®

FLAVORFUSION®/
FLAVOROVERLOAD

Training Manual

Publication Number: TP01070

Revision Date: November 16, 2007
Revision: F
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
FLAVORFUSION®/FLAVOROVERLOAD
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 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:
www.cornelius.com
800-238-3600
Trademarks and Copyrights:
Aurora, Cornelius, FlavorFusion, Focus, Leopard ERV, Nordic, Optifill, Pinnacle, SFV1,
Smart-Pour, Totalflex II, and Vanguard 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 © 2004-2007, All Rights Reserved, IMI Cornelius Inc.
 FlavorFusion®/FlavorOverload Training Manual

TABLE OF CONTENTS
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Programming Mode Flashing Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Setting Water Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjusting Syrup/Water Ratio (Brix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Setting a Button to Dispense Non-carbonated Water Only . . . . . . . . . . . . . . . . . 5
Setting a Button to Dispense Carbonated Water Only . . . . . . . . . . . . . . . . . . . . 5
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Carbonator Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Plumbing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Plumbing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Interface Board and Harness Pin-out Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Point-Point Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ladder Type Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Diagnostics Guide for the Main Control Board (see FIGURE 22) . . . . . . . . . . . . . . 19

© 2004-2007, IMI Cornelius Inc. -i- Publication Number: TP01070

FlavorFusion®/FlavorOverload Training Manual

Publication Number: TP01070 - ii - © 2004-2007, IMI Cornelius Inc.

 FlavorFusion®/FlavorOverload Training Manual

PRODUCT OVERVIEW
• Brand density - 16 brands (14 chilled, 2 ambient) plus up to 8 bonus flavors in 30” wide;
• 255 lbs capacity cube ice only hopper;
• Internal cold carbonation with remote pump;
• Total carb/non-carb flexibility on each brand;
• Eye catching merchandising;
• Improved serviceability of agitator motor;
• Bonus flavors programmable for 1-4 second dispense;
• Valve positions programmable without special tools or PDA;
• Front inlet fittings;
• Key lock switch;
• 10” cup clearance;
• 30% more drip tray capacity;

THEORY OF OPERATION
• The FlavorFusion®/FlavorOverload machine is an above counter ice/beverage unit with multi flavor
nozzles and the capability to inject bonus flavors into the finished drink.
• The beverage is cooled via ice melting on an aluminum cold plate. Ice is kept on the cold plate by
means of an opening in the hopper that drops ice onto the surface during agitation of the ice in the
hopper.
• The unit contains a mechanical ice chute and gate mechanism.
• The ice agitation gear motor is removable from the gear box to ease removal of the motor during ser-
vice and lower repair cost.
• The unit has six nozzles for dispensing brand and bonus flavors.
• Each brand nozzle serves four discreet flavors fed by four syrup valves, one plain water, and one carb
water valve. Every position is flexible for use with either carb or non-carb water.
• Each bonus nozzle serves four individual flavors intended for injection into the finished drink. Bonus
nozzles are fed by four syrup valves only. There is no option to dispense water out of the bonus nozzle
without significant plumbing changes.
• Bonus flavors require a separate regulator setting on their BIB pumps (20 psi maximum).
• Brand and bonus flavors are controlled by means of six interface boards (one interface board per noz-
zle). The interface boards are common for each nozzle. Valve positions are configured on the mem-
brane switch. No special tool or PDA is required.
• Valve flow rates are adjustable for 3.0-3.75 oz/sec finished drink dispense rate.
• Unplug the unit or turn off the key switch before attempting any electrical service on the unit, failure to
do this can cause damage to the electrical components!

© 2004-2007, IMI Cornelius Inc. -1- Publication Number: TP01070

FlavorFusion® Training Manual

SYSTEM REQUIREMENTS
Dimensions (in): . . . . . . . . 29 x 30 x 39 (l x w x h). Height is measured to top of bin. Lid adds 3 in to
height.
Counter Weight (lb): . . . . . 320 (plus ice weight)
Shipping Weight (lb): . . . . 330
Capacity: . . . . . . . . . . . . . 250 lb ice bin capacity (cube ice only)
Indoor installation only
40 to 90 oF ambient temperature
Electrical Rating: . . . . . . . . 103-132 Volts
11 Amps
Water supply pressure: . . 50-60 psi at pump
Water volume: . . . . . . . . . 125 gph
CO2: . . . . . . . . . . . . . . . . . 75 psi at carbonator tank
Syrup (brands): . . . . . . . . 60 psi min
Syrup (bonus): . . . . . . . . 20 psi max
Syrup supply lines: . . . . . . .375” ID tubing min
NOTE: If water pressure is below 50 psi a water pressure booster is required for still water drinks.

Publication Number: TP01070 -2- © 2004-2007, IMI Cornelius Inc.

 FlavorFusion®/FlavorOverload Training Manual

PROGRAMMING
NOTE: The programming mode is exactly the same for both brand and bonus keypads.
To enter the programming mode, press and hold the two program buttons (see FIGURE 3) at the top of
the keypad for approximately 4 seconds. All keypad LEDs will flash off for approximately 1 second to
indicate the start of the programming mode.
To exit programming mode, press and hold the two program buttons for approximately 4 seconds. All
keypad LEDs will flash off for approximately 1 second, resuming normal operation mode.

Programming Mode Flashing Sequences

Once in programming mode, each dispense button LED flashes in a sequence cycle according to one (1)
of six (6) dispense types. For Brand Keypads, only dispense types 1 and 2 should be used. For Bonus
Flavor Keypads, dispense types 3 through 6 are used. The six (6) dispense types are described below,
and shown in a timing diagram in FIGURE 1:
• Dispense Type 1, Carbonated water dispense: Solid LED
• Dispense Type 2, Non-carbonated dispense: Flashing LED 1.5 seconds ON, 1.5 seconds OFF
• Dispense Type 3, 1-second flavor shot: LED flashes once for ¼ second, followed by 3 seconds
OFF
• Dispense Type 4, 2-second flavor shot: LED flashes twice for ¼ second ON, ½ second OFF,
followed by 3 seconds OFF
• Dispense Type 5, 3-second flavor shot: LED flashes three (3) times for ¼ second ON, ½ second
OFF, followed by 3 seconds OFF
• Dispense Type 6, 4-second flavor shot: LED flashes four (4) times for ¼ second ON, ½ second
OFF, followed by 3 seconds OFF
Start Exit
proramming programming
mode mode

1. Carbonated water dispense

2. Non-carbonated dispense

3. 1-second flavor shot

4. 2-second flavor shot

5. 3-second flavor shot

6. 4-second flavor shot

0 1 2 3 4 5
Time
(seconds)

FIGURE 1
NOTE: It is possible to program a flavor shot into a keypad. It is also possible to program a cove
dispense (type 1 or 2) into a flavor shot keypad. Both instances result in an incorrect operation
and should be corrected.

© 2004-2007, IMI Cornelius Inc. -3- Publication Number: TP01070

FlavorFusion® Training Manual

Setting Water Flow Rate

Setting the water flow rate will require a timed dispense. To accomplish this, the following procedure
should be followed:
1. Enter programming mode for the valve
block by simultaneously pressing and
holding both programming buttons for 4
seconds (see FIGURE 3). The LED’s for
flavors 1-4 should flash off and then back
on. The drink icon should turn off.
2. Set the valve block to a 4 second pour
mode by simultaneously pressing and
holding Flavor 1 and Flavor 4 buttons until Flow Adjuster Detail
the flash pattern for all four buttons (Water)
changes.
3. Place an empty ratio cup under the
appropriate nozzle and press the left
program button for a 4 second dispense of
carbonated water. There should be
approximately 10 oz. dispensed.
4. If necessary, adjust the water flow control
FIGURE 2. Valve with Flow Adjusters
(see FIGURE 2), empty ratio cup, and
(see plumbing diagram for plumbing and valve
repeat step 3. Otherwise empty ratio cup
configuration)
and repeat step 3 using the right program
button for plain water.
5. Exit 4 second pour mode by simultaneously pressing and holding Flavor 1 and Flavor 4
buttons until the flash pattern for all for buttons changes.
6. Exit programming mode by simultaneously pressing and holding both programming buttons
for 4 seconds.

Brand Flavor
Programming
Buttons
(Left and
Bonus Flavor Right)
Programming
Buttons
(Left
and Right)

Drink Icon
Bonus Flavor Icon

Bonus Flavor Button 1

Brand Flavor Button 1

Bonus Flavor Button 2 Brand Flavor Button 2

Bonus Flavor Button 3 Brand Flavor Button 3

Brand Flavor Button 4

Bonus Flavor Button 4

Bonus Flavor Nozzle

Brand Flavor Nozzle

Publication Number: TP01070 -4- © 2004-2007, IMI Cornelius Inc.

 FlavorFusion®/FlavorOverload Training Manual

FIGURE 3
Adjusting Syrup/Water Ratio (Brix)
Timed Dispense Procedure
1. Enter programming mode for the valve block by simultaneously pressing and holding both
programming buttons for 4 seconds (see FIGURE 3). The LED’s for flavors 1-4 should flash off and
then back on. The drink icon should turn off.
2. Set the valve block to a 4 second pour mode by simultaneously pressing and holding Flavor 1 and
Flavor 4 buttons until the flash pattern for all for buttons changes.
3. Place the water end of the ratio cup under the appropriate nozzle and press the left program button
for a 4 second dispense of carbonated water. (Push the right program button for still water pour.)
4. Place the syrup end of the ratio cup under the nozzle and press the appropriate flavor button for a 4
second dispense of syrup. The fill line should be the same for both water and the syrup. Adjust the
syrup flow control if necessary, then empty cup and repeat steps 3 and 4.
5. Repeat for all syrups in valve bank.
6. Exit 4 second pour mode by simultaneously pressing and holding Flavor 1 and Flavor 4
buttons until the flash pattern for all for buttons changes.
7. Exit programming mode by simultaneously pressing and holding both programming buttons
for 4 seconds.
Setting a Button to Dispense Non-carbonated Water Only
1. Program the designated button to dispense non-carbonated water (see Programming Mode.)
2. Do not connect a syrup source to the inlet circuit of the designated button (1-14 or A1-A2.) If circuit
1 through 14 is chosen leave the coldplate inlet circuit plugged with the red cap. If circuit A1 or A2 is
chosen, plug the end of the inlet tube with a red cap from the coldplate, or with tape.

Setting a Button to Dispense Carbonated Water Only

1. Program the designated button to dispense carbonated water (see Programming Mode.)
2. Do not connect a syrup source to the inlet circuit of the designated button (1-14 or A1-A2.) If circuit
1 through 14 is chosen leave the coldplate inlet circuit plugged with the red cap. If circuit A1 or A2 is
chosen, plug the end of the inlet tube with a red cap from the coldplate, or with tape.
NOTE: The ambient circuits A1 and A2 do not give up a cold plate circuit.

© 2004-2007, IMI Cornelius Inc. -5- Publication Number: TP01070

FlavorFusion® Training Manual

MECHANICAL
DISASSEMBLY
Control Box Components
Ballast for Merchandiser Valve Flow Controls
24 Volt Transformer (2)
Light

Motor Start Capacitor Starter Merchandiser Light

Main Control Board/Agitator Timer

FIGURE 4 FIGURE 5

Adjustment Pots Agitation Board

Interface
Board

FIGURE 6 FIGURE 7

Publication Number: TP01070 -6- © 2004-2007, IMI Cornelius Inc.

 FlavorFusion®/FlavorOverload Training Manual

VALVE REMOVAL
1. Pull on retaining bracket (both sides) so the switch panel will rotate out of the way (see FIGURE 9).

Retaining
Bracket

FIGURE 8 FIGURE 9
2. Unscrew the switch panel (one on each side).

FIGURE 10 FIGURE 11
3. Place the tabs into the slot over the merchandiser lights.

FIGURE 12 FIGURE 13
4. Place the valve removal tool on the back
block release latch, keep the handle flat.

Valve Removal Tool

FIGURE 14

© 2004-2007, IMI Cornelius Inc. -7- Publication Number: TP01070

FlavorFusion® Training Manual

5. Tilt the valve removal tool up to release the latch.

Back Block
Valve Removal Tool Release Latch

FIGURE 15 FIGURE 16
6. Pull the valve off the back block.

FIGURE 17
7. Push the valve on the back block and push
up on the back block release latch to
replace the valve.

FIGURE 18

Publication Number: TP01070 -8- © 2004-2007, IMI Cornelius Inc.

 FlavorFusion®/FlavorOverload Training Manual

VALVE SERVICE
NOTE: Before servicing the valve the BIB connector must be disconnected an the pressure must
be relieved.

1. Remove the locking screw after removing the valve from its mounting block.

2. Twist the solenoid 90o. Spring Clip Locking Screw

3. Pull the solenoid loose from the valve body.
4. To remove the tubing squeeze the spring
clip together and pull off.

FIGURE 19
CARBONATOR TANK
Grounding Connection/ Upper and Lower Level
Always disconnect water and CO2 and relieve CO2 Inlet Control Probes
the carbonator pressure before removing the car-
bonator probe.

Relief
Valve

FIGURE 20
MOTOR REMOVAL Heater, Agitation
NOTE: Apply anti seizing lubricant to the Motor, & Gear Box Heater Spring
threads of mounting bolts when service is
required.

Motor
Mounting
Screws

FIGURE 21

© 2004-2007, IMI Cornelius Inc. -9- Publication Number: TP01070

FlavorFusion® Training Manual

SYSTEM PLUMBING DIAGRAM

Publication Number: TP01070 - 10 - © 2004-2007, IMI Cornelius Inc.

 FLAVOR FUSION -16 BRAND A = AMBIENT (NON-CHILLED)
SYRUP FLAVOR
B1-N2 B5-N5 XX = OUTLET LINE
1 2 5 6 8 9 11 12
B2-N2 B6-N5

© 2004-2007, IMI Cornelius Inc.

KEYPAD KEYPAD B# = AMBIENT (NON-CHILLED)
BUTTONS B3-N2 BUTTONS B7-N5 BONUS SYRUPS 1-8
3 4 7 A1 10 A2 13 14
PLUMBING DIAGRAM

B4-N2 B8-N5 N# = NOZZLE #1-6

PW = PLAIN WATER
NOZZLES N1 N2 N3 NOZZLES N4 N5 N6
CW = CARBONATED WATER

BONUS FLAVORS BONUS FLAVORS

N1 N1 N1 N2 N2 N3 N3 N3 N4 N4 N4 N5 N5 N6 N6 N6 CARB TANK

1 2 3 B3 B4 5 7 A1 8 9 10 B7 B8 11 13 14
5.500 ICE
N1 N1 N1 N2 N2 N3 N3 N3 N4 N4 N4 N5 N5 N6 N6 N6
CW PW CW PW CHUTE CW PW CW PW
W3 W2 B1 B2 W3 W2 W3 W2 A2 B5 B6 12 W3 W2

- 11 -
4 6 IN
OUT
VALVE BACK BLOCK VALVE BACK BLOCK

PLAIN WTR IN

CARB WTR IN
CARB TANK IN

CARB TANK OUT

PW
PW

CW
CW

COLDPLATE
1 3 5 7 W3 9 11 13 W3
W2 W2
W1 W2 W3 W1
2 4 6 8 10 12 14
7 6 5 4 3 2 1 14 13 12 11 10 9 8

INLET OUTLET SYRUP INLETS OUTLET

THIS EQUIPMENT MUST BE INSTALLED WITH ADEQUATE BACKFLOW PROTECTION

620920670 REV. 7 TO COMPLY WITH APPLICABLE FEDERAL, STATE AND LOCAL CODES.

10.000

Publication Number: TP01070

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FlavorFusion® Training Manual

INTERFACE BOARD AND HARNESS PIN-OUT DETAIL

C P S S S S
C C C C W W C 4 3 2 1 C

12 11 10 9 8 7 6 5 4 3 2 1

CW PW S4 S3 S2 S1

TO SOLENOID VALVES

INTERFACE BOARD DETAIL

Publication Number: TP01070 - 12 - © 2004-2007, IMI Cornelius Inc.

 10.250

© 2004-2007, IMI Cornelius Inc.

WIRING DIAGRAM FLAVOR FUSION
ELECTRIC SHOCK HAZARD.
DISCONNECT POWER
BEFORE SERVICING UNIT.
WHT
620920673 REV 5 BLK HEATER
ICE
BLK AGIT.
WHT BLK BLK WHT ORG YLW GRN/YLW MOTOR
BRN
WHT WHT WHT GRN BLU
WHT BRN
YEL EARTH
GRN
AGIT L2_AGIT AGIT
EARTH_IN
EARTH
YEL CARB.
POINT-POINT WIRING DIAGRAM

CARB MTR
MOTOR
TIME CARB MOTR L2
ON
PUMP
ASY
WHT

CARB MOTR
TIME

YEL
YEL
OFF
BLK
L2

HEATR BLK
HEATR

CAPACITOR L1

TRANSFORMER WHT BLK

TRANSFORMER BLK
J4
XFORMR
L2_

RED L1 WHT
XFORMR

BLK J3
BLK BALLAST
BLK
L2_

WHT POWER
BALST

L1_BALST

YEL CORD
BLK

- 13 -
J7
WHT

WHT
WHT
L1_IN
L2_IN

BLK BLK
WHT WHT
6.000 BLK

WHT
BLK
WHT

WHT
BLK

BLK
BLK
BLK
WHT

WHT
WHT
BLK

STARTER
BLK

KEY
SWITCH
WHT

LIGHT LIGHT
SOCKET SOCKET
WHT

BRAND BONUS BRAND BRAND BONUS BRAND

SYRUP SYRUP SYRUP SYRUP SYRUP SYRUP
KEY PAD KEY PAD KEY PAD KEY PAD KEY PAD KEY PAD

GRN LT BLU RED BLU WHT

RED

RED
WHT LT BLU
RED

YEL
YEL
GRN
GRN

RED
GRN LT BLU
YEL

YEL
RED

GRN GRN WHT

RED

LT BLU
BLK

YEL

WHT
YEL

WHT
ICE BLK
BLU

2 3 B3 B4 5 7 A1 GATE 9 10 B3 B4 11 13 14
1 8
SWITCH
CARB.
WHT

LED.

BLU
CW PW CW PW CW PW CW PW

BLK
W3 W2 4 B1 B2 6 W3 W2 ICE CUBE W3 W2 A2 B1 B2 12 W3 W2 TANK
GRAPHIC
LT BLU SOLENOID BLU LT BLU SOLENOID
VALVE BLOCK VALVE BLOCK

Publication Number: TP01070

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FlavorFusion® Training Manual

LADDER TYPE WIRING DIAGRAM

L1
N

KEY SWITCH
BEV. X-FRMR

24V

24V

INTERFACE INTERFACE
BOARD-1 BOARD-4

INTERFACE INTERFACE
BOARD-2 BOARD-5

INTERFACE INTERFACE
BOARD-3 BOAR-6

BALLAST

LIGHT STARTER

SWITCHING PERFORMED
ON PC BOARD

CARB MOTOR CARB MOTOR

RELAY

BLK BLK
AGIT TIMER
RELAY YELLOW

BRN BRN
RED

ORG
ORG
WHT

ICE DISP. AGIT MOTOR

SWITCH

AGIT HEATER

WIRING LADDER SCHEMATIC 115V- FLAVOR FUSION

Publication Number: TP01070 - 14 - © 2004-2007, IMI Cornelius Inc.

 FlavorFusion®/FlavorOverload Training Manual

TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.

WARNING: If repairs are to be made to a product system, remove quick disconnects from the
applicable product tank, then relieve the system pressure before proceeding. If repairs are to be
made to the CO2 system, stop dispensing, shut off the CO2 supply, then relieve the system
pressure before proceeding. If repairs are to be made to the electrical system, make sure
electrical power is disconnected from the unit or the key switch has been turned off.

Should your unit fail to operate properly, check that there is power to the unit and that the hopper
contains ice. If the unit does not dispense, check the following chart under the appropriate symptoms to
aid in locating the defect.
Troubleshooting the LED Lighting on Customer Interface Keypad (see page 19)

Symptom Cause Remedy

1 Bonus Flavor Icon and/ A. This indicates a poor A. Turn the keyswitch to disconnect
or Drink Icon LEDs (see connection in the lighting power to the interface boards. Check the
FIGURE 3) are ON synchronization harness electrical connections between the
continuously with four that connects the interface harnesses that interconnect the right
quick flashes every 30 boards together. side of all interface boards together. Turn
seconds. back the keyswitch to reconnect power.
2 Bonus Flavor Icon and/ B. This may result over time B. Unplugging the unit and performing a
or Drink Icon LEDs (see as the lighting sequence power up will re-synchronize the lighting
FIGURE 3) are not in between push button pads sequence.
sync with the lighting can become slightly out of
sequence, synchronization.
3 Keypad LED lighting is A. Poor connection between A. Turn the keyswitch to disconnect
not working interface board and keypad power at the interface boards. Check
PCB harness connections at each interface
board.
B. Keypad LED's are burnt B. Turn the keyswitch to disconnect
out power at the interface boards. Unplug
the ribbon cable from one interface
board and test it by plugging it into the
neighboring interface board. If the
keypad still doesn't light up replace the
keypad PCB.
C. Interface board is C. Turn the keyswitch to disconnect
defective. power at the interface boards. Unplug
the ribbon cable from one interface
board and test it by plugging it into the
neighboring interface board. If the LED's
light up the interface board is defective.
Replace the interface board.
D. Corrosion at connector D. Replace keypad circuit board and
between keypad and ribbon ribbon cable.
cable.
E. Main control board is E. Replace the main control board.
defective.
4 During standby mode, Bonus buttons are Check the programming of each keypad
the brand and bonus incorrectly programmed as and set each button as CW, PW, or
LED icons do not brand buttons, or vice versa. timed dispense based upon the flavor
alternate back and forth lineup.
- instead they light
together.

Contact your local syrup or beverage equipment distributor for additional information and troubleshooting
of beverage system.

© 2004-2007, IMI Cornelius Inc. - 15 - Publication Number: TP01070

FlavorFusion® Training Manual

Dispenser Troubleshooting

Symptom Cause Remedy

Blown fuse or circuit Short circuit in electrical wiring Repair Wiring

breaker

Inoperable agitator motor (shorted Replace gear motor

motor)

Agitator does not No power Restore power or plug in unit

turn

Improperly installed upper ice chute Check the upper ice chute assembly for
assembly (Reed switch is not being proper assembly and operation
activated)

Inoperable reed switch Replace reed switch

Electrical board driver circuit is Replace main control board

defective

Gear motor has open circuit Replace gear motor

Reed switch is not activated Improper Check to make sure tongue of upper
assembly of upper ice chute to lower chute engages into the back of the
chute. lower chute, ensure upper chute
engages outside the lower chute, and
snap front of chute into place.

Broken wire in the 2-wire harness Repair of replace 2-wire harness

leading to the reed switch

Bad connection at main control board, Repair connection or replace 2-wire

J3, pins 2 &3 harness

Ice dispenses Ice gate mechanism is stuck in open Inspect gasket for proper position.
continuously position Examine gate plate to see if it slides
freely behind the lower ice chute.

Stuck or bent ice lever (does not allow Examine ice dispense lever to see if it is
gate to close and open reed switch) bent.

Slushy ice or water Blocked drains in cold plate Remove access covers in cold plate
in hopper cover & inspect/clean drains

Poor ice quality due to water quality or Correct water quality or repair ice maker
ice maker problems

Beverage does not No 24VAC to valves Restore 24 VAC to valves

dispense

No CO2 pressure Restore CO2 pressure

Beverage is too Valve brix requires adjustment Adjust valve brix

sweet

Carbonator is not operating Repair carbonator

No CO2 in carbonator Restore CO2 pressure in carbonator

Publication Number: TP01070 - 16 - © 2004-2007, IMI Cornelius Inc.

 FlavorFusion®/FlavorOverload Training Manual

City water pressure supply low or Booster pump must be used if dynamic
inconsistent water pressure drops below 40 psig.

Unit will not CO2 pressure in carbonator tank is too Check CO2 pressure regulator setting.
dispense high. 75 psig recommended. Relieve
carbonated drinks. pressure from carbonator tank.
Dispenses syrup
only.

Water valve will not open Check electrical connection to water

valve. Check resistance of coil (should
be 9 ohms). Check for voltage at coil
when brand button is depressed.

Unit will not Carbonator tank is empty, because tank Unplug the unit and reconnect the unit.
dispense was emptied while power was applied Main control board will reset, ice
carbonated drinks. to unit. 5 minute time-out of carbonator agitation will occur, and carbonator tank
Spurts CO2 and pump/motor occurred, and carbonator will refill to normal level.
syrup only. pump is locked off.

Note that this can occur while the water 1) low water pressure switch
filter system is serviced or water supply deactivates carbonator pump, 2) after 5
is shutoff. If drinks are drawn from the minutes reset and retry carbonator
dispenser while water pressure is pump. If water supply is restored, the 5
shutoff, the carbonator pump starts and minute timeout will not occur. Repeat
runs continuously, then shuts off on the reset a second time, but on a third time,
5 minute timeout. then lockout carbonator pump, which
will generate a service call.

Carbonated drinks CO2 is out Replace CO2

are flat (low on
carbonation)

Carbonator tank is 100% filled because CO2 setting for the carbonator tank is
the city water pressure exceeds the 75 psig, max water pressure is 60 psig.
carbonator tank CO2 pressure regulator If necessary, install a water pressure
setting. regulating valve.

Low water pressure Could be caused by excessively long Increase line size to 1/2”
runs (over 40 ft.) of 3/8” water supply
line.

Low water pressure Add water pressure booster pump

Plugged water filter. Change water filter

Water booster bladder has burst Replace water booster tank/bladder

No Syrup or Syrup supply is empty Replace BIB

Watered down drink
dispensed

BIB pump not working Replace BIB pump

No CO2 or compressed air supply to Check CO2 pressure regulator setting.

BIB pump, or not enough pressure 65 psig recommended. Replace CO2
tank or fix compressor.

Carbonator pump Power cord for the carbonator pump Carbonator pump is powered off the
does not start to fill motor is not connected. main control board inside the electrical
tank box of the unit. Check that the umbilical
cord is connected from the unit to the
pump motor terminal box.

© 2004-2007, IMI Cornelius Inc. - 17 - Publication Number: TP01070

FlavorFusion® Training Manual

Power cord is Carbonator pump motor is disabled. Check the enable/disable switch on the
connected but carbonator pump terminal box and
carbonator pump enable it, if necessary.
does not run.

Probes were dry, unit was powered up, This results in a 5 minute timeout.
water was not turned on, and Unplugging the unit and plugging it in
carbonator did not fill. will reset the unit and start the
carbonator pump.

Water service was interrupted for more Unplugging the unit and plugging it in
than 5 minutes. will reset the unit and start the
carbonator pump.

Carbonator pump is Lower liquid level probe reads “dry” Check color of leads going to probes.
short cycling with while upper probe reads “wet” Black should go to bottom probe and
every drink drawn white to top probe. Reverse if incorrect.

Carbonator tank A. Poor electrical connections between A. Check connections at carbonator

overfills, overflows carbonator tank and main control board tank and at connector J4 on the main
through relief valve, control board.
and pump shuts off
after 5 minutes.

B. Broken wires between carbonator B. Replace wire harness

tank and main control board

C. Defective liquid level probes C. Replace both liquid level probes

Publication Number: TP01070 - 18 - © 2004-2007, IMI Cornelius Inc.

 FlavorFusion®/FlavorOverload Training Manual

DIAGNOSTICS GUIDE FOR THE MAIN CONTROL BOARD (SEE FIGURE 22)
Observed State
State Sensor Input Control Response Service Remedy
of Red LED
0 Flash rate 3 Both probes read “wet” Standby mode. No service required
seconds Pump = OFF
1 Flash rate Pump is OFF and HIGH Waiting for level to No service required
1/2 second probe reads “dry” and LOW drop below LOW
probe reads “wet” probe. Pump = OFF
2 Flash rate Both HIGH and LOW Normal mode. No service required
1/2 second probes read “dry” Pump = ON
3 Flash rate Entered when HIGH probe Normal mode. No service required
1/2 second does not detect liquid, and Pump = ON
LOW probe does detect
liquid, and pump is ON
4 Flash rate 1 Entered when HIGH probe THIS IS AN ERROR - Check electrical
second reads “wet” and LOW probe CONDITION. connections at the
reads “dry” carbonator tank, and at
connector J4 on the main
control board
- Black wire should be
connected to the LOW
probe and also to Pin 4 of
Connector J4
- Reverse the connections
if incorrect
- Replace harness if
necessary
5 ON Poor signal connection to Able to continue to Check the harness
continuously, the carbonator tank. May function but connections of the red
but “flickers” result in short cycling of the carbonator pump signal wire at both ends:
every 3 carbonator pump. short-cycles. Pump 1) at the carbonator ring
seconds will come on each terminal and
time a drink is drawn. 2) at Pin 5 of the J4
THIS SITUATION connector at the main
SHOULD BE control board
CORRECTED.
6 ON Entered when pump has THIS IS AN ERROR Unplug the unit and plug it
continuously run continuously for 5 CONDITION. back in. This will reset the
minutes unit's main control board
and restart the carbonator
pump.

LED

FIGURE 22

© 2004-2007, IMI Cornelius Inc. - 19 - Publication Number: TP01070

 IMI Cornelius Inc.
www.cornelius.com