Wunder-Bar Mark 4 - User Manual

CONTENTS PAGE NUMBER
Installation..........................................................................................
2
Brixing—Standard Manifold..............................................................
3
Flow Regulator Manifold....................................................................
4
Configuration and Maintenance........................................................
5
Repair…...............................................................................................
6-8
Model Numbers, Buttons, and Butterfly Plates…...........................
9
Butterfly Maps....................................................................................
10-11
Sanitizing and Cleaning………………………………………………….
12-13
Troubleshooting…………………………………………………………..
14
Exploded Parts Drawings……………………………………………….
15-26
SERVICE AND FACTORY ASSISTANCE:
Please record your Installer/Service Agent's name and phone number here for future reference:
SERVICE AGENT NAME: ___________________ DATE OF INSTALLATION: _______________
SERVICE AGENT PHONE: ___________________ SERIAL NUMBER: ______________________
Or, call the Wunder-Bar Service Hotline 1-866-WUNDERBAR (1-866-986-3372) anytime or
(707) 448-5151 Monday through Friday, 7:00 AM to 5:00 PM Pacific Time.
MARK 4 MANUAL
REV041410
Mark 4
POST-MIX
BEVERAGE
DISPENSER
For 1 to 14 Button
Post-Mix
and
Juice Dispensers
Standard and Flow Regulator Manifold
Copyright 1988, 2010 by Automatic Bar Controls, Inc.
www.wunderbar.com

Summary

Installation Procedures

Sanitary Drip Cup Installation

Instructions for installing the sanitary drip cup and hose hanger assembly.

Brixing and Flow Rate Settings

Setting Soda and Water Flow Rates

Adjusting soda and water flow rates using brix screws on the manifold.

Adjusting Brix Ratios

Setting syrup to soda/water ratios using brix screws for proper product taste.

Secondary Water Brix Adjustment

Using the secondary water adjustment screw for specific juice and mixer ratios.

Flow Regulator Manifold Operation

Overview and Operation

Explains the purpose and working mechanism of flow regulators for precise brix ratios.

General Operating Instructions

Steps to set flow rates and ratios, including CO2 pressures and product ratios.

Flow Regulator Adjustment

How to adjust syrup flow regulator screws to achieve correct ratios.

Configuration and Maintenance

Buttons and Butterfly Plates

Changing button configurations and replacing butterfly plates for custom setups.

Manifold Shut-Offs

How to use manifold shut-off screws to isolate beverage lines for servicing.

Disconnecting from Brix Manifold

Procedure for safely separating the dispenser from the brix manifold.

Repair Procedures

Handle O-Ring Replacement

Steps to replace O-rings in the dispensing handle for leak prevention.

Stem O-Ring Replacement

How to remove and replace stem O-rings to fix leaks under the button plate.

Valve Plunger Assembly Replacement

Replacing valve plunger assemblies to fix leaks from the nozzle.

Model Number Explanation

Post-Mix & Energy Drink Dispenser Models

Decoding model numbers for post-mix and energy drink dispensers.

Post-Mix Juice Dispenser Models

Decoding model numbers for post-mix juice dispensers.

Butterfly Maps

M4 Dispenser Button Layouts

Diagrams illustrating button configurations for various M4 dispenser models.

M4 Dispenser Button Layouts

Diagrams illustrating button configurations for various M4 dispenser models.

Cleaning and Sanitizing Instructions

Equipment and Supplies

List of necessary items for cleaning and sanitizing the dispenser.

Cleaning Solution Preparation

How to prepare the recommended sanitizing solution concentration.

Sheathing and Nozzle Cleaning

Detailed steps for cleaning the dispenser sheathing and removing/cleaning the nozzle.

Post-Mix System Wash Procedure

Procedure for washing post-mix system circuits with cleaning solution.

Post-Mix System Rinse Procedure

Procedure for rinsing post-mix system circuits with clean water.

Post-Mix System Sanitize Procedure

Procedure for sanitizing post-mix system circuits using cleaning solution.

Troubleshooting Guide

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The Wunder-Bar Mark 4 Post-Mix Beverage Dispenser is a mechanical flex hose bar dispenser designed for the efficient and precise dispensing of post-mix beverages, including soda, water, and juices. This device is available in various button configurations, ranging from 1 to 14 buttons, allowing for a wide array of beverage combinations. It is field-convertible, meaning its configuration can be modified without shutting off the dispenser, offering flexibility in beverage offerings.

Function Description:

The Mark 4 dispenser operates mechanically, using buttons to push down on tiny valves that control the flow of water, soda, and syrup. Unlike electrical solenoids, this mechanical operation eliminates the need for electricity, making it suitable for wet bar environments and allowing for cleaning by soaking in lukewarm or cold water without damage. The dispenser is designed to provide a consistent brix ratio (syrup concentrate to soda or water) for each beverage, crucial for taste and quality.

The system utilizes a manifold assembly where input fittings connect to product lines. These fittings are secured by kwik klips, allowing for easy removal and re-installation for tubing connections. The dispenser can be equipped with either a standard metering screw manifold or a flow regulator manifold. The flow regulator manifold is designed to provide a more precise brix ratio by compensating for pressure fluctuations, automatically adjusting product flow as pressure varies. This is achieved through a piston mechanism that opens or closes outlet holes based on the adjusted tension spring.

Important Technical Specifications:

• Button Configurations: Available in 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, and 14-button models.
• Input Fitting Configurations: Straight, 90-degree, and 45-degree configurations with 1/4", 5/16", 3/8", or 1/2" barbed ends. 3/8" and 1/2" fittings are available in "short" and "long" lengths for staggered installation.
• Tubing Types: Standard syrup tubes, barrier syrup tubes (for energy drinks and pungent syrups), and soda/water tubes. Barrier tubes are indicated by yellow highlighted numbers on the manifold label.
• Flow Regulator Operating Pressures:
  • SODA: 40 to 110 PSI
  • SUGAR BASED SYRUPS: 20 TO 80 PSI
  • DIET SYRUPS: 10 TO 40 PSI
• Finished Product Flow Rate: Factory pre-set and tested at 1.5 ounces per second.
• CO2 Pressures:
  • High CO2: 90 PSI (for carbonator)
  • Low CO2: 60 PSI (for BIB pumps for sugar-based syrups)
  • Diet CO2: 20 PSI (for BIB pumps for diet syrups)
• Sanitation: ETL Sanitation Listed, Intertek 3016449, conforms to NSF STD 18.

Usage Features:

• Brixing: Essential for accurate beverage taste. Can be performed using a syrup separator and Brix Cup (PH10-83 and PH10-35) or a refractometer. Requires chilling the cold plate or refrigerated unit to normal operating temperature before measurement.
• Flow Rate Adjustment: Soda and water flow rates are set to a nominal 5 oz in 3 seconds. Brix screws on the manifold are adjusted counter-clockwise to increase flow and clockwise to decrease flow. Shut-offs are not used for brix ratio adjustment.
• Secondary Water Brix Screw: All post-mix and juice dispensers feature a secondary water adjustment screw for juices and beverages with 2:1 and 1:1 ratios, located under the lower right butterfly plate.
• Configuration Flexibility: Buttons and butterfly plates can be removed and interchanged while the dispenser is under pressure, allowing for customization of carbonated or non-carbonated beverage configurations. Butterfly maps are provided to guide various standard and special configurations.
• Shut-Offs: Each syrup, soda, and water line on the manifold is equipped with individual shut-offs that function like gate valves. Turning a shut-off 90 degrees clockwise stops the flow of product, allowing for internal maintenance without affecting other dispensers.
• Dispenser Disconnection: The dispenser can be disconnected from the brix manifold by depressing all buttons to release pressure, pulling up on kwik klips, and pushing the cam knob sideways while pulling the manifold away from the tube collector. This allows for repairs or replacement of the flex-hose assembly.

Maintenance Features:

• O-Ring Replacement (Stem O-Ring): If syrup, soda, or water leaks from under the button plate, the stem O-ring for that flavor needs replacement. This can be done from the top of the handle without depressurizing the dispenser, although closing the shut-off for the specific position is recommended. The process involves removing the button plate, butterfly plates, O-ring retainer plate, and using a specialized tool (PH10-112) to remove and install the O-ring.
• Valve Plunger Assembly Replacement: If product leaks through the nozzle, the valve plunger assembly may need replacement. This requires confirming all shut-offs are in the OFF position, relieving pressure by pressing buttons, removing the button plate and bottom plate, and using a locking hat plug tool (PH10-126) to remove and install the new plunger assembly.
• Product Tube Replacement: Individual product tubes can be replaced by disconnecting the handle and sheathing, removing tube collector cover screws, and unsnapping the desired tube's interconnect fitting. New tubes are ordered from the factory and installed by taping the new tube to the old one and pulling it through the sheathing.
• Cleaning and Sanitizing:
  • Equipment: Requires a 5-gallon bucket, clean cloth towel, safety goggles, and rubber gloves.
  • Cleaning Solution: Kay-5® Sanitizer/Cleaner (chlorinated alkaline product) mixed at 2 oz per 5 gallons of potable water (not >100°F) to achieve 100 PPM chlorine solution. Bleach is not recommended due to its abrasive nature.
  • Sheathing Cleaning: Involves immersing a flexible soft plastic bristle brush in the cleaning solution and scrubbing the sheathing from heel to manifold.
  • Nozzle Cleaning: Nozzles (compression fit or twist-lock) are removed and soaked in cleaning solution for 2 minutes, then scrubbed with a clean brush.
  • Post-Mix System Cleaning (Wash, Rinse, Sanitize):
    1. Wash: Fill sanitizer tank or bucket with cleaning solution. Disconnect BIB connectors from syrup containers. Attach BIB connectors to the sanitizer tank outlet or cleaning adapters in the bucket. Pressurize the tank to 30-40 PSI. Dispense cleaning solution through each flavor button until no syrup is present. Allow to remain for 2 minutes.
    2. Rinse: Rinse and fill sanitizer tank or bucket with clean warm water (100°F/38°C). Attach BIB connectors and dispense pure water through each flavor button until no cleaning solution is present.
    3. Sanitize: Refill sanitizer tank or bucket with cleaning solution. Attach BIB connectors and dispense approximately 10 ounces of cleaning solution through each flavor button.

The Mark 4 dispenser is designed for durability and ease of service, with detailed instructions for common repairs and routine maintenance to ensure long-lasting, trouble-free operation.

Wunder-Bar Mark 4 Specifications

General

Brand	Wunder-Bar
Model	Mark 4
Category	Dispenser
Language	English