installed ice
machine does not require any adjustment.
To ensure proper operation, always follow the
Operational Checks:
•
when starting the ice machine for the first time
•
after a prolonged out of service period
•
after cleaning and sanitizing
NOTE: Routine adjustments and maintenance
procedures outlined in this manual are not covered by
the warranty.
WATER LEVEL
The water level sensor is set to maintain the proper
water level above the water pump housing. The water
level is not adjustable.
NOTE: Make sure the water curtain is in place when
performing this check. It prevents water from splashing
out of the water trough.
1. Inspect the bridge connecting the cubes. It should
be about 1/8" (3.2 mm) thick.
2. If adjustment is necessary, turn the ice thickness
probe adjustment screw clockwise to increase
bridge thickness, counterclockwise to decrease
bridge thickness. Set at 1/4” gap between ice
machine and evaporator as starting point, then
adjust to achieve a 1/8” bridge thickness.
NOTE: Turning the adjustment 1/3 of a turn will change
the ice thickness about 1/16" (1.5 mm).
ADJUSTING SCREW
If the water level is incorrect, check the water level probe
for damage (probe bent, etc.). Repair or replace the
probe as necessary.
1/8” ICE BRIDGE THICKNESS
SVITP
Ice Thickness Check
3. Make sure the ice thickness probe wire and the
bracket do not restrict movement of the probe.
3-6
Part Number 000002477
Section 3
Ice Machine Operation
HARVEST SEQUENCE WATER PURGE
The harvest sequence water purge adjustment may be
used when the ice machine is hooked up to special
water systems, such as a de-ionized water treatment
system.
! Warning
45 second
setting
Disconnect electric power to the ice machine at the
electrical disconnect before proceeding.
Important
The harvest sequence water purge is factory-set at
45 seconds. A shorter purge setting (with standard
water supplies such as city water) is not
recommended. This can increase water system
cleaning and sanitizing requirements.
0 second
setting
SV3139
SV3140
Water Purge Adjustment
•
The harvest sequence water purge is factory set for
45 seconds. Repositioning the jumper will set the
harvest water purge to 0 seconds. This setting does
not affect the SeCs or AuCs (cleaning) sequences.
•
During the harvest sequence water purge, the water
fill valve energizes and de-energizes by time. The
water purge must be at the factory setting of 45
seconds for the water fill valve to energize during the
last 15 seconds of the water purge. If it is set to less
than 45 seconds, the water fill valve will not energize
during the water purge.
For your safety and to eliminate errors, we recommend
that a qualified service technician make the harvest
water purge adjustment.
! Warning
Disconnect the electrical power to the ice machine
at the electrical disconnect before proceeding.
Part Number 000002477
3-7
Ice Machine Operation
Section 3
THIS PAGE INTENTIONALLY LEFT BLANK
3-8
Part Number 000002477
Section 4
Maintenance
Section 4
Maintenance
Interior Cleaning and Sanitizing
GENERAL
Step 3 Remove all ice from the bin/dispenser.
Clean and sanitize the ice machine every six months for
efficient operation. If the ice machine requires more
frequent cleaning and sanitizing, consult a qualified
service company to test the water quality and
recommend appropriate water treatment. The ice
machine must be taken apart for cleaning and sanitizing.
Step 4 Place the toggle switch in the CLEAN position.
The water will flow through the water dump valve and
down the drain. Wait until the water trough refills and
water flows over the evaporator, then add the proper
amount of ice machine cleaner.
! Caution
Use only Manitowoc approved Ice Machine Cleaner
and Sanitizer for this application (Manitowoc
Cleaner part number 94-0546-3 and Manitowoc
Sanitizer part number 94-0565-3). It is a violation of
Federal law to use these solutions in a manner
inconsistent with their labeling. Read and
understand all labels printed on bottles before use.
CLEANING PROCEDURE
! Caution
Do not mix Cleaner and Sanitizer solutions together.
! Warning
Wear rubber gloves and safety goggles (and/or face
shield) when handling ice machine Cleaner or
Sanitizer.
Ice machine cleaner is used to remove lime scale and
mineral deposits. Ice machine sanitizer disinfects and
removes algae and slime.
Model
S0600C/S0800C
S1000C/S1200C
S1470C/S1870C/S2070C
IB620C/IB820C/IB1020C
Amount of Cleaner
3 ounces (90 ml)
9 ounces (270 ml)
5 ounces (150 ml)
Step 5 Wait until the clean cycle is complete
(approximately 35 minutes) then place the toggle switch
in the OFF position and disconnect power to the ice
machine (and dispenser when used).
! Warning
Disconnect the electric power to the ice machine at
the electric service switch box.
Step 6 Remove parts for cleaning.
Please refer to the proper parts removal for your
ice machine.
S600C/S850C/S1000C/S1200C - Page 4-2 & 4-3.
S1470C/S1870C/S2070C - Page 4-4 & 4-5.
IB620C/IB820C/IB1020C - Page 4-6 & 4-7.
Step 1 Remove front door and top cover. This will allow
easiest access for adding cleaning and sanitizing
solutions.
Step 2 Set the toggle switch to the OFF position after
ice falls from the evaporator at the end of a Harvest
cycle. Or, set the switch to the OFF position and allow
the ice to melt off the evaporator.
! Caution
Never use anything to force ice from the evaporator.
Damage may result.
Part Number 000002477
4-1
Maintenance
Section 4
PARTS REMOVAL FOR CLEANING/SANITIZING
S600C/S850C/S1000C/S1200C
A. Remove the water curtain
E. Remove the water level probe
•
Gently flex the curtain in the center and remove it
from the right side.
•
Pull the water level probe straight down to
disengage.
•
Slide the left pin out.
•
Lower the water level probe until the wiring connector
is visible.
•
Disconnect the wire lead from the water level probe.
•
Remove the water level probe from the ice machine.
B. Remove the ice thickness probe
•
•
Compress the hinge pin on the top of the ice
thickness probe.
Pivot the ice thickness probe to disengage one pin
then the other. The ice thickness probe can be
cleaned at this point without complete removal. If
complete removal is desired, disconnect the ice
thickness control wiring from the control board.
C. Remove the water distribution tube
NOTE: Distribution tube thumbscrews are retained to
prevent loss. Loosen thumbscrews but do not pull
thumbscrews out of distribution tube.
•
•
Loosen the two outer screws (do not remove screws
completely they are retained to prevent loss) and pull
forward on the distribution tube to release from slip
joint.
Disassemble distribution tube by loosening the two
(2) middle thumbscrews and dividing the distribution
tube into two pieces.
D. Remove the water trough
•
Depress tabs on right and left side of the water
trough.
•
Allow front of water trough to drop as you pull forward
to disengage the rear pins.
4-2
F. Remove the water pump.
•
Grasp pump and pull straight down on pump
assembly until water pump disengages and electrical
connector is visible.
•
Disconnect the electrical connector.
•
Remove the water pump assembly from ice machine.
•
Do not soak the water pump motor in cleaner or
sanitizer solution.
G. Remove the evaporator tray from the bottom of
the evaporator.
•
Loosen thumbscrew on left side of tray.
•
Allow left side of tray to drop as you pull the tray to
the left side. Continue until the outlet tube
disengages from the right side.
NOTE: Proceed to page 4-8, Step 7.
Part Number 000002477
Section 4
Maintenance
C.
B.
A.
G.
E.
F.
D.
Part Number 000002477
4-3
Maintenance
Section 4
S1470C/S1870C/S2070C
A. Remove Splash Shields.
•
Grasp the top center of splash shields.
•
Lift up and then out.
B. Remove ice thickness probe.
•
•
Compress the hinge pin on the top of the ice
thickness probe.
Pivot the ice thickness probe to disengage one pin
then the other. The ice thickness probe can be
cleaned at this point without complete removal. If
complete removal is desired, disconnect the ice
thickness control wiring from the control board.
C. Remove distribution tubes.
•
Distribution tubes thumbscrews are retained to
prevent loss. Loosen thumbscrews but do not pull
thumbscrews out of distribution tube.
•
Loosen the two outer screws and pull forward on the
distribution tube to release from slip joint.
•
Disassemble distribution tube by loosening the two
(2) middle thumbscrews and dividing the distribution
tube into two pieces.
D. Remove the water trough shield.
•
Grasp the water trough shield in the center and the
left end.
•
Flex the water trough shield in the center and pull the
left end forward until clear of the side wall. Repeat for
the right end.
•
Pull water trough shield forward to remove.
4-4
E. Remove ice dampers.
•
Grasp ice damper and apply pressure toward the
back mounting bracket.
•
Apply pressure to the front mounting bracket with
thumb.
•
Pull ice damper downward when the front ice damper
pin disengages.
F. Remove the water pump assembly.
•
Disconnect the vinyl distribution tube from the water
pump.
•
Disconnect the water pump and water level probe
electrical connections.
•
After the wires are disconnected squeeze the two
tabs and lift the water pump assembly out of the ice
machine.
•
Do not immerse the water pump motor in cleaner or
sanitizer solutions.
G. Remove the water trough.
•
Depress the two tabs on the top of the water trough.
•
Turn left and right ice dampers down to clear water
trough.
•
Pull forward on the water trough to remove.
NOTE: Proceed to page 4-8, Step 7.
Part Number 000002477
Section 4
Maintenance
A.
B.
C.
F.
E.
G.
D.
Part Number 000002477
4-5
Maintenance
Section 4
IB620C/IB820C/IB1020C
A. Remove the splash shield
F. Remove the water distribution tube
•
Remove quarter turn connector from the right side of
splash shield.
•
Remove the clamp from the vinyl water hose on the
right side of the distribution tube.
•
Gently bow the center of the splash shield and lift up
and forward to remove.
•
Loosen the two thumbscrews which secure the
distribution tube.
•
Lift the right side of the distribution tube up, and then
rotate it backward and to the right until the left side of
the distribution tube disengages the thumbscrew.
Important
Splash Shield must be reinstalled to prevent water
leakage.
! Caution
Do not force this removal. Be sure the locating tab is
clear before rotating the distribution tube back.
B. Remove the water curtain
•
•
Gently flex the curtain in the center and remove it
from the right side.
•
Slide the left pin out.
Disassemble for cleaning:
C. Remove the ice thickness probe
•
Compress the hinge pin on the top of the ice
thickness probe.
•
Pivot the ice thickness probe to disengage one pin
then the other. The ice thickness probe can be
cleaned at this point without complete removal. If
complete removal is desired, disconnect the ice
thickness control wiring from the control board.
•
Twist both of the inner tube ends until the tabs line up
with the keyways.
•
Pull the inner tube ends outward.
G. Remove the water pump.
•
Note position of water ump outlet, and then
disconnect vinyl hose from the pump outlet.
•
Rotate the thumbscrew that secures the pump to the
bulkhead 1/4 turn clockwise.
•
Rotate the water pump assembly 1/4 turn
counterclockwise.
•
Lower the pump assembly into the evaporator
compartment.
•
Disconnect the water pump power cord.
•
Remove water pump assembly from ice machine.Do
not soak the water pump motor in cleaner or sanitizer
solution
D. Remove the water level probe
•
Loosen the screw that holds the water level probe in
place. The probe can easily be cleaned at this point
without complete removal. If complete removal is
desired, remove the top cover, left and right side
panels and control box cover. Disconnect the wire
lead from the control board inside the electrical
control box.
E. Remove the water trough
•
Remove the quarter turn fasteners (turn
counterclockwise) securing the trough in place.
•
Pull forward on the water trough until the rear pins
disengage from the water trough.
•
Lift up and forward on the front of the water trough
while allowing the rear of the water trough to drop.
•
Remove the water trough from the ice machine.
4-6
Pull the vinyl hose off the distribution tube.
H. Remove the bin thermostat probe
•
Loosen the 2 screws that holds the probe in place.
The probe can easily be cleaned at this point without
complete removal.
NOTE: Proceed to page 4-8, Step 7.
Part Number 000002477
Section 4
Maintenance
F.
C.
B.
D.
G.
H.
A.
E.
Part Number 000002477
4-7
Maintenance
Section 4
Step 7 Mix a solution of cleaner and warm water.
Depending upon the amount of mineral buildup, a larger
quantity of solution may be required. Use the ratio in the
table below to mix enough solution to thoroughly clean
all parts.
Solution Type
Cleaner
Water
1 gal. (4 l)
Mixed With
16 oz (500 ml) cleaner
Step 8 Use 1/2 of the cleaner/water mixture to clean all
components. The cleaner solution will foam when it
contacts lime scale and mineral deposits; once the
foaming stops use a soft-bristle nylon brush, sponge or
cloth (NOT a wire brush) to carefully clean the parts.
Soak parts for 5 minutes (15 - 20 minutes for heavily
scaled parts). Rinse all components with clean water.
Step 9 While components are soaking, use 1/2 of the
cleaner/water solution to clean all foodzone surfaces of
the ice machine and bin (or dispenser). Use a nylon
brush or cloth to thoroughly clean the following ice
machine areas:
•
Side walls
•
Base (area above water trough)
•
Evaporator plastic parts - including top, bottom, and
sides
•
Bin or dispenser
Rinse all areas thoroughly with clean water.
Step 12 Use 1/2 of the sanitizer/water solution to
sanitize all foodzone surfaces of the ice machine and bin
(or dispenser). Use a cloth or sponge to liberally apply
the solution. When sanitizing, pay particular attention to
the following areas:
•
Side walls
•
Base (area above water trough)
•
Evaporator plastic parts - including top, bottom and
sides
•
Bin or dispenser
Do not rinse the sanitized areas.
Step 13 Replace all removed components.
Step 14 Reapply power to the ice machine and place
the toggle switch in the CLEAN position.
Step 15 Wait about two minutes or until water starts to
flow over the evaporator. Add the proper amount of
Manitowoc Ice Machine Sanitizer to the water trough by
pouring between the water curtain and evaporator.
Model
S0600C/S0800C
S1000C/S1200C
IB620C/IB820C
IB1020C
S1470C/S1870C/S2070C
Amount of Sanitizer
3 ounces (90 ml)
3 ounces (90 ml)
3.5 ounces (104 ml)
12 ounces (355 ml)
Step 10 Mix a solution of sanitizer and warm water.
Solution Type
Sanitizer
Water
6 gal. (23 l)
Mixed With
4 oz (120 ml) sanitizer
Step 11 Use 1/2 of the sanitizer/water solution to
sanitize all removed components. Use a cloth or sponge
to liberally apply the solution to all surfaces of the
removed parts or soak the removed parts in the
sanitizer/water solution. Do not rinse parts after
sanitizing.
4-8
Part Number 000002477
Section 4
Maintenance
Step 16 The ice machine will stop after the sanitize
cycle (approximately 35 minutes). Place the toggle
switch in the OFF position and disconnect power to the
ice machine.
! Warning
Disconnect the electric power to the ice machine at
the electric service switch box.
Step 17 Refer to step 6 and disassemble components.
After dissembling proceed to step 18.
Step 18 Mix a solution of sanitizer and warm water.
Solution Type
Sanitizer
Water
6 gal. (23 l)
Mixed With
4 oz (120 ml) sanitizer
Step 19 Use 1/2 of the sanitizer/water solution to
sanitize all removed components. Use a cloth or sponge
to liberally apply the solution to all surfaces of the
removed parts or soak the removed parts in the
sanitizer/water solution. Do not rinse parts after
sanitizing.
Step 20 Use 1/2 of the sanitizer/water solution to
sanitize all foodzone surfaces of the ice machine and bin
(or dispenser). Use a cloth or sponge to liberally apply
the solution. When sanitizing, pay particular attention to
the following areas:
•
Side walls
•
Base (area above water trough)
•
Evaporator plastic parts - including top, bottom and
sides
•
Bin or dispenser
Do not rinse the sanitized areas.
Step 21 Install the removed parts, restore power and
place the toggle switch in the ICE position.
Part Number 000002477
4-9
Maintenance
Section 4
ADDITIONAL COMPONENT REMOVAL
The following components may be removed for easier
access in some installations or they may need to be
removed and cleaned to correct an operational problem.
Door Removal
1. Use a phillips screwdriver to loosen the two screws
securing the left and right doors. Do not remove they
are secured to prevent loss.
2. 30 Inch and 48 Inch Models: To remove right front
door lift up and remove (22 inch ice machines have
a single door, lift to remove entire door).
Water Inlet Valve
The water inlet valve normally does not require removal
for cleaning. Refer to Section 5 for a list of causes for
“No Water Entering Water Trough” or “Water Overflows
Water Trough”.
1. When the ice machine is off, the water inlet valve
must completely stop water flow into the machine.
2. When the ice machine is on, the water inlet valve
must allow the proper water flow through it. Set the
toggle switch to ON. Watch for water flow into the ice
machine. If the water flow is slow or only trickles into
the ice machine, refer to Section 5.
Follow the procedure below to remove the water inlet
valve.
4
! Warning
2
Disconnect the electric power to the ice machine
and dispenser at the electric service switch box and
turn off the water supply before proceeding.
1. Remove the 1/4” hex head screws.
2. Remove, clean, and install the filter screen.
FILTER
ACCESS
SCREWS
SCREEN
LOCATION
1
Door Removal
WATER
INLET
VALVE
3. Open left front door to 45 degrees.
4. Support with right hand, depress top pin, tilt top of
door forward and lift out of bottom pin to remove.
4-10
Part Number 000002477
Section 4
Maintenance
Water Dump Valve
The water dump valve normally does not require
removal for cleaning. To determine if removal is
necessary:
COIL
SPRING
1. Set the toggle switch to ICE.
2. Verify the water trough fills with water at the
beginning of the freeze cycle.
3. While the ice machine is in the freeze mode, check
the water trough to determine if the dump valve is
leaking. If there is no or little water in the water
trough (during the freeze cycle) the dump valve is
leaking.
PLUNGER
NYLON GASKET
DIAPHRAM
A. If the dump valve is leaking, remove,
disassemble and clean it.
B. If the dump valve is not leaking, do not remove
it. Instead, follow the “Ice Machine Cleaning
Procedure”.
MOUNTING BRACKET
Follow the procedure below to remove the dump valve.
! Warning
Disconnect the electric power to the ice machine at
the electric service switch box and turn off the water
supply before proceeding.
1. Leaving the wires attached, twist coil and rotate it
counter-clockwise1/4 turn.
VALVE BODY
2. Lift the coil assembly off the valve body.
3. Remove the spring, plunger, and nylon gasket from
the valve body.
Dump Valve Disassembly
NOTE: At this point, the water dump valve can easily be
cleaned. If complete removal is desired, continue with
step 4.
NOTE: During cleaning, do not stretch or damage the
spring.
4. Remove the tubing from the dump valve by twisting
the clamps off.
5. Twist the valve body to remove from mounting
bracket.
Part Number 000002477
4-11
Maintenance
Water-Cooled Condenser
and Water Regulating Valve CVD1486 Only
Section 4
Cleaning the Condenser
GENERAL
Symptoms of restrictions in the condenser water circuit
include:
•
Low ice production
•
High water consumption
•
High operating temperatures
•
High operating pressures
If the ice machine is experiencing any of these symptoms,
the water-cooled condenser and water regulating valve
may require cleaning due to scale build-up.
Because the cleaning procedures require special pumps
and cleaning solutions, qualified maintenance or service
personnel must perform them.
Ice Machine Inspection
Check all water fittings and lines for leaks. Also, make
sure the refrigeration tubing is not rubbing or vibrating
against other tubing, panels, etc.
Do not put anything (boxes, etc.) on the sides or back of
the ice machine. There must be adequate airflow
through and around the ice machine to maximize ice
production and ensure long component life.
Exterior Cleaning
Clean the area around the ice machine as often as
necessary to maintain cleanliness and efficient
operation. Use cleaners designed for use with stainless
steel products.
Sponge any dust and dirt off the outside of the ice
machine with mild soap and water. Wipe dry with a
clean, soft cloth.
Heavy stains should be removed with stainless steel
wool. Never use plain steel wool or abrasive pads. They
will scratch the panels.
! Warning
Disconnect electric power to the ice machine head
section and the remote condensing unit at the
electric service switches before cleaning the
condenser.
A dirty condenser restricts airflow, resulting in
excessively high operating temperatures. This reduces
ice production and shortens component life. Clean the
condenser at least every six months. Follow the steps
below.
! Warning
The condenser fins are sharp. Use care when
cleaning them.
Shine a flashlight through the condenser to check for dirt
between the fins. To remove dirt:
A. Blow compressed air or rinse with water from
the inside out (opposite direction of airflow). Be
careful not to bend the fan blades.
B. Use a commercial condenser coil cleaner if
required to remove dirt/grease. Follow the
directions and cautions supplied with the
cleaner.
6. Straighten any bent condenser fins with a fin
comb.Straighten any bent condenser fins with a fin
comb.
“COMB” DOWN
ONLY
CONDENSER
FIN
COMBS
SV1515
Straighten Bent Condenser Fins
4-12
Part Number 000002477
Section 4
Maintenance
Guardian
This product can be used on models S600C/S850C/
S1000C/S1200C/S1470C/S1870C/S2070C - this
product cannot be used on IB600C/IB800C/IB1000C
due to space constraints. Slime is a leading cause of ice
machine breakdowns and biological growth is a health
concern. The Guardian system releases chlorine dioxide
on a controlled basis to inhibit the growth of bacteria and
fungi that form slime and cause malodors in the food
zone of ice machines.
SACHET INSTALLATION/REPLACEMENT
PROCEDURE
1. Loosen the left screw and open the left front door.
The right front panel does not need to be removed.
The Guardian will not control mineral or other water
borne buildup. Your water quality will determine the
length of time before mineral buildup affects ice machine
performance. Mineral buildup must be removed as often
as necessary to ensure trouble-free operation of the ice
machine.
The Guardian sachet holder is included with the sachet
packets. Refer to installation/replacement procedure to
install/change sachet holder/ packet.
Loosen
Screw
Screw Location
2. Inside the front panel there are two pegs for
mounting the sachet holder. S1470C/S1870C/S2070C
Only - The sachet holder mounts to the front top
support (mounting holes may be covered by
insulation).
Inside Left
Front Door
Guardian
3. Attach the sachet holder to the front panel by
hanging on the pegs. S1470C/S1870C/S2070C Only Attach sachet holder with reusable ties.
4. Remove the new sachet packet from foil package
and install into holder. Removing the foil package
allows moisture in the air to activate the sachet
contents.
5. Close the left front door and tighten the screw.
Guardian Location
6. Discard the used sachet packet in the trash.
GUARDIAN SACHET REPLACEMENT FREQUENCY
Sachet packet(s) require replacement every thirty (30)
days or whenever they come in direct contact with water.
Refer to chart below for requirements.
Ice Machine
S600C
S850C/S1000C/S1200C/S1470C
Sachet Use
1
1 or 2*
*Although one sachet is recommended, extreme conditions may
necessitate using two sachet packets.
Guardian sachet packets are available through your
local Manitowoc ice machine dealer.
Part Number 000002477
CLEAN UP PROCEDURE FOR DAMAGED SACHET
PACKET
1. Remove all ice from bin/dispenser and discard.
2. Initiate a cleaning and sanitizing sequence on the
ice machine.
3. Clean the bin/dispenser. Flush the drain thoroughly
to prevent future drain blockage.
4. Sanitize the bin/dispenser.
5. Install a replacement sachet packet and reinstall all
panels.
4-13
Maintenance
Section 4
Removal from Service/Winterization
CVD 1486 WATER COOLED CONDENSING UNIT
GENERAL
1. Perform steps 1-11 in previous column.
Special precautions must be taken if the ice machine is
to be removed from service for an extended period of
time or exposed to ambient temperatures of 32°F (0°C)
or below.
2. Disconnect the incoming water and drain lines from
the water-cooled condenser.
3. Insert a large screwdriver between the bottom spring
coils of the water regulating valve. Pry upward to
open the valve.
! Caution
If water is allowed to remain in the ice machine in
freezing temperatures, severe damage to some
components could result. Damage of this nature is
not covered by the warranty.
Follow the procedure below.
1. Clean and sanitize the ice machine.
2. Move the ICE/OFF/CLEAN switch to OFF.
3. Disconnect the electric power at the circuit breaker
or the electric service switch.
4. Turn off the water supply.
5. Remove the water from the water trough.
6. Disconnect and drain the incoming ice-making water
line at the rear of the ice machine.
7. Energize the ice machine and wait one minute for
the water inlet valve to open.
8. Blow compressed air in both the incoming water and
the drain openings in the rear of the ice machine
until no more water comes out of the inlet water lines
or the drain.
9. Make sure water is not trapped in any of the water
lines, drain lines, distribution tubes, etc.
10. Fill spray bottle with sanitizer and spray all interior
food zone surfaces. Do not rinse and allow to air dry.
SV1624
Pry Open the Water Regulating Valve
4. Hold the valve open and blow compressed air
through the condenser until no water remains.
11. “Frontseat” (shut off) the receiver service valves.
Hang a tag on the switch as a reminder to open the
valves before restarting.
4-14
Part Number 000002477
Section 5
Before Calling For Service
Section 5
Before Calling For Service
Checklist
If a problem arises during operation of your ice machine, follow the checklist below before calling service. Routine
adjustments and maintenance procedures are not covered by the warranty.
Problem
Ice machine does not operate.
Possible Cause
No electrical power to the ice machine and/or
condensing unit.
High pressure cutout tripping.
ICE/OFF/CLEAN toggle switch set
improperly.
Water curtain stuck open.
Remote receiver service valve and/or Liquid/
suction line shut off valves are closed.
IB Only - Dispenser level thermostat open.
Ice machine stops, and can be
restarted by moving the toggle
switch to OFF and back to ICE.
Ice machine does not release
ice or is slow to harvest.
Ice machine is dirty.
The six-minute freeze time lock-in has not
expired yet.
Ice thickness probe is dirty.
Ice thickness probe is disconnected.
Ice thickness probe is out of adjustment.
Uneven ice fill (thin at the top of evaporator).
Ice quality is poor (soft or not
clear).
Poor incoming water quality.
Water filtration is poor.
Ice machine is dirty.
Water dump valve is not working.
Water softener is working improperly (if
applicable).
Part Number 000002477
Water curtain or ice damper must be installed
and swinging freely. (See Section 4)
Open the valve(s). (See Section 2)
Adjust thermostat to maintain correct
dispenser level.
Safety limit feature stopping the ice machine. Refer to “Safety Limit Feature” on the next
page.
Ice machine is not level.
Low air temperature around ice machine
head section.
Fan cycling control does not de-energize
condenser fan motor.
CVD1486 - Water regulating valve incorrectly
adjusted or will not close.
Ice machine does not cycle into
harvest mode.
To Correct
Replace the fuse/reset the breaker/turn on the
main switch.
Clean condenser coil. (See Section 4)
Move the toggle switch to the ICE position.
Clean and sanitize the ice machine.
(See Section 4)
Level the ice machine. (See Section 2)
Air temperature must be at least 35°F
(1.6°C).
Verify pressure is below cut-out setpoint,
replace fan cycling control.
Check for water at condenser water drain
outlet. Contact a qualified service company to
adjust/replace valve.
Wait for the freeze lock-in to expire.
Clean and sanitize the ice machine.
(See Section 4)
Connect the wire.
Adjust the ice thickness probe.
(See Section 3)
Verify sufficient water level in sump trough.
Contact a qualified service company to check
refrigeration system.
Contact a qualified service company to test the
quality of the incoming water and make
appropriate filter recommendations.
Replace the filter.
Clean and sanitize the ice machine.
(See Section 4)
Disassemble and clean the water dump valve.
(See Section 4)
Repair the water softener.
5-1
Before Calling For Service
Problem
Ice machine produces shallow or
incomplete cubes, or the ice fill pattern on
the evaporator is incomplete.
Low ice capacity.
Section 5
Possible Cause
Ice thickness probe is out of adjustment.
To Correct
Adjust the ice thickness probe.
(See Section 3)
Water trough level is too high or too low. Check the water level probe for damage.
(See Section 3)
Water inlet valve filter screen is dirty.
Remove the water inlet valve and clean
the filter screen. (See Section 4)
Water filtration is poor.
Replace the filter.
Hot incoming water.
Connect the ice machine to a cold water
supply. (See Section 2)
Water inlet valve is not working.
Clean or replace the water inlet valve.
(See Section 4)
Incorrect incoming water pressure.
Water pressure must be 20-80 psi
(137.9 - 551.5 kPA)
Ice machine head section is not level.
Level the ice machine head section.
(See Section 2)
Water inlet valve filter screen is dirty.
Remove the water inlet valve and clean
the filter screen. (See Section 4)
Incoming water supply is shut off.
Open the water service valve.
Water inlet valve stuck open or leaking.
Replace the water inlet valve.
The condenser is dirty.
Clean the condenser. (See Section 4)
High air temperature entering condenser. Air temperature must not exceed 130°F
(54°C)
CVD675/CVD2075 - 120°F (49°C)
CVD1486 - 110°F (43°C)
The harvest assist air compressor is not Call for service.
functioning.
Safety Limit Feature
In addition to the standard safety controls, such as the
high pressure cutout, your Manitowoc ice machine
features built-in safety limits which will stop the ice
machine if conditions arise which could cause a major
component failure.
Before calling for service, re-start the ice machine using
the following procedure:
1. Move the ICE/OFF/CLEAN switch to OFF and then
back to ICE.
A. If the safety limit feature has stopped the ice
machine, it will restart after a short delay.
Proceed to step 2.
B. If the ice machine does not restart, see “Ice
machine does not operate” on the previous
page.
2. Allow the ice machine to run to determine if the
condition is recurring.
A. If the ice machine stops again, the condition has
recurred. Call for service.
B. If the ice machine continues to run, the condition
has corrected itself. Allow the ice machine to
continue running.
5-2
Part Number 000002477
Manitowoc Ice, Inc.
2110 South 26th Street
P.O. Box 1720
Manitowoc, WI 54221-1720
Phone: (920) 682-0161
Service Fax: (920) 683-7585
Web Site - www.manitowocice.com
Manitowoc Foodservice International
S.A.S.
18 Chemin de Charbonnières
F-69132 Ecully Cedex
Téléphone : +33 (0)4 72 18 22 50
Fax : +33 (0)4 72 18 22 60
Site Web – www.manitowocice.com
Manitowoc (China) International Refrigeration
Company, LTD
No. 151 Jian Ye Road
Hangzhou Hi-Tech Industry Development Zone
(Bin Jiang)
Hangzhou, Zhejiang 310052
P.R. China
Telephone: 86-571-86888688
Service Fax: 86-571-86622707
Web Site – www.manitowoc.com.cn
MANITOWOC ICE, INC.
Web Site - www.manitowocice.com
© 2006 Manitowoc Ice, Inc.
Ice Machine Parts List for
Series S2070C Models
SD2072C
CVD2075
SD2074C
S2070C – 1
S2070C CONTROL BOX
7
1
6
4
2
DESCRIPTION
1
Control Board (for use with all voltages) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. 7 Amp Fuse – Mounted on Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Toggle Switch Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Toggle Switch Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Refrigeration Service Valve Assembly (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous – Brackets, Screws, etc.
4
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Control Box Cover (Not shown). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Control Board Mounting Supports (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Screw, #10-24 x .50 Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Star Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Control Box Wiring Harness (Not shown)
a. 115V/60Hz/1Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. 230V/50Hz/1Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2070C – 2
PART NO.
20-0619-9
25-1100-3
20-0793-9
000001927
83-7326-3
000001811
000001812
43-0225-3
52-0216-9
55-7320-9
25-0016-3
000001930
000001931
S2070C EVAPORATOR COMPARTMENT
11
6
1
6f
8
12
7
9
2
17
3
DESCRIPTION
PART NO.
1
Evaporator Assembly
a. Dice Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Half Dice Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Water Pump
a. 115V/60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. 230V/50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Water Level Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Wire, control box to probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. Screw (to mount water level probe holder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Ice Thickness Control Probe (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Clip (holds ice thickness probe wire to bulkhead) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Magnetic Bin Switch
a. Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Water Distribution Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Molded Vinyl Tube (to Right Hand Distribution Tube) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Molded Vinyl Tube (to Left Hand Distribution Tube) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Barbed Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. Clamp (for barbed fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
e. Clamp (vinyl tubes to distribution tubes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
f. Fitting (through bulkhead) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
g. Fitting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Ice Damper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Spash Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Water Trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Evaporator Top Filler Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Evaporator Right/Left Filler Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Front Panel Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Evaporator Top Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 Evaporator Bottom Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous – Brackets, Screws, etc.
15 Screw, (Water Distribution Tube Mounting) Each (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 Screw, #12-16 x .687 Used to Mount Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 Water Pump Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 Water Pump Base O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 Water Pump Outlet O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 Screw (water pump to pump mount). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 Washer (water pump to pump mount) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2070C – 3
000001153
000000259
20-0654-9
20-0655-9
000002070
20-0798-9
52-0232-9
20-0802-9
56-5090-9
000001756
000001757
000001421
76-0219-3
000001118
000001117
000001986
56-5060-9
56-5053-9
40-1469-3
000001923
000002056
000001097
000002176
000002097
000002190
000001416
50-0479-9
50-0462-9
50-1231-9
000001202
50-0465-9
50-0467-9
52-0206-9
000002476
S2070C REFRIGERATION COMPARTMENT – COMMON PARTS
9
34
13
13
7
4b
5
11
2
2
6
3
15
27
16
26
23
1
9c
4
8
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
PART NO.
Water Dump Valve
a. 115V/60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. 208/230V / 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Harvest Valve
a. Solenoid Valve with Electrical Coil (115V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Solenoid Valve with Coil (208/230V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. 115V/60 Hz Electrical Coil Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. 208/230V 50 Hz Electrical Coil Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Inlet Valve
a. Water Inlet Valve Including 115V/60 Hz Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Water Inlet Valve Including 208/230V 50 Hz Electrical Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Expansion Valve Body Insulation Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Expansion Valve Bulb Insulation Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Shut-off Valve Suction Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Shut-off Valve Liquid Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Valve Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Line Solenoid Valve
a. Liquid Line Solenoid Valve Including 115V/60 Hz Coil (Danfoss). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. 115V/60 Hz Coil Only Danfoss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Liquid Line Solenoid Valve Including 208/230V 50 Hz Electrical Coil (Danfoss) . . . . . . . . . . . . . . . . . . . . . .
d. 208/230V 50 Hz Coil Only Danfoss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Bracket (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Bracket (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. Pushnut, Bolt Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strain Relief (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor
a. Air Compressor Pump 115V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Air Compressor Pump 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Manifold Tee (air pump tubing outlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2070C – 4
000001767
000001768
000002048
000002049
000000377
000000378
76-0225-3
40-0040-3
40-0092-3
83-7328-3
603626-1
55-4510-9
50-3345-9
83-7327-3
† 83-7316-9
56-5075-3
000002048
76-3012-1
000002049
76-2959-3
000001779
000001780
630721-4
54-7488-9
83-7315-9
89-3027-9
25-0228-3
76-0352-9
000000444
40-1173-9
000001496
Miscellaneous – Brackets, Screws, etc.
14 Dump Valve Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
000001911
15 Water Inlet Valve Wing Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87-0609-3
16 Water Inlet Valve Wing Adapter Plastic Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-6096-1
17 Water Drain Female Wing Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87-0608-3
18 Water Drain Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
000002340
19 Clamp, Water Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56-5070-9
20 Clamp, Expansion Valve Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56-5052-9
21 Strap, Expansion Valve Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-0050-3
22 Screw, #10-24 x .50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52-0206-9
23 Water Inlet Valve Tubing (molded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40-1043-9
24 Mylar Shield, water inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
000002250
25 Bracket, manual shut-off valve liquid line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
603672-1
26 Water Inlet Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44-2029-1
27 Water Inlet Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000002064 & 000001980
28 Service Valve Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
000002251
29 Vinyl Tubing (0.25 ID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44-2088-3
30 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
000001932
31 Thumbscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-0001-3
32 Screw (Slot Hex). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
000002466
33 Compression Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56-5072-3
34 Clamp .799/.899 ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56-5070-3
S2070C – 5
Rev 02/08
S2070C PANELS
4
2
6
9
8
3
1
15
5
7
DESCRIPTION
PART NO.
1
Left Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Back Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Right Side Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Coupling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous – Brackets, Screws, etc.
7
Front Door Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Shoulder Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Nut (for shoulder screw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Front Vertical Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Front Top Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Plastic Dome Head Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Bottom Front Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Screw, Top Cover, Side & Back Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Spacer, Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Terminal Block 3 Pole 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 Electrical Connection Box Cover
a. 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 Control Box
a. 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
000002464
000002462
000002463
40-1548-3
000002190
000002016
S2070C – 6
50-0559-3
000000260
000000305
000001139
000001447
52-0209-9
000002246
000001138
50-0509-9
50-0037-3
000002288
20-0614-9
606398-9
000002317
000002230
000002316
CVD2075 CONDENSING UNIT
3
9
10
4
5
14, 15, 16, 17
8
6
11, 12, 13
7
2
1
pt1305
DESCRIPTION
PART NO.
1
Compressor
a. 208-230V/60 Hz/1 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 76-0059-3
b. 208-230V/60 Hz/3 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 76-0060-3
c. 220-240V/50 Hz/1 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-0061-3
d. Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-5096-3
2
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-5047-3
3
Access Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-7325-3
4
Fan Motor
a. 208-230V/60 Hz/1 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 20-0018-9
b. 208-230V/50 Hz/1 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 20-0058-3
5
Fan Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-5008-3
6
Air Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-5141-3
7
Head Pressure Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-5007-3
8
Suction Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 82-5055-9
Miscellaneous – Brackets, Screws, etc.
9
Fan Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603870-1
10 Fan Motor Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-0025-3
11 Fan Motor Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 50-3358-9
12 Fan Motor Mounting Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 55-4511-9
13 Fan Motor Mounting Hexnut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 54-2952-9
14 Fan Bracket Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 50-3358-9
15 Fan Bracket Mounting Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 55-4511-9
16 Fan Bracket Mounting Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 55-7305-9
17 Fan Bracket Mounting Rubber Wellnut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 54-2955-9
† Refer to Cross Reference Guide
S2070C – 7
Rev (09/06)
CVD2075 CONDENSING UNIT
14
7
6
10
4
8
5
11
1
2a
3
12
13
pt1302
2b
DESCRIPTION
PART NO.
1
High Pressure Cut-Out Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 20-0124-3
2
Fan Cycling Control
a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 20-0127-3
b. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 20-0126-3
3
Low Pressure Cut-Out Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-0222-9
4
Contactor
a. 208-230V/50-60/1 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-0030-3
b. 208-230V/50-60/3 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1031-3
Start Components Copeland
5
Start Relay 208-230V/60 Hz/1 Ph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Start Relay 230V/50 Hz/1 Ph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Start Capacitor 208-230V/60 Hz/1 Ph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Start Capacitor 230V/50 Hz/1 Ph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Run Capacitor 208-230V/60 Hz/1 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Run Capacitor 230V/50 Hz/1 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous – Brackets, Screws, etc.
8
Screw, #10-24 x .50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Capacitor Mounting Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Capacitor Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Ground Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 Tenninal Block 230V/50 Hz/1 Ph Only (location only shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 Wiring Harness (Not shown)
a. 208-230V/60 Hz/1 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. 230/50 Hz/1 Ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-0757-9
20-0757-9
000000021
85-0552-3
82-5024-3
85-0449-3
† 52-0206-9
602160-1
603498-1
† 52-0216-9
† 25-0016-9
† 25-0002-9
20-0614-3
20-0024-9
20-0059-3
† Refer to Cross Reference Guide
Rev (09/06)
S2070C – 8
CVD2075 CONDENSING UNIT PANELS
6
4, 5
7
3
9
2
8
1
pt1303
DESCRIPTION
PART NO.
1
Condenser Fan Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-0014-3
2
Control Box Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 604017-1
3
Control Box Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603707-1
4
Left Side Panel 1875 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603876-1
5
Left Side Panel 2075 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603877-1
6
Cover Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603875-1
7
Right Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603874-1
8
Tubing Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 604226-1
Miscellaneous – Brackets, Screws, etc.
9
Screw, #10-24 x .50 Hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . † 52-0206-9
† Refer to Cross Reference Guide
S2070C – 9
Rev (07/02)
S2070C – 10
MR. ZIPPY’S ICE & WATER MACHINE
Texas Health Regulations
1. Texas Regulations For Vended Water Through A Machine
Texas Administrative Code
TITLE 25
PART 1
CHAPTER 229
SUBCHAPTER F
HEALTH SERVICES
DEPARTMENT OF STATE HEALTH SERVICES
FOOD AND DRUG
PRODUCTION, PROCESSING, AND DISTRIBUTION OF BOTTLED AND
VENDED DRINKING WATER
RULE §229.86
Processing of Vended Water
(a) Water dispensing device requirements are as follows:
(1) Any device from which any operator or consumer dispenses servings of water in bulk shall
comply with Title 21, Code of Federal Regulations (CFR), §129.40, Equipment and
Procedures, and §165.110, Requirements for Specific Standardized Beverages. Except
§129.40, the provision pertaining to the cleaning, sanitizing, filling, and capping or
sealing of containers shall not apply to containers furnished by the consumer.
(2) Water dispensing devices shall:
(A) be designed and constructed to permit thorough cleaning, sanitization, and maintenance of
all exterior and interior surfaces and component parts;
(B) have all parts and surfaces that come into contact with the water constructed of corrosionresistant, and nonabsorbent material acceptable to the department and capable of
withstanding repeated cleaning and sanitizing treatment;
(C) be designed so all treatment of the water by distillation, ion-exchange, filtration, ultraviolet
light, reverse osmosis, mineral addition, or any other acceptable process is done in an
effective manner;
(D) have an effective system of collection and handling of drip, spillage, and overflow of water;
(E) have a backflow prevention device approved by the department or local authority for all
connections with the water supply;
(F) disinfect water by ultraviolet light or other method approved by the department immediately
prior to delivery into the customer's container;
(G) comply with the American Water Works Association (AWWA) specifications for granular
activated carbon if used in the treatment of potable water (AWWA B604-74);
(H) be maintained in a clean and sanitary condition; and
(I) be free from dirt and vermin.
(b) Vending machines, in addition to requirements in subsection (a) of this section, shall:
(1) have a recessed or guarded corrosion-resistant dispensing spout;
(2) be equipped with monitoring devices designed to shut down operation of the machine when
the disinfection unit fails to function;
(3) be equipped with a self-closing, tight-fitting door on the vending compartment;
(4) be located in an area that can be maintained in clean condition and in a manner that avoids
insect and rodent harborage; and
(5) display in a position clearly visible to customers, the following information:
(A) the name and address of the operator;
(B) a statement to the effect that the water is obtained from an approved source; and
(C) a local or toll-free telephone number that may be called for further information, service, or
complaints.
Jim Coleman Company
Page 1 of 18
Health Regulations
Rev. 7/21/10
MR. ZIPPY’S ICE & WATER MACHINE
(c) Service, sampling and records shall meet the following requirements:
(1) All parts and surfaces of the water dispensing device shall be maintained in clean condition
by the vended water operator. The dispensing chamber and dispensing nozzle shall be cleaned
and sanitized each time the device is serviced; whereas, all surfaces in contact with the vended
water shall be maintained as a deposit free, visibly clean system. A record of cleaning and
maintenance operations shall be kept by the operator for each water dispensing device for a
period of two years and be available for inspection upon request.
(2) The vended water from each water dispensing device shall have a bacteriological analysis
conducted a minimum of once every 90 calendar days and if required by the department,
shall also be analyzed for other physical, chemical, or microbiological parameters.
(A) Sample results reported as coliform positive or unsuitable for analysis shall be submitted by
facsimile to the department within 24 hours of receipt of the sample results from a laboratory
acceptable to the department. The person shall submit the results to the Foods Group,
Policy/Standards/Quality Assurance Unit by facsimile at (512) 834-6681, or by e-mail at
[email protected]
(B) The person operating a water dispensing device shall maintain the original of all sample
results for a period of two years. The drinking water analyses shall be performed by a laboratory
acceptable to the department. A copy of the analysis shall be available for review and copying
during inspections.
(3) Each person operating a water dispensing device shall maintain a written maintenance
program. The written maintenance program shall include written servicing instructions for the
operator; technical manuals for the machine and water treatment appurtenances involved; and
records of service. The written maintenance program shall be available for inspection by the
department.
(4) The vended water operator shall clean and perform servicing of the water vending machine
a minimum of once per month.
(A) More frequent cleaning and servicing may be required to maintain sanitation or as required
by the manufacturer of the equipment.
(B) Sampling results of positive coliform or unsuitable for analysis are indications that servicing
of machine may be required at a higher frequency than once per month as detailed in paragraph
(5) of this subsection.
(5) Methods of testing for maximum contaminant levels (MCLs) for microbiological contaminants
in water dispensed from water dispensing devices shall be performed as follows:
(A) if any sample collected from a water dispensing device is determined to be unsatisfactory for
any reason (i.e. coliform positive or unsuitable for analysis), the operator shall notify the
department in accordance with paragraph (2)(A) of this subsection; and
(B) the water dispensing device shall be cleaned, sanitized and resampled immediately. Until
the sample results are known the device shall remain out of service; and
(C) if after being cleaned and sanitized, the vended water is determined to be unsatisfactory, the
machine shall remain out of service until the source of the contamination has been located and
corrected and a negative sample obtained. The negative sample result shall be maintained in
accordance with paragraph (2)(B) of this subsection.
Source Note: The provisions of this §229.86 adopted to be effective July 3, 2003, 28
TexReg 4908; amended to be effective June 4, 2006, 31 TexReg 4432
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If your machine is not in the State of Texas then consult the state where the machine is located
for specific regulations. You will need to comply with your state regulations. This section of the
manual briefly covers the state of Texas regulations. However, for a detailed manual, go to the
website www.tdh.state.tx.us/bfds/foods/bvw/index.html
What does the Texas law require of water vending machines?
A. Texas law requires a state water vending license issued by the state. (See attached
copy of license application). You will need a license for each location you operate.
B. Also Texas law requires the distribution of vended water to be performed by or under the
guidance and control of a bottled water and vendor operator who holds a certificate of
Competency. This test will certify the individual and this individual can operate many
vending machines(See attached copy of application to take test)
C. Texas laws also require a water sample to be tested for Bacteriological tests every 90
days. The results of the test must be submitted to the state of Texas and a copy kept for
two years. If the machine ever fails the test the machine must be shut down and cleaned
and sanitized until the machine passes the Bacteriological test. (See vended water
sampling section)
D. Texas law requires copies of the written maintenance program to be available for
inspection.( see record keeping section)
E. Texas law also requires copies of cleaning and Maintenance records to be available for
inspection. (see record keeping section)
F. Texas law requires a water vending unit to be inspected and cleaned monthly. However
JCC recommends weekly testing and cleaning not monthly.(See Maintenance log sheet)
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Section 1
Introductory Information
VENDED WATER OPERATOR CERTIFICATION
REQUIREMENTS
The Texas Health and Safety Code Chapter 441 requires a bottled water operator to
hold a certificate of competency issued by the Department of State Health Services
(DSHS) in order to furnish or distribute bottled water to the public. Furthermore, Title
25, Texas Administrative Code, Section 229.88 prohibits a person from
furnishing bottled water to the public or for distribution to the public unless the
processing, bottling, and distribution of the bottled water is performed by or under the
full-time supervision of a bottled and vended water operator who holds a certificate of
competency. Additionally, a person may not furnish vended water to the public or for
distribution to the public unless the processing, bottling, and distribution of the vended
water is performed by or under the guidance and control of a bottled and vended water
operator who holds a certificate of competency
The law authorizes DSHS to issue a certificate of competency to a qualified bottled and
vended water operator who files an application, pays a $110 certification
fee, and passes an examination with a score of 70 or higher. All certificates are valid for
two years. After filing the application and paying the fee, the applicant will be notified by
DSHS in writing that they are eligible to take the exam. At that time the applicant must
contact the regional DSHS office selected on the application (within 90 days of the date
on the confirmation letter) and schedule a mutually convenient time to take the
examination. DSHS examination sites and contacts are identified on the following page. If an
applicant fails the exam, the applicant must reapply and pay a re-application fee of $50.
Renewal certificates are $110 and are valid for two years.
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BOTTLED AND VENDED WATER OPERATOR
CERTIFICATION EXAMINATION SITES
For further information contact the Foods Group at (512) 834-6670; FAX (512) 834-6681.
For an appointment to take the Bottled and Vended Water Operator certification examination
after receiving an approval notice, contact:
Jane Nichols, R.S.
4601 South First
Suite L
Abilene, TX 79605
(325) 795-5865
Gary Fromlath
601 W. Sesame Dr.
Harlingen, TX 78550
(956) 423-0130 x620
Kathy McKeon
1301 South Bowen Rd.
Suite #200
Arlington, TX 76013
(817) 264-4682
Dana Cotton, R.S.
5425 Polk Avenue, Ste J
Houston, TX 77023
(713) 767-3242
Denette Plessala
8407 Wall Street
Austin, TX 78754
(512) 834-6670
Deborah Runk, R.S.
1233 Agnes St.
Corpus Christi, TX 78401
(361) 889-3435
Sherry Jackson, R.S.
401 E. Franklin Ste 200
El Paso, TX 79901
(915) 834-7712
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Patrick Moore
1109 Kemper
Lubbock, Texas
(806) 744-3577
Joe Collie, R.S.
622 South Oaks, Suite 8
San Angelo, TX 76903
(915) 659-7850
David Sueltenfuss, R.S.
7430 Louis Pasteur Dr.
San Antonio, TX 78229
(210) 949-2117
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OBJECTIVES
The objectives of this manual are to assist operators:
1) Identify hazards that a reasonably likely to occur in bottled and vended water
2) Understand the processes and equipment that prevent, eliminate, or reduce hazards
3) Understand and comply with bottled and vended water regulations
RESPONSIBILITIES AND DUTIES OF OPERATORS
It is the responsibility of the Certified Vended Water Operator to provide water that is produced
under good manufacturing practices and that complies with standards of quality and identity.
The duties of vended water operators frequently include:
.. Supervising equipment maintenance and operation
.. Supervising plant sanitation
.. Monitoring processes
.. Collecting samples
.. Maintaining and reviewing records
.. Coordinating corrective actions
.. Training and supervising employees
.. Working with regulatory agencies
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A. Vended Water Sampling
Bacteriological Quality:
The vended water from each water vending machine shall be analyzed a minimum of
once every 90 calendar days by a laboratory acceptable to DSHS. The locations of
acceptable laboratories in Texas may be obtained by contacting the DSHS Bureau of
Laboratories at (512) 458-7318. The sample shall be submitted in sterilized containers.
The sterilized containers may be obtained from your local laboratory.
Sample Results:
There are several testing methods that laboratories use to conduct bacteriology tests on vended
water.
Routine industry bacteriology testing: Any method conducted by an approved laboratory that is
equivalent to those specified in 21 CFR 165** can be used for routine testing. This includes
Colilert, Multiple Tube Fermentation, and Membrane Filtration (there may be others)
If any sample collected is determined to be unsatisfactory for any reason (i.e. coliform positive
or unsuitable for analysis):
(1) The operator shall notify the department within 24 hours of receipt of the sample results by
facsimile or e-mail.
(2) The water dispensing device shall be cleaned, sanitized and resampled immediately. Until
the sample results are known, the machine shall remain out of service
(3) If after being cleaned and sanitized, the vended water is determined to be unsatisfactory, the
machine shall remain out of service until the source of the contamination has been located and
corrected and a negative sample obtained.
These samples must be tested by either Multiple Tube Fermentation or Membrane Filtration
methods. The Manufactured Foods Division WILL NOT accept Colilert or Colilert quanti trays for
these follow up samples.
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B. Sample Results
The laboratory will report bacteriological sample results as either “Coliforms Found” or
“Coliforms Not Found”. A good sample is when coliforms are NOT found. A bad
sample is when coliforms ARE found because coliform organisms indicate the water
may be contaminated. If coliforms are found, the bottled and vended water operator
should initiate corrective action. This usually includes removing contaminated product
from distribution, identifying and correcting the cause, and re-sampling. Operators are
encouraged to contact the TDH regional office for guidance. Failure to take appropriate
corrective action may lead to public notification, recall, or legal remedy.
If a sample is “Unsuitable for Analysis”, the sample is not valid and another sample
must be submitted. For a water bottler, this sample should preferably come from the
same lot as the original sample. This is why it is a good practice to hold reserve
samples of each production until sample results are returned from the laboratory. If
available, multiple tube fermentation test methods are less susceptible to interference
than the membrane filter test method.
If results for chemical or radiological samples exceed the standards in 21 CFR 165,
contact the Public Health Region Office in your area for guidance. A list of all Regional
offices is located in Appendix G.
When the microbiological, physical, chemical, or radiological quality of bottled water is
below standards, the label shall bear a statement of substandard quality. Bottled water
containing a substance at a level considered injurious to health is deemed adulterated
regardless of whether the water bears a label statement of substandard quality.
Sample Result Submission to the Department of State Health Services
Samples reported Coliform Positive or Unsuitable for Analysis:
Must be sent to the Foods Group, Policy/Standards/Quality Assurance Unit with
24 hours of receipt from the laboratory either by fax at 512-834-6681 or by email to
[email protected]
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C. Record Keeping
All records required for Bottled and Vended Water facilities must be kept for 2 years and
available for review by Department of State Health Services investigators.
Vended Water
*TAC - Texas Administrative Code
Record Type
Certificate of Competency
Rule or Regulation
*TAC 229.88 – A person may not furnish vended
water to the public or for distribution to the public
unless the processing, bottling, and distribution of
the vended water is performed by or under the
guidance and control of a bottled and vended water
operator who holds a certificate of competency
under this chapter.
Cleaning and Maintenance Records
*TAC 229.86(c)(1) – A record of cleaning and
maintenance operations shall be kept by the
operator for each water dispensing device for a
period of two years and be available for inspection
upon request.
Sampling Records
*TAC 229.86(c)(2) – The vended water from each
water dispensing device shall have a bacteriological
analysis conducted a minimum of once every 90
calendar days and if required by the department,
shall also be analyzed for other physical, chemical,
or microbiological parameters. All records shall
maintained for a period of two years. The analysis
shall be performed by a laboratory acceptable to the
department to perform drinking water analysis, and a
copy of the analysis shall be available for inspection.
NOTE: See new sample result submission
requirements Section 3.5
Written Maintenance Program
*TAC 229.86(c)(3) – Each person operating a water
dispensing device shall maintain a written
maintenance program. The written maintenance
program shall include written servicing instructions
for the operator; technical manuals for the machine
and water treatment appurtenances involved; and
records of service. The written maintenance
program shall be available for inspection by the
department.
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DEPARTMENT OF STATE HEALTH SERVICES
MANUFACTURED FOODS DIVISION
Production, Processing, and Distribution of
Bottled and Vended Drinking Water
'229.81. General Provisions.
(a) Purpose. These sections establish definitions and standards for the processing and bottling
of drinking and vended water. The sections also will supplement ''229.181-229.184 of this title
(relating to Licensure of Manufacturers of Food and Wholesale Distributors of Food--Including
Good Manufacturing Practices) and federal regulations in Title 21, Code of Federal Regulations,
Part 165 concerning standards of quality, and Part 129 concerning processing and bottling of
bottled drinking water.
(b) Requirements for specific standardized beverages. The department adopts by reference
Title 21 Code of Federal Regulations, '165.110 concerning the identity, nomenclature, other
label statements and label declarations for both bottled and vended water, except as modified
by the Texas Board of Health in '229.85(b) of this title (relating to Labeling and Advertising).
(c) Definitions. The following words and terms, when used in this chapter, shall
pertain to both bottled and vended water and shall have the following meanings unless
the context clearly indicates otherwise.
(1) Approved source (when used in reference to a plant's product water or operations water)--A
source of water and the water there from, whether it be from a spring, artesian well, drilled well,
municipal water supply, or any other source, that has been inspected and the water sampled,
analyzed, and found to be of a safe and sanitary quality according to applicable laws and
regulations of State and local government agencies having jurisdiction. The presence in the
plant of current certificates or notifications of approval from the government agency or agencies
having jurisdiction constitutes approval of the source and the water supply.
(2) Artesian water--Water from a well tapping a confined aquifer in which the water level stands
at some height above the top of the aquifer is "artesian water" or "artesian well water."
(3) Bottled water--Water that is intended for human consumption and that is sealed in bottles or
other containers with no added ingredients except that it may optionally contain safe and
suitable antimicrobial agents.
(4) Department--Department of State Health Services.
(5) Distilled water--Water which has been produced by a process of distillation and meets the
definition of purified water in the United States Pharmacopeia, 23rd revision, January 1, 1995,
which the department adopts by reference. (Copies may be obtained from the United States
Pharmacopial Convention, Inc., 12601 Twinbrook Parkway, Rockville, MD 20852).
(6) Drinking water–All water from the point of the approved source intended for the purpose of
human consumption or which may be used in the preparation of foods or beverages.
(7) Fluoridated water--Water containing added fluoride.
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(8) Ground water--Water from a subsurface saturated zone that is under a pressure equal to or
greater than atmospheric pressure.
(9) Mineral water--Water containing not less than 250 parts per million (ppm) total dissolved
solids (TDS), coming from a source tapped at one or more bore holes or springs, originating
from a geologically and physically protected underground water source.
(10) Person–Includes individual, partnership, corporation, or association.
(11) Purified water--Water that has been produced by distillation, deionization, reverse osmosis,
or other suitable processes and that meets the definition of "purified water" in the United States
Pharmacopoeia, 23rd revision, January 1, 1995, which the department adopts by reference.
(Copies may be obtained from the United States Pharmacopial Convention, Inc., 12601
Twinbrook Parkway, Rockville, MD 20852).
(12) Sparkling bottled water--Water that after treatment and possible replacement of carbon
dioxide, contains the same amount of carbon dioxide that it had at emergence from the source.
(13) Spring water--Water derived from an underground formation from which water flows
naturally to the surface of the earth.
(14) Sterile water or sterilized water--Water that meets requirements under "Sterility Tests" in
the United States Pharmacopeia, 23rd revision, January 1, 1995, which the department adopts
by reference. (Copies may be obtained from the United States Pharmacopial Convention, Inc.,
12601 Twinbrook Parkway, Rockville, MD 20852).
(15) Vended water--Vended water is:
(A) water dispensed from any vending machine; or
(B) servings of water dispensed in bulk by any operator or consumer from any water dispensing
device.
(16) Vending machine--Any self-service device which upon insertion of a
coin, coins, or token, or upon receipt of payment by other means, dispenses servings of
water in bulk, without the necessity of refilling the machine between each operation.
(17) Water dispensing device--Any water unit that dispenses water in bulk without the necessity
of refilling the machine between operations. This term includes stores that are manned by an
operator at all times in which consumers bring containers to be filled by the operator, facilities
that are not manned by an operator and where consumers dispense their own water, and
vending machines. A water dispensing device may have several dispensing faucets in the case
of a store. However, each vending machine is considered a separate water dispensing device.
(18) Well water--Water taken from a hole bored, drilled, or otherwise constructed in the ground
which taps the water of an aquifer.
(d) Other requirements for specific standardized beverages.
(1) Artesian water may be collected with the assistance of external force to enhance the natural
underground pressure. On request, a bottler or vendor shall demonstrate to the department that
the water level stands at some height above the top of the aquifer.
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(2) For bottled water or drinking water, fluoride may be optionally added within the limitations
established in 21 Code of Federal Regulations (CFR) Part 165.110(b)(4)(ii). Bottled water may
be used as an ingredient in beverages (e.g., diluted juices, flavored bottled waters). It does not
include those food ingredients that are declared in ingredient labeling as "water," "carbonated
water," "disinfected water," "filtered water," "seltzer water," "soda water," "sparkling water," and
"tonic water." The processing and bottling of bottled water shall comply with applicable
regulations in 21
CFR, Part 129.
(3) For fluoridated water, the total fluoride content levels cannot exceed levels contained in 21
CFR 165.110(b)(4)(ii).
(4) Ground water must not be under the direct influence of surface water as defined in 40 CFR
141.2.
(5) Mineral water shall be distinguished from other types of water by its constant level and
relative proportions of minerals and trace elements at the point of emergence from the source,
due account being taken of the cycles of natural fluctuations. No minerals may be added to this
water.
(6) Water processed by demineralization that meets the purified water definition may
alternatively be called "demineralized water." Alternatively, water that has been processed by
deionization may be called "deionized water," and water processed by distillation may be called
"distilled water," and water that has been processed by reverse osmosis may be called "reverse
osmosis water." Also, if the water has been processed by either of the previously listed methods
the water may be called "(blank) drinking water," with the blank being filled in with one of the
defined terms describing the method of processing.
(7) Spring water shall be collected only at the spring or through a bore hole tapping the
underground formation feeding the spring. There shall be a natural force causing the water to
flow to the surface through a natural orifice. The location of the spring shall be identified. Spring
water collected with the use of an external force shall be from the same underground stratum as
the spring, as shown be a measurable hydraulic connection using a hydrogeologically valid
method between the bore hole and the natural spring, and shall have all the physical properties,
before treatment, and be of the same composition and quality, as the water that flows naturally
to the surface of the earth. If spring water is collected with the use of an external force, water
must continue to flow naturally to the surface of the earth through the spring's natural orifice.
'229.82. Sampling. Bottled water must be sampled in accordance with the compliance
procedures of Title 21, Code of Federal Regulations, Part 129. All required analyses must be
performed by a laboratory acceptable to the department, certified by the U.S. Environmental
Protection Agency (EPA) or certified by the primacy enforcement authority in any state which
has been granted primacy by EPA, or certified by a third party organization acceptable to a
primacy state.
'229.83. Water Hauling.
(a) Water that is distributed by truck or trailer in lieu of distribution piping, shall comply with the
Health and Safety Code, Chapter 431, Subchapter C, concerning drinking water standards and
rules adopted thereunder by the Texas Commission on Environmental Quality, 30 Texas
Administrative Code (TAC), §§290.44(i) (relating to Water Distribution).
(b) A person receiving water transported by truck or trailer shall test and record the chlorine
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residual for compliance with the required minimum chlorine residual (30 TAC, §290.44(i)(2)(K)).
(c) Operational records detailing the amount of water received, the source of the water, and the
chlorine residual readings, shall be maintained by the person receiving water that has been
transported by truck or trailer. The records shall be kept at the receiving facility for a period of
two years and be available for inspection upon request.
'229.84. Standards for Microbiological Control. Bottled and vended water production including
transporting, processing, packaging, and storage, shall be conducted under such standards and
controls as are necessary to minimize the potential for microbiological contamination of the
finished product. These standards and controls shall include the following.
(1) Bottled and vended water shall be subject to effective germicidal treatment by ozonation,
chlorination, exposure to ultraviolet light, or other equivalent disinfection approved by the
department.
(2) Bottled and vended water shall not be transported or stored in bulk tanks or processed
through equipment or lines used for any non-food product.
(3) In order to minimize the potential for microbiological contamination of the finished product,
non-carbonated bottled water shall not be transported, stored, processed, or bottled in or
through lines through which has passed milk, fruit juice, or other food products likely to
contribute nutrients for microbial growth. However, multifood fillers may be used for the filling of
bottled water as long as the fillers are properly cleaned and sanitized prior to the bottling of
water, and provided that they are in compliance with Title 21, Code of Federal Regulations,
'129.80. Any parts which are not designed to be cleaned-in-place shall be disassembled and
removed, and shall be cleaned and sanitized prior to reassembly.
'229.85. Labeling and Advertising.
(a) Claims of medicinal and health-giving properties shall not be placed on labels and
references shall not be made to bacterial purity or to laboratory examinations which may have
been made by department laboratories.
(b) The label must state the source of all artesian water, spring water, mineral water, well water,
or drinking water sold. Source refers to the point of origin. Examples: Brook Hollow Spring
Water from Buck Hollow, Arkansas; drinking water obtained from Austin municipal water supply,
Austin, Texas; well water from Bandera, Texas. Except that water processed by distillation,
deionization, reverse osmosis, or other suitable process that alters the water’s physical
properties enabling it to meet the definition of purified as defined in '229.81(c)(11) of this title
(relating to General Provisions) is not required to state the source. This exception only applies if
all the water used in the finished product is processed to meet the definition of purified.
(c) Other label statements.
(1) If the Total Dissolved Solids (TDS) content of Mineral water is below 500 ppm, or if it is
greater than 1,500 ppm, the statement "low mineral content" or the statement "high mineral
content," respectively, shall appear on the principal display panel following the statement of
identity in type size at least one-half the size of the statement of identity but in no case less that
one-sixteenth of an inch. If the TDS of mineral water is between 500 and 1,500 ppm, no
additional statement need appear.
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(2) When the label or labeling of a bottled water product states or implies (e.g., through label
statements or vignettes with reference to infants) that the bottled water is for use in feeding
infants, and the product is not commercially sterile, the product label shall bear conspicuously
and on the principal display panel the statement "Not sterile. Use as directed by physician or by
labeling directions for use of infant formula."
'229.86. Processing of Vended Water.
(a) Water dispensing device requirements are as follows.
(1) Any device from which any operator or consumer dispenses servings of water in bulk shall
comply with Title 21, Code of Federal Regulations (CFR), §129.40, Equipment and Procedures,
and §165.110, Requirements for Specific Standardized Beverages. Except §129.40, the
provision pertaining to the cleaning, sanitizing, filling, and capping or sealing of containers shall
not apply to containers furnished by the
consumer.
(2) Water dispensing devices shall:
(A) be designed and constructed to permit thorough cleaning, sanitization, and maintenance of
all exterior and interior surfaces and component parts;
(B) have all parts and surfaces that come into contact with the water constructed of corrosionresistant, and nonabsorbent material acceptable to the department and capable of withstanding
repeated cleaning and sanitizing treatment;
(C) be designed so all treatment of the water by distillation, ion-exchange, filtration, ultraviolet
light, reverse osmosis, mineral addition, or any other acceptable process is done in an effective
manner;
(D) have an effective system of collection and handling of drip, spillage, and overflow of water;
(E) have a backflow prevention device approved by the department or local authority for all
connections with the water supply;
(F) disinfect water by ultraviolet light or other method approved by the department immediately
prior to delivery into the customer’s container;
(G) comply with the American Water Works Association (AWWA) specifications for granular
activated carbon if used in the treatment of potable water
(AWWA B604-74);
(H) be maintained in a clean and sanitary condition; and
(I) be free from dirt and vermin.
(b) Vending machines, in addition to requirements in subsection (a) of this section, shall:
(1) have a recessed or guarded corrosion-resistant dispensing spout;
(2) be equipped with monitoring devices designed to shut down operation of the machine when
the disinfection unit fails to function;
(3) be equipped with a self-closing, tight-fitting door on the vending compartment;
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(4) be located in an area that can be maintained in clean condition and in a manner that avoids
insect and rodent harborage; and
(5) display in a position clearly visible to customers, the following information:
(A)the name and address of the operator;
(B) a statement to the effect that the water is obtained from an approved source; and
(C) a local or toll-free telephone number that may be called for further information, service, or
complaints.
(c) Service, sampling and records shall meet the following requirements.
(1) All parts and surfaces of the water dispensing device shall be maintained in clean condition
by the vended water operator. The dispensing chamber and dispensing nozzle shall be cleaned
and sanitized each time the device is serviced; whereas, all surfaces in contact with the vended
water shall be maintained as a deposit free, visibly clean system. A record of cleaning and
maintenance operations shall be kept by the operator for each water dispensing device for a
period of two years and be available for inspection upon request.
(2) The vended water from each water dispensing device shall have a bacteriological analysis
conducted a minimum of once every 90 calendar days and if required by the department,
shall also be analyzed for other physical, chemical, or microbiological parameters.
(A) Sample results reported as coliform positive or unsuitable for analysis shall be submitted by
facsimile to the department within 24 hours of receipt of the sample results from a laboratory
acceptable to the department. The person shall submit the results to the Foods Group,
Policy/Standards/Quality Assurance Unit by facsimile at (512) 834-6681, or by e-mail at
[email protected]
(B) The person operating a water dispensing device shall maintain the original of all sample
results for a period of two years. The drinking water analyses shall be performed by a laboratory
acceptable to the department. A copy of the analysis shall be available for review and copying
during inspections.
(3) Each person operating a water dispensing device shall maintain a written maintenance
program. The written maintenance program shall include written servicing instructions for the
operator; technical manuals for the machine and water treatment appurtenances involved; and
records of service. The written maintenance program shall be available for inspection by the
department.
(4) The vended water operator shall clean and perform servicing of the water vending machine
a minimum of once per month.
(A) More frequent cleaning and servicing may be required to maintain sanitation or as required
by the manufacturer of the equipment.
(B) Sampling results of positive coliform or unsuitable for analysis are indications that servicing
of machine may be required at a higher frequency than once per month as detailed in paragraph
(5) of this subsection.
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(5) Methods of testing for maximum contaminant levels (MCLs) for microbiological contaminants
in water dispensed from water dispensing devices shall be performed as follows.
(A) If any sample collected from a water dispensing device is determined to be unsatisfactory for
any reason (i.e. coliform positive or unsuitable for analysis), the operator shall notify the
department in accordance with paragraph (2)(A) of this subsection; and
(B) The water dispensing device shall be cleaned, sanitized and resampled immediately. Until
the sample results are known the device shall remain out of service; and
(C) If after being cleaned and sanitized, the vended water is determined to be unsatisfactory,
the machine shall remain out of service until the source of the contamination has been located
and corrected and a negative sample obtained. The negative sample result shall be maintained
in accordance with paragraph (2)(B) of this subsection.
'229.87. Requirements for Approved Sources. Sources in Texas shall comply with the
following requirements.
(1) Public water systems. Sources in Texas which are public water systems shall comply with
the Texas Health and Safety Code, Chapter 341, Subchapter C, concerning drinking water
standards and rules adopted by the Texas Commission on Environmental Quality, at 30 Texas
Administrative Code (TAC) ''290.101-290.121 (relating to Drinking Water Standards Governing
Drinking Water Quality and Reporting Requirements for Public Water Supply Systems), and
''290.38-290.47 (relating to Rules and Regulations for Public Water Systems).
(2) Other sources. Any other sources in Texas shall comply with 30 TAC ''290.101-290.121
concerning drinking water standards, and 30 TAC ''290.38-290.43 and 290.46 concerning rules
and regulations for public water systems, except where variances are permitted in '229.81 of
this title (relating to General Provisions).
(3) Compliance with these sections is required as if the source were a public water system.
'229.88. Certificates of Competency. A person may not furnish bottled or vended water to the
public or for distribution to the public unless the bottled or vended water operator holds a
certificate under this chapter.
(1) A person may not furnish bottled water to the public or for distribution to the public unless the
processing, bottling and distribution of the bottled water is performed by or under the full-time
supervision of a bottled and vended water operator who holds a certificate under this chapter.
(2) A person may not furnish vended water to the public or for distribution to the public unless
the processing, bottling, and distribution of the vended water is performed by or under the
guidance and control of a bottled and vended water operator who holds a certificate of
competency under this chapter. '229.89. Examination.
(a) After payment of the required fee, an applicant shall pass a written examination prescribed
by the department. To pass the examination for a certificate, the applicant must achieve a score
of 70% or more on the examination.
(1) The examination must be taken within 90 days of the date the department receives the fee. If
the 90-day time frame lapses without the applicant taking the examination, the applicant must
submit a new application and fee in order to take the examination.
(2) If the applicant fails the examination, the applicant may repeat the examination 30 days after
the failed examination. The applicant must reapply and pay a reapplication fee of $50.
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(b) An instructor may administer the department=s examination provided the
instructor signs and complies with the department=s security agreement.
'229.90. Certification and Renewal Fees. The fees for certification shall be established as
follows.
(a) This subsection applies to all new and renewal applications.
(1) Certification fee--$100.
(2) Renewal fee--$100.
(3) A certificate can be obtained by submitting an application with the $100 certification fee and
receiving a passing score on the examination. Certificates can be renewed by submitting a
completed application with the $100 renewal fee. Certificates are valid for two years from the
date of issuance or renewal. Certificates expire two years from the date of issuance. Fees will
not be prorated. If the department has not received a completed application for renewal within
60 days following the expiration date, the certificate holder shall submit a new application and
retake the examination.
(b) An applicant or holder of a certificate shall pay the required fee before taking the
examination or receiving a certificate.
(c) All fees shall be made payable to the Department of State Health Services and are not
refundable.
(d) All applicants shall be in compliance with §1.301 of this title (relating to Suspension of
License for Failure to Pay Child Support).
'229.91. Suspension, Denial, or Revocation of Certificate.
(a) Basis for suspension. The certificate shall be suspended if the operator practices fraud or
deceit against the department or the public; or fails to use reasonable care, judgment or
application of knowledge in the performance of their duties.
(b) Basis for denial. The certificate shall be denied if it is found:
(1) that the application is incomplete or false;
(2) that the operator obtained the certificate through fraud or deceit; or
(3) that the operator practiced fraud or deceit; or failed to use reasonable care, judgment or
application of knowledge in the performance of their duties.
(c) Basis for revocation. The certificate shall be revoked if it is found:
(1) that the certificate was issued in error; or
(2) that the operator obtained the certificate through fraud, deceit or through the submission of
incorrect data on the application; or
(3) that the operator practiced fraud and deceit, or failed to use reasonable care, judgment or
Jim Coleman Company
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Health Regulations
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MR. ZIPPY’S ICE & WATER MACHINE
application of knowledge in the performance of their duties.
(d) Examination of charges. When the department has reason to believe that charges against
an operator may be valid, the department shall notify the operator by personal service or
certified mail at his last known address:
(1) of the charges;
(2) that it intends to conduct an examination of the charges; and
(3) that the operator may request a formal hearing.
(e) Formal hearings. The department shall conduct hearings in accordance with the
Administrative Procedure Act, Texas Government Code ''2001.051 - 2001.902; and the
department=s formal hearing procedures in ''1.21, 1.23, 1.25, and 1.27 of this title (relating to
Formal Hearing Procedures).
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Mr. Zippy’s Express Ice and Water
Limited Warranty
The Manufacturer warrants any component or part of the Mr. Zippy’s Express Ice and Water
equipment to be free from defects in material and workmanship for a period of one year from
date of shipment, with the exception of such parts as are commonly recognized to be subject to
wear in normal usage, such as decals., which are warranted for ninety (90) days. Electrical
motors shall be covered under manufacturer's warranty for a period of one year, unless
otherwise specified. Jim Coleman Company electronic controls, such as timers, coin acceptors
and computer monitoring equipment, carry a one-year warranty. Claims under this warranty
must be asserted in writing within the one-year period covered by this warranty.
The Obligation of Jim Coleman Company and the rights and remedies of the owner/user
under this warranty are exclusively limited to, the repair or replacement of parts or
assemblies that in Jim Coleman Company opinion are defective within one year after
original date of installation. This warranty does not include any labor warranty.
Any component or part alleged to be defective in material or workmanship shall, at option of
Manufacturer, be returned with shipping cost prepaid. All parts must be returned within 15 days
to be eligible for parts warranty coverage. If, upon examination, such component or part is
found to be defective in workmanship or materials, Manufacturer, at its option, will either repair
or replace such component or part, and shall ship such repaired or replaced component or parts
F.O.B. factory, Houston, Texas. Manufacturer reserves the right to use “Like New” or
Remanufactured parts in repair of warranty items that exceed 6 months in service. The cost of
such replacement or repair shall be the exclusive remedy for any breach of any warranty and
Manufacturer shall not be liable to any person for consequential damages for injury or
commercial loss resulting from any breach of any warranty. This warrant does not cover any
labor installation cost, either with respect to the original equipment, the repaired or replaced
component, or part defective in workmanship or materials. Jim Coleman Company does not
warrant loss of income should there be any during such time repairs are being made.
This warranty does not apply to components or parts which have been misused, altered,
neglected, not installed, adjusted, maintained, or used in accordance with applicable codes and
ordinances and in accordance with Manufacturer's recommendations as to such factors.
This warranty does not include Parts or Labor for components failure or other damage resulting
from:
• External electrical power failure or miswiring to product for any reason.
• Lightning strikes causing damage to electronic or electrical components.
• Incoming voltage that exceeds the manufacturer’s recommendation of 240 v.
• Incoming voltage that is too low and does not meet the minimum recommendation of
208v.
World Class Manufacturing of Car Wash Equipment
5842 West 34tth Street • Houston, TX 77092
800-999-9878 • 713-683-9878 • Fax: 713-683-9624
[email protected] • www.jcolemanco.com • www.hannacarwash.com
Page 1 of 2
The Manitowoc ice makers are covered under the warranty from Manitowoc. Manitowoc offers a
separate warranty on the ice makers please refer to that warranty for information regarding the
ice makers and condensers.
Jim Coleman Company is not responsible for the operation of the unit and it meeting the local or
state health codes or standards. Jim Coleman Company has designed the unit to meet the
federal guidelines but careful testing and monitoring by the owner operator is required to ensure
clean bacteria free water and/or ice is being delivered to the customer.
Compliance with any local governmental laws or regulations relating to the location, use or
operation of the equipment, or its use in conjunction with other equipment, shall be the
responsibility of the purchaser. The rights and obligations of the parties shall be governed by
the State of Texas.
LIMITATION OF LIABILITY AND OTHER WARRANTIES
Jim Coleman Company assumes no liability for misuse or inadequate maintenance of this
product. In no event shall the owner/user be entitled to recover incidental or consequential
damages, including but not limited to, damages for inconvenience, loss of profits, water damage
or any other commercial loss.
THIS WARRANTY IS IN LIEU OF ALL WARRANTIES, EXPRESS OR IMPLIED, OF EITHER
MANUFACTURER OR SELLER, AND MAKES NO WARRANTY AGAINST INFRINGEMENT
OF THE LIKE, MAKES NO WARRANTY OF MERCHANTABILITY, MAKES NO WARRANTY
OF FITNESS FOR A PARTICULAR PURPOSE, AND MAKES NO WARRANTY, EXPRESS
OR IMPLIED, INCLUDING IMPLIED WARRANTY ARISING FROM COURSE OF DEALING
OR USAGE OF TRADE.
World Class Manufacturing of Car Wash Equipment
5842 West 34tth Street • Houston, TX 77092
800-999-9878 • 713-683-9878 • Fax: 713-683-9624
[email protected] • www.jcolemanco.com • www.hannacarwash.com
Page 2 of 2

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