020001448 A&W Tower - Whaley Food Service

020001448 A&W Tower - Whaley Food Service
BLADE TOWER
2 Valve Root Beer Dispenser
INSTALLATION & SERVICE GUIDE
Part Number 020001448
Notice: DO NOT throw this manual away.
This manual contains important information
regarding this product.
Keep this manual at the dispenser location.
Manitowoc Beverage Equipment
2100 Future Drive Š Sellersburg, IN 47172-1868
Tel: 812.246.7000, 800.367.4233 Š Fax: 812.246.9922
www.manitowocbeverage.com
In accordance with our policy of continuous product development and
improvement, this information is subject to change at any time without notice.
April 01, 2008 REV0
FOREWORD
Manitowoc Beverage Equipment (MBE) developed this manual as a reference guide for the owner/
operator, service agent, and installer of this equipment. Please read this manual before installation
or operation of the machine. A qualified service technician should perform installation and startup of this equipment, consult the Troubleshooting Guide within this manual for service assistance.
If you cannot correct the service problem, call your MBE Service Agent or Distributor. Always have your model and
serial number available when you call.
Your Service Agent ___________________________________________________________________
Service Agent Telephone Number ______________________________________________________
Your Local MBE Distributor ___________________________________________________________
Distributor Telephone Number _________________________________________________________
Model Number ______________________________________________________________________
Serial Number _______________________________________________________________________
Installation Date _____________________________________________________________________
UNPACKING AND INSPECTION
Note: The unit was thoroughly inspected before leaving the factory. Any damage or irregularities should
be noted at the time of delivery.
WARRANTY INFORMATION
Consult your local MBE Distributor for terms and conditions of your warranty. Your warranty specifically
excludes all beverage valve brixing, general adjustments, cleaning, accessories and related servicing.
Your warranty card must be returned to Manitowoc Beverage Equipment to activate the warranty on this
equipment. If a warranty card is not returned, the warranty period can begin when the equipment leaves
the MBE factory.
No equipment may be returned to Manitowoc Beverage Equipment without a written Return Merchandise
Authorization (RMA). Equipment returned without an RMA will be refused at MBE’s dock and returned to
the sender at the sender’s expense.
Please contact your local MBE distributor for return procedures.
TABLE OF CONTENTS
FOREWORD ........................................................................................................ 2
UNPACKING AND INSPECTION ......................................................................... 2
WARRANTY INFORMATION ............................................................................... 2
SAFETY ............................................................................................................... 5
IMPORTANT SAFETY INSTRUCTIONS ........................................................................... 5
CARBON DIOXIDE WARNING ......................................................................................... 5
QUALIFIED SERVICE PERSONNEL ................................................................................ 5
SHIPPING, STORAGE, AND RELOCATION ..................................................................... 5
ADDITIONAL WARNINGS ................................................................................................ 5
INSTALLATION .................................................................................................... 6
UNIT INSPECTION ........................................................................................................... 6
PRE-INSTALLATION CHECK LIST .................................................................................. 6
STARTING YOUR BEVERAGE SYSTEM AND DISPENSER ............................................ 6
SPECIFICATIONS ............................................................................................................ 6
BLADE TOWER DIMENSIONS ........................................................................................ 7
COUNTER TOP FOOTPRINT ........................................................................................... 7
UNIT INSTALLATION ....................................................................................................... 8
BASIC B-I-B SYSTEM & PRESSURES ............................................................................ 8
DRAINAGE OPTIONS ...................................................................................................... 9
PLUMBING DIAGRAM LOCATION .................................................................................. 9
SINGLE TOWER PLUMBING ......................................................................................... 10
DUAL TOWER PLUMBING ............................................................................................ 10
TRIPLE TOWER PLUMBING .......................................................................................... 11
BRIXING PROCEDURE ................................................................................................... 11
SYRUP DELIVERY SYSTEM .......................................................................................... 12
BACK ROOM PACKAGE ............................................................................................... 12
RACKING ....................................................................................................................... 13
B-I-B ............................................................................................................................... 13
PUMPS ........................................................................................................................... 13
AUTO BAG SELECTORS ............................................................................................... 13
TABLE OF CONTENTS
USER MAINTENANCE ...................................................................................... 13
PREVENTATIVE MAINTENANCE .................................................................................. 13
WINTERIZATION ............................................................................................................ 13
CO2 HANDLING ............................................................................................................. 13
HOW TO DISASSEMBLE TOWER COMPONENTS ....................................................... 14
CLEANING EQUIPMENT AND SUPPLIES ..................................................................... 14
CLEANING & SANITIZING THE DISPENSING VALVES & PRODUCT LINES ............... 14
MAINTENANCE SCHEDULE ......................................................................................... 15
NIGHTLY SHUTDOWN PROCEDURE ............................................................................ 15
CLEANING AND SANITIZING PROCEDURE ................................................................. 16
BEVERAGE SYSTEM CLEANING ................................................................................. 16
BAG-IN-BOX SYSTEM ................................................................................................... 17
TROUBLESHOOTING ....................................................................................... 18
DRINKS .......................................................................................................................... 18
Installation and Service Manual
SAFETY
IMPORTANT SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual. Learn how to operate the A&W Tower unit
properly. Do not allow anyone to operate the unit without proper training and keep it in proper
working condition. Unauthorized modifications to the A&W Tower may impair function and/or
safety and affect the life of the unit.
CARBON DIOXIDE WARNING
DANGER: Carbon Dioxide (CO2) displaces oxygen. Exposure to a high concentration of CO2 gas
causes tremors, which are followed rapidly by loss of consciousness and suffocation. If a CO2 gas leak
is suspected, particularly in a small area, immediately ventilate the area before repairing the leak. CO2
lines and pumps should not be installed in an enclosed space. An enclosed space can be a cooler or
small room or closet. This may include convenience stores with glass door self serve coolers. If you
suspect CO2 may build up in an area, venting of the B-I-B pumps and / or CO2 monitors should be utilized.
QUALIFIED SERVICE PERSONNEL
WARNING: Only trained and certified electrical and plumbing technicians should service this unit.
All wiring and plumbing must conform to national and local codes.
SHIPPING, STORAGE, AND RELOCATION
CAUTION: Before shipping, storing, or relocating this unit, syrup systems must be sanitized. After
sanitizing, all liquids (sanitizing solution and water) must be purged from the unit. A freezing environment causes residual sanitizing solution or water remaining inside the unit to freeze, resulting
in damage to internal components.
ADDITIONAL WARNINGS
Installation and start-up of this equipment should be done by a qualified service technician. Operation,
maintenance, and cleaning information in this manual are provided for the user/operator of the equipment.
Save these instructions.
5
INSTALLATION
UNIT INSPECTION
Installation and Service Manual
Included with each Blade Tower should be one (1) installation kit (020001441) and if multiple towers are being
installed a tee kit (020001411) is included with each additional tower. Listed below are the contents of each kit;
020001441- KIT INSTL 2 VLV RB BLADE TOWER
Item
Description
Quantity
00861302
020001403
11.3-505R
15514500
18.5-706R
020001448
0901803
020002097
00850812
5006594
SPLICER 1/4 X 3/8 BARB SS
UBEND BARB 1/2 X 1/2 X 28 1/4
CLAMP STEPLESS SS
CLAMP STEPLESS SS 14.5MM
CLAMP STEPLESS SS
MAN A AND W BLADE TOWER
WASHER FLAT #10 ZINC
SCR 10-24 X 2 SS
NUT HEX 10-24 SS
WASHER STAR #10 SS
2
1
4
2
2
1
4
4
4
4
020001411- KIT CONDUIT TEE 4 LINE
Item
Description
Quantity
00854996
5009851
15514500
18.5-706R
1900315
5029545
ELL 1/2 X 1/2 BARB SS
TEE 3/8 BARB
CLAMP STEPLESS SS 14.5MM
CLAMP STEPLESS SS
BAG 9X12 CLR ZIPLOCK
TAPE 3IN X 60FT BLK
2
2
6
4
1
1
Thoroughly inspect the unit upon delivery. Immediately report any damage that occurred during transportation to
the delivery carrier. Request a written inspection report from a claims inspector to document any necessary claim.
PRE-INSTALLATION CHECK LIST
When installing any system, first make sure the major components are available. Generally the major components
necessary for an installation are:
Pre-mix system:
B-I-B System:
†
†
†
†
†
†
†
†
†
CO2 regulator set
Product connectors for tank
Gas connectors for tank
Beverage dispenser
†
†
†
†
B-I-B connectors
†
†
†
†
Water line
B-I-B regulator set
B-I-B rack
B-I-B syrup boxes
Also consider the location of the following items before installation:
Beverage tubing
CO2 tank
Beverage tanks
Stepless (Oetiker) clamps
Chain for CO2 tank
Drain
Power outlet
Heating and air conditioning ducts
Double Check:
† Do you have enough space to install the dispenser?
† Is the counter top level?
† Can the counter top support the weight of the
tower?
STARTING YOUR BEVERAGE SYSTEM AND DISPENSER
Upon completion of the beverage dispenser and / or system installation, all tubing, dispenser, and system components must be cleaned and sanitized prior to use.
NOTE: At installation equipment, dispensers, and tubing
get moved through many environments, dirt, dust, chases,
insulation, drywall, etc. It is an important procedure and
best practice to address cleaning to deliver the best quality
drink to your customer.
Clean and sanitize the water and syrup circuits according
to instructions provided in this manual. Clean and sanitize
the dispenser components according to instructions provided in this manual. Seal the unit to the counter top. Consult and use local health codes if a discrepancy occurs
between this manual and your local health codes.
SPECIFICATIONS
Blade Tower has a stainless steel cabinet standard. Beverage valves, tubing connections, valves are top serviceable.
The tower drains through either an existing counter top drain or the optional drain for this unit. Optimum ambient
conditions for Blade Tower operation is between 500F and 950F.
6
Installation and Service Manual
INSTALLATION
BLADE TOWER DIMENSIONS
11.86
9.68
3.00
.750
5.00
7.39
1.750
17.30
3.29
10.75
Counter Top Weight
25 Lbs (11.34 Kgs)
4.88
COUNTER TOP FOOTPRINT
COUNTER TOP AREA
CAUTION: Cutting the counter top may decrease its strength. Counter should
be braced to support the dispenser counter top weight plus ice storage capacity and weight of icemaker, if applicable.
7
Installation and Service Manual
INSTALLATION
UNIT INSTALLATION
3. Run the beverage lines and water lines; make sure to
install the water connections to the proper inlets. If
installing more than one tower connect the tee tower
kit at this time, 1 per additional tower installed.
(See the Plumbing Section)
4. If installing the optional flush mount drain plumb for
drain(s) and insulate at this time.
5. Turn water supply on to the dispenser. Water pressure should be between 40 and 55 psi with the carbonator pump running. If not in between those pressures, proper measures must be taken to regulate
them to correct settings.
6. Once water is supplied to unit air needs to be purged
from the carbonator tank. Do so by lifting the pressure
relief valve tab on the carbonator tank until water
comes out of the relief valve.
7. Check water and beverage lines for leaks, if there
are no leaks fasten the tower to the counter top
using the bolts included in the installation kit and
seal to the counter top using a silastic sealant such
as Dow Corning RTV 731 or equivalent on the base
bottom edges.
8. Meet all local code requirements.
9. Brix beverage valves. (See the Brixing Section)
10. Attach tower top riser.
1. Using the footprint cut holes in the desired counter
top location(s). If installing the optional flush mount
drain cut the hole for the drain(s) at this time also.
Repeat this step for each tower being installed if
this is a two or three tower system.
Use an existing drain or the optional flush mount drain as
Illustrated above (See Drain Options).
NOTE: The minimum to maximum ambient temperature that the unit should be installed and operated at is 40 degrees F to 105 degrees F (4.44
C to 40.56 C)
2. Place the tower(s) in the desired location(s). Each
tower must be placed and operated in a horizontal
(level) position.
BASIC B-I-B SYSTEM & PRESSURES
NOTE:
Typical A&W
Blade Tower Rootbeer
Dispensing System (BIB)
This is a simplified schematic to
show the basic operation of the
beverage system.
Blade Tower Valves
Countertop
2
SYRUP
SYRUP
SYRUP
CARBONATED WATER
CARBONATED WATER
BIB
Syrup Pump
3
SYRUP
1800
1
ox
n-B
g-I
Ba yrup
S on
t
r
Ca
90
60
SYRUP
CO2
Multiplex
1. Incoming tap water - should be at a minimum dynamic pressure of 40 psi and maximum static pressure of 80 psi. (measured at inlet to pump).
2. BIB pressure gauge set for 35-40 psi or according to
your line run.
8
CO2
Cylinder
CO2
Tap Water
CO2
SYRUP
3. CO2 supply regulator should be set between 26-30 psi.
NOTE: If incoming water pressure is under 40 psi, a water booster is recommended. If incoming water
pressure is over 80 psi, a water regulating valve
is required.
Installation and Service Manual
INSTALLATION
DRAINAGE OPTIONS
Flush Mount Drain - 020001388
The Blade Tower can be set up to use an existing drain or an optional drain can be ordered for use with the tower.
The illustration below shows the optional flush mount drain setup (Part Number 020001388). If using the optional
flush mount drain be sure to plumb according to local codes.
PLUMBING DIAGRAM LOCATION
A plumbing diagram for the A&W rootbeer system can be found on the remote refrigeration unit or see the
Plumbing Section for the plumbing diagram that fits your installation.
9
Installation and Service Manual
INSTALLATION
SINGLE TOWER PLUMBING
DUAL TOWER PLUMBING
10
Installation and Service Manual
INSTALLATION
TRIPLE TOWER PLUMBING
BRIXING PROCEDURE
NOTE: This tower consists of two valves combined as one with a mixer block, mixer tube and mixer. One Pre-ME
valve (CMBEGKER) and one Flomatic 424 Flow Control Base
Syrup Shut-off
Water Shut-off
Water Flow Rate
Adjustment
Syrup Flow Rate
Adjustment
Set water flow rate first:
1. Turn off syrup shut-off at post-mix (424) valve block.
2. Use stop watch to time the dispense of soda water
only.
3. Dispense for 5 seconds.
4. Record volume in a volume cup or ratio cup.
5. Adjust the water flow rate as needed until 10 ounces
of water is measured in a 5 second (2 oz/sec) dispense.
Set the syrup flow rate:
1. Adjust the ratio (brix) of water to syrup (4.75:1) or 12.3
to 12.7 brix)
2. Turn on syrup shut-off and turn off the water shut-off.
3. Use a stop watch to time the dispense of syrup only.
4. Dispense for 5 seconds.
5. Record volume in a volume cup or ratio cup.
6. Adjust syrup flow rate as needed until 2 ounces of
syrup is measured in a 5 second dispense.
7. Use a refractometer if possible to get final brix ratio of
12.3 to 12.7. You will have to rely on volume adjustment above for diet products.
11
Installation and Service Manual
OPERATION
SYRUP DELIVERY SYSTEM
Your syrup location can vary depending on the volume of beverages served and ease of accessibility. Your beverage system may set in a back storage room or under the counter of the dispenser. Configurations are almost
limitless. Check the temperatures expected for the storage location. Adverse temperatures can affect the storage
and quality of beverage products. It is recommended the temperature of storage location should not fall below 40o
F or rise above 90o F.
BACK ROOM PACKAGE
1. Incoming tap water - should be at a minimum dynamic pressure of 40 psi and maximum static pressure of 55 psi.
2. Carbonator Water pump motor - Powers the water
pump. The water pump motor is part of the carbonator pump deck.
3. Carbonator Water pump - Pumps tap water into the
carbonator tank. The water pump is part of the carbonator. The incoming water for the carbonator must
be first ran through the pump before connecting to
the proper cold plate inlet.
4. Internal/External Carbonator tank - Combines CO2
gas and tap water to form carbonated water. The “carbonator” is the carbonator tank, water pump and water pump motor.
5. CO2 cylinder - Holds highly pressurized carbon dioxide (CO2). The CO2 cylinder is a steel or aluminum
cylinder tank. CO2 gas flows through the primary pressure regulator.
12
6. BIB pressure gauge - Set for a minimum of 60 psi.
Indicates CO2 pressure going to B-I-B pumps.
7. Primary pressure regulator - Lowers the CO2 gas
pressure, to 100 psi, so the CO2 gas will be at the
proper pressure to enter the carbonator regulator.
8. Lowered outgoing pressure - Set for 75 psi. Gauge
indicated lowered outgoing pressure from the CO2 cylinder after being routed through the primary pressure
regulator at 100 psi..
9. Secondary pressure regulator - Lowers the CO2 gas
pressure before the CO2 gas flows to the syrup pump.
CO2 pressure, activates the syrup pump.
10. Syrup pump - Draws syrup out of the bag-in-box
syrup package. Syrup flows through the syrup lines
to the dispenser for chilling, then dispensing. There
is a syrup pump for each bag-in-box syrup system.
11. Bag-In-Box syrup cartons - Box which contains a
plastic bag, filled with syrup.
Installation and Service Manual
OPERATION
RACKING
Regardless if you are working on pre-mix or post-mix (B-I-B or Figal) system, a place will be designated for placement
of the product. A rack (or shelf) system affords systematic placement and complete usage of the beverage paid for. The
B-I-B rack allows the boxes to lay properly for syrup dispersal. Please check with your B-I-B syrup supplier. Some boxes
must be slightly tilted down, while others may be in virtually any position. The Figal tank rack keeps the newer and full
tanks organized at one end of the beverage line with the partial tanks at the other.
B-I-B
The Bag-In-Box system refers to a plastic disposable bag. The B-I-B normally contains 5 gallons of syrup, however
some locations offer 2 1/2 or 3 gallon B-I-B units. This plastic bag is then held inside a cardboard or other container. BI-B systems are for post-mix applications only.
PUMPS
The syrup in a B-I-B system is delivered to the beverage system through gas operated pumps. These pumps extract the
syrup out of the bags forcing the syrup throughout the system.
AUTO BAG SELECTORS
These are used on higher volume B-I-B systems where two or more bags of the same product are connected to one
pump and one system. An auto bag selector is essentially a valve that automatically changes from one bag (or series of
bags) to another bag (or series of bags) of syrup as the bags empty, allowing a constant flow of product.
USER MAINTENANCE
PREVENTATIVE MAINTENANCE
Preventative maintenance is a vital part of keeping your Servend dispenser in top condition. Following the guidelines
below will assist you in continued trouble free operation of your unit. Contact MBE at 1-800-367-4233 for more
information about our ProActive Maintenance Program.
1. Conduct the daily and nightly recommended maintenance of the machine.
2. Perform the monthly recommended maintenance of
the machine.
3. Perform periodic maintenance and sanitizing of beverage system.
5. Do not allow the dispenser to sit for prolonged periods
of non use.
WINTERIZATION
Servend equipment is rated for indoor use only. This
equipment will not operate in sub-freezing temperatures.
In a situation when temperatures drop below freezing
the equipment must be turned off immediately and properly winterized. Contact the manufacturer for winterization processes.
NOTE: The minimum to maximum ambient temperature
that the unit should be installed and operated at is 40 degrees F to 105 degrees F (4.44 C to 40.56 C).
CO2 HANDLING
Breathing high
concentrations of carbon
dioxide gas can cause
tremors, followed by loss
of consciousness and
suffocation
Route CO2 vent tube
outside or to an
CO 2 DISPLACES OXYGEN
All CO2 tanks must be chained and/or affixed to a permanent
post or wall. Changing of or recharging tanks should be
done by a trained individual. Contents of the tanks are
stored at an extreme high pressure and can cause physical
damage if not handled properly.
DANGER: Carbon Dioxide (CO2) displaces oxygen. Exposure to a high concentration of CO2 gas causes tremors,
which are followed rapidly by loss of consciousness and
suffocation. If a CO2 gas leak is suspected, particularly in a
small area, immediately ventilate the area before repairing
the leak. CO2 lines and pumps should not be installed in an
enclosed space. An enclosed space can be a cooler or
small room or closet. This may include convenience stores
with glass door self serve coolers. If you suspect CO2 may
build up in an area, venting of the B-I-B pumps and / or CO2
monitors should be utilized.
13
Installation and Service Manual
USER MAINTENANCE
HOW TO DISASSEMBLE TOWER COMPONENTS
Note: This tower consists of two (2) valves combined as one (1) with a mixer block, mixer tube, and mixer. One
pre-mix valve (CMBECKER) and one (1) Flomatic 424 flow control base.
Tower & Valve Disassembly:
1
1. Remove tower housing cover by removing the
thumb screw on the side.
2. Turn OFF both shut-off valves on the flow control
base and remove pressure by pulling the dispense
handle to the ON position.
Water Shut-off
Syrup Shut-off
3. Remove the latch pin on the mixer block by pulling
straight up.
4. Unscrew the inside flange nut on the pre-mix valve.
Water Flow Rate
Adjustment
Syrup Flow
Rate Adjustment
5. Remove the pre-mix valve and mixer tube out the
front of the tower.
6. Remove the 424 flow control base by lifting up on
its latch pin.
Flow Control
Mixer Block
To reassemble follow these steps in reverse order.
Base Latch Pin
Latch Pin
CLEANING EQUIPMENT AND SUPPLIES
•
•
Recommended cleaner: Any caustic-base (low
sudsing, non-perfumed, easily rinsed) detergent solution which provides a minimum 2% sodium hydroxide. The solution should be prepared in accordance
with the manufacturer's instructions. Solution temperature should be between 90°F (32°C) to 110°F (43°C).
Temperatures in excess of this can cause internal damage to the dispensing valve components.
Recommended sanitizer: Any sanitizer which provided a minimum of 100 parts per million (100 milligrams per liter) of available chlorine. Solution temperature should be between 90°F (32°C) to 110°F
(43°C). Temperatures in excess of this can cause internal damage to the dispensing valve components.
•
•
•
•
•
•
•
Two five gallon (figals) syrup tanks and fittings,
cleaned and sanitized (one for cleaner; one for
sanitizer).
Containers for cleaner and sanitizer solutions
Clean, non-abrasive cloths
Bucket
Small Brush
Extra Nozzles
Extra Jumpers
CLEANING & SANITIZING THE DISPENSING VALVES & PRODUCT LINES
All cleaning must meet your local health department regulations. The following cleaning instructions are
provided as a guide.
CAUTION: Use only warm soapy water to clean the exterior of the dispensing tower. Do not
use solvents or other cleaning agents.
14
Installation and Service Manual
USER MAINTENANCE
MAINTENANCE SCHEDULE
Everyday
Dispensing Valves
For the pre-mix dispensing valve, run carbonated water
ONLY through the valve and dispense nozzle for 10
seconds. Turn syrup shut OFF, and block the dispense
nozzle base with a clean new napkin. Dispense carbonated water only for a few seconds to fully fill the dispense
nozzle. Then unblock the dispense nozzle and flow
carbonated water for 10 seconds. Wipe external nozzle
surfaces with carbonated water, then turn syrup shut off,
ON. Clean other nearby surfaces with carbonated water or
cleaning solution.
Everyday
Drip pan and drain hose
Wash with mild detergent. Rinse with clean water.
Everyday
Quick disconnects
Wash with mild detergent. Rinse with potable water.
Weekly
Outside, dispenser cabinet
Wash with clean water and mild detergent. Wipe dry.
Every 3 months
Syrup circuits
Sanitize each syrup circuit. See ”Cleaning and Sanitizing
Procedure“.
Every 3 months
Water bath
Drain, melt ice and clean using detergent and brush; rinse
with potable water. Do not use water over 140°F (60°C).
Every 6 months
Condenser
Vacuum fins or use soft bristle brush (scrub brush).
Every 6 months
Air purifier filter (if equipped)
Replace.
NIGHTLY SHUTDOWN PROCEDURE
It is recommended that the following steps are followed to keep your Blade Tower clean and running properly;
1
2
Remove tower top piece to gain access to the
valves.
Turn the syrup shut off valve to the OFF position on
all valves (2 valves per tower).
3
4
Dispense carbonated water for 10 seconds from all
valves.
Leave valves off overnight and turn back on in the
morning for use.
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Installation and Service Manual
USER MAINTENANCE
CLEANING AND SANITIZING PROCEDURE
Note:
Cleaning and sanitizing is not required for potable water circuits. Potable water lines should remain connected and operational during the cleaning and sanitizing procedures for syrup circuits.
Caution: It is required that the Carbonated Water Lines should remain connected and operational during cleaning and sanitizing of the syrup circuits. Sanitizing of the valve without the
Carbonated Water side operation may leave bacteria in the nozzle, diffuser, and syrup tube.
CLEANING THE DISPENSING VALVES
1. Disconnect each syrup container from its product line,
tank connector, or bag-in-box connector. Remove
product from the lines by purging with clean warm
tap water until syrup has been fully purged from the
product lines and valves.
2. Clean all lines and fittings with cleaning solution and
rinse with clean, room temperature water to remove
all traces of residual product.
3. For the A&W pre-mix valve, clean dispense nozzle in
place with sanitizing solution and nozzle brush, up to
internal shut off port.
CLEANING THE PRODUCT LINES
1. To clean each valve product line, attach the valve
product lines to the pressure tank containing the
cleaning solution or place the bag-in-box connector
in cleaning solution. Remove branch port cover on
bag-in-box connector to allow suction of cleaning
solution. Make sure each line is completely filled.
Pressurize the lines by pulsing the valves.
Caution: Do not allow cleaning and sanitizing solutions to remain in syrup systems longer than
recommended contact time. Exceeding contact time will result in damage to valve components.
PRESSURIZING THE PRODUCT LINES
1. For 15 seconds turn dispensing valve “on”, “off”,
and then immediately “on” again for 15 cycles.
2. Allow the valve to remain flowing for 3 minutes.
3. Repeat pulsing and flowing the valves again until all
cleaning solution has been used.
4. Flush the cleaning solution from the lines with clean
water after a minimum of 3 minutes, by pulsing the
valves as described above.
5. Attach each valve product line to the pressure tank
containing the sanitizing solution or place the bag-inbox connector in sanitizing solution. Remove branch
port cover on bag-in-box connector to allow suction
of sanitizing solution. Be sure all connections are
cleaned and sanitized before connecting to each product line.
6. Pressurize and fill the lines with sanitizing solution.
Make sure lines are completely filled. Allow the sanitizing solution to flow through each valve while activating the valves for 15 cycles (as described in “Pressurizing the product lines”).
a. Leave valves “off” and allow to stand pressurized for 30 minutes.
b. Activate the valves for two (2) cycles (as described in “Pressurizing the product lines”). Flush
remaining sanitizer continuously through the
valves.
7. Reconnect the syrup containers to their respective
circuits. Prepare the unit for operation.
8. Draw drinks to refill lines and flush the sanitizing
solution from the dispenser. Taste the beverage to
verify that there is no off-taste (chlorine).
BEVERAGE SYSTEM CLEANING
Sanitize the beverage system at initial start-up as well as regularly scheduled cleaning. The drain pan must be in
place under soda valves, to carry away detergent and sanitizing agents that will be flushed through valves.
16
Installation and Service Manual
USER MAINTENANCE
BAG-IN-BOX SYSTEM
The procedure below is for the sanitation of one syrup circuit at a time. Repeat to sanitize additional circuits.
You will need the following items to clean and sanitize
the Bag-in-Box (BIB) beverage system:
•
•
•
•
Three (3) clean buckets
Plastic brush or soft cloth
Mild detergent
Unscented bleach (5% Na CL O) or
Commercial sanitizer
• Bag-In-Box bag connector
1. Prepare the following in the buckets:
• Bucket 1 - warm to hot tap water for rinsing.
• Bucket 2 - mild detergent and warm to hot water.
• Bucket 3 - mix a solution of unscented bleach
(5% Na CL O) or commercial sanitizer and warm
to hot water. Mixture should supply 100 PPM available chlorine (1/4 oz. bleach to 1 gallon water).
2. Disconnect the “syrup-line side” of the bag-in-box
connector.
3. Rinse connector with warm tap water.
4. Connect syrup connector to BIB connector and immerse both into Bucket 1. A “bag-side” connector
can be created by cutting the connector from an
empty disposable syrup bag.
5. Draw rinse water through system until clean water
is dispensed. Most beverage valves allow the syrup
side to be manually activated by depressing the
syrup pallet.
6. Connect Bucket 2 to system.
7. Draw detergent solution through system until solution is dispensed.
8. Repeat steps 2-7 until all syrup circuits contain detergent solution.
9. Allow detergent solution to remain in the system for
5 minutes.
10. Connect Bucket 3 to system.
11. Draw sanitizing solution through system until solution is dispensed.
12. Repeat step 11 until all syrup circuits contain sanitizer solution.
13. Allow sanitizer solution to remain in system for 15
minutes.
14. Remove nozzles and diffusers from beverage
valves.
15. Scrub nozzles, diffusers and all removable valve
parts (except electrical parts) with a plastic brush
or a soft cloth and the detergent solution.
17
Installation and Service Manual
TROUBLESHOOTING
DRINKS
CONDITION
Water only dispensing
Syrup and CO2 only
dispensing
INVESTIGATION
No pressure
Carbonator
CHECK
CORRECTION
Regulator(s) out of
adjustment
Check/adjust regulator(s)
Out of CO2
Install fresh tank
Defective regulator(s)
Check/repair/replace regulator(s)
CO2 line pinched, kinked or
obstructed
Check/repair/replace CO2 line
No power
Check power supply. Plug in
carbonator or reset breaker.
Water supply
Make sure water is turned "on"
Replace water filter
Check/clean/replace pump strainer
Check/clean/repair water check
valve
Check for frozen water line.
Internal Carbonator unit only.
Syrup and plain water
only dispensing
One valve will not
dispense anything
Beverage dispensed
is too sweet
No pressure
Is there power to the
valve?
Is the ratio (brix) of
the drink correct?
Defective carbonator
Check/repair/replace carbonator
pump, motor, electrode or liquid
level control.
Out of CO2
Install fresh tank
HP regulator out of
adjustment
Adjust HP regulator to the proper
setting
Defective HP regulator
Check/repair/replace HP regulator
CO2 line pinched, kinked or
obstructed
Check/repair/replaceCO2 line
Broken wire or loose
connection
Replace/repair wire or connector
Bad microswitch
Replace microswitch
Flow control out of
adjustment
Adjust the flow control
Insufficient soda flow due to Adjust CO2 pressure or change the
low carbonator pressure
tank
Beverage is not sweet
enough
Drinks are foaming
18
Is the ratio (brix) of
the drink correct?
Are system
pressures correct?
Low CO2 pressure due to
leaks
Repair CO2 leaks
Obstruction in the water or
soda line
Clean out the lines
Flow control out of
adjustment
Adjust the flow control
Soda flow too high
Reset CO2 pressure or replace
regulator if necessary
Obstruction in syrup line
Clean out the syrup line
Over carbonation
Check CO2 supply. Reset
pressure or replace regulator if
necessary
Dirty lines/valves
Clean/sanitize entire system
Installation and Service Manual
TROUBLESHOOTING
CONDITION
INVESTIGATION
CHECK
CORRECTION
Water Only Dispensing
No Pressure
BNB Fittings Clogged
Clean and Sanitize
Tank Fittings Clogged
Clean and Sanitize
No Power
Check Power Supply
Check Liquid Level
Replace Control
Syrup and CO2 only
Carbonator
Dispensing
Control Board
One Valve will not
Pre-Mix Valve
dispense anything
(CMBecker)
Post-Mix Valve
For Clogging
Clean and Sanitize
For Mechanical
Replace if Necessary
For Clogging
Clean and Sanitize
For Mechanical
Replace parts or entire
(Flomatic 424)
valve if necessary
Beverage Dispense is
too sweet
Drinks are Foaming
Are system
Syrup Push Pressure
Adjust to 30-40 PSI per
Tower Manual. Lower
pressures correct
equals less foaming.
Too low will limit flow
volume.
Drink Stratification
Visually verify Soda
Check Valves in Water
too great
Water and Syrup flowing
and Product Lines.
at the same time in
If soda water check
mixer block, when
valve is bad, Syrup will
initially dispensing
overcome soda water
Replace check valve(s)
when first dispensing
product. If syrup check
valve is bad, soda water
will overcome syrup flow
when first dispensing
product
19
Manitowoc Beverage Equipment
2100 Future Drive Š Sellersburg, IN 47172-1868
Tel: 812.246.7000, 800.367.4233 Š Fax: 812.246.9922
www.manitowocbeverage.com
In accordance with our policy of continuous product development and
improvement, this information is subject to change at any time without notice.
020001448 April 01, 2008 REV0
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