Cornelius Post Mix Valves Ufb 1 Users Manual TD863 UF Training
UF-1 to the manual f5e79301-60f4-4233-9574-7b31680343a5
2015-02-05
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UF-1 AND UFB-1 VALVES TRAINING MANUAL CARBON DIOXIDE WATER SYRUP/CONCENTRATE MECHANICAL REFRIGERATION CONTROLS & ELECTRICAL Blank Page UF-1 and UFB-1 Valves Training Manual UF-1 and UFB-1 VALVES TRAINING MANUAL The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being meet, in addition to the information contained in this manual. To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact: IMI Cornelius Inc. Internet: www.cornelius.com Email: tech.service@cornelius.com Trademarks and copyrights: Aurora, Cornelius, Decade, Hydro Boost, Optifill, Sitco, Spirit, UF-1, Vanguard, Venture, and Vista are registered trademarks of IMI Cornelius Inc. This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius. Printed in U.S.A. Copyright © 1999-2005, All Rights Reserved, IMI Cornelius Inc. © 1999-2005, IMI Cornelius, Inc. - -3 - UF-1 Valves Manual NOTES: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Preview Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Key Things To Know / Do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Dimensions & Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SYSTEM DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Adjusting Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Calculating Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Syrup/Concentrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Setting Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mechanical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 UF-1 Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Mounting Block Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Controls and Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 UF-1 Portion Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Portion Control Valve Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 UF-1 OptifillTM Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 OptifillTM Valve Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Requirements Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Installation & Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 UF-1 Valve Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Retrofitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Mounting Block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Preventative Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Cleaning Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 © 1999-2005, IMI Cornelius, Inc. - -1 - TABLE OF CONTENTS UF-1 and UFB-1 Valves Training Manual TABLE OF CONTENTS UF-1 and UFB-1 Valves Training Manual ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 REVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 -0- © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual INTRODUCTION 1. PREVIEW QUESTIONS Check your current knowledge by taking a few minutes to answer the following questions: 1. What are the flow capacities of a UF-1 valve? _____________________________________ 2. What are the flow capacities of a UFB-1 valve? ____________________________________ __________________________________________________________________________ 3. Which syrup has the greatest pressure drop, diet or sugar?____________________________ __________________________________________________________________________ 4. How do juice valves differ from carbonated beverage valves? _________________________ __________________________________________________________________________ 5. Can you program “top-off” on a portion control valve? ______________________________ __________________________________________________________________________ 6. What components must be replaced when retrofitting SF-1 to UF-1 valves? ______________ __________________________________________________________________________ 2. KEY THINGS TO KNOW / DO • For quality drinks — keep the nozzles and the water/syrup system clean; and have the correct ratio, temperature, and carbonation! • Set the water/syrup ratio accurately — and leave it alone! • To set the ratio accurately, set the water flow first, then the syrup! • Be sure to cool below 40°F the syrup and water before setting the ratio. © 1999-2005, IMI Cornelius, Inc. -1- INTRODUCTION __________________________________________________________________________ UF-1 and UFB-1 Valves Training Manual 3. OVERVIEW 3.1 Product Description The UF-1 and UFB-1 valve provides accurate flow capability and dependability. The UF-1 and UFB-1 valves are capable of flow rates of 1 ½ to 3 ounces per second (high flow), 2 to 4 ounces per second (UFB-1), or 3 to 4 ½ ounces per second (ultra flow). The valve flow control modules are the only parts that differ in the three versions. INTRODUCTION Note: The flow rate is also dependent on the capacity of the dispensing, cooling, and carbonation systems. An ultra flow capacity valve will not make up for a slow system flow rate or inadequate supplies of cooled water and syrup. The following is a list of Cornelius units and the valve flow rates they support: Fast Flow 1.5 to 3.0 oz./sec. Vanguard Value Line 2323 (10 circuit cold plate) Venture Vantage 1522 1722 2224 2230-100 DB 90 DB 150 DB 200 DB 250 DB 275 TJ 45 TJ 90 TJ 150 TJ 200 TJ 250 TJ 300 TJ 400 -2- Fast Flow, UFB-1, or Ultra Flow 2 to 4 oz./sec. or 3.0 to 4.5 oz./sec. Vanguard 245 Premium 2323 (12 circuit cold plate) 2230 3030 ED 150 ED 200 ED 250 ED 300 DF 150 DF 200 DF 250 © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual There are four varieties of UF-1 and UFB-1 valves: • The cup activated valve dispenses by means of a lever engaged by the cup. • A push button valve has a press and hold button on the front cover of the valve. • • The OptifillTM valve dispenses with an activation lever but stops after the liquid fills the cup and touches the lever A portion control valve has four programmable drink size buttons that provide timed deliveries, top off, and a manual dispensing button. Push Button Valve INTRODUCTION Cup Activated Valve OptifillTM Valve Portion Control Valve The UF-1 and UFB-1 valves are the same as described above with minor differences for juice applications. In the UF-1 and UFB-1 valve concentrate enters the nozzle assembly higher providing a better mix of concentrate and water in the cup. In addition, the orifices for concentrate are larger to avoid clogging. The concentrate diffuser is gray allowing for easy identification. Note: The beverage (syrup) diffuser must be installed in order to use a diversion tube to ratio the concentrate valve. Note: Concentrate valves have only one hole in their sleeve and are only offered in fast flow capacities of 1.5 to 3.0 oz./sec. Syrup outlet Black diffuser © 1999-2005, IMI Cornelius, Inc. Concentrate outlet (better mixing) Gray diffuser -3- UF-1 and UFB-1 Valves Training Manual Concentrate valve sleeve has only one hole INTRODUCTION A side water lever kit can be added to a valve allowing for dispensing of water without syrup or concentrate. The side water lever can be added to either a carbonated drink valve or a noncarbonated drink valve. Syrup valve sleeve has six holes Mounting screw Water lever Post-mix valves control: • the ON–OFF of syrup and water, • the flow rates of syrup and water, • the mixing of the two ingredients as they pour into the cup, and • in some instances - dispensed portion. 3.2 Dimensions & Capacities Fast Flow - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 ½ to 3 oz./sec. UFB-1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 to 4 oz./sec. Ultra Flow - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 to 4 ½ oz./sec. Operational temperature range:- - - - - - - - - - - - - - 10°C (50°F) to 43°C (110° F) Voltage requirements: - - - - - - - - - - - - - - - - - - - - 22 to 27 VAC (50/60 Hz) Transformer (electronic valves) - - - - - - - - - - - - - - - - - - - - - - 80 VA min. Operating Pressure (flowing)- - - - - - - - - - - - - - - - - - - - syrup = 20 psi min. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - water = 35 psi min. Concentrates and juices that contain particulates must be dispensed from a juice valve. A slanted drip tray is necessary when using an OptifillTM valve. -4- © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual SYSTEM DETAILS 1. WATER 1.1 Water Quality Water quality issues have an affect on dispensing valves. Chloramine, a combination of chlorine and ammonia is responsible for some degradation of rubber components. Chloramine is used in many U. S. water supplies. Its affects can be minimized by installing and maintaining a water filtration system. Ultra pure water affects the sensitivity of the Optifill™ valve. Because ultra pure water has less mineral content, it reduces the conductivity of the water keeping the circuit open and overfilling the beverage container. 1.2 Water Flow The size of the orifice in the piston varies depending on whether the piston is used for syrup or water, and whether it is high flow or ultra flow valve. Notch in piston In operation the liquid flows through the knife–edged orifice in the bottom of the piston and then out the orifices in the sleeve. The outlet orifice size in the sleeve is regulated by the position of the piston. In the illustration, the piston is restricting approximately 1/2 of the outlet orifices. UFB-1 Flow Module Orifice Sleeve Piston © 1999-2005, IMI Cornelius, Inc. -5- SYSTEM DETAILS Note: The notched water piston on the Ultra Flow and UFB-1 valve. results in at least one orifice in the sleeve always open. This eliminates pulsating and smooths water flow at higher flow rates. UF-1 and UFB-1 Valves Training Manual Lower Fluid Pressure BUT Higher Fluid Pressure BUT Same Volume Of Syrup/Water Flows From Orifices Knife edge Syrup/Water Flow Lower Fluid Pressure Pushing Against Piston & Spring Higher Fluid Pressure Pushing Against Piston & Spring The position of the piston inside the sleeve is determined by the upward pressure of the liquid against the base of the piston and the downward pressure of the spring inside the piston (not shown here). The pressure of the spring is regulated by the adjusting screw. SYSTEM DETAILS If the pressure of the liquid increases, the flow rate through the knife–edged orifice will increase. The piston is moved upward closing off more of the outlet orifices. The same flow rate is thereby maintained. 1.3 Adjusting Flow Rates Flow rates of the water and syrup are adjusted based on the desired ratio. For example: if the desired ratio is 5:1, then the flow rate of the water is 5 times that of the syrup. If the desired finished drink total flow rate is 3.0 ounces per second, then the water flow rate is 2.5 oz./sec and the syrup flow rate is 0.5 oz./sec. (The water at 2.5 oz./sec is five times the 0.5 oz./sec syrup flow rate.) -6- © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual Note: Always adjust water within its range. Water Flow Rates At Selected Ratios Water To Syrup Water at 1.5 oz./ Water at 3.0 oz./ Water at 3.75 oz./ Water at 4.5 oz./ Ratio sec. Total Flow sec. Total Flow sec. Total Flow sec. Total Flow 2 to 1 1.00 oz./sec. 2.00 oz./sec. 2.50 oz./sec. 3.00 oz./sec. 3 to 1 1.13 oz./sec. 2.25 oz./sec. 2.81 oz./sec. 3.38 oz./sec. 4 to 1 1.20 oz./sec. 2.40 oz./sec. 3.00 oz./sec. 3.60 oz./sec. 5 to 1 6 to 1 7 to 1 1.25 oz./sec. 1.29 oz./sec. 1.31 oz./sec. 2.50 oz./sec. 2.57 oz./sec. 2.63 oz./sec. 3.13 oz./sec. 3.21 oz./sec. 3.28 oz./sec. 3.75 oz./sec. 3.86 oz./sec. 3.94 oz./sec. 1.4 Calculating Flow Rates The most frequent ratio is 5:1. The charts above list the breakdown for many ratios and flow rates. It is useful to be able to calculate flow rates when a chart is not available. An example of calculating the water and syrup flow rates given the finished drink flow rate and the water to syrup ratio: SYSTEM DETAILS Given: 1. Finished Drink Flow Rate = 3.0 oz./sec. 2. Water to Syrup Ratio = 5 to 1 To calculate Water Flow Rate: 1. Calculate the Total Portions = Water Portion + Syrup Portion (example 5 + 1 = 6) 2. Calculate Syrup Flow Rate = Finished Drink Flow Rate ÷ Total Portions (example 3.0 oz./sec ÷ 6 = .5 oz./sec) 3. Calculate Water Flow Rate = Finished Drink Flow Rate – Syrup Flow Rate (example 3.0 oz./sec - .5 oz./sec = 2.5 oz./sec) Prove the calculation is correct by adding water flow rate of 2.5 oz./sec + syrup flow rate of .5 oz./sec = finished drink flow rate of 3.0 oz./sec. Water flowing at 2.5 oz./sec and syrup flowing at .5 oz./sec achieves a ratio of 5:1 and 3.0 oz./sec. flow rate. © 1999-2005, IMI Cornelius, Inc. -7- UF-1 and UFB-1 Valves Training Manual 2. SYRUP/CONCENTRATE Syrup should always be precooled before setting the ratio. Syrup takes a path through the valve parallel to the water path. It is introduced in the block, travels through a syrup flow control, banjo, valve head and out the nozzle. Note, concentrate is not cooled. High sugar syrups are more viscous (thicker) than diet syrups and consequently have more pressure drop within a system. This pressure drop results in less flow at the valve and therefore a slower fill time. Increasing the pump pressure will help overcome the pressure drop caused by high sugar syrups. 3. SETTING RATIOS If the ratio varies and must be adjusted often, it is probably the result of a restricted syrup system. It is then time to clean and sanitize the syrup tubing and cooling coils and check for other problems such as syrup pumps, etc. Note: Try raising the pressure on the pump before cleaning. SYSTEM DETAILS Set the water flow rate first, then adjust the syrup to the desired ratio. This gives the most accurate valve flow setting possible. Measure the ratio and adjust the syrup flow, if necessary. This will result in uniform flow, better carbonation retention, and improved drink quality. When using a ratio cup always take these precautions to ensure accuracy: • After installing the separator tube, open the valve to fill the syrup tube before starting the ratio test. • Clean the cup thoroughly between tests so there is no carry–over from one test to the next. • Fill the cup to approximately 3/4 full and use approximately the same quantity for each test to ensure accurate settings. • Take another sample to verify the settings. -8- Ratio Cups Syrup Separator © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual 4. MECHANICAL 4.1 UF-1 and UFB-1 Valve Disassembly 1. Sequence for disassembly (refer to UF-1 Post-mix Dispensing Valve Illustrated Parts List) is as follows: 2. Remove front cover by lifting. SYSTEM DETAILS 3. Remove valve cover. Wiring Harness 4. Unplug wiring harness. © 1999-2005, IMI Cornelius, Inc. -9- UF-1 and UFB-1 Valves Training Manual 5. Remove valve from mounting block by pushing locking tab to left and push down on top plate of block. . Locking tab Locking tab Mounting screw 6. Remove water screw and lever (if it is installed on the valve). Water lever 7. Remove nozzle – turn left ¼ turn. SYSTEM DETAILS 8. Remove diffuser assembly. Note: The diffuser must be cleaned daily. Do not use bleach, do not use detergent, do not put in dishwasher. Use lukewarm water or soak in carbonated water. 9. Remove bottom plate by disengaging side tabs. Tabs Retainer wire 10. Remove U-shaped retainer wire from back of valve. 11. Grasp flow control module assembly and pull up. Note: O-rings on bottom of inlets and outlets. O-rings - 10 - © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual 12. Note that the flow rate (1 ½ - 3, 3 – 4 ½ or 1 ½ - 3 juice) and date code are printed on the retainer plate. Flow rate & date code 13. To disassemble the flow control: Remove screws and pull retainer forward. Remove top flow control subassemblies exposing flow controls. Note the difference between high flow and ultra flow valves. Concentrate valve sleeve has one hole Note: Top Flow control is an assembly and cannot be dissasembled. Ultra Flow notched piston for water Syrup valve sleeve has six holes Solenoid plunger Pry here Solenoid cover Spring 15. Carefully remove banjo lever springs. © 1999-2005, IMI Cornelius, Inc. - 11 - SYSTEM DETAILS 14. Pop off solenoid cover. Remove solenoid assembly from valve body by prying with screwdriver. Note: Check plunger for corrosion and dirt – replace as necessary. UF-1 and UFB-1 Valves Training Manual 16. Then remove 5 screws that secure the valve head to the valve body. Pry here 17. To remove the dispensing lever return spring pry the end of the spring and pull up. This spring stops the lever from vibrating. 4.2 Mounting Block Disassembly To disassemble mounting block: 1. Turn off water and syrup supplies. SYSTEM DETAILS 2. Remove 2 screws from top plate and pull spools out from the bottom of the mounting plate exposing spools and O-rings. Note: When replacing mounting block use replacement O-rings for the inlet fittings. O-rings Block closed (up) 3. When installing a new block, make sure it is locked in the open position.. Block open (down & locked) - 12 - © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual 5. CONTROLS AND ELECTRICAL All UF-1 and UFB-1 valves have a 24 volt solenoid that should be powered by an 80 kVA rated transformer. Voltage at the coil with the solenoid energized should be 22 and 27 VAC. 5.1 UF-1 and UFB-1 Portion Control Valve The UF-1 and UFB-1 Portion Control Valves are push and release that dispense for a programmed duration. There are four settings: small, medium, large, and extra-large. There is also a Cancel/Pour rectangular button with red and green arrows. If this button is pressed during dispensing, the flow stops. If the valve is not dispensing and the button is pressed, the valve dispenses as long as the button is held. The portion controls are factory programmed to the following default settings: Portion Size S M L XL Pour Time 2 sec. 3 sec. 4 sec. 6 sec. To set the amount of beverage dispensed, follow this procedure: 1. Press the hidden program switch until the PGM light turns on. (This light shows only when the programming mode is turned on.) 2. Put desired amount of ice in cup. Press and hold a portion button until the desired level in the appropriate sized cup is reached. Release the button. 3. Continue with other portion buttons that need programming. Portion buttons may be reprogrammed as many times as necessary. Only the last time values entered for each button will be saved when exiting the programming mode. 4. Press the program switch until the PGM light turns off. PGM lights (not visible unless in programming mode) Program switch (hidden) © 1999-2005, IMI Cornelius, Inc. - 13 - SYSTEM DETAILS Portion Control Valve Programming UF-1 and UFB-1 Valves Training Manual NOTE: The portion control valve does not have a top-off function. NOTE: When in programming mode, press and release any of the portion size buttons to return to the factory portion settings. NOTE: Portion controls will not operate below 22 volts. This is known as the “brown-out feature”. 5.2 UF-1 and UFB-1 OptifillTM Valve The OptifillTM Valve is activated by pressing a cup against the dispensing lever. The valve dispenses only until foam from the cup touches the lever*. If a top-off delay is set, the valve will dispense again after a preset delay. This “topping-off” fills the cup after the foam settles. The top-off delay is can be adjusted from 0 to 15 seconds, the factory default is 2 seconds. *Note: A metal rivet in the valve body supplies electricity through the beverage being dispensed. When the foaming beverage comes in contact with the metal dispensing lever it completes the electrical circuit and the flow module closes the dispensing valve — even though the lever is still activated. SYSTEM DETAILS Note: The cup must stay in place against the lever for the top-off to operate. Note: A slanted cup rest must be used with an OptifillTM valve. OptifillTM Valve Programming The OptifillTM module provides a timed dispensing function to set water flow rates. To access this function: 1. Press the program switch until the LED turns on. 2. Hold a graduated cup under the valve nozzle without touching the lever. Press the large rectangular switch. The valve dispenses for 2 seconds. The dispensed liquid divided by 2 equals the oz./sec dispensed rate. 3. Press the program switch to exit the program. 4. To program the top off function follow this procedure: 5. Remove the front valve cover. 6. Press the program switch until the LED turns on (can be seen from the top of the module.) 7. Place cup against the lever for initial dispensing. When the foam touches the lever the valve stops and the LED flashes. - 14 - © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual 8. When the foam in the cup has lowered, press and release the large rectangular button. The valve dispenses a top-off and shuts off when the foam again touches the lever. The LED is now on steady. 9. Press the program switch until the LED turns off. 10. If you wish to disable the top-off, follow steps 1 through 3. Remove the cup from the lever. This will enter a zero value for the delay time and disable the top-off fill. Press the program switch for 3 seconds. PGM lights (not visible unless in programming mode) Program switch (hidden) Note: The OptifillTM valve does not have an adjustment for sensitivity. SYSTEM DETAILS © 1999-2005, IMI Cornelius, Inc. - 15 - UF-1 and UFB-1 Valves Training Manual INSTALLATION CAUTION — Only trained and certified technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. 1. INSTALLATION REQUIREMENTS 1.1 Requirements Summary The beverage dispenser that the UF-1 or UFB-1 valve(s) will be installed on should be capable of supplying an adequate flow of water (for the beverage and for cooling) and syrup. environment: . . . . . . .indoor installation only temperature: . . . . . . . .50 to 110° F ambient temperature syrup BIB: . . . . . . . . .60 to 80 psi carbonated water: . . . .65 to 110 psi plain water:. . . . . . . . .50 to 110 psi electrical: . . . . . . . . . .24 volts AC (22-27 volts), 80 VA, 50/60 Hz 1.2 Electrical Requirements Before connecting electrical power to the beverage dispenser refer to nameplate to see if it requires 50 or 60 Hz power. DANGER — To avoid possible serious injury or death the ELCB (earth leakage circuit breaker) must be installed in the electrical circuit of all 50 Hz units. WARNING — To avoid possible electrical shock the unit must be electrically grounded using the green grounding screw provided inside the electrical contractor box. CAUTION — The wiring must be properly grounded and connected through a INSTALLATION 15-amp disconnect switch (slow–blow fuse or equivalent HACR circuit breaker). ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES. MAKE SURE UNIT IS PROPERLY GROUNDED. 2. INSTALLATION & START-UP 2.1 UF-1 and UFB-1 Valve Installation Procedure 1. Shut off syrup, unplug carbonator, shut off CO2 and water supply to the unit. 2. Release pressure in lines by activating valves and lifting relief valve of carbonator - 16 - © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual 3. Detach current valves: – Remove front cover by lifting. – Remove valve cover. – Unplug wiring harness. – Remove valve. 3. INSTALLATION CHECKLIST 1. Voltage and proper grounding. 2. Valve properly secured (latched) to block. 3. CO2 pressure to carbonator. 4. Water flow rate. 5. Syrup delivery pressure. 6. Finished product temperature less than 40°F. 7. Water to syrup ratio. 8. Portion size / top-off. 9. Water, syrup, CO2 leaks. 10. Cover secured to valve. 11. Valves flavor correctly marked. 4. RETROFITTING UF-1 and UFB-1 valves will retrofit any valve with an identical mounting block screw pattern. Note: Replacement of mounting block inlet fitting O-rings (part # 4073) is required when retrofitting valves. 4.1 Mounting Block Removal © 1999-2005, IMI Cornelius, Inc. - 17 - INSTALLATION To remove valve mounting block from the front panel, take out and save 4 screws. IMPORTANT: Before installing block replace O-rings on each outlet fitting. Lubricate with Dow 111 or equivalent silicone lubricant. Do not use petroleum jelly. SERVICE UF-1 and UFB-1 Valves Training Manual SERVICE CAUTION — Only trained and certified technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. 1. PREVENTATIVE MAINTENANCE 1.1 Preventative Maintenance Procedures Preventative Maintenance Procedure Procedure 1. Check valve operation (does it dispense properly) 2. Replace worn or missing parts 3. Clean valves 4. Check voltage (22 to 27 VAC with the valve activated) 5. Check product temperature (less than 40°F) 6. Check water flow rate (use syrup bypass tube and ratio cup) 7. Check ratio 8. Check portion size / top-off 9. Check for leaks Frequency 6 months 6 months 6 months 6 months 6 months 6 months 6 months 6 months 6 months NOTE: These procedures should be performed every six months OR after a service call. 1.2 Cleaning Valve 1. Remove the valve nozzle and the syrup diffuser. 2. Wash the nozzle and diffuser in water. Soak in carbonated water overnight if possible. Use a soft brush as needed to remove any accumulated syrup deposits. 3. Remove cover and bottom plate and clean with a soft cloth and warm soapy water. 4. Wipe the valve surface with a clean soft cloth. CAUTION — Do not soak valve components in chlorine. - 18 - © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual SERVICE TROUBLE SHOOTING Excess Foam Problem: excess foam Check product temperature Temp ? Check system above 40° below 40° Remove nozzle Clean ? yes Check flow rates no Clean Correct ? yes Check system no Problem corrected Set flow rate and ratio Problem corrected © 1999-2005, IMI Cornelius, Inc. - 19 - SERVICE UF-1 and UFB-1 Valves Training Manual Off Taste Problem: off taste Remove nozzle Clean ? yes Check ratio no Clean Correct ? yes Check system no Problem corrected Set ratio Problem corrected - 20 - © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual SERVICE Valve Stuck Open Problem: valve stuck open Check solenoid visually working ? yes (solenoid up) Check for damaged banjos no (solenoid down) Damage ? Check for power at solenoid Power ? no Undetermined problem call 800-238-3600 yes yes Replace dispensing switch Replace banjos Problem corrected Problem corrected no Clean or replace solenoid Problem corrected © 1999-2005, IMI Cornelius, Inc. - 21 - SERVICE UF-1 and UFB-1 Valves Training Manual No Product Problem: no product Check solenoid visually yes Check system Check voltage (22-27 AC) no Check transformer Power ? yes Check resistance of coil Working ? no no Replace switch no Check switch yes 40 ohms ? yes Check system no Problem corrected Replace solenoid Problem corrected - 22 - © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual ATTACHMENTS The following attachments should be included with this lesson: ATTACHMENTS UF-1 Post-Mix Dispensing Valve Illustrated Parts List Post Mix Valves Critical Grounding Information Service Bulletin © 1999-2005, IMI Cornelius, Inc. - 23 - UF-1 and UFB-1 Valves Training Manual REVIEW DATE: _______________________________________________ NAME: ______________________________________________ LOCATION: __________________________________________ The following questions summarize important points in the training lesson on UF-1 and UFB-1 Valves and the UF-1 and UFB-1 Product Manual. REVIEW 1. What component(s) differ between High Flow and Ultra Flow valves? (circle the correct answer) A. Sleeve B. Piston C. Spring D. All of the above. 2. What two things determine the position of the flow control piston inside the sleeve? (circle the correct answer) A. Flowing pressure and spring pressure B. Syrup and water pressure C. Temperature and pressure D. Syrup and water flow. 3. How might chloramine affect a dispensing valve? (circle the correct answer) A. Restriction in the flow controls B. Color of the valve body C. Cracking of the flow control D. Degradation of rubber components. 4. If a ratio setting changes, what should you check for? (circle the correct answer) A. Syrup pressure B. Water pressure C. Line restriction D. All of the above. - 24 - © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual 5. Which flow rate should be set first? (circle the correct answer) A. Syrup B. Water C. Either syrup or water D. Both at the same time. 6. What functions does the Cancel/Pour Button on the Portion Control Valve perform? (circle the two correct answers) A. Cancel portion B. Manual portion C. Reset default D. All of the above. 7. UF-1 valves control? (circle the correct answer) A. On-Off of syrup and water B. Flow rates of syrup and water C. Mixing of syrup and water D. All of the above. 9. If the finished drink flow rate is 4.0 oz./sec. and the desired ratio is 7 to 1. What should the water flow rate be? (circle the correct answer) A. 3.0 B. 3.5 C. 4.0 D. 2.5. 10. What is the function of the notch in the Ultra Flow water piston? (circle the correct answer) A. Let dirt pass through B. Prevent carbonation loss C. Used in manufacturing process D. Eliminates pulsing and smooths water flow. © 1999-2005, IMI Cornelius, Inc. - 25 - REVIEW 8. When replacing the UF-1 valve mounting block you must? (circle the correct answer) A. Drill new holes B. Replace the wiring harness C. Replace the inlet fitting D. Replace the inlet fitting O-rings. UF-1 and UFB-1 Valves Training Manual 11. Which of the following will cause the valve ratio to change? (circle the correct answer) A. Flow control restrictions B. Low CO2 pressure C. Weak BIB pump D. All of the above. 12. What two things are different between a concentrate diffuser and a syrup diffuser? (circle the two correct answers) A. Color B. Position of the product outer holes C. Size D. Shape. REVIEW 13. How can you identify a concentrate sleeve? (circle the correct answer) A. Number of outlet holes B. Color C. Shape D. Size. 14. What is the flow rate range of a Fast Flow valve? (circle the correct answer) A. 1.0 to 2.5 oz./sec. B. 1.5 to 3.0 oz./sec. C. 2.5 to 4.0 oz./sec. D. 3.0 to 4.5 oz./sec. 15. What is the flow rate range of a Ultra Flow valve? (circle the correct answer) A. 1.0 to 2.5 oz./sec. B. 1.5 to 3.0 oz./sec. C. 2.5 to 4.0 oz./sec. D. 3.0 to 4.5 oz./sec. 16. What is the range of a concentrate valve? (circle the correct answer) A. 1.0 to 2.5 oz./sec. B. 1.5 to 3.0 oz./sec. C. 2.5 to 4.0 oz./sec. D. 3.0 to 4.5 oz./sec. - 26 - © 1999-2005, IMI Cornelius Inc. UF-1 and UFB-1 Valves Training Manual 17. What are the three basic steps to set the ratio on a valve? (circle the three correct answers) A. Adjust syrup ratio B. Set water flow rate C. Set portion size D. Cool product. 18. How can you identify the valve flow rate? (circle the correct answer) A. Decal on inside of cover B. Printed on valve body C. Color of valve D. Printed on flow control retainer. 19. What is the minimum VA transformer required for a valve? (circle the correct answer) A. 40 B. 60 C. 80 D. 100. © 1999-2005, IMI Cornelius, Inc. REVIEW 20. At what intervals (frequency) should maintenance procedures be performed? (circle the two correct answers) A. Every 30 days B. Every 3 months C. Every 6 months D. After every service call. - 27 - UF-1 and UFB-1 Valves Training Manual NOTES: _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ - 28 - © 1999-2005, IMI Cornelius Inc. IMI Cornelius Inc. www.cornelius.com Part No. 315222001 February 2, 2005
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