WILSHIRE JUICE TRAINING MANUAL Distributed By: Commercial Refrigeration Service, Inc. WWW.JuiceSystems.
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Wilshire Juice Training Manual Wilshire Juice 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.
Wilshire Juice Training Manual NOTES: _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _________________________________________
TABLE OF CONTENTS INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Preview Questions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Key Things To Know / Do - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 Product Description - - - - - - - - - - - - - - - - - - - -
TABLE OF CONTENTS Wilshire Juice Training Manual Dryer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 Air Flow - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 Refrigerant Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 Filter/Dryer Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14 Condenser Cleaning - - - - - - - - - - - - - - -
Wilshire Juice Training Manual INTRODUCTION 1. PREVIEW QUESTIONS Check your current knowledge by taking a few minutes to answer the following questions: 1. Water and concentrate thermostats are interchangeable? _____ True _____ False The transformer does NOT control the cooling system? _____ True _____ False 3. Condenser airflow passes over the compressor first? _____ True _____ False 4. ”Ratio” refers to the amount of water required to dilute one part of concentrate? _____ True _____ False 5.
Wilshire Juice Training Manual 3. OVERVIEW Transformer & Relay Concentrate Compartment INTRODUCTION Water Cooling Coil Fan Compressor Condenser Air intake through bottom 3.1 Product Description Dispensers manufactured under the Cornelius/Wilshire name have a long and distinguished history of service in the frozen juice industry. As with their previous names, (Alco and Reynolds) they have set the standard for utility, reliability and long service lives against which their competitors are judged.
Wilshire Juice Training Manual Each dispenser has two cooling evaporators, one for water and one for concentrate. Each evaporator has its own thermostat. The dispensers are not self defrosting. A lighted merchandiser is an option. 3.2 Dimensions & Capacities All Quantum™ Dispensers: - - - - - - - - - - - - - - - - - - 1.6 – 2.2 oz./sec. 115 VAC, 60 cycle, single phase, 9.
Wilshire Juice Training Manual SYSTEM DETAILS 1. WATER 1.1 Water Quality Water quality has an affect on juice dispensing systems. • odor • taste • clarity/foaming Water filtration is recommended to assure the best beverage taste. 1.2 Water Flow Inlet water pressure should be regulated to 45 psi max. (3.1 bar) to prevent damage to pump tubing. 1.3 Adjusting Flow Rates SYSTEM DETAILS Adequate water flow is necessary and should be at least 3.0 ounces per second (89 ml) at the inlet. 2.
Wilshire Juice Training Manual 2.1 Miscellaneous CONCENTRATE Tips SLJ Units If the concentrate causes a false refill light, the refill circuit can be bypassed (jumped). Jumper the two probes just above the dispense-flush lever. QLT Units QLT’s usually use 5 to 1 concentrate which can look thawed in the bag but still be semi-frozen. Concentrate that is too thick to flow properly may cause a false refill light because the syrup may not have filled the tube.
Wilshire Juice Training Manual 4. MECHANICAL At least once a year the concentrate pumps should be checked, cleaned, and the pump tubing replaced. 4.1 Concentrate Pump Disassembly: 1. See “Installation And Service Manual” for pump platform removal procedure. Housing 2. Remove four thumb screws, housing cover, and impeller. Rotor Assembly SYSTEM DETAILS Thumb Screws 3. Remove and replace clamps and pump tubing with new ones (pump tubing and clamps kit p/n 4509B). Clamps Pump Hose 4.
Wilshire Juice Training Manual 4.2 SLJ Rinse/Flush Valve Rebuilding: Valves should be rebuilt if they are leaking. Cornelius supplies a kit which includes all the O-rings (p/n 45026100). 1. See “Installation And Service Manual” for pump platform removal procedure. Valve Assembly 2. Remove four screws and lift valve assembly up, disconnect wires in the back of the valve. Screws 3. Remove two screws holding the valve to the bracket. SYSTEM DETAILS Syrup Line Port 4.
Wilshire Juice Training Manual Bottom Of Valve 5. Remove four screws from bottom of valve. Screws & Plate Top Of Valve 6. Pull off bottom of valve and center section. Bottom of Valve Center Section Of Valve 7. Rebuild the valve and reassemble. Be sure the cam-lock washer is in the groove of the syrup line. NOTE: O-rings should be lubricated with sanitary lubricant. SYSTEM DETAILS NOTE: Red O-ring at bottom of valve plate must be a tear resistant teflon. Use p/n 31525064.
Wilshire Juice Training Manual 4.3 SLJ Valve Mixing Block Rebuilding: Valves should be rebuilt if they are leaking. Cornelius supplies all the parts necessary for rebuilding. Loosen cam lock-washer 1. Loosen cam lock-washer on both water lines. cam lockwashers SYSTEM DETAILS Screws 2. Remove two screws on the bottom of the plate. © 1999, IMI Cornelius Inc.
Wilshire Juice Training Manual Solenoid Wires 3. Remove Solenoid wires. 4. Remove nut and Solenoid coil. Solenoid Coil Nut SYSTEM DETAILS Screws On Front Of Plate 5. Remove all screws. Screws 6. Separate valve halves. Flow Control Sleeve - 10 - Flow Control Piston © 1999, IMI Cornelius Inc.
Wilshire Juice Training Manual 7. If necessary, remove and replace flow control and check valve components. Check Valve 8. Rebuild the valve and reassemble. Replace all O-rings making sure they are not pinched or twisted. Be sure the cam-lock washers are in the grooves of the water lines. NOTE: O-rings should be lubricated with sanitary lubricant. 4.4 Miscellaneous Mechanical: • • © 1999, IMI Cornelius Inc. - 11 - SYSTEM DETAILS SLJs can be converted to QLTs (see IMI Cornelius QLT Training video).
Wilshire Juice Training Manual 5. REFRIGERATION The two evaporators in our design are independently controlled so that they don’t both cool at once. This prevents the cabinet or water thermostats from over-cooling one evaporator while trying to satisfy the other. This is accomplished by using two thermostats wired parallel, a control relay to connect them to the compressor and a liquid line solenoid valve to isolate the water cooling evaporator during cabinet cooling cycles.
Wilshire Juice Training Manual Compressor Moves the refrigerant through the system. Pressurizes the refrigerant for heat dissipation in the condenser. Condenser Dissipates heat from the compressor and refrigeration action. Condenser Fan Circulates air across the compressor and condenser to facilitate heat removal. Dryer Cleans and removes moisture from the refrigeration system. A standard dryer was in use for the SLJ until recently. The dryer currently in use is a Parker style dryer.
Wilshire Juice Training Manual problem may be a low charge. If a low charge is suspected, it is recommended that the system be evaluated and leak tested by standard methods. NOTE: Hooking up a high side hose to a system with only 6.25oz of refrigerant causes a quarter or more of the charge to backup into the hose, immediately resulting in an incorrect reading. It is for this reason that operating pressures are not published.
Wilshire Juice Training Manual 2. Remove four screws on front holding electrical box and two screws on each side of the fan shroud. Remove Two Screws On Each Side Of Fan Shroud Remove Four Screws In Front 3. Pull fan shroud forward. Fan Shroud SYSTEM DETAILS Fan 4. Clean condenser with brush and compressed air. If necessary, remove three screws on each side of the fan and move it out of the way. Condenser 3 Screws On Each Side 5.
Wilshire Juice Training Manual 6. CONTROLS AND ELECTRICAL l • Transformer blue leads are 26 VAC and go to the pumps, red leads are 24 VAC and go to the merchandiser. Blue leads go to pumps The unit’s ON/OFF switch may be on the underside of the unit or on the inside of the door. There is also a switch on the bottom of the door that turns on and off as the door is opened and closed. Both of these switches turn off the pumps but not the refrigeration.
Wilshire Juice Training Manual TROUBLE SHOOTING TROUBLESHOOTING QLT DRINK QUALITY PROBLEMS ACTUAL PROBLEM & SYMPTOMS Concentrate too cold: • • • • • Low brix False refill light Poorly mixed drink Unmixed concentrate at bottom of cup Poor flow rate Concentrate too warm CUSTOMER REACTION Decrease water flow • • • • • Increase water flow • High brix Piercing device created a “flap” when it pierced through the pouch • Low brix • False refill light • Floats higher in the cup indicating high brix © 1999,
Wilshire Juice Training Manual TROUBLESHOOTING QLT DRINK QUALITY PROBLEMS ACTUAL PROBLEM & SYMPTOMS Pouch in holder wrong (flow restriction) • Low brix • False refill light Pump slide not fully engaged • Low brix • False refill light Sticky pump rollers • Low brix Ambient water to dispenser CUSTOMER REACTION Decrease water flow • • • • • Decrease water flow • Can’t achieve good brix • False refill light • Poorly mixed drink Decrease water flow • Can’t achieve good brix • False refill light • Poorly mi
ATTACHMENTS The following attachments should be included with this lesson: Minute Maid Orange Juice 6L Pouch Helpful Hints guide SLJ1000-1 Voltage Regulator Board Installation Instructions Installation Instructions Wilshire QLT180 VRB INSTALLATION INSTRUCTIONS WILSHIRE QLT180 VOLTAGE REGULATOR BOARD (VRB) The VRB is located in the front electrical box directly behind the lower splash panel. Remove the drip tray and splash panel to gain access to the electrical box.
ATTACHMENTS Wilshire Juice Training Manual QLT Juice Dispenser Wiring Installation Instructions IMI Cornelius QLT Training video tape - 20 - IMI Cornelius QLT Training © 1999, IMI Cornelius Inc.
Wilshire Juice Training Manual REVIEW DATE: _______________________________________________ NAME: _______________________________________________ LOCATION: __________________________________________ The following questions summarize important points in this training lesson. REVIEW 1. What function does the refrigerant solenoid valve perform? A. Turns the compressor on/off B. Controls refrigerant pressure. C. Controls refrigerant flow to the water coil. D. Controls cabinet temperature. 2.
REVIEW Wilshire Juice Training Manual 7. The voltage regulator board provides DC power for the pump motor. _____ True _____ False 8. Pump hoses should be replaced? A. monthly B. whenever flavors are changed C. annually D. when they wear out. 9. If the juice machine has been laid down on its side, it should be allowed to stand upright for at least one hour before starting. _____ True _____ False 10. Ratio is a measure of the amount of water verses concentrate in the finished juice drink.
Wilshire Juice Training Manual 16. The SLJ and QLT circuit boards wire in the same way. _____ True _____ False 17. The SLJ circuit board uses a continuity test to check for the sold out or refill condition. _____ True _____ False 19. The QLT circuit board differs from the SLJ primarily in the way they sense the sold out or refill condition. _____ True _____ False © 1999, IMI Cornelius Inc. - 23 - REVIEW 18. The function of the speed switch is to: A.
Wilshire Juice Training Manual NOTES: _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _________________________________________
IMI Cornelius Inc. One Cornelius Place Anoka, MN 55303-1592 U.S.A. Distributed By: Commercial Refrigeration Service, Inc. WWW.JuiceSystems.COM (866) 423-6253 (623) 869-8881 Part No.
