Summary of Contents for ICI TOPPER
- Page 1 TOPPER INSTALLATION AND SERVICE MANUAL INTERNATIONAL CARBONIC INC. 16630 KOALA ROAD ADELANTO, CALIFORNIA 92301 800 854-1177...
- Page 2 IMPORTANT: This manual is a guide for installing, operating, servicing and maintaining this equipment. Refer to Table of Contents for page location of detailed information to answer questions that arise during installation, operating, service and maintenance, or installation of this equipment.
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Page 3: Table Of Contents
THEORY OF OPERATION................1-10 CHAPTER II INSTALLATION ..................2-1 UNPACKING AND INSPECTION ..............2-1 SELECTING LOCATION ................2-1 LOCATION RECOMMENDATIONS FOR TOPPER........2-2 INSTALLATION....................2-2 INSTALL HIGH-PRESSURE CO2 REGULATOR, CO2 CYLINDER AND LINES ....................2-3 INSTALL LOW-PRESSURE REGULATOR AND LINES....... 2-3 INSTALL WATER FILTER ASSEMBLY, (OPTIONAL)........ - Page 4 CARBONATION TROUBLESHOOTING FLOW CHART #3 ......6-8 NOTE SECTION ......................6-9 LIST OF FIGURES Figure Title EXPLODED VIEW OF TOPPER ............1-3 ILLUSTRATED PARTS BREAKDOWN OF TOPPER ...... 1-4 EXPLODED VIEW OF TOPPER-J ........... 1-6 ILLUSTRATED PARTS BREAKDOWN OF TOPPER-J ....1-7...
- Page 5 TABLE OF CONTENTS (CONT’D) Figure Title PAGE ELECTRICAL SCHEMATIC 110V ............ 1-8 ELECTRICAL SCHEMATIC S-1309 JUICE ........1-9 ELECTRICAL SCHEMATIC 24V ............1-10 SAMPLE OF A POSSIBLE INSTALLATION ........2-2 HIGH-PRESSURE CO2 REGULATOR, (S-101) ......2-3 LOW-PRESSURE CO2 REGULATOR, (S-121)....... 2-3 SUGGESTED WATER FLOW INSTALLATION .......
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Page 6: Preface
PREFACE INTERNATIONAL CARBONIC INC. has enjoyed over 53 years of manufacturing excellence in the field of carbonation and in the beverage related industry. We have had a long and proud history with quality as our standard and innovation as our goal. Originally started just after World War II in Canfield, Ohio as Carbonic Dispensers. -
Page 7: Chapter I General Description
For proper function the TOPPER must have a water supply, and electrical supply and drainage. The TOPPER is designed with a unique lift off drain pan that can be emptied at any convenient drain outlet. Other items that will be required if used in B.I.B., (Bag in Box), or transfer tank, (FIGAL), installations will be High-pressure regulator, Low- pressure regulator, connecting lines, quick couplers, or disconnects and C02. - Page 8 Electrical Requirements: The cooling unit requires a 115 VAC, single phase, 60 Hertz power circuit. Topper Topper-J Circuit Ampacity ....10.5 Amps......... 3.8 Amps Condensing Unit....2.5 Amps ........2.5 Amps Water Pump Motor ..6.2 Amps ........NA Transformer....5 Amps ........5 Amps Agitator......8 amps ..
- Page 9 TITLE INTERNATIONAL CARBONIC INC. TOPPER I C I DATE 1/4/05 DRN. BY CHK. BY APPR. BY ADELANTO, CALIFORNIA FIGURE 1-1...
- Page 10 TOPPER PART NO. DESCRIPTION S0777 NYLON FASTENER S0776-G TOP GRID S0776-V REAR VENT S0775 COVER ONLY S0774 ITEMS 1,2,3, AND 4, (COMPLETE COVER) S0103 PUMP PROTECTOR S0785 WATER LINE, COPPER S0104 PUMP PROTECTOR BRACKET S0170 HALF UNION BRASS, 3/8 MF X 3/8 MP...
- Page 11 TOPPER Cont. PART NO. DESCRIPTION S0788 SYRUP COIL S0264 CARBONATOR TANK ASSEMBLY S0075-40 SENSING PROBE ASSEMBLY S1304-A ICE BANK BULB BRACKET S0208-A WATER REGULATOR, OPTIONAL AEA1360YXAXA CONDENSING UNIT, 1/5 H.P. AEA1360YXA COMPRESSOR ONLY, 1/5 H.P. G0016 TY-RAP LARGE S0835 AGITATOR PUMP...
- Page 12 TITLE TOPPER INTERNATIONAL CARBONIC INC. I C I JUICE DATE 1/4/5 DRN. BY CHK. BY APPR. BY ADELANTO, CALIFORNIA FIGURE 1-3...
- Page 13 TOPPER JUICE SYM QTY PART NO. DESCRIPTION S0777 NYLON FASTENER S0776-G TOP GRID S0776-V REAR VENT S0775 COVER ONLY S0774 ITEMS 1,2,3, AND 4, (COMPLETE COVER) E0276 TRANSFORMER, 55 VA E0664 STRAIN RELIEF S1309 TERMINAL BOARD S1335 TERMINAL BOARD SPACER, NYLON, 3/8"...
- Page 14 S-68-B ELECTRICAL SCHEMATIC 120 VOLT FAN MOTOR ICE BANK CONTROL COMPRESSOR TRANSFORMER GREEN GREEN WHITE INTERNATIONAL CARBONIC INC. 120 VAC BLACK POWER IBC1 IBC2 CU1 ON/OFF ON/OFF ON/OFF MOTOR2 CONDENSING WHITE BLACK UNIT MOTOR1 AGITATOR PUMP SHORT LONG WHITE BLACK...
- Page 15 BLACK GREEN GROUND TERMINAL SCREW IN CONTROL GREEN BLACK CONDENSING UNIT 110 VAC ICE BANK ON/OFF CONTROL SWITCH TITLE INTERNATIONAL CARBONIC INC. S-1309 ELECTRICAL I C I SCHEMATIC DATE 1/29/99 DRN. BY CHK. BY APPR. BY ADELANTO, CALIFORNIA FIGURE 1-6...
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Page 16: Electrical Schematic 24V
VALVE SCHEMATIC BLACK BLUE WHITE 24 VOLT WHITE YELLOW 24 VOLT SINGLE DUAL 24 VOLT VALVES KEY SWITCH 24 VOLT TRANSFORMER ELECTRICAL SCHEMATIC 24 VOLT FIGURE 1-7 1-10... -
Page 17: Theory Of Operation
In both cases, carbonated or juice drinks, this procedure is performed. If the TOPPER is a carbonated unit the water is now routed into a carbonator tank where this cold water is mixed with CO2. - Page 18 The water source should be regulated, this is normally performed by the use of an in line water regulator. If the water is not regulated and the water pressure is equal or greater than the incoming CO2 the act of carbonation will be greatly inhibited or completely eliminated.
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Page 19: Chapter Ii Installation
Upon receiving unit, immediately remove unit from shipping carton and inspect for shipping damage. NOTE: Before leaving the factory all TOPPER units were carefully inspected and the carrier has accepted and signed for them. Any damage or irregularities should be noted at the time of delivery and immediately reported to delivering carrier. -
Page 20: Location Recommendations For Topper
Position unit as close as possible to floor drain. FIGURE 2-1. SAMPLE OF POSSIBLE INSTALLATION. INSTALLATION Make all connections: C02 gas, plain water and syrups. Place TOPPER in position. Make sure sufficient space between bulkheads, walls and overheads is available for proper air circulation around cooling unit. -
Page 21: Install High-Pressure Co2 Regulator, Co2 Cylinder And Lines
INSTALL HIGH-PRESSURE C02 REGULATOR, C02 CYLINDER AND LINES (FOR CARBONATED UNITS ONLY) 1. Install high-pressure C02 regulator, (S-101) on C02 cylinder using a new seal gasket. MAKE SURE NEW WASHER IS INSIDE REGULATOR ASSEMBLIES COUPLING NUT BEFORE CONNECTING TO CYLINDER. WARNING-: To avoid personal injury and/or property damage, always secure C02 cylinder with safety chain to prevent cylinder from falling. -
Page 22: Install Water Pressure Regulator (Optional)
2. Connect water filter assembly to inlet of valve on water supply line using minimum 3/8" I.D. water line. Connect water filter assembly outlet to TOPPER plain water inlet fitting using minimum 3/8" I.D. water line. See CONNECTING WATER INLET. -
Page 23: Install Drain Line
ACCORDING TO FEDERAL, STATE, AND LOCAL LAWS. The water connection on the TOPPER is made to a flexible water line by means of a 3/8”, male flare. Due to the large capacity of the pump, any restriction of the incoming fresh water supply would starve the water pump and create noise within the pump, poor carbonation and extremely long running time. -
Page 24: Chapter Iii, Preparation
717). 4. Open water inlet supply line. 5. Plug TOPPER power cord into electrical receptacle box, turn power switch to the "ON" position. Make sure compressor, condenser fan motor, agitator motor start. The process of cooling the water bath will now commence. With ambient and water temperature of 75 degree “F”... -
Page 25: Activate Low-Pressure Co2 Gas And Syrup Systems
3. Dispense water from dispensing valves until the carbonator activates, carbonated units only. 4. Allow carbonator to run until it automatically shuts off. Pump is fully primed and carbonator is now ready for use, carbonated units only. 5. Check all connections on high-pressure C02 system for leaks. Repair any leaks that are found. -
Page 26: Chapter Iv Operators Instructions
CHAPTER IV OPERATORS INSTRUCTIONS This chapter covers operator’s responsibilities for daily pre-operation check, adjustments, replenishing C02 and syrup supplies, cleaning, and sanitizing. DAILY PRE-OPERATION CHECK 1. Make sure high-pressure C02 regulator's pound per square inch indicator is not in shaded portion of dial. If so, C02 cylinder is almost empty and must be replaced. NOTE: This reading should be carried out at normal room temperature. -
Page 27: Checking Water Bath
CHECKING WATER BATH Periodically check water level in water bath. If it is low more water should be added as instructed for maximum product cooling. This dehydration will normally not occur in normal temperate climate zones. With normal humidity the opposite will occur therefore a condensate drain is installed. - Page 28 4. All connections including cylinder valve should be coated with a soap solution. If bubbles appear a leak is apparent. S. Always be sure that the low-pressure adjusting screw is completely backed off before testing carbonator circuit for leaks. Otherwise, gas going into syrup tanks would cause this high-pressure gauge needle to balance with pressure in syrup tanks, which would be a false indication of a leak in the carbonator circuit.
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Page 29: Chapter V Service And Maintenance
CHAPTER V SERVICE AND MAINTENANCE This chapter describes service and maintenance procedures to be performed on TOPPER units and related components. PERIODIC INSPECTION AND CLEANING Daily: 1. Clean any syrup from storage tanks/B.I.B. racks, connecting sockets/Q.C.D.s and general syrup storage area with warm water. -
Page 30: Topper Cabinet Maintenance
TOPPER CABINET MAINTENANCE PERIODIC CLEANING Periodically wash all external surfaces of TOPPER cabinet, rinse with clean water, then wipe dry with a clean soft cloth. DO NOT USE ABRASIVE TYPE CLEANERS. CLEANING CONDENSER COIL IMPORTANT: Air circulation through the condenser coil is required to cool the compressor. -
Page 31: Water Pump Maintenance
1. Unplug power cord from electrical socket. 2. Shut off plain water supply to water pump by closing shutoff valves in water supply line. 3. Shut off CO2 supply to TOPPER by closing shutoff valve on CO2 cylinder. Remove cover from unit. -
Page 32: Carbonator Maintenance
S-650 S-650A S-200 FIGURE 5-1 WATER PUMP, “Y” STRAINER & SCREEN CARBONATOR MAINTENANCE 1. Unplug refrigeration unit power cord from electrical socket. 2. Remove cover, lift up hinged refrigeration deck to gain access to water bath. 3. Look down into water bath (if necessary, use flashlight) and inspect carbonator tank for leak. -
Page 33: Lubrication
LUBRICATION Water pump motors bearing must be oiled periodically. Refer to oiling instruction on motors. DO NO OVER OIL. SERVICING CHECK VALVES It is not recommended to disassemble the check valves unless it is absolutely necessary. As stated before this necessity would be prompted by earthquakes, disruption of water service, etc. The symptoms of a malfunctioning check valve would be: Water check valve Carbonation through out water supply, i.e., basins,... - Page 34 SYM QTY PART NO. DESCRIPTION S-229 S-14 HOUSING, CHECK VALVE 1/4" M.F. S-13 SEAT "O" RING CHECK VALVE S-12 SLEEVE, SEAT RETAINER CHECK VALVE S-11 BALL, CHECK VALVE S-10 SPRING, CHECK VALVE GASKET, CHECK VALVE S-6 1/8 BODY, BASE, CHECK VALVE S-29 OFF SET TEE S-16...
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Page 35: Replenishing Co2 Supply
C02 cylinder. The other gauge will show regulated pressure that will be delivered to the TOPPER carbonation system. This gauge can be indicated from 0-160 psi up to 0-300 psi. By turning the high-pressure regulator adjustment screw clockwise we will increase pressure supplied to our carbonator which will be indicated on this gauge. -
Page 36: Low-Pressure Co2 Regulator
INLET C02 PRESSURE TO CARBONATION SYSTEM SHOULD NOT EXCEED 75 PSI LOW-PRESSURE C02 REGULATOR The low-pressure C02 regulator setting can and will vary dramatically from one installation to the next. Variables such as distance from syrup containers to point of serving, horizontal or vertical runs, baume of product, to whether B.I.B. -
Page 37: Brix Instruction
BRIX INSTRUCTIONS Make sure carbonator/water flow is in an operating condition, i.e., high-pressure regulators set, water and power on and refrigeration in a ready to go mode. In the case of juice systems make sure water flow is un-restricted. It is also recommended that a water pressure regulator be utilized on all systems. - Page 38 Brix Instructions Continued BRIXING PFC-II VALVE The water and syrup flows are individually adjusted by their respective metering pin or flow-controls. Located under the valve cover on the top rear of the valve, see illustration. One recommended method utilizes the ratio brix cup. The brix cup is divided into two sections, one to hold up to 9 parts water and the smaller section to hold one or two parts of syrup.
- Page 39 SANITIZING PROCEDURES Your local health department rules and general area cleanliness should determine the frequency at which the unit should be sanitized. EQUIPMENT REQUIRED: 1. Stainless Steel containers (product tanks), or large volume container. 2. CO2 Supply If applicable (Same as used with dispensing unit). 3.
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Page 40: Water Pump Motor Will Not Operate
TROUBLE SHOOTING IMPORTANT: Only qualified personnel should service the TOPPER unit and components. WARNING: To avoid personal injury and or property damage, always disconnect electrical power, shut off plain water and CO2 supplies before starting any repairs. If repairs are to be made to the carbonated water system, bleed carbonated water system pressure before proceeding. -
Page 41: Frozen Water Bath
Frozen water Bad ice bank control. Replace bad ice bank control. bath Refrigerant leak causing Repair leak, evacuate and re- undercharge. charge. Defective agitator motor. Replace defective agitator. Dirty water bath. Melt ice, empty & clean bath. Replenish w/fresh water. Cooling or No electrical power. -
Page 42: Compressor Will Not Stop After Sufficient
Note: Ice bank freezes from bottom of evaporator upward. A refrigerant leak or insufficient charge might show ice at bottom and not at top of evaporator. Compressor will Ice bank control capillary tube Replace ice bank control. not stop after kinked or broken. -
Page 43: No Syrup Being Dispensed
No syrup being Syrup container empty. Replenish syrup supply. dispensed Syrup lines crimped. Straighten syrup lines. CO2 cylinder empty. Change CO2 cylinder. QCD of syrup installed in- Re-install QCD correctly. correctly. Low-pressure regulator defective Repair or replace low-pressure or plugged. regulator. -
Page 44: Water-To-Syrup "Ratio" Too Low Or Too High
Water-to-syrup Syrup flow regulator not properly Adjust water-to-syrup ratio (see ratio to low or adjusted. dispensing station installation too high instructions. CO2 gas pressure in syrup tanks Adjust low-pressure regulator as insufficient. instructed. Syrup tubing I.D. insufficient. Increase syrup tubing I.D. Note: see “Brix instructions”... -
Page 45: Carbonation Troubleshooting Flow Chart #1
CARBONATION TROUBLE SHOOTING FLOW CHART #1 MOTOR/PUMP NOT OPERATIONAL Valves dispensing gas & syrup only Electrode Carbonator short cycles Disconnect electrical Disconnect Check ground electrical connection at Remove spades from board and box terminal Motor #1 on LLC & install on any Remove spade from open "A"... -
Page 46: Carbonation Troubleshooting Flow Chart #2
CARBONATION TROUBLE SHOOTING FLOW CHART #2 MOTOR/PUMP DOES NOT COME ON Non-carbonated water & syrup being dispensed only Check water pressure Check CO2 supply Water pressure greater than or close to CO2 pressure will stop the carbonation process C02 cylinder is empty Install or adjust water Change C02 cylinder regulator... -
Page 47: Carbonation Troubleshooting Flow Chart #3
CARBONATION TROUBLE SHOOTING FLOW CHART #3 CARBONATOR NOT OPERATIONAL Water Pump Motor runs continuously NO EXCESSIVE PRESSURE AT VALVE OR PRESSURE RELIEF EXCESSIVE PRESSURE AT VALVE SYMPTONS SYMPTONS Valve will dispense syrup and gas Valve will dispense syrup only and/or only. -
Page 48: Note Section
NOTE SECTION Frequently Called Numbers: __________________________________ ____________________________ __________________________________ ____________________________ __________________________________ ____________________________ __________________________________ ____________________________ __________________________________ ____________________________ __________________________________ ____________________________ CO2 SETTINGS: High Pressure ________________________ PSI Low Pressure ________________________ PSI Product Setup: _____________________________________ __________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ ___________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ ___________________________________________________...