Product Manual Viscount IV series of carbonators and chillers Part Number 3B3075 Issue 01 [16-04-07]
Contents Section Page Section Page Introduction 2 Safety 2 Description 2 Schematics 4 Fault Finding 12 Replacement of Parts 15 Removal, Transportation and Disposal 16 Installation & Commissioning 7 Cleaning 8 Daily Clean 8 Deep Clean 9 General Clean 9 Sanitisation 10 Introduction Safety The unit should be isolated from the electricity supply before removal of the covers. Great care must be employed when working with high pressure CO2, and in no cases should the normal operating pressure of 2.4 bar (35 psi) be exceeded. Description The Viscount IV series is a range of chillers providing either still only or still and carbonated water outputs, and can include up to 2 syrups, which are generally cooled on carbonator models and at ambient temperature on still only models. The units all incorporate an ice bath to provide the capacity for extended drinks performance, and share the same fridge, bath and control components. The schematics from Page 4 onwards show the individual circuits for water, carbon dioxide and syrup. Page 2
Introduction Description continued On carbonator models, carbonated water is generated in the carbonator can and is dispensed via a solenoid valve, flow adjuster and the dispense harness, under the pressure generated within the can. The can is replenished by a water pump which is controlled by the PCB and a level probe within the can. For a still drink, water passes through the pressure regulator, used to set the flow rate, through the pump which is not energised for still water dispense. It then is passed through the stainless steel water coil in the ice bath to the dispense harness via a solenoid valve. Both still and carbonated water are dispensed from the same tube within the dispense harness. If fitted, syrups are chilled via stainless steel coils in the ice bath, and dispensed via individual syrup pumps. The still only models do not include a water pump, the flow rate being controlled by a proprietary flow regulator. Water is chilled via the same water coil within the ice bath as the carbonators, but is dispensed directly via the dispense harness. No syrup cooling is provided on the still only models, the syrup merely being dispensed via the syrup pumps. Viscount IV carbonator models are controlled by the Booth CLIP2 PCB which provides the following features. Water pump timeout - interrupts the water pump supply after 55 seconds continuous operation Electronic ice probe control - replaces the conventional thermostat used on earlier models Fridge hi-side protection - interrupts the compressor supply if the operating temperature rises above its limit Fridge overrun protection - interrupts the compressor supply if the output is detected as being on for 10 hours continuous Refer to the Fault Finding section on Page 12 for further information. Page 3
Schematics Water Circuit Schematic - Carbonator Water Inlet Inlet Pressure Regulator Water Pump Water Coil Immersed in Ice Bath Double Back Check Valve Still Water Dispense Solenoid Dispense Harness Carb Flow Control Carbonated Water Dispense Solenoid Pressure Relief Valve Dip Tube Carbonator Can Water Circuit Schematic - Chiller Water Inlet Flow Regulator Water Coil Immersed in Ice Bath Dispense Harness CO 2 Circuit Schematic Syrup Circuit Schematic Supply from Bottle CO2 Pressure Regulator CO2 Non Return Valve Supply from Syrup Container to Inlet Syrup Pump Dispense Harness Carbonator Can Syrup Coil Immersed in Water Bath (Carbonators Only) Page 4
Schematics Blank Page Page 5
Schematics Water Pump Compressor Condenser Fan GN/YE Agitator Motor GN/YE WH/BK Flush Switch WH/BK YE YE WH/OG GN/YE WH/BK GN/YE YE WH/RD BK HI Side Sense BK RD BK LED 1 2 2 3 4 2 3 4 5 6 7 8 9 J3 J7 J1 J9 K2 Inlet K3 K4 T1 Valve Relay Water Fridge Pump Comp. Transformer Relay Relay F2 5 amp J2 13121110 9 8 7 6 5 3 1 F1 5 amp BN BU BN BU BU WH WH Main Earth BU BN BU GN/YE WH/RD VT YE WH/OG Ice Probe Carb Can Water Bath Still Still 2 Carb Carb 2 Syrup 1 Syrup 2 RD RD RD RD RD RD 12-Way Molex Fuse 1A RD GN 10 12 11 1 10 12 11 1 SWITCHED 0V DC TO INLET VALVE 0V DC SUPPLY +24V DC SUPPLY 0V DC STILL WATER YE/GN 6 6 0V DC STILL WATER-AQUA VT 2 2 OV DC CARB WATER YE/VT 3 3 0V DC CARB WATER-AQUA YE/BU 4 4 0V DC SYRUP1 YE/RD 5 5 0V DC SYRUP2 Note: Syrup 1 and Syrup 2 - VIS402 and VIS419 only Still 2 and Carb 2 - VIS419 only BN BU GN/YE Carbonator Electrical Schematic - VIS Series 1 1 Page 6
Installation & Commissioning Installation 1. Secure the unit through top fixing holes to the host machine. 2. Connect the water inlet at the point in the top, left rear of the chiller. 3. If syrup pumps are fitted: Insert the syrup dip tubes into the syrup containers. 4. Place the overflow pipe into suitable container. 5. Connect the dispense harness to the dispense nozzle on the host machine. 6. Make all electrical connections between the chiller and the host machine. Commissioning 1. Remove the plastic cover on the combined bath fill and overflow, fill the bath with cold water until it overflows from the outlet. 2. Carbonator Only: Ensure the gas bottle regulator is set to 2.4 bar (35 psi) and connect the braided CO2 pipe to it. 3. Ensure there is a water supply available to the unit, and that any isolating valves are open. 4. Turn on mains electrical supply to unit by overriding the door interlock on the host machine (refer to the host machine instructions for this procedure). 5. With mains power and water on the following will happen. The agitator will start to turn. The compressor and fan will start. Carbonator Only: The water pump will start and fill the carbonator can. 6. After approximately 10 seconds, press and hold the flush switch. Carbonated water will be dispensed until the carbonator can is emptied. Allow the can to vent for at least 5 seconds to allow any air to be purged from the system. Then release the flush switch. The pump will then switch on and fill the carbonator can. 7. If Syrup pumps are fitted: Prime the syrup pumps using the method recommended in the instructions for the host machine. 8. If Syrup pumps are fitted: Set the syrup flow rates, refer to the host machine instructions. Important: Correct carbonation will not occur until ice has started to form in the bath and the water temperature has fallen below 5 C. Note: If the bath has been filled to the point of overflow, approximately half a litre of water will be displaced as ice forms in the bath. 9. Test both still and carbonated drinks for correct operation. Page 7
Cleaning Important: The frequency of the following cleaning procedures should be determined locally and may vary depending on machine usage and environmental conditions. Warm water should be no higher than 45 C. After any cleaning procedure, dispense 3 drinks from each selection to ensure all cleaning fluid residue is flushed out. Routine Clean - Use the appropriate methods below for parts in contact with food products. Important: It is recommended that the routine clean procedure be performed at least weekly. Multi Purpose Disposable Cloth Use the cloth to apply the cleaning agent. Submerge a clean cloth into the cleaning agent (concentration recommended by manufacturer s instructions). Remove the cloth and remove excess water. Clean the dispense components wiping the cloth over the entire area re-submerging the cloth as necessary. Rinse the cloth in clean warm water and wipe off excess cleaning agent residue and soil. Dry using disposable paper towels, replace dispense components. Spraying on Cleaning Agent Remove the dispense nozzles from the dispense bush. Liberally spray the cleaning agent at the concentration recommended by the manufacturer onto the dispense components ensuring that the whole area has been covered. Finish the clean by exchanging the cleaning agent for warm water, remove the soil with a multi purpose disposable cleaning cloth and dry the components with disposable paper towels. Food Grade Antibacterial Wipe Remove the dispense nozzles from the dispense bush, wipe the dispense components with the food grade antibacterial wipe, remove all visible soil. Replace dispense components. Soaking Post Mix Dispense Nozzle Remove the dispense nozzles from the dispense bush and submerge the dispense components into the cleaning agent solution. Leave the dispense components submerged for the desired contact time (2 to 10 minutes). After the contact time is over remove the dispense components, rinse in warm water and dry using disposable paper towels. If not removable, clean using cleaning agent solution and brush. Page 8
Cleaning Deep Clean - Parts in contact with food products Important: It is recommended that the deep clean procedure be performed at least monthly. Remove dispense components, pre clean using a damp multi purpose disposable cleaning cloth soaked in warm water. Soak cloth in cleaning agent solution, remove excess water and clean dispense components. Using a brush, brush dispense head to dislodge any dried on soil. Remove soil with the cloth. Rinse dispense head with a new multi purpose disposable cleaning cloth soaked in warm water until all soil and cleaning agent residues have been removed. Soak multi purpose disposable cleaning cloth in disinfectant solution, apply to dispense component, ensure that the whole area is wiped. Leave for 10 minutes. Rinse off disinfectant using multi purpose disposable cleaning cloth that has been soaked in clean warm water. Dry dispense component with disposable paper towels. Refit all dispense components. General Cleaning - Parts not in contact with food products Important: It is recommended that the procedure should be performed at least every 6 months. Condenser. At regular intervals, determined by local environmental conditions, the condenser should be thoroughly cleaned with a small stiff brush and/or a vacuum cleaner. Do not use screwdrivers or other sharp implements which may puncture the fins. Warning: Failure to clean the condenser can shorten the life of the compressor causing premature failure of the unit. Outer Panels. Clean the outside panels, pay particular attention to the edges of the panels where spillage from ingredients could have ingressed and the area around the base of the unit. If necessary, remove the unit and thoroughly clean around the base and floor. Important: If ingredients are present inside the unit, the cause must be found and rectified. Page 9
Cleaning Sanitisation Important: It is recommended that the procedure is performed at least every 6 months. Prepare the Unit 1. Purge the carbonator can by operating the flush switch until the carbonator is empty and CO2 is dispensed for 5 seconds. Disconnect electrical power before the carbonator can refills. 2. Remove the top & front panels. 3. Ensure that the waste bucket is in place. 4. Lift syrup dip tubes above liquid level in product container & prime the pumps to empty the lines, then place in a container of clean water and prime through to dispense nozzle then lift out of water & continue until empty. 5. Carefully follow the manufacturer s instructions and prepare a solution of proprietary sanitising fluid such as DIVERSAL BX4A. A clean 5-litre syrup container is ideal for this operation. 6. The water bath should not need cleaning. In the unlikely event it does require cleaning, refer to Cleaning the Ice Bath on Page 11. Sanitise the Water System 7. Where a filter is fitted remove the cartridge, put sanitiser into the chamber and flush through. Where a complete filter is fitted, dummy filters are available for this purpose. or alternatively 8. Disconnect flexible water inlet tube from the water supply and place the end into a container of sanitising fluid. If the unit being sanitised does not incorporate a water pump, flushing through of sanitising solution can be achieved either using a pressurised container, or by using a siphon. I the latter case, the sanitiser fluid needs to be held at a height sufficient to allow fluid to flow through the chiller. 9. Switch on power & allow the water pump to begin refilling the carbonator. 10. Draw 1 cup of carbonated water followed by 1 cup of still water to ensure all tubes are full of sanitiser. 11. Switch off power & leave to stand for period recommended by sanitiser manufacturer. 12. Follow Routine Clean procedure to clean dispense nozzles. Page 10
Cleaning Sanitise the Syrup Lines 13. Switch on the main power. 14. Place dip tubes into the container of sanitising fluid & operate the syrup priming switches until the fluid pours from the dispense nozzle. 15. Switch off power and leave to stand for the period recommended by the sanitiser manufacturer. Recommission the Unit 16. Switch on power supply. 17. Place syrup dip tubes into a 5-litre container of clean cold water and flush 1 litre through each syrup line. 18. Reconnect inlet water supply tube to machine supply & dispense 3 litres of still water. 19. Dispense 3 litres of carbonated water. 20. Re-connect syrup tubes to the appropriate syrup containers and refit all covers. 21. Prime waters and syrups through to dispense nozzle & check drink strength with a brix cup. 22. Close vending machine door & test vend all cold drinks. Cleaning the Ice Bath. (If required) 23. Drain the bath by siphoning off the water into a suitable container. Ensure all ice is melted and drained off using warm water (Max 45 C) if necessary. 24. Fill the water bath with sanitiser solution until the solution starts to spill from the bath overflow. 25. Switch off power & leave to stand for period recommended by sanitiser manufacturer. 26. Siphon off water bath and refill with cold water. Important: The ice bath should be siphoned off and refilled a second time as any sanitiser fluid left in the bath could cause the unit to freeze up due to the use of ice probes for control purposes. Page 11
Fault Finding Prior to any fault finding, please ensure all water connections to the chiller are sound and that the incoming water supply is turned on. Also ensure that all electrical connections to the chiller are secure and that any syrup containers are not empty and the syrup pumps are primed, and that the chiller has had adequate time to build ice in the ice bath. A status LED is located on the top rear panel and indications are: Status LED Normal operation OFF Water pump timeout ON 1 second - OFF 2 second Compressor high-side protect ON (constant) Compressor timeout ON 2 seconds - OFF 1 second Timeout and protection events can be reset by cycling mains power off then on. The cause of the event should be investigated and corrected. Symptom Possible Cause Corrective Action No Still Water Still water dispense valve not opening Check supply to valve (24V DC) If voltage present, replace valve If voltage not present, check 1 Amp in-line chiller fuse If fuse OK and voltage not present, check host machine output PCB Inlet valve not opening Check J3 connector on PCB (signal to the host machine PCB) Check host machine output PCB Water pressure regulator failed Ice bath frozen up Replace regulator assembly Check ice probe for possible shortcircuit to ground Check for ice bath contamination, melt ice, drain bath and refill. If contaminated,identify & rectify source of contamination PCB failed - replace Page 12
Fault Finding Symptom Possible Cause Corrective Action No No CO2 pressure, check Check CO2 bottle, regulator and non- Carbonated by operating pressure return valve. Supply pressure should Water relief valve on carbonator be 2.4 bar (35 psi), adjust or replace as can necessary Carbonated water dispense Check supply to valve (24V DC) valve not opening If voltage present, replace valve If voltage not present, check 1 Amp inline chiller fuse If fuse OK and voltage not present, check host machine output PCB Carbonator can not filling Check carbonator probe for possible short circuit to ground Check LED for pump timeout indication (1sec ON, 2sec OFF), if timed out, cycle power off & on then purge carbonator Check supply to water pump (230V AC), if voltage present & pump inoperative - replace pump If voltage not present & pump is not timed out, replace PCB No Syrup Syrup pump inoperative Check supply to pump (24V DC) If voltage present, replace pump If voltage not present, check 1 Amp inline chiller fuse If fuse OK and voltage not present, check host machine output PCB Page 13
Fault Finding Symptom Possible Cause Corrective Action Poor quality Incorrect CO2 pressure Check CO2 bottle, regulator and carbonation non-return valve. Supply pressure should be 2.4 bar (35 psi) Air in carbonator can Residue in carbonator can Purge the carbonator can by operating the flush switch until empty and CO2 is dispensed for 5 seconds After prolonged use, a surface film can develop within the carbonator can preventing good carbonation. This can be removed by flushing the system using a solution of citric acid, refer to cleaning and sanitising instructions Carbonator can is overfilled If pump runs continuously, check connections to can level probe If problem persists, replace the PCB Warm Drinks Insufficient water in the Fill the bath until water overflows from bath preventing the ice the outlet probe from switching on the compressor Insufficient cooling air flow through the fridge Control failure Check that the condenser is not blocked by debris Check that the fan is running, if not and the supply is present (230V AC), replace fan Check if compressor and fan are running, if not, check the supply is present (230V AC) If voltage not present, check PCB connections If connections secure, replace PCB Fridge failure If compressor & fan are running and there is no cooling, replace the chiller Page 14
Replacement of Parts Important : If any water or syrup carrying components are replaced, the sanitisation procedure from page 10 should be carried out. Item No Description Part No 1 24V DC Dispense Valve VA11911000 Note: This valve is not suitable for use on VIS202, 203, 204 and 205 models 2 Water Pump Assy ME10857000 3 Syrup Pump Assy ME11912000 4 Syrup Pump Tube Kit ME11913000 5 Recirc Pump/Agitator (VIS419 only) ME11343000 6 Agitator Assy ME07238000 7 Water Pressure Regulator ME03072000 8 Condenser Fan ME03278000 9 CO2 Non-return Valve ME11914000 10 CLIP2 PCB EL11915000 Spare parts are available from the host machine manufacturer 1 2 3 5 4 8 10 6 7 9 Page 15
Removal, Transportation & Disposal Important: Ensure the unit can be transported safely and in a hygienic manner without leaving ingredients residue at the customer s premises and the vehicle used. To Remove from Host Machine 1. If fitted, place syrup dip tubes into a container of clean water and prime through until the water is coming from the nozzle. Whilst still priming, lift the dip tubes above the level of the water until all tubes are empty. 2. Siphon all water from the Ice Bath. 3. Disconnect water supply, CO2 supply, and all electrical connections. End of Life Disposal It is illegal to simply scrap a refrigeration system. Before a fridge can be scrapped it must first have the gas removed by a specialist using specialist equipment. Please contact Booth Dispensers for further information and a quotation for disposal. Transportation Important: This unit must be transported in an upright position As with all refrigeration systems, irreparable damage can be caused by laying the unit on its side or even transporting it upside down. Where the unit is transported by a 3 rd party agent, the packaging should always be marked in a conspicuous manner, indicating the correct upright position in which it must be handled. If a unit has been transported incorrectly it should be placed in the correct upright position and left for 24 hours before attempting to run the system. Failure to observe the above precautions could seriously damage the system. Page 16