Cornelius Quest NT 4000 User manual

QUEST NT

4000

Service Manual

Release Date: February 19, 2004

Publication Number: 720901117SER

Revision Date: November 23, 2004

Revision: C

Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

QUEST NT 4000

SERVICE 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 varia-

tions 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

met, 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:

Trademarks and copyrights:

Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olympus,

and Vista are registered trademarks of IMI Cornelius Inc.

Optifill trademark is pending.

This document contains proprietary information and it may not be

reproduced in any way without permission from Cornelius.

Printed in U.S.A.

IMI Cornelius Inc.

Corporate Headquarters

One Cornelius Place

Anoka, MN 55303-6234

U.S.A.

Internet:

www.cornelius.com

Email:

tech.service@cornelius.com

In the U.S.A.:

phone:763-421-6120

800-238-3600

FAX:800-535-4231

Outside the U.S.A.:

phone:763-421-6120

FAX:763-422-3297

TABLE OF CONTENTS

UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Concentrate Handling & Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Loading Concentrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Changing Concentrate Containers: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Brixing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Checking/Adjusting the Brix Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Planned Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Flush System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Clean Splash Zones & Dispense Nozzles: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Sanitize the Juice Dispenser: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Semi-Annual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Clean Water Inlet Strainer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Clean Chassis Interior: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Check and Top-Off Water Ice Bath: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Replace Pump Tubing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Removing Pump Platform(s): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Replacing Pump Tubing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Main Electrical Box Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Quest Series Juice Dispenser - 115VAC (based on 10 machines) . . . . . . . . . . . . . 15

Quest Series Juice Dispenser - 230VAC (based on 10 machines) . . . . . . . . . . . . . 16

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

IMI CORNELIUS INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Quest Service Manual

UNIT SPECIFICATIONS

Nameplate Data: Model QST 4000, 115 VAC, 4.5 amps, 1 phase 60 hertz, 6.75 oz. (191-193g) R-134a

refrigerant. Test press: High side 400 psi (27.6 bar). Low side 100 psi (6.9 bar).

Model QST 4000, 230 VAC, 3 amps, 1 phase 60hertz, 6.75 oz. (191-193g) R-134a refrigerant. Test

press: High side 400 psi (27.6 bar. Low side 100 psi (6.9 bar).

Concentrate Storage: Four 0.8 gallon (3.0 liter) disposable bottles.

Clearance Recommended: 12”(30.48 cm) on top and 4”(10.16 cm) required in back for air circulation.

Electrical Connection: 6 ft. long (1.83 m) power cord with 3-prong plug attached to dispenser. Export

models have line cord less plug.

Power Supply: 15 amps at 120 volts dedicated power supply.

10 amps at 230 volts dedicated power supply.

Water Connection: 3/8 in. (0.95 cm) SAE male flare fitting on dispenser.

Water Supply Requirements: 80 psi (5.5 bar) maximum static pressure. 20 psi (1.4 bar) minimum

dynamic pressure; i.e., flowing pressure measured at dispenser water inlet with 3.0 ounces (88.7 ml) per

second water flow, see part number 720901017 Rev. D for reference.

Ice Bank/Pull Down: Weight 14-16 lbs. Pull Down: 3.5 - 5 hours at 75°F (24°C)

Quest Service Manual

CONCENTRATE HANDLING & LOADING

It is recommended that the concentrate be thawed in a refrigerated 35°F-40°F (1.6°C-4.4°C) compart-

ment for a minimum of 48 hours prior to loading into the Quest Juice Dispenser.

WARNING: Concentrate must be completely thawed and within the temperature range of 35°F-

40°F (1.6°C-4.4°C) prior to loading. Failing to supply concentrate inside the recommended tem-

perature range, especially below 35°F (1.6°C), will cause an out of brix drink (refer to the Brixing

Procedure section for details).

LOADING CONCENTRATE

The Quest Juice Dispenser is designed to use either disposable juice concentrate

containers or the optional Cornelius generic refillable container sold separately.

1. Thoroughly shake concentrate prior to use.

2. Place concentrate containers on the dispensing platform shelf inside the refriger-

ated cabinet.

3. Engage the concentrate container by pressing it downward into the bottle

adapter opening on the dispensing platform.

NOTE: Be sure to lubricate the o-ring seal on the container nozzle. This will ensure a good seal

and allow the pumps to draw concentrated from the containers more easily. Failure to create a

good seal at this connection may result in weak drinks and/or seepage of concentrate.

4. Prime each pump by closing the cabinet door and press each dispense button until concentrate

flows from the dispense nozzles.

CHANGING CONCENTRATE CONTAINERS:

1. Open the cabinet door and move the valve handle from “Dispense”to “Flush”

2. Close the door. Depress and hold the dispense button until clear water flows from the dispense noz-

zle.

3. Open the cabinet door and return the handle to “Dispense”.

4. Depress and hold the dispense button for 1-2 seconds. This will relieve water pressure from the

concentrate pump system.

5. Load concentrate container (see

Loading Concentrate

Quest Service Manual

BRIXING PROCEDURE

NOTE: If concentrate is not properly thawed, it will adversely affect the amount of concentrate

dispensed. Thawed product should be between 35°F/1.6°C to 40°F/4.4°C.

SUPPLIES

•1-Small 12 oz. cup (354.8 ml)

•1-Large 21 oz. cup (621.1 ml)

•1-Straw

•Paper Toweling

•1-Thermometer

•1-Refractometer

Your will also need a flat blade screwdriver to turn a screw if brix adjustments are required.

NOTE: The refractometer shown above, P/N 511004000, is available through your local Cornelius

Distributor.

CHECKING/ADJUSTING THE BRIX SETTING

The following instructions are for use with a refractometer.

1. Dispense approximately 8 oz. (236 ml) of drink and discard. Now draw a second 8 oz. drink.

2. Check drink temperature with a reliable thermometer (target is 35-45°F, or 1.6-7.2°C). Discard this

drink after checking temperature.

NOTE: If drink temperature is not within the target range, refer to the basic troubleshooting sec-

tion.

3. Dispense a 12 oz (354.8 ml) drink sample into a clean, dry cup. Thoroughly stir the sample using a

straw.

4. Using a straw, transfer a small sample of finished drink to the refractometer lens (refer to operating

instructions supplied with your refractometer). Check the brix reading against the brix chart below.

NOTE: The following brix chart is generic and intended for reference use only. Contact your fro-

zen concentrate supplier for specific brix readings.

Brix Reference Chart

Flavor Ratio Brix

Orange Juice 4+1 11.8

Grapefruit Juice 5+1 10.6

Cranberry Cocktail 4+1 13.5

Apple Juice 5+1 12.0

Grape 5+1 13.0

Lemonade 5+1 10.5

Tropical Punch 5+1 11.8

Sweetened Iced Tea 7+1 6.0

Pineapple Juice 4+1 12.8

Prune Juice 2+1 16.0

Quest Service Manual

5. To change the brix setting, simply readjust the water flow rate.

Located on each of the valve assemblies inside the refrigerated

compartment are the adjusting screws for the water flow rate (one

per valve).

If the brix reading is too high or low, rotate the appropriate water flow

control according to the diagram below. Repeat steps 1-5 until the brix

setting is achieved.

IMPORTANT: When making changes to the water flow control, do not rotate more than 1/4 turn

per adjustment. Additionally, prior to taking your next brix reading, “tap” the corresponding dis-

pense button several times prior to drawing a sample. This will clear remnant drink from the dis-

pense nozzle AND help move the flow control to its new setting.

Lowers Brix by increasing water

Raises Brix by reducing water

Quest Service Manual

PLANNED MAINTENANCE SCHEDULE

DAILY

Flush System:

1. Move Dispense/Flush levers located on the platform assembly in

the refrigerated cabinet to the “Flush”position. Place an empty

cup on the drip tray below each dispense nozzle.

2. Close the door and depress each dispense button for 2-3 sec-

onds or until clear water flows from each dispense nozzle.

3. Return the Dispense/Flush levers to the “Dispense”position.

4. Press each dispense button for 1-2 seconds to release the water

pressure present in the concentrate pump system.

Clean Splash Zones & Dispense Nozzles:

1. On a daily basis, clean the external cabinet and

splash areas using a clean damp cloth. Remove

and wash the cup rest and drip tray using a mild

dish soap.

2. Remove the dispense nozzles and static mixers

by rotating each 90°and pulling down. Remove

the mixing chambers by pulling straight forward.

Wash using a mild dish soap.

IMPORTANT: DO NOT wash nozzles, static mixers, or mixing chambers in a dish washer. This

will distort the plastic and damage the o-rings. Additionally, do not soak them in sanitizing solu-

tion longer than 2 minutes.

WEEKLY

Check concentrate to water brix ratio (refer to the Brixing Procedure in this manual).

Sanitize the Juice Dispenser:

Step 1 - Rinse With Hot Water

1. Prepare two 2 oz. packets of Stera-Sheen Green Label sanitizing solution (or similar brand) by dis-

solving each packet in 1 gallon (3.8L) of potable water to insure 200 ppm of available chlorine.

IMPORTANT: Use potable water at 80°F-100°F (26.7°C-37.8°C). Water above this range will break-

down the chlorine count and minimize sanitation.

2. Remove the juice concentrate containers and place them in separate refrigerated compartment.

3. “Flush”the system by following the instructions in the Daily Section.

4. Fill a clean empty concentrate container with one quart of extremely hot tap water, approximately

140°F (60°C) and place into unit. Dispense all of the hot water into a large container. Repeat for the

remaining dispense valves.

5. Remove the mixing chambers, nozzles, and static mixers. Rinse in hot water to remove excess pulp

and concentrate.

6. Place the mixing chambers, nozzles, and static mixers in a separate container of sanitizing solution

and agitate vigorously. Allow the parts to soak for two minutes. Rinse thoroughly with fresh tap

water.

7. Reinstall the static mixer, nozzles, and mixing chambers.

Quest Service Manual

Step 2 - Sanitize Pump System

1. Fill a clean concentrate container with 2 quarts (1.9L) of fresh sanitizing solution.

2. Place handles in the “dispense”position and close the door.

3. Press and hold the dispense button for 90 seconds then stop. Allow sanitizing solution to remain in

the lines for 5 minutes.

4. After 5 minutes, dispense the remaining sanitizing solution.

Step 3 - Prepare Dispenser for Use

1. Replace sanitizing solution container with a concentrate container and close the door.

2. Press and hold the dispense button until juice appears from the nozzle. Next dispense and discard

at least two 8 oz. (236.6ML) cups of juice in order to prime the system and prepare it for operation.

SEMI-ANNUAL

CAUTION: The following procedures require removal of the dispenser side panel(s). Disconnect

the power cord from the receptacle prior to proceeding.

Clean Water Inlet Strainer:

1. Remove the right side panel from the dispenser.

2. Turn off the water supply to the dispenser.

3. Remove the access port from the “Y”shaped water inlet solenoid

located on the right side of the dispenser.

4. Clean and reinstall the stainless steel water strainer.

Clean Chassis Interior:

1. Clean the condenser cooling fins.

2. Clean the air inlet grilles located on the rear and top panels of the dis-

penser.

3. Clean the interior base.

4. Wipe the fan blade clean.

5. Reinstall the right side panel, turn on the water supply, and plug the dispenser into the power recep-

tacle.

Check and Top-Off Water Ice Bath:

1. Remove the drip tray and lower splash panel.

2. If the Ice bath level is below the “Full”indicator, top it off with water. Refer to the Filling the Ice Bath

procedure in the Installation section of this manual.

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