Cornelius CB1522, CB2323, CB3023 Installation Manual

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.

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.

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

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

gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is suspected, particularly

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.

Displaces Oxygen. Strict Attention must be observed in the prevention of

gas will experience tremors which are followed

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

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

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

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

:................................................................................................................. 75 psi at unit

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

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.

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.

IntelliCarb Drop-In Ice Cooled Installation Guide

NOTE: Do not route beverage make up water through polyphosphate feeder.

+ 26 hidden pages

Cornelius CB1522, CB2323, CB3023 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual