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®
INTELLICARB
ICE COOLED DISPENSER
CB1522 (75lbs), CB2323 (80 & 100lbs), and CB3023
(130lbs) with 8X4 carbonator (80lbs) and 12X4
carbonator (75, 100, & 130lbs), with Flexible manifolding.
Installation Manual
Release Date: January 29, 2003
Publication Number: 630460204INS
Revision Date: July 1, 2005
Revision: D
Visit the IMI Cornelius web site at www.cornelius.com
for all your Literature needs.
Page 2
INTELLICARB DRINK DISPENSERS
INSTALLATION GUIDE
The products, technical information, and instructions contained in this manual are subject
to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation,
operation or maintenance of this equipment. This manual assumes that the person(s)
working on the equipment have been trained and are skilled in working with electrical,
plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety
precautions are taken and that all local safety and construction requirements are being
met, in addition to the information contained in this manual.
To inquire about current revisions of this and other documentation or for assistance with
any Cornelius product contact:
www.cornelius.com
800-238-3600
Trademarks and copyrights:
Aurora, Cornelius, FlavorFusion, Hydro Boost, Optifill, Pinnacle, and Vanguard are registered trademarks of IMI Cornelius Inc.
This document contains proprietary information and it may not be
reproduced in any way without permission from Cornelius.
Printed in U.S.A.
Copyright © 2005, All Rights Reserved, IMI Cornelius, Inc.
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Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TABLE OF CONTENTS
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Read and follow all safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Recognize safety alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Different types of alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Qualified Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drop-In Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drop-In Dimensions (CB1522) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drop-In Dimensions (CB2323) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drop-In Accessories — Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Custom Compact Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drop-in Dimensions (CB3023) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Requirements Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Delivery Inspection and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Back Room Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1522-2323-3023 Drop-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conversion Instructions for Valves Connected into Manifold . . . . . . . . . . . . . . 10
Conversion Instructions for 1522 Valve #1 from Carb to Non/Carb . . . . . . . . . 11
Drop-In Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjust Water-To-Syrup Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cold Plate Plumbing & Wiring Diagram for CB2323 & CB3023 8 Valve . . . . . . 17
Cold Plate Plumbing & Wiring Diagram for CB2323 6 valve . . . . . . . . . . . . . . . 18
Cold Plate Plumbing & Wiring Diagram for CB1522 6 Valve . . . . . . . . . . . . . . 19
IntelliCarb Back Room Plumbing and Settings . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal and Installation of Carbonator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Carbonator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Carbonator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Manifold Parts Breakdown (1522, 2323, 3023) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CB 1522 IntelliCarb Stainless Tower 75lb with 12 x 4 Carbonator . . . . . . . . . . . . . 24
CB 2323 IntelliCarb Stainless Tower 100lb with 12 x 4 Carbonator . . . . . . . . . . . . 25
CB 2323 IntelliCarb Stainless Tower 80lb with 8 x 4 Carbonator . . . . . . . . . . . . . . 26
CB 3023 IntelliCarb Stainless Tower 130lb with 12 x 4 Carbonator . . . . . . . . . . . . 27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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SAFETY
SAFETY INSTRUCTIONS
Read and follow all safety instructions
Read and follow all safety instructions in this guide and on the machine (decals, labels, and laminated
cards).
Read and understand all applicable OSHA (Occupation Safety and Health Administration) safety regulations before operating the machine.
Recognize safety alerts
This is the safety alert symbol. When you see it in this guide or on the machine be
alert to the potential of personal injury, or damage to the machine.
Different types of alerts
There are three types of safety alerts:
IntelliCarb Drop-In Ice Cooled Installation Guide
DANGER — Indicates an immediate hazardous situation which if not avoided WILL result in seri-
ous injury, death, or equipment damage.
WARNING — Indicates a potentially hazardous situation which, if not avoided, COULD result in
serious injury, death, or equipment damage.
CAUTION — Indicates a potentially hazardous situation which, if not avoided, MAY result in
minor or moderate injury or equipment damage.
SAFETY TIPS
• Carefully read all safety messages in this guide and safety signs on the machine.
• Keep safety signs in good condition and replace missing or damaged safety signs.
• Learn how to operate the machine and how to use the controls properly.
• Do not let anyone operate the machine without proper training.
• Keep your machine in proper working condition and do not allow unauthorized modifications to the
machine.
QUALIFIED SERVICE PERSONNEL
CAUTION — Only trained and certified electrical, plumbing and refrigeration technicians should
service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL
CODES.
CO2 (CARBON DIOXIDE) WARNING
WARNING — CO
CO
gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is suspected, particularly
2
in a small area, immediately ventilate the contaminated area before attempting to repair the leak.
Personnel exposed to high concentration of CO
rapidly by loss of consciousness.
© 2003-2005, IMI Cornelius Inc. - 1 - Publication Number: 630460204INS
Displaces Oxygen. Strict Attention must be observed in the prevention of
2
gas will experience tremors which are followed
2
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IntelliCarb Drop-In Ice Cooled Installation Guide
SHIPPING AND STORAGE
CAUTION
and all sanitizing solution must be purged from the syrup systems. All liquids, after sanitizing, must
be purged from the unit. A freezing ambient environment will cause residual sanitizing solution or
water remaining inside the Unit to freeze resulting in damage to the internal components.
— Before shipping, storing, or relocating the Unit, syrup systems must be sanitized
Publication Number: 630460204INS - 2 - © 2003-2005, IMI Cornelius Inc.
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SYSTEM OVERVIEW
DROP-IN PRODUCT OVERVIEW
The Drop-In IntelliCarb consists of the following:
• Front inlet fittings
• 75 lbs., 80 lbs., 100 lbs., and 130 lbs. capacity ice bin
• Foamed polyurethane insulation
• Key lock switch
• 9 3/4 inch cup clearance
• Extended drip-tray for cup staging, removable for cleaning
• High capacity 11/18 cold plate, 5-2-1 configuration
• All fittings are 3/8 inch
• Supports UF-1 fast flow (3.0 oz./sec.), UF-1 Ultra flow (4.5 oz./sec.), and UFB 2.0 - 4.0 valves
• Improved ability to clean outlet line area
• Lighted and non-lighted merchandiser options
IntelliCarb Drop-In Ice Cooled Installation Guide
• Optional cabinet stand for free standing installations.
SPECIFICATIONS
Drop-in Unit
Drop-In Dimensions (CB1522)
Counter Top Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1/4 x 23 1/4 inches
Height above counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 inches
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 inches
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 inches
Shipping weight (approx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 pounds
© 2003-2005, IMI Cornelius Inc. - 3 - Publication Number: 630460204INS
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IntelliCarb Drop-In Ice Cooled Installation Guide
Drop-In Dimensions (CB2323)
Counter Top Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 1/4 x 23 1/4 inches
Height above counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 inches
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches
Shipping weight (approx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 pounds
Drop-In Accessories — Optional
Lighted marquee merchandiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166208004
Cabinet stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165492000
Custom Compact Dimensions
Counter Top Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 1/4 x 23 1/4 inches
Height above counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 inches
Height of Merchandiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 inches
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches
Shipping weight (approx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 pounds
Drop-in Dimensions (CB3023)
Counter Top Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 1/4 x 23 1/4 inches
Height above counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 inches
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 inches
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches
Shipping weight (approx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285 pounds
Publication Number: 630460204INS - 4 - © 2003-2005, IMI Cornelius Inc.
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INSTALLATION
CAUTION — Only trained and certified electrical, plumbing and refrigeration technicians should
service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL
CODES.
INSTALLATION REQUIREMENTS
Requirements Summary
Weight:...................................................counter must be level and able to support 450 lbs.
Environment:..................................................................................... indoor installation only
Temperature:................................................................... 40 to 100° F ambient temperature
CO
:................................................................................................................. 75 psi at unit
2
Syrup: ....................................................................... 60 psi. min,.70 – .75 ounces per sec.,
...............................not to exceed 3.75 oz/sec Finished Product Flow Rate (.6 gpm) at unit
Water pressure: ....................................................................................60 psi max. at pump
Electrical: ..................................................................................................... see name plate
Water volume...........................................................................................................125 gph
Product supply beverage tubing ............................................................................ .375 min.
IntelliCarb Drop-In Ice Cooled Installation Guide
© 2003-2005, IMI Cornelius Inc. - 5 - Publication Number: 630460204INS
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IntelliCarb Drop-In Ice Cooled Installation Guide
DELIVERY INSPECTION AND UNPACKING
Inspection
Upon delivery inspect the unit for damage or irregularities and immediately report problems to the delivering carrier and file a claim with that carrier.
1. Open loose parts packages and inspect parts.
Loose
parts
Make sure all items are present.
Part Name
Pump &motor assy. 629087457 1
4" legs n/a n/a
Clamps Oetiker n/a
Drain pan drain line 167090002 1
Cold plate drain line 167467072 1
Merchandiser assy. 166167010 1
Transformer 630000601 1
Ftg-3/4 Soc x 3/4 fpt n/a n/a
Ftg-3/4 mptx1" barb n/a n/a
Drop-In
P/N Qty.
Publication Number: 630460204INS - 6 - © 2003-2005, IMI Cornelius Inc.
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INSTALLATION PROCEDURE
Back Room Package
TUBING
NOTE: Tubing, hoses, and cabling can come from underneath or in back of the unit.
1. Run bundled tubing from back room to dispenser location.
WATER
1. Install water filter system between booster pump and water pressure regulator.
IntelliCarb Drop-In Ice Cooled Installation Guide
p/n 605620
Pre filter
p/n 605625ST
Main filter
p/n 605600
Polyphosphate feeder (Ice
Maker water)
NOTE: Recommended shut off valve be installed on outlet side of filter system.
2. Run water line from source to inlet connection on booster pump.
3. Connect water line from booster pump outlet to water filter system inlet.
© 2003-2005, IMI Cornelius Inc. - 7 - Publication Number: 630460204INS
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IntelliCarb Drop-In Ice Cooled Installation Guide
NOTE: Do not route beverage make up water through polyphosphate feeder.
Publication Number: 630460204INS - 8 - © 2003-2005, IMI Cornelius Inc.
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4. Connect from water filter system outlet to
water regulator assembly and tee to surge
tank.
5. Connect water lines from manifold outlet to
water line going to each dispenser.
IntelliCarb Drop-In Ice Cooled Installation Guide
2-wide BIB
shelf assembly
P/N 561300067
shelf assembly
P/N 561300066
SYRUP
6. Connect syrup lines from bundled tubing to BIB
pump outlet fitting.
HIGH PRESSURE CYLINDER CO
2
1. Connect primary regulator manifold to high pres-
sure cylinder CO
source and connect tubing to
2
the secondary regulator mounted on the side of
BIB rack.
2. Connect one CO
line from the bundled tubing to the primary regulator manifold on CO2 source to
2
supply each dispenser.
BULK CO
1. Connect bulk CO
TA NK
2
tank to the secondary regulator mounted on the side of BIB rack. DO NOT USE
2
PRIMARY REGULATOR WITH BULK CO
TANKS.
2
connection
from filters
3-wide BIB
Secondary
regulator
BIB
pumps
Water
Water
connection
to unit(s)
© 2003-2005, IMI Cornelius Inc. - 9 - Publication Number: 630460204INS
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IntelliCarb Drop-In Ice Cooled Installation Guide
1522-2323-3023 DROP-IN
Conversion Instructions for Valves Connected into Manifold
1. Remove the cup rest, front panel, and drip tray.
2. Remove insulation pad, 2 screws, and bracket (as shown below).
3. Pull out the plug fitting and tubing with barb fitting of the desired valve for conversion.
4. Place tubing with barb fitting into desired outlet on the manifold.
5. Replace plug fitting in open outlet.
6. Reassemble bracket, 2 screws, and insulation pad.
7. Reassemble drip tray, front panel, and cup rest.
BRACKET
PLUG FITTING
FRONT CONNECTION
CARBONATED WATER
OPTION
TUBING WITH
BARB FITTING
SCREW
OETIKER CLAMP
MANIFOLD
REAR CONNECTION
NON-CARB WATER
OPTION
Publication Number: 630460204INS - 10 - © 2003-2005, IMI Cornelius Inc.
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IntelliCarb Drop-In Ice Cooled Installation Guide
Conversion Instructions for 1522 Valve #1 from Carb to Non/Carb
1. Remove the cup rest, front panel, and drip tray.
2. Remove insulation pad, 2 screws, and bracket (as shown above on page 10).
3. Pull out a plug fitting from the rear connection of the manifold.
4. Disconnect soda line from valve #1.
5. Assemble straight fitting and oetiker clamp to soda line from valve #1 (as shown on page 10).
6. Assemble soda line from valve #1 to manifold.
7. Assemble hose plug and clamp oetiker to soda line valve #1 (as shown on page 10).
8. Reassemble bracket, 2 screws, and insulation pad.
9. Reassemble drip tray, front panel, and cup rest.
Drop-In Installation
1. Install dispenser in counter following standard procedures.
2. Use the Template supplied to mark the location of the hole to be cut into the counter top. Cut the
hole as marked and remove the material.
3. Apply the double stick tape (if supplied with the loose shipped parts).
NOTE: To comply with the National Sanitation Foundation (NSF) requirements, the unit must be
sealed to the counter top.
4. Liberally apply a sealant, such as Dow Corning RTV 731 or equivalent, to the unit flange bottom sur-
face.
5. Lower the unit into position to complete the seal of the rim to the counter top. Apply additional seal-
ant around the rim to ensure a complete seal.
NOTE: Do not move the unit after positioning or the seal will be broken.
6. Remove any excess sealant.
NOTE: For non-electrical valves, skip the next step.
7. Mount the Transformer power supply under the counter, in a position to allow access to the electrical
outlet and to allow the 24V power cord to reach the dispenser.
8. Install the drain hose to the ice bin drain fitting and route the drain hose to a permanent drain.
9. Mount secondary CO
regulator, carbonator pump with motor, and valve transformer in a conve-
2
nient location, no more than 7 feet from the unit.
Secondary
regulator
Carbonator
motor and
pump
assembly
Valve
transformer
10. Connect carbonator motor 3 wire plug to the tower 3 wire harness.
Connect the tower 2 wire harness to the transformer.
© 2003-2005, IMI Cornelius Inc. - 11 - Publication Number: 630460204INS
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IntelliCarb Drop-In Ice Cooled Installation Guide
11. Connect CO2 line from bundled tubing to fixed secondary regulator inlet fitting.
Connect tubing from secondary regulator outlet to
carbonator tank CO
Route CO
line down center channel raceway with
2
inlet.
2
wire harness.
12. For 2323 Drop-In install a tee in water line (must be
before pump). Run one line to carbonator pump inlet.
Connect carbonator pump outlet to “S”.
13. Connect syrup lines.
14. Connect fittings and drain hoses to ice bin and drip tray drains.
Run separate hoses all the way to the drain. Allow a 3” air gap
between the drain and the end of the hose. All connections
must comply with local plumbing and health codes.
CO2 line
2323 Drop-In
W1
15. Turn water supply on.
Plug in water booster pump (on BIB rack).
After the booster pump cycles off, check that water pressure
regulator is set at 60 psi.
16. Turn CO
source on. Set secondary regulator for BIB pumps
2
(located on side of rack) at 60 psi min. Bleed carbonator.
17. Fill bin with ice.
18. Plug in Pump Motor and valve transformer.
The carbonator tank should fill in 7 to 12 seconds.
Water
manifold
assembly
Water
pressure
regulator
Open each valve until carbonated water comes out.
19. Connect syrup lines to bag-in-boxes.
Bleed syrup from each valve.
Free-Standing Dispenser
1. Install the 6” legs to the dispenser cabinet if they are to be used.
2. Place the dispenser in the location selected. Be sure the dispenser is level. This is important to
ensure that the bin drains properly.
3. Mount the Transformer power supply in a convenient location to allow access to the electrical outlet
and to allow the 24V power cord to reach the dispenser.
4. Install the drain hose to the ice bin drain fitting and route the drain hose to a permanent drain.
Publication Number: 630460204INS - 12 - © 2003-2005, IMI Cornelius Inc.
Page 17
IntelliCarb Drop-In Ice Cooled Installation Guide
SANITIZING PRODUCT COLD PLATE TUBING
Preparing the Cleaning Solution: Using a clean tank (tank system) or a five-gallon container (bag-inbox system), prepare a full tank or container of liquid dishwasher detergent by using 70°F (21°C) to
100°F (38°C) potable water and 0.5 oz. (15 ml) of liquid dishwasher detergent (such as Joy, Ivory, ect.) to
one gallon of potable water. Shake detergent solution to thoroughly mix the solution.
Preparing the Sanitizing Solution: Using a clean tank (tank system) or a five-gallon container (bag-inbox system), prepare sanitizing solution using 70°F (21°C) to 100°F (38°C) potable water and 0.5 oz. (15
ml) of household liquid bleach such as non-scented Hi-Lex or Chlorox that contains a 5.25% sodium
hypochlorite concentration to one gallon of potable water. This mixture
must not
exceed 200 PPM of
chlorine. Shake sanitizing solution to thoroughly mix.
STEP 1. WASH PRODUCT/SYRUP SYSTEMS
1. Using a clean tank (tank system) or a five-gallon container (bag-in-box system), prepare a full tank
or container of liquid dishwasher detergent by using 70°F (21°C) to 100°F (38°C) potable water and
0.5 oz. (15 ml) of liquid dishwasher detergent (such as Joy, Ivory, ect.) to one gallon of potable
water. Shake detergent solution to thoroughly mix the solution.
Tank Systems.
• Observe and note CO
pressure settings on the tanks CO2 regulator, then re-adjust CO2 regula-
2
tor to 60 to 80-psi. Pressurize the tank containing detergent solution to 60 to 80-psi.
• Connect detergent solution tank, pressurized at 60 to 80-psi, into one of the tubing systems.
Bag-in Box Systems.
• Install bag valves (cut empty bag-in-box syrup containers) on ends of syrup containers syrup outlet tubes connectors.
• Place all syrup outlet tubes, with bag valves on their ends, in container containing detergent
solution.
2. Flush the syrup system and dispensing valve as follows:
• Place waste container under applicable dispensing valve.
• Activate the dispensing valve for one minute to purge all syrup and flush out the syrup system.
• Continue to activate the dispensing valve in cycles (“ON” for 15-seconds, “OFF”, then “ON” for
15-seconds). Repeat “ON” and “OFF” cycles for 15-cycles.
3. Connect detergent solution to remaining syrup systems and flush syrup out of syrup systems as
instructed in step 2 preceding.
4. Remove detergent solution source from the syrup system.
STEP 2. FLUSH COOLING SYSTEMS
Tank Systems.
1. Connect tank containing potable water, pressurized at 60 to 80-psi, into one of the tubing systems.
Bag-in-Box Syrup System
2. Fill five-gallon container with potable water, then place all bag-in-box syrup containers syrup outlet
tubes in container containing potable water.
• Flush detergent solution out of syrup system and dispensing valve as follows:
• Place waste container under applicable dispensing valve.
• Activate the dispensing valve for one minute to purge all detergent solution and flush out of the
syrup system.
• Continue to activate the dispensing valve in cycles (“ON” for 15-seconds, “OFF”, then “ON” for
15-seconds).
3. Connect potable water source to remaining syrup systems and flush detergent solution out of syrup
systems as instructed in step A preceding.
4. Remove potable water source from the syrup system.
© 2003-2005, IMI Cornelius Inc. - 13 - Publication Number: 630460204INS
Page 18
IntelliCarb Drop-In Ice Cooled Installation Guide
STEP 3. SANITIZE COOLING SYSTEMS
1. Using a clean tank (tank system) or a five-gallon container (bag-in-box system), prepare a full tank
or container of liquid dishwasher detergent by using 70°F (21°C) to 100°F (38°C) potable water and
0.5 oz. (15 ml) of liquid dishwasher detergent (such as Joy, Ivory, ect.) to one gallon of potable
water. Shake detergent solution to thoroughly mix the solution
Tank Systems.
• Connect sanitizing solution tank, pressurized at 60 to 80-psi, into one of the tubing systems.
Bag-in-Box Syrup System.
• Place all bag-in-box syrup containers syrup outlet tubes in container containing sanitizing solution.
2. Sanitize the syrup system and dispensing valve as follows:
• Place waste container under applicable dispensing valve.
• Activate the dispensing valve for one minute to purge all water from and install sanitizing solution
in the syrup system and dispensing valve.
• Continue to activate the dispensing valve in cycles (“ON” for 15-seconds, “OFF”, then “ON” for
15-seconds). Repeat “ON” and “OFF” cycles for 15-cycles.
3. Repeat steps to flush water out of and install sanitizing solution in the remaining syrup systems and
dispensing valves.
4. Remove sanitizing solution source from the syrup system.
5. Allow sanitizing solution to remain in the syrup systems for not less than 10 or no more than 15-minutes (max.) contact time.
STEP 4. WATER FLUSH SYSTEMS
WARNING: Flush sanitizing solution from the systems as instructed. Residual sanitizing solution
left in the systems could create a health hazard.
1. Fill tank (tank system) or a five-gallon container (bag-in-box system) with potable water.
Tank Systems.
• Connect tank containing potable water, pressurized at 60 to 80-psi, into one of the systems.
Bag-in-Box Syrup Systems.
• Place all bag-in-box syrup containers syrup outlet tubes in container containing potable water.
2. Flush sanitizing solution from the syrup system and the dispensing valve as follows:
• Place waste container under applicable dispensing valve.
• Activate the dispensing valve for one minute to purge all sanitizing solution out of the syrup sys-
tem and the dispensing valve.
• Continue to activate the dispensing valve in cycles (“ON” for 15-seconds, “OFF”, then “ON” for
15-seconds). Repeat “ON” and “OFF” cycles for 15-cycles.
3. Repeat preceding steps to purge sanitizing solution out of the remaining syrup systems and dispensing valves.
4. Remove potable water source from the syrup system.
STEP 5. PURGE WATER (RESTORE OPERATION)
Tank Systems.
1. Noting tanks CO
regulator pressure setting observed in step 4 preceding, readjust CO2 regulator to
2
the observed pressure setting.
• Connect tanks containing the product into the system.
Publication Number: 630460204INS - 14 - © 2003-2005, IMI Cornelius Inc.
Page 19
IntelliCarb Drop-In Ice Cooled Installation Guide
Bag-in-Box Syrup Systems.
• Remove all bag valves from bag-in-box syrup containers outlet tubes connectors.
• Connect bag-in-box containers into the syrup system.
2. Place waste container under dispensing valves. Dispense from all dispensing valves to permit
syrup to purge all potable water from the syrup systems and the dispensing valves. Continue to dispense from the dispensing valves until only syrup is dispensed from the syrup systems and valves.
WARNING: To avoid possible personal injury or property damage, do not attempt to remove the
syrup tank cover until CO
pressure has been released from the tank.
2
3. Dispose of waste sanitizing solution in sanitary sewer, not in storm drain, then thoroughly rinse
inside and outside of the container that was used for sanitizing solution to remove all sanitizing solution residue.
CLEANING THE ICE BIN
1. Prepare a mild detergent soap solution in 100°F potable water.
2. Using a nylon (not wire) bristle brush, clean the cold plate and the interior of the ice bin with the
soap solution.
3. Rinse the cold plate and interior bin surfaces with clean potable water.
4. Using a mechanical spray bottle, prepare a sanitizing solution according to the manufacture’s directions and spray the entire interior bin surfaces. Allow to air dry.
CONNECTING PRODUCT TO THE DISPENSER
NOTE: All inlet connections are clearly marked with a label adjacent to the inlet connections.
NOTE: Always leak check all connections.
Post-Mix units must have syrup, carbonated water and plain water connected. The number of syrups will
depend on the number of valves on the dispenser. Refer to the plumbing diagram for details of the
hookup.
Pre-Mix units must have a pre-mix supply connected to each inlet for each valve supplied. Refer to
plumbing diagram for details of the hook-up.
NOTE: A plumbing diagram when supplied with the unit, can be found in the dispensing tower.
PREPARING FOR OPERATION
On units Without Electrically Operated Valves, Skip Steps 1 and 2 Below
1. Plug transformer into electrical outlet. The 24V supply must be connected in the dispensing tower.
2. Turn the key-switch to the ON position. The ice-bin lid must be closed to allow the valves to operate.
3. Adjust the CO
regulators as indicated in the following chart:
2
Post-Mix
Regulator Pressure Setting
Primary (Carbonator) feed line to Carb secondary regulator 90-120 PSI
Secondary, Sugared Syrup Tank 55 PSI min.
Secondary, Diet Syrup Tank 8-12 PSI
Secondary, B-I-B 60 PSI min
4. Operate each valve until product is flowing.
5. Fill the bin with 32°F ice. DO NOT use ice taken directly from the freezer.
6. Adjust the brix (water-to-syrup ratio) for post-mix valves.
© 2003-2005, IMI Cornelius Inc. - 15 - Publication Number: 630460204INS
Page 20
IntelliCarb Drop-In Ice Cooled Installation Guide
Adjust Water-To-Syrup Ratio
Water-To-Syrup
ratio cup
1. Remove valve cover and install syrup separator over the diffuser and through the nozzle.
2. Hold cup under valve and dispense beverage for a specific time (i.e. 2 seconds).
3. NOTE: Water and syrup must be cold before checking ratios.
4. Adjust carbonated water flow to the desired rate (such as 90 to 110 ml (3 to 3.75 oz.) per second).
Turn the flow adjuster 1/4 of a turn at a time and recheck the flow.
To increase reading turn clockwise.
5. Set syrup flow adjuster to get the desired ratio.
6. Test the valve and adjust until a consistent ratio is delivered three consecutive times.
7. Repeat procedure for other valves.
Separator
Valve Type
Manufacturer
Maximum Operating
Portion Control
Cornelius 130 psi
Flowmatic 100 psi
Pushbutton
Cornelius 130 psi
Flowmatic 100 psi
Lever Type
Cornelius 130 psi
Flowmatic 100 psi
Autofill Lever
Cornelius 130 psi
Flowmatic 100 psi
Non-Electric
Cornelius 130 psi
Pressure
Publication Number: 630460204INS - 16 - © 2003-2005, IMI Cornelius Inc.
Page 21
IntelliCarb Drop-In Ice Cooled Installation Guide
© 2003-2005, IMI Cornelius Inc. - 17 - Publication Number: 630460204INS
Cold Plate Plumbing & Wiring Diagram for CB2323 & CB3023 8 Valve
CONTINUOUSLY
BK
REMOTE TRANSFORMER BOX
WH
WH
BK
VALVE WIRE HARNESS
PLUG
24 VAC
LOCKOUT
1
2
3
MERCHANDISER
CONNECTION TO
HAVE MERCHANDISER
SWITCH
OPTIONAL
LIGHTED
BY KEYSWITCH
CONTROLLED
KEY
OUTLET
BK
BK
WH
2
3
1
24 VAC
BK
BK
COM
24 VAC MERCH.
OPTIONAL
CONNECTION
(SOME UNITS)
TO HAVE
WIRE HARNESS
SWITCH
BK
WH
BK
WH
BK
VALVES
24 VAC
VALVE
NO
REMOTE MOTOR/PUMP BOX
GRND
GRND
SUPPLY
115 VAC
POWER
WH
BK
BK
125 GPHB
PUMP
WH
WATER OUT - S
WATER IN
POWER
SUPPLY
115 VAC
WIRE
GROUND
GRND
WH
WH
CIRCUIT BOARD
BK
GRND
WH
WH
BK
BK
CARBONATOR
MANIFOLD LEFT
PLAIN WATER
FROM MOTOR/PUMP
CARBONATOR
8 VALVE UNIT
(FRONT VIEW)
PLUMBING DIAGRAM
DISPENSING VALVES
COLDPLATE INLETS
S
W1
12
M4
W4
M1
W1
M2
W2
M3
W3
SL SR
POST-CHILL
PRE-CHILL
12
M1 1W1M2 2
SODA OUT
WATER IN
GAS
VALVE
CO-2
345678
WIRING DIAGRAM
M5
W5
S5
S4
S1
S2
S3
MANIFOLD RIGHT
S8
W8
M8
S7
S6
W7
M7
W6
M6
435
SL
M3 3 M4 4 M5 5
WATER
678
M7SR6M6
W1
7M88
PROBE
SODA
Page 22
IntelliCarb Drop-In Ice Cooled Installation Guide
Publication Number: 630460204INS - 18 - © 2003-2005, IMI Cornelius Inc.
Cold Plate Plumbing & Wiring Diagram for CB2323 6 valve
CONTINUOUSLY
REMOTE TRANSFORMER BOX
PLUG
24 VAC
VALVE WIRE HARNESS
GRND
LOCKOUT
3
2
1
MERCHANDISER
HAVE MERCHANDISER
CONNECTION TO
SWITCH
OPTIONAL
LIGHTED
CONTROLLED
BY KEYSWITCH
KEY
OUTLET
2
3
1
24 VAC
BK
BK
COM
24 VAC MERCH.
(SOME UNITS)
CONNECTION
TO HAVE
OPTIONAL
SWITCH
WIRE HARNESS
BK
WH
BK
WH
BK
VALVE
NO
24 VAC
VALVES
REMOTE MOTOR/PUMP BOX
GRND
SUPPLY
115 VAC
POWER
WH
BK
BK
PUMP
125 GPHB
WH
WATER OUT - S
WATER IN
115 VAC
POWER
SUPPLY
WIRE
GROUND
GRND
WH
WH
CIRCUIT BOARD
BK
GRND
WH
BK
CARBONATOR
MANIFOLD LEFT
PLAIN WATER
FROM MOTOR/PUMP
CARBONATOR
6 VALVE UNIT
(FRONT VIEW)
PLUMBING DIAGRAM
DISPENSING VALVES
2
COLDPLATE INLETS
S
W1
1
M3
S3
W3
W2
M2
S2
M1
W1
S1
SL SR
POST-CHILL
PRE-CHILL
1
W1
SL
M1 1 M2
SODA OUT
WATER IN
GAS
VALVE
CO-2
23 456
WIRING DIAGRAM
M4
W4
S4
M5
W5
MANIFOLD RIGHT
S6
W6
M6
S5
M5
34
M3234M4
WATER
56
SR
5M66
W1
PROBE
SODA
Page 23
IntelliCarb Drop-In Ice Cooled Installation Guide
© 2003-2005, IMI Cornelius Inc. - 19 - Publication Number: 630460204INS
Cold Plate Plumbing & Wiring Diagram for CB1522 6 Valve
W
S
4
COLDPLATE INLETS
12 3
213
45
M6656
DISPENSING VALVES
PLUMBING DIAGRAM
(FRONT VIEW)
6 VALVE UNIT
WIRING DIAGRAM
SODA OUT
WATER IN
CARBONATOR
PROBE
CO-2
VALVE
POST-CHILL
FROM MOTOR/PUMP
PLAIN WATER
PRE-CHILL
SR S1
GAS
WATER
SODA
6
HAVE MERCHANDISER
REMOTE TRANSFORMER BOX
CONTINUOUSLY
LIGHTED
GRND
GRND
VALVE WIRE HARNESS
BK
WH
1
PLUG
24 VAC
CONNECTION
SWITCH
CONNECTION TO
OPTIONAL
KEY
BY KEYSWITCH
MERCHANDISER
CONTROLLED
TO HAVE
OUTLET
24 VAC
3
1
2
BK
BK
2
3
24 VAC MERCH.
WIRE HARNESS
OPTIONAL
(SOME UNITS)
BK
BK
WH
VALVES
24 VAC
BK
GRND
125 GPHB
REMOTE MOTOR/PUMP BOX
SUPPLY
POWER
115 VAC
PUMP
WH
BK
WH
BK
CIRCUIT BOARD
WATER OUT - S2
WATER IN
WIRE
GROUND
POWER
SUPPLY
115 VAC
WH
WH
BK
CARBONATOR
GRND
WH
FLEXIBLE MANIFOLD
M2
W2
S2
SR
W1
S3 S6
M3
W3
M6
W6
S1 1 M2 M323 M54M4 5
W5
S5
S4
W4
M5M4
Page 24
IntelliCarb Drop-In Ice Cooled Installation Guide
IntelliCarb Back Room Plumbing and Settings
Publication Number: 630460204INS - 20 - © 2003-2005, IMI Cornelius Inc.
Page 25
Removal and Installation of Carbonator
IntelliCarb Drop-In Ice Cooled Installation Guide
Carbonator Removal
1. Remove ice from bin.
2. Disconnect the power to the unit and to the pump and motor.
3. Shut off the CO
4. Shut off the water supply that is connected to the pump and motor.
5. Remove Cup Rest, Splash Panel, Drip Tray, Sliding Lid and Sanitary Plate.
6. Relieve pressure in the system by flipping the pressure relief valve to the up position on the Carbonator.
7. Remove front cover, back cover and valve body of No. 8 (left side).
8. Remove the plug button on the left side of tower and cover hole with tape (safety).
9. Disconnect the barb fitting for the CO
10. Disconnect the barb fitting on the Carbonator lines to the coldplate tubes.
11. Disconnect probe wire from pump and motor harness.
12. Cut the silicone seal with putty knife around Carbonator a minimum of 1.5” deep and remove.
Relief
Val ve
supply that is connected to the Carbonator.
2
line on Carbonator.
2
© 2003-2005, IMI Cornelius Inc. - 21 - Publication Number: 630460204INS
Page 26
IntelliCarb Drop-In Ice Cooled Installation Guide
Carbonator Installation
1. Clean around Carbonator tank opening removing all silicone, and make sure cavity is clean and dry.
2. Place new Carbonator in place of the old one.
3. Reconnect probe wire harness to pump and motor.
4. Seal top of Carbonator with silicone.
5. Connect the CO
replace white gasket).
6. Reconnect the Carbonator lines to the Carbonator.
7. Reinstall valve body, back cover and front cover of the valve No. 8 to unit.
8. Turn on the CO
9. Turn on the water supply that is connected to the pump and motor.
10. Reconnect the power to the unit and to the pump and motor.
11. Test system and pump and motor for leaks.
12. Apply insulation tape as needed to cover tubes on Carbonator.
13. Remove and clean all foreign substance from bin and replace ice.
14. Replace Sanitary Plate, Sliding Lid, Drip Tray, Splash Panel and Cup Rest.
line from the barbed fitting Carbonator and tighten to 80+/- 10 in pounds (Note:
2
supply that is connected to the Carbonator.
2
Publication Number: 630460204INS - 22 - © 2003-2005, IMI Cornelius Inc.
Page 27
IntelliCarb Drop-In Ice Cooled Installation Guide
MANIFOLD PARTS BREAKDOWN (1522, 2323, 3023)
1
2
3
4
5
7
8
6
Item No. Part No. Name Qty.
1 620407728 MANIFOLD FLEX 5 POS 2
2 164126000 SCREW SM 08 TA TRPH 16 SS 10
3 620519005 PLUG MANIFOLD 12
4 630201533 BRKT MANIFOLD BLOCK 2
5 77051500 FITG-VAL DOLE ELB 102 DEGREE 8
6 309854000 CLAMP OETR 413 OPEN STPLS #10.5 8
7 630201532 BRKT RETAINER MANIFOLD 2
8 630600024 HOSE .375 B 5.00” C-PLT TO MANIFOLD BLOCK 4
© 2003-2005, IMI Cornelius Inc. - 23 - Publication Number: 630460204INS
Page 28
IntelliCarb Drop-In Ice Cooled Installation Guide
CB 1522 INTELLICARB STAINLESS TOWER 75LB WITH 12 X 4 CARBONATOR
Item No. Part No. Name Item No. Part No. Name
1 630201449 Frame Dec CB1522 14 630300373 Harn Wire Jumper (Opti-
TM
only)
Fill
2 630000601 Transfrmr 115/24 RMT
75VA
3 630001125 Tank Carb Foam Asy
4X12
4 167491001 Splashguard Panl SBR
TWR GE
15 318308000 Screw TR 10-32 PAPH
32 SS HRD
16 630200858 Cup-Rest CB1522 Opti
TM
(Opti-Fill
only)
167787000 Cup-Rest 1522SST
STND
5 163545001 Switch Key-Lock Termi 17 630900910 Drip-Tray 18” 1522 Intel-
liCarb
6 161168014 Screw Ma 1032 012TR
SS PH
7 630000794 Tower W/A 18” SS BLT
DN 1522
8 167244008 Cover TWR 18.5 x 3.5
SS
18 630001101 Plate Sanitary 75# Intelli-
Carb
19 630001100 Lid Sliding 1522 Intelli-
Carb
20 162865010 Strainer Corner Drain W/
A
9 162968004 Hose 0.265F 16” 21 168745001 Bolt MA 1/4-20 HX 16
STZI
10 630201568 Panel 6VLV 18” SS TWR 22 630300341 Harn Wire TWR 96” 2
CR 25R
11 630300344 Harn Wire 6VLV 2CR
23 629087457 Pump Asy MTR
3.50SPC
12 163518000 Conn Elec Mate-N-Lok
2CR
13 168462002 Plug-Butn 1/2 Hole STNI
SWC
24 630000952 Hose Asy Carb to C-PLT
S-Tube 1522
25 630201516 Lid Top 1522 Sliding (not
shown)
Publication Number: 630460204INS - 24 - © 2003-2005, IMI Cornelius Inc.
Page 29
IntelliCarb Drop-In Ice Cooled Installation Guide
CB 2323 INTELLICARB STAINLESS TOWER 100LB WITH 12 X 4 CARBONATOR
78
2
20
1
31
16
17
18
30
19
13
3
4
15
10
14
9
12
11
25
24
23
22
6
5
21
Item No. Part No. Name Item No. Part No. Name
1 630201423 Decorative Frame 16 630900042
2 630000601 Transformer Ass’y, 115/
167787002 Cup Rest (Standard)
Cup Rest, Grille (Opti-Fill
24V RMT 75V
3 630001125 Carbonator (12 X 4) 17 630150005 Drip Tray
4 167491003 Panel, Splash 18 630001129 Plate, Sanitary
5 163545001 Switch, Key Lock 19 630200832 Lid, Sliding
6 161168014 Machine Screw, Phil
20 162865010 Strainer
Truss Hd., No. 10-32 By
3/8-In. Long
7 630000631 Tower 21 630300357 Lead Wire, Black)
8 167244007 Cap, Tower 22 167570001 Switch, Valve Lockout
9 162968004 Hose, .265 I.D. 23 21633 Hex Nut, No. 4-40
10 630201561 Panel Valve, 6-Flavor 24 21632 Machine Screw, Rd Hd, No.
4-40 By 3/4-In. Long
630201551 Panel Valve, 8-Flavor 25 168745001 Machine Screw, 1/4-20 By
1/2-In. Long
11 630300344 Wire Harness, 6-Flavor 26 630300341 Wire Harness, Power Sup-
ply to Tower
630300345 Wire Harness, 8-Flavor 27 41710 Fitting, 3/4-MPT By 3/4-Barb
12 163518000 Connector, 2 Circuit 28 161508006 Fitting, 3/4-FPT By 3/4-Barb
13 168462000 Button Plug 29 629087457 Pump and Motor with Dou-
ble Check Valve
14 630300373 Wire Harness (Opti-Fil
Valves only)
15 318308000 Thread Rolling Screw,
Phil Pan Hd., No. 10-32
30 630000951 Hose Ass’y, Carb to Cold
Plate
31 630000952 Hose Ass’y, Carb to Cold
Plate S-Tube
By 1-In. Long
TM
)
© 2003-2005, IMI Cornelius Inc. - 25 - Publication Number: 630460204INS
Page 30
IntelliCarb Drop-In Ice Cooled Installation Guide
CB 2323 INTELLICARB STAINLESS TOWER 80LB WITH 8 X 4 CARBONATOR
31
30
Item No. Part No. Name Item No. Part No. Name
1 630201423 Decorative Frame 16 630900042 Cup Rest, Grille (Opti-Fil)
2 630000601 Transformer Ass’y, 115/
167787002 Cup Rest (Standard)
24V RMT 75V
3 630001124 Carbonator (8 X 4) 17 630150005 Drip Tray
4 167491003 Panel, Splash 18 630001129 Plate, Sanitary
5 163545001 Switch, Key Lock 19 630200832 Lid, Sliding
6 161168014 Machine Screw, Phil
20 162865010 Strainer
Truss Hd., No. 10-32
By 3/8-In. Long
7 630000631 Tower 21 630300357 Lead Wire, Black)
8 167244007 Cap, Tower 22 167570001 Switch, Valve Lockout
9 162968004 Hose, .265 I.D. 23 21633 Hex Nut, No. 4-40
10 630201561 Panel Valve, 6-Flavor 24 21632 Machine Screw, Rd Hd, No.
4-40 By 3/4-In. Long
630201551 Panel Valve, 8-Flavor 25 168745001 Machine Screw, 1/4-20 By
1/2-In. Long
11 630300344 Wire Harness, 6-Flavor 26 630300341 Wire Harness, Power Sup-
ply to Tower
630300345 Wire Harness, 8-Flavor 27 41710 Fitting, 3/4-MPT By 3/4-Barb
12 163518000 Connector, 2 Circuit 28 161508006 Fitting, 3/4-FPT By 3/4-Barb
13 168462000 Button Plug 29 629087457 Pump and Motor with Dou-
ble Check Valve
14 630300373 Wire Harness (Opti-Fil
Valves only)
15 318308000 Thread Rolling Screw,
Phil Pan Hd., No. 10-32
30 630000952 Hose Ass’y, Carb to Cold
Plate
31 630000951 Hose Ass’y, Carb to Cold
Plate
By 1-In. Long
Publication Number: 630460204INS - 26 - © 2003-2005, IMI Cornelius Inc.
Page 31
IntelliCarb Drop-In Ice Cooled Installation Guide
CB 3023 INTELLICARB STAINLESS TOWER 130LB WITH 12 X 4 CARBONATOR
29
Item No. Part No. Name Item No. Part No. Name
1 630201420 Frame Dec CB3023 16 167787013 Cup-Rest CB3023 Opti
TM
only)
2 630000601 Transfrmr 115/24 RMT
75VA
(Opti-Fill
167787007 Cup-Rest 3023SST
STND
3 630001125 Carbonator Tank Assy 17 167481019 Drip-Tray 30” TWR BLK
4 167491009 Splashguard Panl 30”
SST
18 630000658 Plate Sanitary W/A 30”
IntelliCarb
5 163545001 Switch Key-Lock Termi 19 630200933 Lid SLI 3023 IntelliCarb
6 161168014 Screw Ma 1032 012TR
SS PH
20 162865010 Strainer Corner Drain W/
A
7 630000847 Tower W/A 30” SS 21 630300357 Lead Wire 22” BK 20G2
187-250
8 167244011 Cover TWR 30” SS TWR 22 167570001 Switch Val Lock-Out
9 162968004 Hose 0.265F 16” 23 21633 Nut Hex 04-40 STZI
10 630001123 Panel Val CB3023 W/A 24 21632 Screw MA 04-40 RD 24
STZI
11 630300345 Harn Wire 8VLV 2CR
2.56SPC
12 163518000 Conn Elec Mate-N-Lok
2CR
13 168462002 Plug-Butn 1/2 Hole STNI
25 168745001 Bolt MA 1/4-20 HX 16
STZI
26 630300341 Harn Wire TWR 96” 2CR
25R
27 629087457 Pump Asy Mtr
SWC
14 630300373 Harn Wire Jumper (Opti-
TM
only)
Fill
15 318308000 Screw TR 10-32 PAPH
28 630001001 Hose Asy Carb to C-Plt
S-Tube
29 630001006
32 SS HRD
© 2003-2005, IMI Cornelius Inc. - 27 - Publication Number: 630460204INS
Page 32
IntelliCarb Drop-In Ice Cooled Installation Guide
TROUBLESHOOTING
Trouble Probable Cause Remedy
ADJUSTMENT OF DISPENSING VALVE SYRUP
FLOW REGULATOR
DOES NOT INCREASE
TO DESIRED WATERTO-SYRUP “RATIO”
ADJUSTMENT OF DISPENSING VALVE SYRUP
FLOW REGULATOR
DOES NOT DECREASE
TO DESIRED WATERTO-SYRUP “RATIO”
DISPENSED PRODUCT
CARBONATION TOO
LOW
A. Dispensing Valve syrup flow regu-
lator, syrup tank quick disconnect,
or syrup line restricted.
B. Syrup tank quick disconnects not
secure.
C. Syrup tanks secondary CO
regu-
2
lator out of adjustment.
D. No syrup supply.
E. Improper syrup Baume.
F. Dirty or inoperative piston or
spring in dispensing valve syrup
flow regulator.
G. Tapered nylon washer inside tube
swivel nut connector distorted
from being overtightened.
A. Dirty or inoperative piston or spring
in dispensing valve syrup flow regu-
lator.
A. Air in carbonator tank.
B. Water, oil or dirt in CO
supply
2
A. Sanitize syrup system as
instructed.
B. Secure quick disconnects.
C. Adjust syrup tanks secondary
CO
regulator as instructed.
2
D. Replenish syrup supply.
E. Replace syrup supply.
F. Disassemble and clean dispens-
ing valve syrup flow regulator.
G. Replace nylon washer and make
sure it seats properly.
A. Disassemble and clean dispensing
valve syrup flow regulator.
A. Vent air out of carbonator tank
through relief valve. Actuate dispensing valve carbonated water
lever to make carbonator pump
cycle on.
B. Remove contaminated CO
Clean CO
system (lines, regula-
2
tors, ect.) using a clean CO
2
.
2
sup-
ply.
DISPENSED PRODUCT
A. Oil film or soap scum in cup or
COMES OUT OF DISPENSING VALVE CLEAR
BUT FOAMS IN CUP OR
B. Ice used for finished drink is sub-
GLASS.
NOTE: Crushed ice in the glass also causes dispensing problems. When finished drink hits
sharp edges of ice, carbonation is released from dispensed drink.
C. Syrup over-carbonated with CO
D. Warm product-No ice in bin,
Publication Number: 630460204INS - 28 - © 2003-2005, IMI Cornelius Inc.
glass.
cooled.
as indicated by bubbles in inlet
syrup lines leading to unit.
bridged ice on cold plate or
plugged drain.
A. Use clean cup or glass.
B. Do not use ice directly from
freezer. Allow ice to become
“wet” before using. (Refer to following NOTE).
C. Remove syrup tanks quick dis-
2
connects. Relieve tank CO
sure, shake tank vigorously, then
relieve tank CO
pressure as
2
many times as necessary to
remove over-carbonation.
D. Replenish ice, break ice up to
eliminate bridging, unplug the
drain.
2
pres-
Page 33
IntelliCarb Drop-In Ice Cooled Installation Guide
Trouble Probable Cause Remedy
NOTE: If water supply is dirty, be sure to flush lines and carbonator completely. It may be necessary to remove lines to carbonator tank. Flush tank and all inlet lines to remove any foreign particles or dirt.
NO PRODUCT DISPENSED FROM ONE
DISPENSING VALVE
ONLY CARBONATED
WATER DISPENSED.
ONLY SYRUP DISPENSED
A. Broken or disconnected wiring.
B. Inoperative dispensing valve sole-
noid coil.
C. Inoperative dispensing valve
micro switch.
A. Quick disconnects not secure on
syrup tanks.
B. Out of syrup.
C. B-I-B connectors not properly
connected.
D. Syrup secondary CO
regulator
2
not properly adjusted.
E. Inoperable dispensing valve.
F. Dispensing valve syrup flow regu-
lator not properly adjusted.
G. Dispensing valve syrup flow regu-
lator, syrup tank quick disconnect,
or syrup lines restricted.
A. Plain water inlet supply line shut-
off valve closed.
B. Carbonator power cord
unplugged from electrical outlet.
A. Repair or connect wiring.
B. Replace solenoid coil as
instructed.
C. Replace micro switch as
instructed.
A. Secure quick disconnects on
syrup tanks.
B. Replenish syrup supply as
instructed.
C. Properly attach the connectors.
D. Adjust syrup tanks secondary
CO
regulator as instructed.
2
E. Repair dispensing valve.
F. Adjust dispensing valve syrup
flow regulator (Water-to Syrup
“Ratio”) as instructed.
G. Sanitize syrup system as
instructed.
A. Open plain water inlet supply line
shutoff valve.
B. Plug carbonator power cord into
electrical outlet.
Trouble Probable Cause Remedy
PUMP MOTOR WILL
NOT RUN
© 2003-2005, IMI Cornelius Inc. - 29 - Publication Number: 630460204INS
TROUBLESHOOTING for Carbonator
A. Locked pump rotor-dirt or pipe
compound in pump; pump seized.
B. Carbonator flooded.
C. No power.
A. Remove and check for free rota-
tion or replace. Also check CO
2
supply, faulty single check valve,
liquid level control or probe.
B. Main water supply pressure
higher than CO
pressure within
2
the carbonator. If maximum water
supply pressure is within 20 PSI
of CO
pressure, install water
2
pressure regulator.
C. Check source of electrical supply
and for loose connections.
Page 34
IntelliCarb Drop-In Ice Cooled Installation Guide
TROUBLESHOOTING for Carbonator
Trouble Probable Cause Remedy
PUMP RUNS CONTINUOUSLY
A. Pump water supply restricted.
B. Pump discharge line restricted.
C. Inefficient or worn pump.
D. Overdrawing.
A. Check water filter and pump inlet
strainer and clean. NOTE: Noisy
pump operation usually indicates
restricted water supply. Also
check for faulty double check
valve, water leak or low pump
bypass.
B. Water inlet check valve may be
plugged. Remove, clean, or
replace rubber O-Rings.
C. To test for efficiency, disconnect
discharge line from pump. Connect a 300 pound gauge and
hand shut off valve to pump discharge. Start pump. Bleed off any
air, close hand valve then observe
pressure. If it is approximately
180 PSI, pump is O.K. If it is significantly below 180 PSI, it may
be increased by adjusting the
pump by-pass. Increasing the bypass is accomplished by removing sealing acorn cap and turning
the adjusting screw in. If pressure
rises to 180 PSI, pump is O.K. If it
is still below 150 PSI, and the
screw is turned all the way in, the
pump is worn. Replace. NOTE:
Abadly worn pump and/or premature failure usually indicates foreign material in the supply water.
Install a water filter in supply line.
Also check for faulty liquid level
control, corroded electrode, or
broken pump shaft.
D. Check capacity of pump. The
combined rate of flow from dispensing valves should not exceed
the stated GPH for pump, or
pump will run continuously.
NOISY PUMP A. Bad motor bearings or worn pump
B. Failure of Triac on liquid level
C. Insufficient water supply.
Publication Number: 630460204INS - 30 - © 2003-2005, IMI Cornelius Inc.
shaft.
control.
A. Repair or replace motor.
B. Repair or replace liquid level con-
trol.
C. Check that water supply is on.
Also check for clogged water filter, ruptured tank or bad double
check valve.
Page 35
IntelliCarb Drop-In Ice Cooled Installation Guide
TROUBLESHOOTING for Carbonator
Trouble Probable Cause Remedy
VALVE DELIVERS CO
2
A. Pump motor will not run.
GAS CONTINUOUSLY
B. Pump water supply restricted.
C. Relief valve venting.
D. Worn pump.
VALVE DELIVERS SODA
WATER AND CO
GAS
2
A. Pump water supply restricted.
INTERMITTENLY
B. Relief valve venting.
C. Inefficient or worn pump.
POOR CARBONATION A. Flooded carbonator.
B. Water temperature too high
(warm).
C. Oil in water supply.
D. Supply water containing too much
air in solution.
E. Poor quality paper cups.
F. Dirty or greasy glassware.
G. Excessive foam.
H. Flat drinks.
A. See
PUMP MOTOR WILL NOT
RUN.
B. Clean strainer. Check for faulty
double check valve.
C. Repair or replace.
D. See
PUMP MOTOR WILL NOT
STOP
.
A. Clean strainer. Check for faulty
single check valve, clogged water
filter, water supply off or blocked,
ruptured tank, faulty liquid level
control or double check valve.
B. Replace or repair.
C. See
A. See
PUMP MOTOR WILL NOT
STOP
.
PUMP MOTOR WILL NOT
RUN.
B. Check water inlet temperature.
Lower temperature provides bet-
ter carbonation.
C. Check pipe thread compound.
Remove and clean and replace
with teflon pipe thread tape.
D. To remove air before it enters
pump, it will be necessary to
install an open tank with float to
control water level.
E. Purchase quality cups made for
this application.
F. Wash all glassware.
G. CO
BIB pump pressure too high,
2
contamination within the bever-
age system, poor quality paper
cups or dirty glassware.
H. Draw drinks against side of glass
or cup. Check for insufficient CO
contamination, bad check valve,
ruptured CO
2
line
2
© 2003-2005, IMI Cornelius Inc. - 31 - Publication Number: 630460204INS
Page 36
IntelliCarb Drop-In Ice Cooled Installation Guide
TROUBLESHOOTING
Trouble Probable Cause Remedy
DRINK HAS OFF-TASTE
OR ODOR (WATER CONTA MI NAT IO N )
A. Leaking check valves.
B. Too much plumbers pipe com-
pound on pipe joints.
C. Soda water and beverage lines
made of brass or copper.
D. High chlorine level.
E. Tank corrosion.
F. Contaminated CO
2
WARRANTY
A. Replace O-Rings in double check
valve or replace double check
valve. See check valve installation instruction section.
B. Remove pipe compound and
clean joints. Use Teflon pipe
thread tape.
C. Carbonated water reacts with
brass or copper and should not
dispensed through lines of this
material. Replace lines with stainless steel or beverage grade plastic.
D. Install water filter to eliminate
chlorine in excess of 1.5 ppm.
Use type that do not remove all
chlorine.
E. Replace tank.
F. Check that CO
grade.
is beverage
2
be
IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius product, in
your country, please write, fax, or telephone the IMI Cornelius office nearest you. Please provide the
equipment model number and the date of purchase.
Publication Number: 630460204INS - 32 - © 2003-2005, IMI Cornelius Inc.
Page 37
Page 38
IMI Cornelius Inc.
www.cornelius.com
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