Coca-Cola BreakMate Service Manual

  1. Coca-Cola BreakMate Level II Service Manual - BreakMateSource.com Edition
    1. Introduction
      1. Features
      2. Operating The Dispenser
      3. Filling The Dispenser
      4. Dispenser Parts Description
      5. General Specifications
    2. BreakMate Installation Guidelines
      1. General Comments
      2. Setting Up The Dispenser, In Your Shop
      3. Filter Specifications
      4. Customer / Client Location Installation
      5. Connecting Water Filter and Supply Line
      6. Flushing the Water Line and Filter
      7. Training The Key Operator
        1. Checking the Dispenser
        2. Troubleshooting Guide
        3. Most Common Problems - Correctable by the Key Operator(s)
    3. Coke BreakMate Accessories
      1. Coin Mech Attachment
        1. Installation Procedure - Standard Coin Mech (GM1000) (missing steps to plug in cables?)
        2. Installation Procedure - 3-coin Coin Mech Installation (GM3000)
        3. Single Coin Coin Mech Operation (GM1000)
        4. 3-Coin Coin Mech Operation (GM3000)
      2. CO2 Cylinder Filling Guidelines - General Comments
        1. Equipment Required
        2. BreakMate CO2 Cylinder Filling Procedure
        3. Sources of Supply
      3. Portable Water Supply System - BA104
        1. Operating Instructions
        2. Operating Comments & Notes
        3. Everpure Filter - BA113 (BA 113)
    4. BreakMate Principles of Operation
      1. Carbonated Beverage Characteristics
      2. Coca Cola BreakMate Drink Specifications
      3. The Dispensing System
      4. The Water Pumping System
      5. The Water Pump Assembly
      6. The Carbonator Assembly
      7. The Agitator
      8. The CO2 Pressure Regulator
      9. The Water Outlet Valve
      10. The Syrup System
      11. The Refrigeration System
        1. The Syrup Cooling Compartment
      12. The Electrical System
      13. The Electronic Control Unit (ECM)
        1. Diagnostic Test Procedure
        2. Preparation for Diagnostics
        3. Normal Button Functions
        4. Indicator Light Status - During Normal Use
        5. Button and Light Circuit Test
        6. Electrical Component Test
        7. Sensor Operation Tests
    5. BreakMate Troubleshooting
      1. Problem: Upper Green Light Flashing
      2. Problem: Won't Accept CO2 In Regulator
      3. Problem: Foreign Taste or Odor in Drinks
      4. Problem: Diet Syrup is Freezing
      5. Problem: Burst Safety Disc(s) on CO2 Bottles
      6. Problem: Drinks are too warm
      7. Problem: Mixing Channel Overflows
      8. Problem: CO2 Leaks
      9. Problem: Lower green light flashes
      10. Problem: Too little water is dispensed
      11. Problem: Water drips out of mixing channel
      12. Problem: No syrup dispensed
      13. Problem: Drink is Too Large
      14. Problem: Low Carbonation
      15. Problem: Coin Mech Inoperative
      16. Refrigeration Decision Tree
    6. BreakMate Repair Procedures
      1. General Comments
      2. Draining the Carbonator
      3. Removing the Control Board (ECM)
      4. Disconnecting the Dispenser
      5. Removing the Front Case of the Dispenser (Dispenser Front)
      6. Disconnecting the Electrical Leads
      7. Reassembling the Front of the Cabinet
      8. Flow Control Removal
      9. Water Outlet Valve Removal
      10. Outer Cabinet Removal
      11. CO2 Regulator Replacement
      12. Agitator Replacement
      13. Water Pump / Inlet Valve Replacement
      14. Dispenser Adjustments
      15. Water Adjustments - Syrup Ratio Settings
      16. Technical Data
      17. Wiring Diagram
      18. Wiring Connections
    7. Technical Specifications
    8. Service Parts List
    9. Service Parts - Cabinet
    10. Service Parts - WaterMate
    11. Service Bulletins
      1. Problem: Slush Ice on Startup Up
      2. Problem: Half cup or short drink delivered
      3. Problem: Check Valve Ball Sticking - Red Vent Pin Stays In
      4. Problem: Safety Disc Bursting on CO2 Cylinder
      5. Return Goods Procedure
      6. Approved Water Filters
      7. Advanced Check Valve Ball Stuck - Release Notes
      8. Syrup Freezing

1.Introduction #

Coke BreakMate Service Manual – Level II (Level 2)
Coca-Cola BreakMate Service Manual – Level II (Level 2)

Background

This manual was first published in the late 1980s and was designed to aid BreakMate service technicians – therefore it was not publicly available.  Some of the information in this manual only applied to Service Technicians and therefore may not help individual end-users in trying to resolve any potential issues.  This version of the manual has been updated, with the last updated date being August 2016, by BreakMate Community Hobbiests and BreakMateSource.com.

The updates to this Guide are mainly to address Frequently Asked Questions, update/address items that are no longer relevant, update/address items that have been discontinued and their suggested replacement strateg(ies).

If you have recommendations you’d like to see in this manual, or if you noticed typos, grammatical problems, or any other comments, please use the “Contact Us” section of BreakMateSource.com to let us know.

Original Background
This manual is designed to assist Service Management in setting up service programs for the proper workshop preparation, field installation, and efficient maintenance and repair of the Siemens GA 3000 (and similar) Coke BreakMate dispenser.

The Coca-Cola BreakMate is a compact, easy-to-use, and highly reliable carbonated soft drink dispensing system, developed and produced by Siemens exclusively for the product of The Coca-Cola Company.

StandardMachine
A Standard 3-button Coke BreakMate machine by Siemens

Although the practical minimum and maximum ranges of this dispenser will vary depending upon local cost factors (e.g. overhead expenses, etc.) the BreakMate is designed to operate efficiently and profitably with a usage of 12 liters per month to 50 liters per month.  For higher daily volume, the use of additional dispensers is recommended.

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1.1.Introduction #

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1.1.1.Features #

In additional to being compact and lightweight, the BreakMate has many advanced design features:

[Photo and Caption of Syrup Cartridge] [Photo and Caption of CO2 Cylinder]

  • Miniature high pressure water pump
  • Stainless steel carbonator with removable top
  • Pre-set syrup valves
  • Electronic controls with built-in diagnostics system
  • Plumbed, filtered water supply for consistent high-quality drink
  • Optional Quarter-Only or Token Coin Mechanism (Coin Mech)
  • Optional Three-Coin Coin Mechanism with 5 cent to $1.55 per cup pricing
  • 4.5, 6.5 or 10 oz drink size setting (per cup)
  • Internal leak sensor and automatic water shut-off valve

These features and others are described in further detail in the operating sections of this manual.

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1.1.2.Operating The Dispenser #

[Photo of Dispenser with Cup]

To obtain a drink, place a cup in the position noted above.  The placement is noted by an arrow and a cup symbol on the drip tray.  Be certain that your cup is larger than the selected drink size (6, 8 or 12 oz cup).  Press the button for the desired flavor.  If a coin mechanism is attached, insert the coin(s) to make your purchase, prior to pressing the selector button.

The dispenser will automatically dispense your beverage and shut off after the fill is complete.

It is advised to leave your cup under the fill area for 5 seconds or so after the fill sound has ended, to ensure that no extra drips are spilled.

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1.1.3.Filling The Dispenser #

[Photos – Replacing the Syrup & Replacing the CO2]

When a drink is dispensed that is weak or has no syrup, the syrup container is empty and must be refilled / replaced.  Remove the empty container and re-fill.

If the amber light near the selector buttons is flashing, the CO2 cylinder is empty and needs to be replaced.  If using BreakMate CO2 canisters, lift the CO2 locking lever, remove the empty cylinder and replace with a full unit.  If using an aftermarket CO2 adapter with a standard CO2 tank, replace and/or have your tank refilled.

Detailed instructions on how to replace ORIGINAL syrup and CO2 components are listed inside of the syrup compartment door.

To replace the syrup container / syrup cartridge

  • Open the syrup compartment cover / door
  • All syrup valves are identical, so you may place the doser valve on any syrup container (diet or otherwise)
  • Pull out the mixing channel and remove the drip tray
  • Rinse the mixing channel and drip tray with hot water, basic soap and a sponge
    • do not use a dishwasher to clean your BreakMate parts
  • Remove the Syrup Doser Valve from the existing container, bottle or cartridge.
    • To remove the Doser Valve, turn the valve 1/4 turn counter-clockwise
  • Refill your Syrup Container or replace with a new syrup cartridge
  • Rinse your doser valve in warm water and replace onto the new or refilled Syrup Container
    • To re-attach the Doser Valve, turn the valve 1/4 turn clockwise until it clicks.  Be certain that the seal/gasket is firmly seated to prevent leakage.
  • Over a sink, quickly flip the container over to prevent syrup from spilling out.  Give a slight squeeze to the container to check for leaks.
    • [Video for refilling Syrup Containers]
  • Re-Insert the container into the BreakMate
    • The placement of the Syrup Containers is as follows:
      • Left Syrup Compartment = Lowest Selection Button
      • Middle Syrup Compartment = Top-Most Selection Button
      • Right Syrup Compartment = Middle Selection Button
  • Replace / Re-Insert the Mixing Channel, it should “click” into place
    • Be certain that both pieces of the Mixing Channel are replaced, the lower and upper cover components.
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1.1.4.Dispenser Parts Description #

[Photo of Parts – Labelled]

 

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1.1.5.General Specifications #

 

Dimensions: 18″ high x 22″ wide x 11″ deep
Weight Empty: 60lbs
Shipping: 66lbs
Full: 78lbs
Capacity Syrup: 3x 1 liter containers
Water: 2 liters carbonated capacity
CO2: Original 20oz cylinder (1.25lbs)
Drink Size(s) 4.5oz, 6.5oz, 10oz options – dependent on installed options
Drink Capacity ~27 6.5oz drinks @ 1 drink per minute
Continuous Draw 1 drink every 4 minutes
Water Supply Plumbed Water Line Connection (preferred)
15psig minimum, 120psig maximum
Flow Rate – 4 quarts / minute minimum
Electrical 115v, 60hz, 3.5A
7A starting current
.85kwh per day run rate
Refrigeration 1/8 HP Danfoss Compressor
Dual evaporators – water and syrup
Static condenser

Serial Number Code:
Example: FD    68    09    A    00123

FD = Manufacturers Code
68 = Year Manufactured (Add 20)
09 = Month Manufactured
A = Model Description
00123 = Serial Number

Serial Number Plate
[Photo of Serial Number Plate Example]

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1.1.2.BreakMate Installation Guidelines #

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1.1.2.1.General Comments #

The recommended procedure for installing a GA 3000 dispenser on location includes the following general steps.  For first-time setup of previously used, newly refurbished, or unknown condition machines, see the specific BreakmateSource.com article on how to setup/refurbish/startup a BreakMate machine [link to post].

  • Set up the dispenser in your shop and run it overnight before transporting the unit to the customer’s location.
  • Equip your shop workbench with a permanently installed BreakMate Premium Filter for setting up dispenser units.
  • When installing the dispenser on location, use an approved water filter, flush the filter before connecting the water line to the dispenser and check the water flow is adequate and at 4 quarters per minute minimum.
  • Listed below is the typical set of parts for connecting the dispenser to the water line on location.  Users are cautioned to be aware of and comply with applicable local regulations concerning connecting appliances to city water lines.
    • Saddle Valve: 3/8 compression
    • Tubing: 3/8 OD Polyethylene
    • Filter – Cuno CC717 or other approved filter with 3/8 compression fittings
    • Dispenser Fitting – Elbow Fitting 3/8 compression
  • Select a position for the dispenser that is convenient for the customer, near a suitable cold water supply source, near a grounded electrical outlet (GFCI recommended), near a sink with hot-water (for cleaning of parts) and storage for components and spare parts.
  • Install on a level mounting surface with 4″ of clearance over the machine, to allow for proper ventilation of the static condenser units.
  • Note where the saddle valve and filter will be physically installed and where the water line will be.
  • BE CERTAIN TO CHECK ALL CONNECTIONS AFTER INSTALLATION TO ENSURE THERE ARE NO LEAKS
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1.1.2.2.Setting Up The Dispenser, In Your Shop #

  • Connect a filtered water line to the dispenser
  • With the main power-switch in the off position, plug the dispenser power cord into a grounded wall outlet.  [photo of power off]
  • Press the CO2 relief valve button, located on the left side of the CO2 compartment, to release any remaining CO2 pressure.  The system must be started up with zero CO2 pressure.
    • Hold the button in until all gas has been released.
  • Turn on the main power-switch for the dispenser.  The pump will run for approximately 2.5 minutes in order to fill the carbonator.
    • Be certain that your water supply is turned on prior to this step.
  • Install a CO2 cylinder in the dispenser.  Drain the carbonator by following the procedure listed (here – page 4-23).
  • Refill the carbonator.
  • If a coin mechanism is to be used, connect it at this time.
  • If larger drink sizes are to be utilized, and no coin mechanism is installed, a 10oz jumper override will need to be installed.
  • Check the dispenser for operation and allow to run overnight before removal to installation location.  Do not drain the carbonator prior to carbonator.
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1.1.2.3.Filter Specifications #

Activated Charcoal filters must meet certain requirements.  Approved filter lists will be issued periodically from BreakTime Enterprises.

BreakTime Enterprises no longer supplies lists.  The latest/last lists published are located below:

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1.1.2.4.Customer / Client Location Installation #

Using a dispenser set up at your workshop, it is only necessary to install the water line and filter, flush the filter and connect the water line to the dispenser.  Finally, install the syrup and the dispenser is ready to use.  Install the dispenser using the following procedures

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1.1.2.5.Connecting Water Line and Supply Line #

  • Locate the water supply line.  The line must be 3/8″ to 3/” copper tube in order to use a saddle valve.
    • BreakMateSource.com recommendation.  Saddle Valves tend to leak.  If possible, utilize a compression fitting “T” that splits your water line size into 3/8″ OD tubing.  Using 3/8″ OD tubing, connect to a 3/8″ barb to Garden Hose (Female) Adapter.  Attach Female Garden Hose adapter to BreakMate Water Supply Inlet and/or filter.  [Photo]
  • Install the 3/8″ compression saddle valve on the cold copper water supply line.
  • Connect the 3/8″ OD Polyethelene tubing from the saddle valve to the water filter inlet fitting
    • For the best taste and to prolong machine life, a water filter must be utilized.
  • Connect the tubing from the filter outlet to the plastic elbow dispenser fitting furnished with the dispenser.  Attach a 2-inch piece of 3/8″ redline tubing and a 3/8″ barb x 1/4″ MPT fitting.  Tighten the clamps with end-cutting pliers.  Apply Teflon tape to the threaded fitting and screw it into the outlet port of the filter
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1.1.2.6.Flushing the Water Line and Filter #

  • Put the end of the hose in a pail, bucket or sink and turn on the saddle valve by turning it fully to pierce the copper tubing.
  • Run a half pail of water through the line, until it runs clear, to flush air, carbon and loose particulates from the filter and lines.
  • Note the water flow rate.  Water must flow at the rate of 4 quarts or more per minute to provide adequate water supply to the BreakMate dispenser.  The BreakMate will not operate to satisfaction or manufacturer specifications at a slower flow rate.
  • Turn off the water at the saddle valve and connect the fitting to the dispenser.
  • Turn on the water and inspect all connections to be certain there are no leaks present.
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1.1.2.7.Training The Key Operator #

  • Demonstrate doser insertion on one cartridge and have the operator(s) install the other two.  (Use empty containers / cartridges if available)
  • Remove the CO2 cylinder/hookup.  Bleed out the CO2 gas using the purge valve (red button) until the yellow CO2 light blinks.
  • Instruct the operator(s) that this indicates that the dispenser is out of CO2.
  • Have the operator(s) install / replace the CO2 cylinder/hookup.
  • Demonstrate the removal of the mixing channel and drip tray.
  • Demonstrate the cleaning procedure for the mixing channel and drip tray.
    • Emphasize that this must be done daily.
  • Show the key operator(s) how to remove, clean, and replace the screen in the mixing channel.
  • Show the key operator(s) how to properly position the mixing channel cover on the mixing channel and be sure the channel “clicks” into place when replacing it into the dispenser.
  • Show the key operator(s) where to store syrup, CO2, cups and other useful items.
  • If possible, ask the operator(s) to keep at least 1 liter of each syrup in the refrigerator.
  • Review the troubleshooting guide with the key operator(s).
  • Write your service phone number on the instructions inside the syrup compartment cover.
  • Demonstrate how to use the coin mechanism, if attached, showing the drink selection switch and ‘free drink’ switch.
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1.1.2.7.1.Checking the Dispenser #

  • Draw one drink of each flavor and not the drink level in the cup.
  • A 6.5oz drink delivered into a standard 7oz (paper) cup should fill the cup to approximately 1/8″ from the top.
  • If one or more drinks differ from this level, the carbonated water flow may be adjusted by turning the water flow adjustment screw (located at the water outlet).
    • A clockwise turn (one full rotation) increases water flow by 2/3 oz.
    • Make only small changes to the water flow at one time.  Large changes or over or under adjusting may cause damage to the dispenser.
  • Clean up the area around the dispenser.  Set out a tub of cups in a convenient sanitary location, if requested.
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1.1.2.7.2.Troubleshooting Guide #

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1.1.2.7.3.Most Common Problems - Correctable by the Key Operator(s) #

Common problems, that may be resolved without advanced troubleshooting, and therefore, correctable by the key operator(s) on-site are indicated by the signal lights on the selector panel.  The taste and drink size selection lights will indicate common problems that can be corrected by the key operator(s).

Problem Description   Resolution Steps / Procedure to Fix the Problem
Weak Drink or No Syrup   Delivery of a short portion of syrup causing a weak drink or a drink with no syrup is caused by a Syrup Cartridge or Syrup Container that is close to or out of Syrup.  Replace or Refill the container to resolve the issue.
Flashing Yellow Light   A Flashing Yellow indicator light on the selector panel indicates that CO2 pressure is low.  Replace / Refill the CO2 cylinder to resolve the issue.
Drink is not Dispensed / No Drink is Delivered   If there are no lights on the selector panel, the unit does not have power.  Restore power by checking GFCI outlets, power strip connections, power cords and the main power switch on the Dispenser.  The on-off switch on the BreakMate dispenser should be in the “up” or I (on) position.
Top Green Light is Flashing   This indicates a water-supply issue.  Check the water supply to the BreakMate dispenser and be certain it is on.  Turn the on-off master switch for the dispenser to the off position, remove the CO2 cylinder, purge all CO2 out of the system by pressing the red CO2 release button until the red button stays depressed and all CO2 has been purged.  Power the unit back on (without CO2).  If the pump runs continuously until the green light flashes again, you may need to call for service.  Do not continually repeat this process as it may cause permanent damage to your dispenser.
Lower Green Light is Flashing   This signal indicates a potential internal water leak or overflow of your BreakMate dispenser unit.  Contact service.
Drinks are Dispensed Slowly   Check the screen outlet in the mixing channel as it may be permanently or temporarily blocked (by ice or debris).  The screen should be removed for cleaning by pushing it up and out of the mixing channel (once removed from the unit).  When replacing the screen, it should be pressed firmly in position.
Mixing Channel Overflows   Check the position of the mixing channel to be sure it is pushed fully into the dispenser, until it clicks.  The mixing channel cover must be positioned correctly into the recess on top of the mixing channel or the syrup may flow over the top of the mixing channel.  If using primarily soda-water, this is a common problem, as there is no Syrup to warm the near-ice-cold carbonated water.  See BreakMateSource.com for a potential fix/replacement screen.
Loud Pump Noise   An unusually loud pump noise indicates water flow has been shut off, or the pump is beginning to fail.  Check the water supply at the inlet valve to be sure water is flowing and there is no air lock in the filter.  Turn the BreakMate unit off and on, remove the CO2 cylinder and purge all CO2 from the system.  Turn the unit back on.  After the pump stops, insert the CO2 cylinder.  Do not repeatedly attempt this process, as doing so may cause permanent damage to your BreakMate dispenser.  Contact your service representative for further assistance.

Syrup Yield is Low
(Expected Drink Count is not met)

  The standard yield for a 1 liter syrup container is ~ 31 +/- 1 drinks for all syrup flavors, at 4.5oz drinks.  If the yield is significantly less, there may be a syrup leak.  Check that the doser valve is completed seated in the container.  Check the doser valves for leakage.  One way to test for a leaking syrup doser valve is to check the drip tray and/or mixing channel screen for pure syrup when no drinks have been dispensed.

Syrup yield estimates are based upon syrup temperature at 45 degrees F.  Warm syrup – such as at room temperature – will yield fewer drinks per liter.

     
     
     
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1.1.2.3.Coke BreakMate Accessories #

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1.1.2.3.1.Coin Mech Attachment #

There are two types of Coin Mech attachments available for the BreakMate.  Both coin mech attachments are attached to the right side of the dispenser.  The cable from the coin mech is fed through the hole at the bottom right rear of the dispenser (if looking at the front of the unit).  The coin mech plug(s) are attached to the control board.

  • Both coin mechs have locked cash boxes and are furnished with two keys.
  • Both coin mechs have 6.5 and 10oz drink size selection switches.
  • Both coin mechs have “free play” or “free drink” selection switches.

With both coin mechs, the drink size selection is only operational when the “free play / free drink” switch is set to the Coin Mech position.  If set for free-vend the drink size selection does not operate and standard sizes are utilized.

Drink size and “free play / free drink” selection switches are located just above the cash box and accessible when the cash box is removed.

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1.1.2.3.1.1.Installation Procedure - Standard Coin Mech #

  1. Turn off power to the Coca Cola BreakMate dispenser.
  2. Unplug the power cord from the power source.
  3. Remove the selector panel cover [insert link to how to].
  4. Remove the control board by loosening the two retaining screws and carefully lift the panel out.  Be careful not to damage the circuits, plug(s) and fuse(s).
  5. Unpack the coin mech.  Feed the cable plug(s) through the hole in the back of the dispenser following this order:
    1. Two white single connectors should be fed through the hole first
    2. The two wire angle connector should be fed through next
    3. The gray connector should be fed through last
    4. Feed the cables towards the front of the machine, until they are visible in the opening behind the control board retaining area.
  6. Remove the “10 oz jumper” if it is installed on the control board.
  7. Slide the grommet down the cable to the hole and snap it into position.
  8. (missing this step here to plug in the cables?
  9. Remove the covering from the self-adhesive pad on the side of the Coin Mech and press the Coin Mech into position on the right-side of the dispenser (looking from the front).
  10. Attach the three mounting brackets (straps) to fasten the coin mech to the dispenser.
    1. One at the top rear
    2. One at the bottom rear
    3. One at the front, underneath
  11. Remove the cash box and set the switch for drink size – regular or large.
    • Be certain that the “Free Play” or “Free Drink” switch is in the “Coin-Op” position, when setting the drink size switch.
  12. If using a GM3000 (3-coin coin mech), set the price switch.
  13. If using a GM1000 (single coin coin mech), check the setting for coin or token.
  14. Replace the cash box into the coin mech.
  15. Apply appropriate price label(s).
  16. Insert coin/token and test machine operation.
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1.1.2.3.1.2.Installation Procedure - 3-coin Coin Mech Installation (GM3000) #

  1. Turn off power to the Coca Cola BreakMate dispenser.
  2. Unplug the power cord from the power source.
  3. Remove the selector panel cover [insert link to how to].
  4. Remove the control board by loosening the two retaining screws and carefully lift the panel out.  Be careful not to damage the circuits, plug(s) and fuse(s).
  5. Unpack the coin mech.  Feed the cable plug(s) through the hole in the back of the dispenser following this order:
    1. Two white single connectors should be fed through the hole first
    2. The two wire angle connector should be fed through next
    3. The gray connector should be fed through last
    4. Feed the cables towards the front of the machine, until they are visible in the opening behind the control board retaining area.
  6. Remove the “10 oz jumper” if it is installed on the control board.
  7. Slide the grommet down the cable to the hole and snap it into position.
  8. Locate the two white plugs for CO2 at the left of the control board compartment [PHOTO]
    1. Attach the two white plugs to the identical plugs on the coin-mech cable (male to female) [PHOTO]
    2. Connect the grey 7-channel plug to the Control Board [PHOTO]
    3. Connect the 2-channel plug to the remaining gap on the Control Board
  9. Remove the covering from the self-adhesive pad on the side of the Coin Mech and press the Coin Mech into position on the right-side of the dispenser (looking from the front).
  10. Attach the three mounting brackets (straps) to fasten the coin mech to the dispenser.
    1. One at the top rear
    2. One at the bottom rear
    3. One at the front, underneath
  11. Remove the cash box and set the switch for drink size – regular or large.
    • Be certain that the “Free Play” or “Free Drink” switch is in the “Coin-Op” position, when setting the drink size switch.
  12. If using a GM3000 (3-coin coin mech), set the price switch.
  13. If using a GM1000 (single coin coin mech), check the setting for coin or token.
  14. Replace the cash box into the coin mech.
  15. Apply appropriate price label(s).
  16. Insert coin/token and test machine operation.
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1.1.2.3.1.3.Single Coin Coin Mech Operation (GM1000) #

[Photo of GM1000]
The GM1000 (GM-1000) single coin mech is shipped for use at $0.25 sale with quarters only.

To set the coin mech to use BreakMate tokens instead of quarters

  • unlock and remove the cash box.
  • Remove the screw at the top of the cash box opening and pull the mech forward.
  • Remove the screw holding the plastic rail.
  • Invert the plastic rail on the side of the coin acceptor and replace the screw.
  • Replace the coin mech back into the cabinet/housing.

[Video or GIF of actions]

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1.1.2.3.1.4.3-Coin Coin Mech Operation (GM3000) #

The GM3000 (GM-3000) 3-coin coin mech accepts any combination of nickels, dimes, and quarters with a single price setting.  Price per cup may be set anywhere from $0.05 to $1.55 in $0.05 increments.

To set the price on the GM3000, use the following steps:

  • [insert instructions to remove the coin mech from the housing]
  • Find the 5 small price switches located in the lower left interior of the coin mech. [photo]
  • Each switch that is turned on adds up to the selling price.
  • Switches are numbered 1-5 and their values are: 5, 10, 20, 40, and 80 cents.
  • Push the switches to the “up” or “on” position that will add up to your desired sale price
    • For example, if you wish to charge $.25 for one drink, you would turn the following switches to the “on” or “up” positions: $.05 and $0.20 [Photo of Switches]
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1.1.2.3.1.2.CO2 Cylinder Filling Guideline - General Comments #

Filling a small CO2 cylinder from a large supply cylinder requires a higher pressure in the supply cylinder than in the small cylinder in order to force the liquid CO2 into the smaller cylinder.  The pressure difference is attained by cooling the small cylinder, since gas pressure drops as temperature drops.  The supply cylinder must be at room temperature of 72 degrees F or higher (do not heat the supply cylinder) and the small cylinder at 0 degrees F or lower to cause liquid CO2 to flow.  A 20lb. supply cylinder will fill approximately 12-13 GA3000 (GA 3000) cylinders.  A 50lb supply cylinder with dip tube will fill approximately 25-28 cylinders.

[Chart of CO2 Pressure (PSIG) vs CO2 Temperature F]

Users must be aware of and comply with all applicable regulatory codes and safety practices when installing equipment and filling cylinders.  Users remain responsible for all decisions, including those with respect to acceptance, rejection, or modification of information contained in these guidelines.

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1.1.2.3.1.2.1.Equipment Required #

  • CO2 cylinder filling head – with gauge and high pressure hose
  • CO2 supply cylinder(s) – 50 lb cylinder with dip tube recommended
  • Scale – 5 lb capacity, 1/2 oz graduations (ex. postal scale)
  • Empty CO2 Cylinders – 1.25 lb (20 oz) capacity (BreakMate Specific)
  • Plastic cylinder caps
  • Chest type freezer set for 0 degrees to -10 degrees F
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1.1.2.3.1.2.2.BreakMate CO2 Cylinder Filling Procedure #

There are two styles of fill stations produced.  The older style BA101 and the newer BA141.  Instructions for using both filling stations are listed in the chart below.

OLD BA101 NEW
BA141
  Instructions
x x   1. Cool the small cylinders by placing them in the freezer.  Allow at least six hours to reach proper cooled temperature.
x x   2. Set up the filled 50lb drip tube supply cylinder in an upright position, or, if using a 20 lb cylinder, invert it on a rack.  The supply cylinder(s) should be secured where it cannot be knocked over.  With the supply cylinder tethered or otherwise secured, ensure that the supply cylinder is at room temperature, 72 to 90 degrees F.  The pressure gauge should read 750 psi or higher.
x x   3.  Attach the CO2 line from the filling head to the supply cylinder.  Be sure the o-ring seal is in place in the connection fitting.  Tighten by hand – a wrench may not be necessary.
x     4.  Close the inlet and vent valves at the filling head.  The closed position is indicated by the valve handle at the right angle to the line.
x x   5.  Place a cooled cylinder into the fill head and firmly secure the latch.
x x   6.  Open the valve on the Co2 supply cylinder.
x     7.  Open the fill valve at the fill head.
x x   8.  Allow gas to flow into the cylinder for 45 seconds or until the gas stops flowing.
x     9.  Shut off the fill valve and open the vent valve.  A loud hiss will be heard and seen as vapor, as the head is vented.
x x   10.  Light the latch and remove and weigh the cylinder.  The cylinder is properly filled if the weight is between 3 lbs 3 oz and 3 lbs 5 oz.  Do not exceed 3 lbs 5 oz (53 oz) total weight, as this may damage the cylinder.  Bleed off any excess gas, if necessary.  Every cylinder must be weight after each fill.  If the cylinder is under-filled, it may be necessary to re-cool it in order to allow the cylinder to accept more CO2.
x     Close the vent valve
x x   Insert an empty cold cylinder and close the latch
x     Open the inlet valve to fill the next cylinder.  Repeat all required steps to re-fill all cylinders, as necessary.

CAUTION:  Use a glove to protect your hand as the cylinders are at 0 to -10 degrees F.  Ensure that all cylinders are properly certified prior to filling and do not fill expired cylinders.

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1.1.2.3.1.2.3.Sources of Supply #

The original sources of supply as listed by BreakTime industries mostly no longer service BreakMate cylinders.  Most CO2 shops no longer carry the proprietary CO2 filling station(s) in order to fill the BreakMate cylinders.  As such, most users will obtain a CO2 external adapter / conversion.  More information on how to create or utilize an external BreakMate CO2 adapter, or for instructions on where you may purchase a pre-made unit, please visit our [CO2 Adapter] page.

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1.1.2.3.1.2.3.Portable Water Supply System - BA104 #

The BA104 portable water supply system provides a means to operate the BreakMate dispenser where it is not feasible to connect the BreakMate to a water line.

A stainless steel tank provides a capacity of 3.0 gallons of water – enough for approximately 75 6.5oz drinks.  The pump provides a constant water pressure to the dispenser, shutting of when the pump outlet pressure reaches about 50 psi.

A built-in timer cuts off the pump if the water tank runs empty.  The system is equipped with an in-line water filter and an elbow connector for the dispenser water inlet.

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1.1.2.3.1.2.3.1.Operating Instructions #

  1. Unpack the supply unit and remove the cover from the water tank.
  2. Inspect the tank interior to be sure no foreign materials have entered the tank.
  3. Place the supply system in a convenient location.
  4. Fill the tank with clean tap water and replace the tank cover.
  5. Prime and flush the system:
    1. Connect the pump inlet fitting to the tank.
    2. Put the filter outlet fitting into the container to catch the flushed water.
    3. Plug the line power cord into an electrical outlet.
    4. Allow at least one gallon of water to flow through the system to flush the filter.
    5. Unplug the power cord.
  6. Connect the system to the BreakMate dispenser.
  7. Remove the CO2 cylinder and purge all existing CO2 from the system.  To purge the system, press and hold the red pressure-release button to the left of the now-removed CO2 tank until no more CO2 is present (and the button remains depressed without pressing it).
  8. Connect the elbow fitting to the rear of the dispenser.
  9. Plug in the power cord and press the reset button on the pump.
  10. The pump will run for a few seconds and stop.
  11. Check all connections/fittings for leaks.
  12. Check that the cover is on the water tank and in the latched position.
  13. Turn on the dispenser and complete the standard BreakMate startup procedure (found elsewhere in this guide).  Replace the CO2 cylinder in the dispenser when the carbonator tank has filled with water.
  14. Fill the water tank, at a minimum, daily.  If the tank runs empty and shuts off the pump it is necessary to fill the water tank and press the reset button.  You will also need to re-purge the BreakMate of CO2 pressure before the system will operate again.
  15. Be sure the cap fitting is not removed from the inlet fitting on the water tank, as this fitting allows air to enter the tank when water is drawn off.
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1.1.2.3.1.2.3.2.Operating Comments & Notes #

  • If the water line fitting is disconnected from the water tank and the line is filled with water, the pump will shut off during pumping.
  • If the BA104 (Water Supply System) tank runs empty, it may be necessary to purge the carbonator of all CO2 and draw a drink several times to push all the air in the line through the system.  To avoid potential system issues and avoid this inconvenience, do not let the water supply tank to be run empty.
  • When latching the tank cover, place the cover in the tank so that when the cover is latched, the cover latch handle is towards the tank handle.
  • The water system is available as separate components for use with other water containers.  The BA105 (BA 105) base/motor assembly and BA103 (BA 103) tank assembly may be purchased separately.  The BA120 (BA 120) water cap kit is used to connect the BA105 (BA 105) to a five gallon water bottle, if you wish to supply your own 5-gallon bottled water to the BreakMate
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1.1.2.3.1.2.3.3.Everpure Filter - BA113 (BA 113) #

Installation Kit for the BA113 (BA 113) Everpure Filter Kit is listed below.  BREAKMATESOURCE.COM NOTE: Sources listed are original and may no longer be available.

Qty Item Part Number Source
1 3/8″ Compression Saddle Valve HV105-D6 Portage
1 10′ 3/8″ OD P.E. Tubing PE-64 Portage
1 Filter Mounting Plate BA-114 (BA114) BTE
1 Everpure Head with 3/8 Compression Elbows BA-115 (BA115) BTE
2 Oetiker Clamp 170 17.0-706R C/W
1 3/8″ Compression to 3/8″ Barb Fitting C/W
1 3/8″ ID Red Line Tubing – Approx 2″ long C/W
*Use plastic elbow shipped in the dispenser with the parts listed above.

       
  *Order filter cartridge(s) separately    
  BreakMate Premium Filter BA-116 (BA116) BTE
  BreakMate Fine Filter BA-118 (BA118) BTE
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1.1.2.3.4.BreakMate Principles of Operation #

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1.1.2.3.4.1.Carbonated Beverage Characteristics #

General Comments

  • A carbonated beverage is composted of three elements: water, CO2 gas, and beverage syrup.
    • These elements must be cooled, combined, mixed, and delivered in the correct proportions by a dispensing mechanism to form a quality carbonated beverage.
    • Each of these elements and the relationship between them are described below.
  • The sections that follow in this chapter describe the mechanisms and operating principles used by the BreakMate system to combine and dispense a quality beverage.

Water

  • The water used to make carbonated beverages must be taste and odor free with minimum amounts of dissolved gases, minerals or other materials.  Additives from many city or municipal water sources may be removed with the use of an activated charcoal filter.

CO2 Gas

  • The CO2 gas used to make carbonated water is furnished in liquid form in a high pressure cylinder containing approximately 1.3 lbs of CO2.
  • BreakMate CO2 Cylinders are obtained from your supplier.
  • The CO2 gas in liquid form is stored in the cylinder at pressures around 800 psi and the liquid is converted to a gas with the pressure being reduced to 75 psi for use in the carbonator.

Syrup

  • Syrup for the BreakMate is required to be dispensed from proprietary patented 1 liter bottles, in a variety of flavors.
  • The date of packaging should be noted for inventory purposes to assure peak flavor of the final product.
  • Be sure to control syrup inventory to assure use within 90 days of the date on the cartridge.
  • BREAKMATESOURCE.COM note:  Syrup is no longer manufactured in the US by Coke, GoodTime Syrup, nor any other supplier; however, GoodTime syrup bottles may be re-filled with off-the-shelf Bag-In-Box (BIB), standard, soda-fountain 5-1 mix soda syrup.  These bottles, two, are becoming more difficult to find due to diminishing stock.

Temperature

  • A quality carbonated beverage must be served at a temperature of 40 degrees F or lower (ideally, 34-36 degrees F)
  • higher drink temperatures will cause a rapid loss or carbonation, once dispensed, and a loss of overall drink flavor and quality.
  • The storage temperatures of ingredients in the BreakMate dispenser are 45 degrees F for syrup and 32 degrees F for carbonated water.

Carbonation

  • Carbonation is the presence of CO2 gas which has been dissolved in water.
  • CO2 gas forms a mild (carbonic) acid when dissolved into water.  Carbonic acid is what gives a drink that “tangy taste” and forms bubbles when the drink is poured.
  • The amount of carbonation in the drink is measured in “volumes”, indicating the number of units of gas dissolved in the same size unit of water.
  • The usual level of carbonation in a finished drink, such as a Coca-Cola, is 3.5 volumes of CO2 gas.
  • The carbonation level is measured with a device called a carbonation tester.

Brix

  • To “brix” a machine, is to measure the amount of sugar that is present in a liquid or soft drink.
  • Brix is measured in degrees (11.5 degrees brix for example) and is the measure of the percentage of sugar, by weight, dissolved in a liquid.
  • A soft drink containing 10% sugar by weight is a 10 degree brix drink.
  • Popular soft drinks have a brix of 10 degree to 12 degrees depending on the type of drink.
  • Brix is commonly measured using a refractometer, a hand-held optical instrument, in which the refraction index of the sugar solution is read in degrees brix directly on the view plate of the refractometer.
  • The sweetness of Sugar Free drinks cannot be expressed or measured in brix, because sugar is not used as a sweetener; therefor, the syrup to water ratio must be used.

Syrup Ratio

  • Syrup Ratio is the proportion of water to syrup used to make carbonated beverages or soft drinks.
  • Syrups are manufactured with different formulations of sweeteners and flavorings and the syrup manufacturers ratio must be followed to obtain the desired flavor level in the drink.
  • Syrups used for the BreakMate dispenser may have ratios between 5.0 and 6.0 units of water to one unit of syrup.
    • For example, Coca-Cola Syrup has a 5.0 to 1.0 oz ratio (5:1) – meaning one ounce of Coca Cola syrup to five ounces of water to make one six ounce drink.
  • Syrup portions for the BreakMate are predetermined by the syrup dispensing valve (doser valve).
  • In the Coke BreakMate machine, you may measure the syrup ratio by removing the mixing channel and measuring the syrup and water separately.
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1.1.2.3.4.2.Coca Cola BreakMate Drink Specifications #

A casual drink (a drink that has been drawn by itself after a machine rest period of a few minutes), is the normal drink served by the dispenser.  The casual drink will be close to the following specifications:

Carbonation   3.6 Volumes
Temperature   34 degrees F
Syrup Ratio / Brix   Coca-Cola    –     5:1 / 11.5 degrees Brix
Diet-Coke     –     5.1 /  N/A Brix
Sprite           –     5:1 / 11 degrees Brix
Syrup Throw   32 ML +/- 1 (1.1 oz)    /   48 ML (1.6 oz)
Water Portion   160 ML +/- 5 (5.4 oz)   /   240 ML (8.1 oz)
Drink Sizes   192 ML (6.5 oz)   /   288 ML (9.7 oz)
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1.1.2.3.4.3.The Dispensing System #

[Photo / Diagram of the Dispensing System]

The diagram above shows the major components of the dispensing system and how they are connected when operating in the Coca-Cola BreakMate dispenser.

The system operates as follows:

  • Water flows under pressure from the water line, through a water filter, to the hose connection and inlet valve at the rear of the unit.
  • When the water pump is energized, the inlet valve opens to allow water to flow into the pump.
  • The pressure is raised by the pump to 75 psi.
  • The high-pressure water is fed into the top of the carbonator through a water line connected to the top of the carbonator.
  • Carbon Dioxide gas (CO2) is stored in the CO2 cylinder in liquid form at a pressure of 800 psi.  The cylinder feeds CO2 gas to the CO2 regulator.
  • The CO2 regulator reduces the 800 psi pressure gas to ~75 psi and then feeds it through a tube into the top of the carbonator where it is available for carbonating the water and providing delivery pressure for carbonated water.
  • The carbonator is a stainless steel water reservoir where the water is cooled through the use of an ice bank.  The water is carbonated through agitation and stored for deliver via the outlet valve.
  • The agitator continously circulates the water in the carbonator, providing cooling to incoming water by directing the water against the ice bank on the inside wall of the carbonator tank.  As the water is circulated, CO2 gas is drawn into and mixed with the water to form carbonated water.  The carbonated water is available for delivery through the outlet water valve.
  • When a drink is dispensed, the outlet valve opens, allowing cabonated water to flow into the mixing channel where it is mixed with syrup and delivered to the cup.
  • The syrup is provided in cartridges fitted with a syrup valve or ‘doser valve’ that delivers two (for 6.5 oz drinks) or three (for 10 oz drinks) measured portions of beverage syrup into the mixing channel.  In the mixing channel, the Syrup dispensed mixes with the carbonated water to form the finished drink being delivered to the cup.
  • The mixing channel blends the syrup and water to insure complete mixing when the drink is poured.  The water flow is timed to wet the channel before the first 1/2 portion of syrup is delivered and to rinse it after the second half portion of syrup is dispensed.  The timing assures complete mixing and eliminates most chances of any carry-over flavor from a previous drink.
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1.1.2.3.4.4.The Water Pumping System #

[Photo of the Water Pumping System]

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1.1.2.3.4.5.The Water Pump Assembly #

The water pump is a high speed impeller pump, operating at 10,000 rpm to deliver water at a rate of 20 gallons per hour, or, 1/3 gpm, into the carbonator against the 85 psi carbonator pressure.

Water entering the dispenser at the fitting at the back of the cabinet is admitted by the inlet valve which opens at the same time the pump is energized.  The inlet valve also contains a flow washer which limits flow to 1/3 gpm.  Water is fed to the pump inlet through a plastic tube.

Water enters the water inlet fitting and is picked up by the cavities in the impeller and delivered at high velocity through the water outlet and check valve to the carbonator.  The impeller is pressed onto the motor shaft and held in place by a woodruff key (shaft key).  The shaft is sealed against leakage by shaft seals.  The pump assembly is fastened to the pump motor by four screws, holding the cover plate to the pump body, sealed by a seal ring.

The check valve prevents carbonated water or CO2 gas from the carbonator backing up into the pump if the inlet water pressure is below 75 psi carbonator pressure.

The water pump is primed by incoming water pressure and must not be run dry nor at zero flow rate or the impeller will overhead and disable the pump.  As discussed under the “installation” section, the CO2 pressure must be vented from the carbonator when initially filling the dispenser to permit full flow rate of water during initial filling.

Note: The pump is mounted on flexible bushings to minimize noise.  When replacing a pump, be certain to remove the plastic bushing supports and transfer them to the new pump.

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1.1.2.3.4.6.The Carbonator Assembly #

[photo of carbonator assembly]

The carbonator is the heart of the dispenser and provides these major functions:

  1. Cooling incoming water to 32 degrees F for the best carbonation conditions and drink cooling.
  2. Maintaining an “ice bank” to provide for capacity to cool successive drinks.
  3. Providing carbonated water by combining CO2 gas with water.
  4. Storing a quantity of carbonated water for ready use when dispensing drinks.

The carbonator body is a stainless steel tank with a capacity of one-half gallon.  A refrigerated coil wrapped around the tank body cools the water and freezes to form the ice bank.  The water inlet and CO2 inlet fittings are located at the top of tank.  A water outlet fitting on the bottom provides an exit for the carbonated water.

A removable top cover provides access to the agitator, mounts the pump electrode water level control probe, and feeds the agitator supply wire into the carbonator.  The top cover is sealed with a plastic gasket.

The pump electrode controls the water level.  When the water level drops below the bottom of the electrode, the flow of electrical current is interrupted and signals the control module to run the pump until the water level reaches the electrode.

The tip of the ice bank electrode is below the water surface and next to the tank wall where ice will cover the exposed tip of the electrode when the water freezes to form the ice bank.  When ice covers the tip of the ice bank electrode, it insulates the tip and interrupts the flow of electrical current to signal the control board to turn off the refrigeration to the carbonator.

A second ice bank electrode in the carbonator is used in overseas units, not in US dispensers.

Under normal operating conditions, the carbonator will have a two-pound ice bank and will store about 40 oz of carbonated water at 32 degrees F.

BREAKMATESOURCE.COM COMMUNITY NOTE: Water cools down to 25 degrees F before ice bank starts to form.  As the ice bank forms, the water temperature goes up to 32 degrees F.  If water is drawn at 25 degrees F, ice crystals will form in the mixing channel and block the mixing tray screen, causing a backup and perhaps overflow the mixing channel.

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1.1.2.3.4.7.The Agitator #

[Photo of Agitator]

The agitator is a continuously running, submerged, motor-driven impeller that circulates water coming into the carbonator.  The constant circulation melts the ice bank to attain a water temperature of 32 degrees F (0 degrees C), the ideal temperature for carbonation.

As the impeller circulates the water, a standpipe extending above the surface of the water into the CO2 gas has two small holes to admit CO2 gas.  The gas it then pulled in and mixed with the water and absorbed as gas bubbles are pumped into the water flow and rise to the surface.  This process continuously carbonates the water and prevents freezing of the water.

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1.1.2.3.4.8.The CO2 Pressure Regulator #

[photo of CO2 regulator]

The CO2 pressure regulator provides the following functions:

  • Reduces pressure of CO2 gas from 800 psi (in the tank / cylinder) to 75 psi for use in the carbonator.
  • Provides a pressure-release valve to bleed off gas pressure in the carbonator before initially filling the carbonator and when replacing parts in the water or CO2 systems.  Pressing the red pin after removing the CO2 tank/cylinder allows the carbonator pressure to be vented.
  • safety valve set for 90 psi will automatically open if the regulated pressure or pressure in the carbonator reaches that level.
  • A ball check valve stops CO2 gas or water from the carbonator from backing up to the regulator and CO2 cylinder when the cylinder is removed or empty.

The CO2 regulator operates to reduce CO2 pressure from 800 psi to 75 psi by controlling the amount of gas pressure against the piston.  When the CO2 cylinder is inserted into the regulator, the pin actuator in the regulator presses against the valve pin in the cylinder head.  Gas coming into the regulator moves the piston back until 75 psi pressure is developed against the piston.  At that point, the piston has moved the pin actuator back far enough to allow the valve pin to move forward, shutting off the gas flow.

As gas is used, the pressure drops, allowing the spring to push the piston and pin actuator forward, thus maintaining a constant pressure.

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1.1.2.3.4.9.The Water Outlet Valve #

The water outlet valve has the following functions:

  • Turns the carbonated water flow on and off as required
  • Maintains a constant flow rate for carbonated water even with variance in carbonator pressure.
  • Provides an external means of adjusting water flow to provide the correct syrup to water ratio.  The adjustment screw is available at the water outlet.
  • Directs the flow of carbonated water into the mixing channel.

The outlet valve is an electronically operated solenoid valve with an adjustable flow control built into the outlet side of the valve.

Carbonated water at 75 psi flows from the bottom outlet of the carbonator to the water inlet of the valve.  When the valve is energized, the valve plunger lifts allowing the water pressure to life the diaphragm and go the flow regulator.  Water pushes the piston downward and flows through a sized hole in the top of the piston, to the water metering holes.  As the holes align, the pressure drop at the holes is counteracted by the pressure of the spring, maintaining a constant flow rate.

Turning the adjustment screw clockwise increases the flow rate by about 20cc (2/3 oz) per turn.

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1.1.2.3.4.10.The Syrup System #

[Photo of Syrup Container and Doser]

The Syrup System is made up of the syrup package / syrup container and the syrup valve or doser.   The syrup package is a sealed one liter (33 oz) container which stores the syrup and provides part of the syrup measuring system in the proportioning device or “spyder” in the neck of the package.  Each package is labelled and dated.  To ensure top quality drinks, syrup should typically be used within 90 days.

BREAKMATESOURCE.COM NOTICE:  The above paragraph is the original description from the L2 manual.  At this time (August 2016), Coca-Cola and GoodTime Syrup no longer produce Syrup packages new.  Any syrup that is still pre-packaged is likely very out of date.  At this time, most consumers re-use the GoodTime syrup bottles by refilling them from BIB (Bag In Box) Syrups.  Also, non-diet Syrups generally last about a year before noticeable syrup flavor distortion is evident.  Diet Beverages (or any syrups made with non-sugar or sugar substitutes may experience flavor distortions after approximately 6 months.

The syrup valve is a volumetric measuring device which accurately measures the amount of syrup dispensed.  When the valve is attached to the syrup package, syrup fills the dosing piston as shown in the diagram above.  When a drink is drawn, an electromagnet in the cabinet lifts the dosing piston, sealing the top of the piston against the proportioning device (spyder).  The seal ring at the lower end of the piston is lifted, allowing the syrup portion to pour into the mixing channel.  The sypder displaces enough syrup to fix the portion for the particular syrup in the package.

One syrup portion is the correct amount for three oz of finished drink.  Two portions are delivered for a six oz drink and three portions are delivered for a nine oz drink.

The syrup valves are set to deliver the correction portion of syrup cooled to a temperature of 45 degrees F (7 degrees C).  Syrup at room temperature will be delivered in slightly larger portions, so, storage of a few liters of syrup in a refrigerator is recommended, for prompt replacement when needed.

The three syrup valves are identical even though they are used on syrups with different viscosities.  The difference between syrups is corrected by the use of an insert in the syrup container, which is put into the container when packaged.

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1.1.2.3.4.11.The Refrigeration System #

[Photo of Refrigeration System]

The purpose of the refrigeration system is to cool the carbonator and the syrup compartments to provide syrup and carbonated water at such temperatures as to deliver a finished drink at 35 degrees F (2 degrees C).  A further purpose is to build an ice bank in the carbonator to provide cooling capacity for drawing drinks in quick succession.

A refrigerator system operates by removing heat from an area to be cooled.  In a system of this type, heat removal is accomplished by compressing freon gas so that the temperature of the gas rises.  The hot gas is then cooled in a condenser, removing heat.  The gas condenses to a liquid which is further cooled in the condenser and fed to the evaporator where it vaporizes by absorbing heat, and then goes back to the compressor.

In the diagram above, the components of the system are shown as used in the GA 3000 BreakMate dispenser.  The compressor is supplied with freon gas at its inlet.  Gas is compressed in the compressor and the gas temperature rises to about 160 degrees F (72 degrees F) and the pressure rises to approximately 150 psi (15 bar).  The hot gas flows to the static condenser where the gas is cooled and condenses to a liquid.  The freon charge in the system is 3 oz or 90 grams.

The liquid freon flows through a dryer to the transfer valve, a three-way solenoid valve which directs the flow to the capillary tube going to the evaporator coils on the carbonator.  The capillary is a small copper tube about 20 feet long, which has a small inside diameter and controls feeon flow.  As the liquid freon flows through the vaporator, it vaporizes and the gas temperature drips to about -10 degrees F (-24 degrees C) as it enters, warming up to 20-30 degrees F as it exits and returns to the compressor.

 

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1.1.2.3.4.11.1.The Syrup Cooling Compartment #

[photo of evaporator/refrigerator system]

When the carbonator cools down, a layer of ice 1/2″ to 3/4″ thick forms on the inner side wall of the carbonator and covers the tip of the ice probe. This event signals the electronic control to operate the transfer valve to direct freon flow to the syrup cooling compartment.  When the syrup is cooled, the temperature sensor signals the electronic control to shut off the compressor.

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1.1.2.3.4.11.12.The Electrical System #

[Diagram of Electrical]

The various electrical components are shown in the ‘block diagram’ above, that shows the general layout and connection of the parts.  The schematic drawing is shown elsewhere in this manual.

When the line cord is plugged into an electrical outlet, power flows to the main switch that controls both sides of the line.  The agitator is connected directly to the line after the main switch, and runs continually as long as the switch is in the powered-on state.

The power line then goes to the control board for electronic control of all other electrical components.  All other components are controlled by the control board circuitry.

The drink dispensing, initiated by pressing a selector button, is controlled by timers in the control board to turn on and off the selected doser coil for the flavor that is desired and to turn on the water outlet valve for the amount of time to dispense carbonated water to make the finished drink.

The water probe in the carbonator senses the water level.  When the water level drops below this electrode, current is interrupted, signaling the control board to start the water pump until the water level again reaches / touches the probe.

The ice bank probe sends a small signal current through the carbonated water.  As long as this current flows, the current flow signals the control board to run the refrigeration compressor to cool the carbonator.  When enough ice forms to cover the probe, the ice insulates the probe, shutting off the current flow.  The control board then energizes the refrigeration transfer valve to divert freon to cool the syrup compartment. 

The syrup temperature control signals the control board to turn off the compressor when an ice bank is formed in the carbonator and the syrup compartment is cold.

The water leak sensor is a contact located just behind at the left of the control board, spaced about 1/16″ (1mm) above the metal base inside the dispenser.  If water leakage from internal parts occurs, or failure of the pump control permits water to leak inside the dispenser, the sensor signals the control board to shut down the water inlet valve, water pump, and selection system so no more water can be admitted to the dispenser.  The lower green light flashes until the problem is corrected.

The CO2 empty indicator light is operated by a separate CO2 light control board, located on the inside of the front panel to the left of the control board.  CO2 pressure is sensed by a pressure switch connected to the water line from the pump to the carbonator.  When the CO2 pressure drops below 45 psi (3 bar), the switch sends a signal to the CO2 light control board to cause the amber light to flash.

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1.1.2.3.4.11.13.The Electronic Control Unit (ECM) #

[Photo of ECM]

The Electronic Control Module (ECM, Control Board, Circuit Board) performs all of the control functions of the dispenser, as well as making possible the diagnostic testing of the controls and electronic components.

The major functions of the ECM include:

  • Providing the flavor selection, using the buttons located on the top of the control board – the first three of the 6 buttons (not all are always exposed to the user).
  • Controlling the water pump by responding to signals from the pump probe.
  • Limiting the pump running time on initial filling to a maximum of 2.25 minutes.
  • Limiting the pump running time in normal operation to 45 seconds, in the event of a water shut off.
  • Controlling the refrigeration by responding to signals from the temperature sensor in the syrup cooling compartments.
  • Controlling the refrigeration by responding to signals from the ice bank probe.
  • Providing for 10 oz drinks when a jumper plug is plugged onto the board.  The upper green light “on” indicates a 6.5 oz drink is selected.  The lower green light is “on” to indicate a 10 oz drink is selected.  Without the jumper installed, the upper green light indicates a 6.5 oz drink is selected and the lower green light is on to indicate a 4.5 oz drink is selected.
  • Flashing the upper green signal light when the pump has run too long, indicating a problem condition.
  • Flashing the lower (second) green light when the water sensor has become wet, indicating a potential internal leak or overflow.

The diagnostic test procedure is outlined later in this manual.

All component circuits are controlled by miniature relays mounted on the board.  The seven relays have heavy duty contacts.  The components on the board are protected by the metal cover fastened to the board.

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1.1.2.3.4.11.13.1.Diagnostic Test Procedure #

General Comments

All of the electrical parts in the GA 3000 may be checked individually, by pressing the buttons on the control board and observing the three indicator lights and the operation of each part.  The buttons are pressed in the sequences shown below and summarized on the attached chart.

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1.1.2.3.4.11.13.2.Preparation for Diagnostics #

Set up the dispenser by connecting the power, water, and CO2 as shown in the “installation guidelines” section of this manual.  Put the syrup valves (dosers) in position in the syrup compartment (with no syrup container attached).  Remove the selector panel cover by removing the screw at the lower left side of the panel, and carefully pry out the lower right corner to release the locking tab.  Life off the cover.  Turn on the power switch by sliding the button to the “up”/on position.

The six buttons and three lights on the panel are now visible in vertical rows.  Buttons are numbered 1-6 from top to bottom and the green lights are identified as A,B,C from top to bottom.  Light A should be “on” at this time, if set for 6.5oz drinks.

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1.1.2.3.4.11.13.3.Normal Button Functions #

During normal operation, not in diagnostics mode, the buttons perform the following tasks:

Button   Function
1   Dispenses drink with doser number 2 (middle doser), labelled “Coke” on the back of the syrup compartment door
2   Dispenses drink with doser number 3 (right-most doser), labelled “Diet Coke” on the back of the syrup compartment door
3   Dispenses drink with doser number 1 (left-most doser), labelled “Sprite” on the back of the syrup compartment door
4*   Changes the drink size selection/option (6.5 / 10 oz or 4.5 / 6.5 oz)
5*   Dispenses carbonated water only
6*   Selects large or normal ice-bank size

Many / most Control Panels only have 3 buttons that are accessible to end-users, buttons 1-3.  6-button front panel units are available and expose all 6 buttons / options to end users of the BreakMate.

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1.1.2.3.4.11.13.4.Indicator Light Status - During Normal Use #

Light On Blinking Off
A Normal – 6.5 oz drink size selected No Water Power off
B  Normal – 4.5 oz drink size selected Water Leak in Unit detected Normal
B  Jumper * – 10 oz drink size selected Water Leak in Unit detected Normal
C Large Ice Bank Selected N/A Standard Ice Bank Selected
Amber / Yellow N/A CO2 Empty / No CO2 Normal

*With 10 oz Jumper, or Coin Mech installed

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1.1.2.3.4.11.13.5.Button and Light Circuit Test #

To begin the test program, turn off the dispenser main power.

  1. Hold in button number 4 while turning the power to the unit on.

The green lights should flash in sequence.  If they do not run in sequence, press button number 6 once.

Press each button starting with the top button and working your way to the bottom button (1 through 6).  The lights should turn “on” and remain steady while pressing each button, to indicate that the button and the light circuits are working properly.  All lights will stay on after pressing button number 6.  Press button number 6 again and the lower green light only will stay on.

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1.1.2.3.4.11.13.6.Electrical Component Test #

Press the buttons in the following sequence:

Buttons   Tests / Results
1   Doser number 2 (Middle) lifts
2   Doser number 3 (Right-Most) lifts
3   Doser number 1 (Left-Most) lifts
1 & 4   Water pump / inlet valve operates
2 & 4   Outlet valve operates (caution!  have a bucket available!)
1 & 5   Compressor runs
2 & 5   Refrigeration valve clicks
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1.1.2.3.4.11.13.7.Sensor Operation Tests #

Press and hold button number 4 and note which indicator light(s) illuminate:

Light On Off
A Water Overflow Sensor Indication Normal
B Carbonator Water Low Carbonator Filled (Normal)
C N/A N/A

Press and hold button number 5 and note which indicator light(s) illuminate:

Light On Off
A No large ice bank (normal) Large ice bank
B No standard ice bank Has normal ice bank
C Syrup compartment is warm Syrup Compartment Cold (*Normal)
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1.1.2.3.4.5.BreakMate Troubleshooting #

The listing of problems shown below is in the approximate order of frequency of occurrence.  Trouble calls due to mechanical failure in the dispenser can be expected to be fewer than one call per year.  Items marked with an asterisk * under each heading are the most likely to occur.

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1.1.2.3.4.5.1.Problem: Upper Green Light Flashing #

 

Potential Problem(s)   Potential Remedy / Resolution(s)
Water supply is shut off   Turn on the water supply
Water supply pressure is too low   Be sure any shut-off valves are turned fully open.  Check for kinked or undersized water lines.   Lines must support a minimum of 2 quarts per min flow rate.
Water filter blocked   Replace the water filter
Air in carbonator – pump cannot fill   Remove CO2 cylinder/attachment and vent all CO2 from Carbonator
Water pump failure   Replace the water pump
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1.1.2.3.4.5.2.Problem: Won't Accept CO2 in Regulator #

Potential Problem(s)   Potential Remedy / Resolution(s)
Check-ball stuck in CO2 Regulator   Loosen the check ball
Pin in Regulator or in CO2 bottle is broken   Replace CO2 Regulator or Bottle/Cylinder, Use another CO2 bottle
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1.1.2.3.4.5.3.Problem: Foreign Taste or Odor in Drinks #

Potential Problem(s)   Potential Remedy / Resolution(s)
Filter cartridge needs replacement   Filters may require replacement every six months, or sooner, depending on local water supply quality – replace the filter and drain and refill the carbonator
Unusual local water conditions   If problems exist while using the standard BreakMate filter (CC-717), upgrade and install the BreakMate Premium Filter, or another high-end compatible filter.
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1.1.2.3.4.5.4.Problem: Diet Syrup is Freezing #

Potential Problem(s)   Potential Remedy / Resolution(s)
Syrup container is sitting too long on the cold evaporator   Place thin insulating strip on the evaporator in the syrup compartment, or move the diet syrup to a different syrup position.
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1.1.2.3.4.5.5.Problem: Burst Safety Disc(s) on CO2 Bottle(s) #

Potential Problem(s)   Potential Remedy / Resolution(s)
Overfilling of CO2 bottles is occurring.   Bottles must not exceed 3 lbs 5 oz (53 oz) in weight when filled, return the bottle for burst disc replacement. BREAKMATESOURCE.COM update:  Coca-Cola no longer offers this service.  It may be possible to replace the safety discs on your own or at a local welding/high-pressure bottle facility, or, you may need to source your own replacement bottles/cylinders.
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1.1.2.3.4.5.6.Problem: Drinks are too warm #

Potential Problem(s)   Potential Remedy / Resolution(s)
Refrigeration inoperative   Use diagnostic sequence to check component sensor operation, that all parts are diagnosed as successfully operating
Refrigeration delay loose   Push the refrigeration delay into position
ECM board defective   Replace the ECM board
Too many drinks drawn in succession   Make sure there is a 4-inch minimum clearance above the air outlet at the top of the dispenser and wait 1-2 minutes before drawing successive drinks
Power was off, allowing dispenser to warm   If powered off for > 4 hours, wait at least 4-8 hours before attempting to draw a beverage.  If powered off for > 12 hours, wait 24 hours before attempting to draw a beverage to allow the ice bank to build
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1.1.2.3.4.5.7.Problem: Mixing Channel Overflows #

Potential Problem(s)   Potential Remedy / Resolution(s)
Mixing Channel not pushed fully into position   Position the Mixing Channel correctly and be certain it “snaps” into place
Mixing Channel cover is not correctly positioned   Position the Mixing Channel Cover in the correct orientation atop the mixing channel
Ice Particles on the screen   This is not a problem unless it causes an overflow.  Usually this occurs with carbonated water only.  If problem only occurs with carbonated water, do not run/press the Carbonated Water button for longer than 2-3 seconds at a time, with a 1-2 second pause in between each press, to allow some melting.
Drink drawn during super cooling mode contains slush ice   The ‘super cool’ ice bank has not yet fully formed.  Allow time for the machine to form the large ice bank before drawing beverages.
Outlet Screen Blocked   Remove the screen from the mixing channel and clean with a soft bristle brush.
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1.1.2.3.4.5.8.Problem: CO2 Leaks #

Potential Problem(s) Potential Remedy / Resolution(s)
Leaks at regulator Replace the CO2 cylinder.  The o-ring seal may be defective.  Check for o-ring seal damage.  Replace the regulator if leak is around the safety relief valve.
CO2 leaks into water supply line Double-Check valve is defective.  Replace with a new double-check safety valve.
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1.1.2.3.4.5.9.Problem: Lower green light flashes #

Potential Problem(s)   Potential Remedy / Resolution(s)
Water sensor is covered   Locate leak source, resolve leak
Internal leak at a connection   Locate leak source, resolve leak
Water overflows through CO2 safety valve   Pump does not shut off properly.  Check the pump probe lead wire.
Water overflows through CO2 safety valve, check-ball valve in CO2 regulator is stuck, and pump was run manually   Loosen the check valve ball or replace the CO2 regulator
Water overflows through CO2 safety valve, with water supply pressure above 75 psi, inlet valve stays open or leaks through, allowing carbonator to overflow through safety valve, water pump does not run when drawing a drink   Replace the water inlet valve
Moisture on sensor connections at the ECM board   Disconnected the plug, allow to dry, reconnect and retry
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1.1.2.3.4.5.10.Problem: Too little water is dispensed #

Potential Problem(s)   Potential Remedy / Resolution(s)
Carbon particles in flow control   Use an approved filter and flush filter to remove any carbon deposits
Water flow control needs adjustment   Turn screw inward to deliver 5.25 oz (160 ml) for a 6.5oz drink (192 ml)
Water flow control sticking   Replace water outlet valve or clean flow control mechanism
CO2 pressure too low   Amber light will likely be flashing – replace CO2 cylinder
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1.1.2.3.4.5.11.Problem: Water drips out of mixing channel #

Potential Problem(s)   Potential Remedy / Resolution(s)
Water outlet valve drips and does not shut off   Replace the water outlet valve
Relay sticks on control board   Replace the ECM (Control Board)
Low CO2 Pressure   Replace CO2 cylinder
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1.1.2.3.4.5.12.Problem: No syrup dispensed #

Potential Problem(s) Potential Remedy / Resolution(s)
Doser plunger does not lift Doser coil may be defective – burned out, not connected or have a broken wire.  Doser plunger may be stuck, clean doser valve or replace doser.  ECM is defective, replace ECM (Control Board).
Out of Syrup Syrup Cartridge is empty, replace with full syrup cartridge/container.
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1.1.2.3.4.5.13.Problem: Drink is Too Large #

Potential Problem(s)   Potential Remedy / Resolution(s)
Dispenser is set for 10 oz drink portion   Remove the 10 oz jumper on the ECM, or, if a coin mech unit is installed, switch the selector switch to “6.5 oz drink”.  If using a 6-button panel, simply use the drink-size selection button to choose a smaller drink portion.
Wrong Cup for Drink Size    Be sure to use an 8 oz cup for a 6.5 oz drink and a 12 oz or larger cup for a 10 oz drink.
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1.1.2.3.4.5.14.Problem: Low Carbonation #

Potential Problem(s)   Potential Remedy / Resolution(s)
Too many drinks drawn in succession   After drawing three or four drinks, in succession, wait at least one minute before drawing any additional drinks
Agitator inoperative or not in position   Place agitator in position, or replace it if necessary
Low CO2 pressure – amber light flashing / amber light blinking   Replace CO2 Cylinder / Cartridge / Tank
Air in Carbonator   Release all CO2 from the system (see here), until the CO2 low-pressure light blinks/flashes, then re-connect CO2 supply
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1.1.2.3.4.5.15.Problem: Coin Mech Inoperative #

Potential Problem(s)   Potential Remedy / Resolution(s)
Will not change drink size   Be sure the toggle switch is set on the “Coin Required” position before changing drink size.
Check for a broken toggle switch.
Returns money and will not dispense a drink   The Power Failure solenoid is stuck in a power-off condition.
The Coin Mech is set on “Free Vend” (and does not require any money).
The CO2 light connectors are not connected properly on a 3-coin coin mech, or the CO2 pressure-low indicator has been activated (Out of CO2)
Free Vends when set to require payment   Broken toggle switch is causing the machine to stay in free-vend mode, replace toggle switch and/or check connections
Accepts money but will not dispense a drink   Check for correct price setting
Coin Switch is broken
     
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1.1.2.3.4.5.16.Refrigeration Decision Tree #

To diagnose issues with the refrigeration components, follow this logic/decision tree

[decision tree map]

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1.1.2.3.4.5.6.BreakMate Repair Procedures #

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1.1.2.3.4.5.6.1.General Comments #

This section describes the procedures for replacing parts and repairing the BreakMate dispenser.  Be sure to follow the sequences shown to avoid inconveniences during the repair procedure.

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1.1.2.3.4.5.6.2.Draining the Carbonator #

[Photo of Draining the Carbonator]

If any part of the water system, such as the water outlet valve, water pump, or carbonator is to be repaired, the system must be vented (all CO2 bled off) and drained before disassembly to avoid water leaks or spills while working on the unit.  Proceed as follows:

  1. Remove the screw at the lower-left side of the selector panel cover.
  2. Carefully pry out the lower-right corner of the selector panel cover.  Lift the panel to disengage the top and remove the cover.
  3. Go through the test sequence, listed on the back of the selector panel (if it is not present, you may find it here) to “component test” and press buttons #2 and #4 at the same time to open the outlet valve and drain the carbonator.
  4. Remove the CO2 cylinder/tank/cartridge or adapter fitting (shut off CO2 if necessary) and press the red CO2 relief valve button to vent/bleed off CO2 gas pressure.  Continue to press the CO2 release valve button until all gas is discharged from the system.
  5. Complete your selected repairs.
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1.1.2.3.4.5.6.3.Removing the Control Board (ECM) #

[Photo of first step]

The procedure for removing the ECM or Control Board is as follows:

  1. Remove the screw on the lower-left side of the selector panel cover.
  2. Carefully pry out the lower-right corner of the selector panel cover.  Life the panel to disengage the top and remove the cover.
  3. Use a phillips head screwdriver to loosen the two screws at the top of the control board. (*note* they do not need to be completely removed)
  4. Carefully tilt the control board forward (toward you) as you lift the control board out.  Remove the three (or four if a coin-mech is attached) connector plugs from the bottom of the control board. *Note: these connectors are keyed for easy identification and replacement later on

When removing the control board, be very cautious as to not bend the board forward any more than is absolutely necessary to remove it from the dispenser.  Bending the board too far forward may damage the 100 MA fuse clip and render the control board inoperable/unrepairable.

[photo of board bent forward]

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1.1.2.3.4.5.6.4.Disconnecting the Dispenser #

To disconnect the dispenser and remove loose parts, use the following procedure:

  1. Remove the drip tray by pressing down on the front edge and lifting it out.
  2. Remove the mixing channel by grasping with one hand on each side and gently pulling the channel out. *Note the syrup compartment door must be open for this to work.
  3. If necessary, remove the syrup compartment door by prying up the head of the black pivot pin.  Pull the pin out, remove the door and reinsert the pin into the door for safe keeping.
  4. Disconnect the electrical plug and if necessary for your repairs, turn off the water and disconnect the water line at the rear of the dispenser.
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1.1.2.3.4.5.6.5.Removing the Front Case of the Dispenser (Dispenser Front Case) #

Many internal repairs require the removal of the front case of the dispenser.  Follow these instructions to remove the front case:

  1. If necessary, drain the carbonator
  2. Remove the mixing channel, drip tray, syrup cartridges, CO2 and syrup compartment door cover.
  3. Remove the selection button cover panel and ECM/Control Board
  4. If necessary (recommended), remove the water source – water-in line.
  5. To remove the front cover, you will remove a total of 12 screws, the outside front contains ten (10) screws that are all the same length, while there are two (2) longer screws inside the CO2 compartment.
    1. Remove the three screws along the top of the panel.
    2. Remove the three screws around the control board
    3. Remove the two screws behind the drip tray
    4. Remove one screw in the center doser position
    5. Remove one screw at the top of the delivery area, behind the water valve.
    6. Remove the two (longer screws), one at the top of the CO2 compartment and one at the CO2 regulator
  6. Pull or gently pry the front panel forward, starting with the top of the panel.  Be careful not to pull too far forward as internal components are still connected.
  7. Swing the panel to the side in order to access the interior of the BreakMate dispenser.

Use extreme care when opening the BreakMate dispenser, so as not to damage the coil or switch terminals.

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1.1.2.3.4.5.6.6.Disconnecting the Electrical Leads #

Do Not Disconnect The Leads Except To Replace The Panel or Parts On The Panel.  All other repairs should be made with the leads in-tact, whenever possible.

  1. Follow the steps to disconnect the front panel of the dispenser [link]
  2. With long-nose pliers, remove the wires from the doser coil by pulling off the terminal connections.
    • Note – the blue wire is a common lead to all coils.
    • The #1 coil wire is orange.
    • The #2 coil wire is yellow.
    • The #3 coil wire is white.
  3. Remove the lead from the power-switch.
    • Black wires are on the top.
    • Blue wires are on the bottom.
    • The White insulated terminals are on the control board side of the switch.
  4. Locate the “empty CO2” light board to the left of the control panel position.  Remove the retaining screw and lift the board out.
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1.1.2.3.4.5.6.7.Reassembling the Front of the Cabinet #

When reassembling the front of the cabinet, the following notes may simply the process

  • Be sure that the CO2 cylinder guide tab is engaged in the slot at the rear of the cabinet – this applies even if you are using an adapter / non-BreakMate CO2 cylinder/supply.
  • Put a paper towel or cloth in the cylinder well to catch any screws, in case they fall.
  • Replace the screw into the outlet valve, then the two screws into the CO2 compartment before replacing the remainder of the screws.
  • Before closing the cabinet, be certain there is no water in the cabinet base or on the water sensor.
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1.1.2.3.4.5.6.8.Flow Control Removal #

To remove the flow control mechanism only, use the following steps:

  1. Loosen the three phillips head screws holding the housing together.
  2. Separate the two housing pieces.
  3. Remove the flow control piston, barrel, and spring.
  4. Check for free movement of the piston in the barrel.  Clean if carbon or dirt is apparent.
  5. Assemble with single hole in the end of the piston opposite 4 holes in the barrel.
  6. Reassemble with spring on spring post inside the piston.
  7. Be sure tab for screw is toward rear of the machine.
  8. Replace the three phillips head screws.
  9. Check for proper water flow after reassembly of the machin.
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1.1.2.3.4.5.6.9.Water Outlet Valve Removal #

[picture of valve here]
Replace the water outlet valve using the following procedure:

  1. Be sure the carbonator is drained (see procedure here), the CO2 cylinder is removed, and the CO2 pressure is vented before proceeding (see procedure here).
  2. Remove the dispenser front as outlined (here).
  3. Remove the wires to the valve coils (see here).
  4. Unscrew the knurled plastic nut to disconnect the valve.
  5. Be sure to remove the plastic dust cap that may be in the inlet of the new valve, prior to installing
  • When replacing the cabinet front, be sure the valve slides into the guides on the front cover.
  • Reassemble the dispenser and check the water portion for the selected drink size 5.4oz or 160ml for a 6.5oz drink.  Adjust as necessary (see here)
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1.1.2.3.4.5.6.10.Outer Cabinet Removal #

  • Remove the six screws on the rear panel as well as two screws at the lower rear and two screws on each side of the bottom that holds the outer cabinet in place.
  • Slide the cabinet towards the back of the dispenser unit.

[Video / photo]

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1.1.2.3.4.5.6.11.CO2 Regulator Replacement #

[Video / Photo of steps]

  1. Remove the cabinet front (see here) and the water outlet valve (see here).
  2. Remove the outer cabinet (see here).
  3. Lift the two black plastic posts holding the top of the condenser coil in position.
  4. Swing back the top of the condenser, far enough to remove the two screws holding the regulator in place.
  5. Remove the two screws and lift the regulator out.
  6. Use a wrench to hold the CO2 Outlet fitting and unscrew the regulator.  *Be careful not to lose the check valve ball under the fitting.  If stuck, use a small screwdriver.
  7. Transfer the black plastic handle and mounting bracket to the new regulator.
  8. Screw the regulator back onto the fitting.
  9. Install the new regulator.
  10. Reassemble.
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1.1.2.3.4.5.6.12.Agitator Replacement #

[Photo/Video]

  • Be sure the carbonator is drained (see here) and that the CO2 is vented before proceeding (see here).
  • Remove the outer cabinet (see here)
  • Remove the four screws holding the carbonator cover and lift the cover off.
  • Slide the wire terminal off the pump electrode on the cover.
  • Turn and pull out the stainless electrode from the fitting. *Be sure the o ring does not fall out.
  • Cut the cable tie holding the agitator wire lead to the CO2 line.
  • Disconnect the white electrical connector plug and pull up to the wire to clear.
  • Remove the plastic “C” retainer clip on the agitator lead fitting and push the fitting into the carbonator cover.
  • Push the carbonator cover into the carbonator, turn it 90 degrees and pull it out.
  • Push the agitator wire and connector through the fitting hole in the carbonator cover to free the cover.
  • Grasp the top of the agitator post with a pair of pliers and turn counter-clockwise 1/4 turn and lift it out.  *Note the position of the agitator for ease of replacement.  The agitator wire lead is towards the front of the cabinet.
  • Install the new agitator, making sure the two bottom locking tabs on the agitator line up with the clearance slots in the fitting in the bottom of the carbonator.  Press the carbinator down in place and turn 1/4 turn clockwise to lock it into position.  Check to be sure it is secure.
  • Thread the plug and wire through the fitting hole in the carbonator cover.
  • Reassemble the dispenser.
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1.1.2.3.4.5.6.13.Water Pump / Inlet Valve Replacement #

[Photo / Video]

  • Cut the two wire ties from the pump cable.
  • Remove wires from the CO2 pressure switch, pump, and ground wire from the pump.
  • Unscrew the knurled nut at the pump outlet.  Be careful to keep the check valve parts from falling out.
  • Remove the two screws in the bracket above the pump.
  • Remove the pump/inlet valve assembly and install the new assembly.
  • Transfer the plastic bushing support from the top of the old pump to the new pump.
  • Be sure to locate and save the three yellow mounting bushings when installing the pump.
  • Locate the guide pin in the rear cabinet wall.
  • Reassemble the unit.
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1.1.2.3.4.5.6.14.Dispenser Adjustments #

6.5 oz or 10 oz drink

Dispensers equipment with a coin mechanism may be switched from six and one-half ounce to ten ounce drink sizes by operating the changeover switch.  The changeover switch is accessible when the cash box is removed from the coin mech.  

Dispensers without a coin mechanism are set for six and one-half ounce drink size when shipped from the factory.  If a ten ounce drink is desired, lift out the control board/ecm (as shown here).  Place the 10oz jumper, P/N 27756 on the open terminal on the board and place the control board back into the dispenser.

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1.1.2.3.4.5.6.15.Water Adjustments - Syrup Ratio Settings #

Syrup portions are fixed and predetermined by the syrup valve and fitting in the neck of the syrup cartridge.  Syrup portions are specified for each flavor to achieve the correct ratio of syrup to water.  For a six and one half ounce drink, the standard syrup portions for some flavors are as follows, using 160ml of water.

Syrup Portion Ratio
Coca-Cola (Coke) 32 ml 5 to 1
Sprite 32 ml 5 to 1
Diet Coke 32 ml 5 to 1

The syrup ratio for a 6.6 oz drink is adjusted to the standard ratio, if necessary, by adjusting the water flow to 5 1/3 ounces or 160ml (157 – 163).  Water flow is adjusted by turning the water adjusting screw, located at the carbonated water outlet valve.

To measure drink portions, use a ration cup set.  These are plastic cups graduated in ounces or milliliters (ml) for syrup and water.  

Remove the mixing channel and catch the water in the water cup and the syrup in the syrup cup.  Compare the figures with the above settings.  The part number for the water cup (220 ml) is 05-0081, 5-1 syrup cup is 05-0170.

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1.1.2.3.4.5.6.16.Technical Data #

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1.1.2.3.4.5.6.17.Wiring Diagram #

[Photo of Wiring Diagram]

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1.1.2.3.4.5.6.18.Wiring Connections #

Photo of wiring connections

 

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1.1.2.3.4.5.6.7.Technical Specifications #

 

Part Number Part Specifications
21547 Temperature Sensor – Warm 850 OHMS @ 75 degrees F
Temperature Sensor – Cold 2350 OHMS @ 32 degrees F
55188 Outlet Valve 1100 OHMS – 120 VAC
55189 Inlet Valve 1100 OHMS – 120 VAC
55190 Transformer – Primary 105 OHMS – 120 VAC
Transformer – Secondary 1.1 OHMS – 12 VAC
55191 Doser Coil 110 OHMS – 110 VDC
84577 Ref. Transfer Valve 3980 OHMS – 140 VDC
104039 Compressor – Start Winding 5 OHMS – 120 VAC
Compressor – Run Winding 8 OHMS – 120 VAC
104350 Agitator Motor 710 OHMS – 120 VAC
104351 Water Pump (Coil Res) 3.5 OHMS Ea. – 120 VAC
Refrigerant Charge 90 Grams – R12
056641 CO2 Regulator Setting 75 psi +/- 5 psi
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1.1.2.3.4.5.6.8.Service Parts List #

Part Number Description Qty / Pkg Price Group
13698 Screw, Machine – Rear 20 01
21457 Strain Relief Bushing 1 01
21547 Cold Control-Syrup Compt 1 01
23156 Grommet 1 01
27506 Fitting – Compressor Mount 1 03
27507 Holder 2 01
27508 Pump Electrode Assembly 1 05
27510 Hose Clamp – Co2 – Oteker 110 4 02
27511 CO2 Water Line 1 01
27512 Hose Clamp – Water – Oteker 165 4 02
27513 Elbow Fitting – Water Outlet 1 01
27514 O-Ring Water Outlet Fitting 10 01
27515 Plastic Nut – Water Outlet 1 01
27517 Clip Nut – CO2 Regulator 5 01
27518 Spring – CO2 Clamp 5 01
27519 Latch 5 01
27524 Pivot Pin – Syrup Door 5 01
27525 Screen Disc – Mixing Channel 1 01
27526 Selector Button 6 01
27527 Selector Button Switch 6 01
27528 Mains Switch (Main Power Switch) 1 04
27530 Seat Seal – Doser 5 03
27531 Lock Ring – Doser 3 02
27532 O-Ring Doser Set 5 01
27533 Rubber Foot – Cabinet (up to FD 6612) 5 01
27534 Starting Relay – Compressor 1 23
27535 Valve Coil – Inlet / Outlet Valve 1 07
27552 Oteker Hose Clamp – Inlet Valve 3 02
27633 O-Ring – Pump Fitting 5 01
27634 Nut – Carbonator Top 3 01
27635 Pump Inlet Fitting 1 02
27755 Check Valve Assembly 1 04
27756 Jumper Plug – for 10oz drink 1 01
27794 Fuse 2.5 AMP 3 01
27795 Fuse .1 AMP 3 02
27881 Clip – Right 5 01
27882 Clip – Left 5 01
27893 CO2 Pressure Switch 1 24
27894 Tee – CO2 Line 1 04
27895 Barb Connector – Pressure Switch 1 06
27896 Suppressor – Compressor 1 04
28173 Selector Button Spacer 5 01
28174 Water Leak Detector 5 01
28175 O-Ring – CO2 Cylinder 5 01
28270 O-Ring – Pressure Switch 10 01
28816 Outlet Fitting Elbow 1 01
28896 Rubber Foot (From FD 6701) 5 01
29295 Plug Board 1 01
29716 Screw 20 01
29717 Screw 20 01
29757 Plastic Bushing, Pump 1 01
29777 Check Ball 2 01
29778 O-Ring 5 01
29788 Connectors 1 02
55173 Carbonator Tank Top 1 07
55174 Carbonator Top Gasket 1 01
55175 Carbonator Top Lock Bracket 1 02
55178 CO2 Regulator Mounting Flange 1 02
55179 CO2 Lock Lever 1 02
55181 Hose – Pump / Valve 1 01
55183 Supressor – Pump (not shown) 1
55188 Outlet Valve Assembly 1 20
55189 Inlet Valve Assembly 1 10
55190 Transformer 1 13
55191 Doser Coil 1 09
55399 CO2 Empty Light Board 1 28
55569 Inlet Fitting – Right angle 1 02
55580 Inlet Fitting – Straight 1 02
56076 Electrode 1
56092 Suppressor 1 15
56500 Doser (Universal) 1 12
56641 CO2 Regulator (Compl) 1 30
56682 Plug Connectors 1
84568 Accumulator 1 02
84569 Dryer 1 02
84571 CO2 Tubing – Reg/Tee 1 01
84572 CO2 Tubing – Tee/Carb 1 01
84573 Gasket – Syrup Compartment 1 04
84577 Refrigeration Valve 1 31
84579 Control Board Assembly (ECM) 1 43
85412 Selector Panel – USA 1 03
85413 Display Card Selection 1 02
86378 Label 1 01
115622 Condenser 1 25
115623 Syrup Compartment 1 34
115625 CO2 Cylinder Housing 1 05
115632 Door – Syrup Compartment 1 23
84579 Control Board Assembly (ECM) 1 43
85412 Selector Panel – USA 1 03
85413 Display Card Selection 1 02
86280 Agitator Upper Assembly 1 03
86378 Label 1 01
115622 Condenser 1 25
115623 Syrup Compartment 1 34
115625 CO2 Cylinder Housing 1 05
115632 Door – Syrup Compartment 1 02
115961 Cover – Mixing Channel 1 02
115962 Mixing Channel 1 02
116415 Carbonator Assembly – Compl 1 45
117352 Grid 1 04
117353 Drip Tray 1 05
140349 Compressor (With Relay) 1 43
140350 Agitator Assembly 1 29
203092 Cabinet Front 1 33
203573 Cabinet Wrapper 1 28
512500 Operating Instructions 1 00
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1.1.2.3.4.5.6.9.Service Parts - Cabinet #

Photo of Parts / Cabinet

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1.1.2.3.4.5.6.10.Service Parts - WaterMate #

Photo Service Parts WaterMate

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1.1.2.3.4.5.6.11.Service Bulletins #

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1.1.2.3.4.5.6.11.1.Problem: Slush Ice On Start Up #

Problem: Slush Ice on Start Up

Some service managers have reported instances of ice crystals or “slush” being delivered into the mixing channel shortly after connecting a dispenser.  During the initial “pull down” period, the temperature of this water in the carbonator  drops well below the 32 degrees – as low as 23 degrees – before ice starts forming.  If a drink is drawn during this time, the water will form into ice crystals as it is delivered from the outlet valve and can cause the valve to stay open and fill the mixing channel with ice crystals.

Solution:

Set up the dispenser in the shop and let it run overnight before installing.  This will permit the ice bank to form in the carbonator and keep drinks from being dispensed during the ice-bank forming period.  This also has the advantage of service cold drinks to customers immediately upon installation.  The carbonator will retain it’s ice bank for many hours even on a very hot day in an installation vehicle because the carbonator is very well insulated.

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1.1.2.3.4.5.6.11.2.Problem: Half cup or short drink delivered #

Problem: Half cup or short drink delivered

Some reports have been received of short drinks immediately after a new installation of the dispenser.

Solution:

  1. Follow the pre-cooling procedure to prevent ice crystal formation causing temporary sticking of the flow control.
  2. Be sure to flush the filter completely to remove any possibility of carbon particles from getting into the water flow regulator and/or outlet valve.  Run the water for five minutes or five gallons of water, before connecting the water line to this dispenser, to be sure all carbon particles are flushed.
  3. Disassemble the flow control on the outlet valve.  Wipe clean the piston cylinder surfaces and reassemble.
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1.1.2.3.4.5.6.11.3.Problem: Check Valve Ball Sticking - Red Vent Pin Stays In #

Problem: Check Valve Ball Sticking – Red Vent Pin Stays In

Carbonator does not accept CO2 gas when the CO2 cylinder is attached.  Problem occurs when setting up a new dispenser after pressing the red pin to relieve carbonator pressure.  The problem is caused by the check valve ball in the CO2 regulator sticking in the seated position when the dispenser has been stored for some time.

Solution:

Be sure that the red pin on the relief valve has been pressed to exhaust the CO2 gas pressure from the carbonator and that the pin stays in.  Insert and remove the CO2 cylinder repeatedly into the regulator until the CO2 flows properly.

If this procedure fails to loosen the check valve ball, insert the cylinder and allow to stand for several hours or overnight.

Occasionally it will be necessary to remove the CO2 regulator and use a paper clip to loosen the ball.  When replacing the regulator be sure to hold the check valve opening pointing upward when turning the regulator back onto the fitting.

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1.1.2.3.4.5.6.11.4.Problem: Safety Disc Bursting on CO2 Cylinder #

Problem: Problem: Safety Disc Bursting on CO2 Cylinder

Reports have been received of safety discs on CO2 cylinders bursting when filled cylinders are stored or transported in a service truck.

Solution: Check weight of the cylinder(s) after filling.

Do not exceed a total weight of 53 oz (3 lbs 5 oz) for a filled cylinder.

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1.1.2.3.4.5.6.11.5.Return Goods Procedure #

BREAKMATESOURCE.COM NOTE:

Because all BreakMate services have been discontinued, this page is for archival purposes only.

When returning complete dispensers please observe the following steps to insure proper handling and to avoid unnecessary charges:

  1. Authorization: Call BreakTime customer service at 404-436-8877 for an equipment return authorization number.  Unauthorized shipments will not be accepted.
  2. Identification: Attach a completed return goods tag to the dispenser showing the date of installation, ER number, your company name and address, the problem with the dispenser and serial number, which must include the four digit prefix (i.e. 6705-000999).
  3. Records: Remove the white copy from the return goods tag and retain for your records and remove the carbon from under the yellow copy to avoid smudging during shipment.
  4. Complete Dispensers: Return the dispenser in a clean condition with all parts except the dosers.  Missing parts will be replaced at the customer expense for parts and labor.
  5. Packing: Pack the dispenser carefully, using the original packing material and carton.  Put the serial number on the outside of the box, crossing out any other serial number.  Note: Damage to the dispenser due to the use of other-than-original packing material will be charged to your account.
  6. Carrier: Ship the dispenser via prepaid UPS or other carrier specified by BreakTime.
  7. Destination: Ship the dispenser, prepaid, to: Spears Refurbishing Center, 106 Ross St., Heflin, AL 36624 or other destinations as specified by BreakTime
  8. Turnaround Time: The expected turnaround time is about 30 days for dispensers return for refrigeration repair.
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1.1.2.3.4.5.6.11.6.Approved Water Filters #

To assure the highest quality drink possible, all BreakMate dispensers MUST be installed with an adequate water filter.

Experience has shown that some filters available to the trade for use on the BreakMate vary in quality and introduce unnecessary or undesirable ingredients into the water supply.  Some do not have sedimentation filters and can pass carbon granules into the dispenser, causing mechanical problems.  The sediment and other ingredients pass-through may also contribute off-flavors to the water and affect the taste of the finished drink.

Filters used on the BreakMate dispenser must meet quality requirements and pass the testing procedures used by The Coca-Cola Company Quality Assurance Lab.  Filters which have met these quality standards to date are listed below.  Other filters are being tested and you will be advised by service bulletin as additional filters are approved.

*Note* Filters for coffee brewers contains phosphates are not to be used with the BreakMate.

Water conditions in different areas of the country vary widely from system to system and can change during different times of the year within the same water system.  Filters for the BreakMate are categorized accordingly.

Water Quality Categories

I. Average water conditions with less than 2.5 ppm chlorine.
II. Heavy chlorine conditions above 2.5 ppm.
III. Heavy chlorine conditions above 2.5 ppm and/or the presence of chloramines in the water supply.

Source Type Name Model Number Water Quality Category (Above)
Cuno In-Line Taste & Odoer CC-717 I
Everpure Wall-Mount BreakMate Fine II
Everpure Wall-Mount BreakMate Premium  

The Cuno and BreakMate filters listed above are available from BreakTime.

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1.1.2.3.4.5.6.11.7.Advanced Check Valve Ball Stuck - Release Notes #

As noted in the previous service bulletin, some dispensers may not accept CO2 gas due to a sticking check valve ball.  This may occur in new or previously used dispensers.  This problem, in some cases, has required the disassembly of the dispenser to loosen the ball.

The stuck ball may be loosened by placing the CO2 cylinder upright into a pail of hot (140 degrees F) tap water, for two or three minutes, to warm up the cylinder and increase cylinder pressure.  Warm the cylinder before placing it into the dispenser and the initial surge of higher pressure should provide enough force to release the ball from its seat in most dispensers.  Once released, the ball remains free.

Notes:

  1. Be sure the CO2 cylinder is not overfilled with CO2 or the increased pressure may cause the safety disc valve to burst.  The maximum cylinder weight is 3 1/4 lbs when filled.
  2. Do not apply heat to the cylinder except in a pail of hot tap water at 125-150 degree F.  Do not use water over 150 degree F, nor boiling water.  Hot tap water is usually around 120-140 degrees F.
  3. The proper use of this procedure is the responsibility of the user.
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1.1.2.3.4.5.6.11.8.Syrup Freezing #

Problem: There have been some cases of syrup freezing in the syrup cooling compartment.  Most often this is diet syrup that is freezing and typically the package is 20 percent full or less.  Freezing occurs when the syrup package sits too long in direct contact with the very cold evaporator.  This contact time is lengthened by leaving the syrup compartment door open or ajar or by putting a fresh container of unrefrigerated syrup in with a partially empty already cold syrup containers.

Solution: Place a strip of thin insulating material on the lower edge of the syrup cooling compartment so that the syrup package rests on it.  This will prevent direct contact between the syrup bottle and the evaporator assembly.  A sample insulating strip is enclosed so that you can make a similar one or order others from BreakTime Enterprises at 800.627.8877

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