Cornelius Cold Beverage Dispenser User Manual

INTELLICARB

Training Manual

Release Date: April 29, 2004 Publication Number: TP01071 Revision Date: NA Revision: A Visit the IMI Cornelius web site at www.cornelius.com

for all your Literature needs.

INTELLICARB TRAINING MANUAL

The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or 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, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olympus,

and Vista are registered trademarks of IMI Cornelius Inc. Optifill trademark is pending.

This document contains proprietary information and it may not be

reproduced in any way without permission from Cornelius.

Printed in U.S.A.

InelliCarb Training Manual

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Delivery Inspection and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Cornelius IntelliCarb Carbonator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Carbonator Time Out Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Carbonator Relief Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Mechanical Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Gate Restrictor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Ice Diverter Kit 02394 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Removal and Replacement of Agitators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

To Remove Agitators For Cleaning (300 shown) . . . . . . . . . . . . . . . . . . . . . . . .10

Post-Mix Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Set-up Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Dimensions & Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

System Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Adjusting Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Calculating Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Syrup/Concentrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Setting Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Shurflo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Shurflow Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Shurflow Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Plumbing Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Flow Diagram 1xx (Six Flavor Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Flow Diagram 1XX (Eight Flavor Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Flow Diagram 2xx (Eight Flavor Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Flow Diagram 2xx (Ten Flavor Models)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Flow Diagram 300 (Twelve Flavor Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

IntelliCarb Training Manual

Electrical Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Carbonator Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Wiring Diagram 1xx (120V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Schematic 1xx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Wiring Diagram 2xx (120V Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Wiring Diagram 2xx (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Wiring Diagram 2xx (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Wiring Diagram 300 (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Wiring Diagram 300 (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Schematic 300 (120V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Schematic 300 (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SHURflow Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Pumping Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Pumps in Series for Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pump Sanitizing / Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

DOES NOT OPERATE / GAS APPLIED / DISPENSER VALVE OPEN . . . 37

OPERATES BUT WILL NOT PRIME / DISPENSER VALVE OPEN . . . . . .37

DOES NOT ACHIEVE SOLD-OUT WITH EMPTY B-I-B . . . . . . . . . . . . . . . 37

AIR IN INLET AND/OR OUTLET TUBING . . . . . . . . . . . . . . . . . . . . . . . . . .37

STROKES WITH DISPENSER VALVE CLOSED . . . . . . . . . . . . . . . . . . . . 37

FLUID FROM EXHAUST OR VISIBLE WITHIN GAS INLET TUBING . . . . . 37

GAS BLOWING FROM EXHAUST CONTINUOUSLY . . . . . . . . . . . . . . . . . 37

Dispenser Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Valve Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Excess Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Off Taste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

No Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Carbonator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Solid State Carbonator Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Test Solid State Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

UNIT DESCRIPTION

• Built-in cold carbonator produces bottle-quality drinks every time

InelliCarb Training Manual

INTRODUCTION

• No seasonal CO

• A complete system for simplified installation

• Reduces service frequency and lowers equipment life cost

• Generates increased beverage sales and greater consumer satisfaction

• Illuminated merchandiser delivers unique, high impact marketing message

• Ice used to cool cold plate kept separate from ice dispensed into cups

• One piece ABS thermoformed plastic ice storage hopper. Durabide™ design provides durability and

ensures all ice in the hopper is dispensable

• Unit readily accepts top mount cubers with manual ice fill capability

adjustments required for changes in water temperature

THEORY OF OPERATION

The rate of CO2 solubility increases with cold water. IntelliCarb System provides pre–chilled cold water from the cold plate and mix with CO high volume 125gph Procon pump and high torque motor.

The amount of carbonated water reserve is controlled by a probe mounted in the tank. The probe is called a “liquid level probe”. The liquid level probe senses the water level in the tank. Probe controls the pump “ON” and “OFF” cycle through the electronic board called “liquid level board”.

NOTE: The probe works on a 5 M.V. D.C. current that continually reverses direction to prevent probe corrosion.

in the carbonator tank. The water is introduced into the tank with a

DESCRIPTION

The “Enduro IntelliCarb” series of ice dispensers solves your ice and beverage service needs in a sanitary, space saving, economical way. Designed to be automatically filled with ice from a top mounted ice machine or manually filled with ice from any remote ice-making source, these dispensers will dispense cubes (up to 1-1/4 inch in size), cubelets, and hard-chipped or cracked ice. In addition, the units include beverage faucets, a cold plate, an internal carbonator tank and an external pump for the carbonator, and are designed to be supplied direct from syrup tanks with no additional cooling required.

IMPORTANT: For dispensing compressed or extruded style ice, an Ice Diverter Kit must be installed on the dispenser, see FIGURE 13 on page 9.

IntelliCarb Training Manual

SPECIFICATIONS

ED150 ED175 ED200 ED250 ED300

B=(Beverage)

Model

Descriptions:

Ice Storage:

Maximum

Number of

Faucets

Available:

Built-in Cold

Plate:

Electrical:

Dimensions:

2 Operating

Pressure

C=(Coldplate) H=(Internal Carb) Z=(No DripTray) 150 Pounds 175 Pounds 200 Pounds 250 Pounds 300 Pounds

Yes Yes Yes Yes Yes

$PSV7RWDO8QLW'UDZ 120/1/60, 3.5 Amps Total Unit Draw

Width 22” Deep 30--11/16” High 35--5/8”

Z--Models Width 22”

Deep 23--1/16” High 35--5/8” 75--psig (max) 75--psig (max) 75–psig (max) 75–psig (max) 75–psig (max)

B=(Beverage) C=(Coldplate) H=(Internal Carb) Z=(No DripTray)

6 8 10 10 12

Outlet should be within 6 feet of dispenser.

Width 24.5” Deep 30--11/16” High 35--5/8”

Width 24--1/2” Deep 23--1/16” High 35--5/8”

B=(Beverage) C=(Coldplate) H=(Internal Carb) Z=(No DripTray)

230/1/50, 2.0 Amps Total Unit Draw

Width 22” Deep 30–11/16” High 35–5/8”

Z–Models Width 22”

Deep 23–1/16” High 35–5/8”

B=(Beverage) C=(Coldplate) H=(Internal Carb) Z=(No DripTray)

Width 24.5” Deep 30–11/16” High 39–5/8”

Width 24–1/2” Deep 23–1/16” High 39–5/8”

B=(Beverage) C=(Coldplate) H=(Internal Carb) Z=(No DripTray)

120/1/60, 4.0 Amps Total Unit Draw 230/1/50, 3.0 Amps Total Unit Draw

Width 44–3/8” Deep 31–1/2” High 37”

Z–Models Width 44–3/8”

Deep 23–1/16” High 37”

REQUIREMENTS

• Weight: counter must be level and able to support 450 lbs.

• Environment: Indoor installation only

• Temp eratu re: 40 to 100

• CO2: 75 psi at unit

• Syrup: 60 psi., 0.70 -- 0.75 ounces per sec. (0.6 gpm) at unit

• Water: 60 psi at pump

• Electrical: See name plate

DELIVERY INSPECTION AND UNPACKING

Upon delivery inspect the unit for damage or irregularities and immediately report problems to the delivering carrier and file a claim with that carrier.

• Open loose parts packages and inspect parts.

Part No. Description Qty.

710000030 Pump and Motor Assy 1

70970 4”Legs 4 70750 Clamps 2

620702201 Brush 1

51774 Drain Pan Drain Line 1 50335 Drain Line Insulation 1

 )LWWLQJ6RF[)SW 1  )LWWLQJ0SW[µ%DUE 1

INSTALLATION

1. Locate the dispenser indoors on a level counter top.

A. LEG OPTION

Unpack the four (4) legs and install them into the threaded holes provided in the bottom of the unit. The installer must provide flexibility in the product and utility supply to permit shifting the position of the dispenser sufficiently to clean the area beneath it.

B. COUNTER MOUNTING

If counter mounted the ice drink dispenser must be sealed to the counter. The template drawing indicates where openings can be cut in the counter. Locate the desired position for the dispenser, then mark the outline dimensions on the counter using the template drawings. Cut openings in counter. Apply a continuous bead of NSF International (NSF) silastic sealant (Dow 732 or equal) approximately 1/4--inch inside of the unit outline dimensions and around all openings. Then, position the unit on the counter within the outline dimensions. All excess sealant must be wiped away immediately.

2. The beverage tubes, drain tube and power cord are routed through the large opening in the bottom

of the unit. See the mounting template for locating the required clearance opening in the counter for these utility lines.

3. Drip tray assembly: Route the drain tube to an open drain with the end of the tube above the “flood”

level of the drain. Use the tubing, fittings, clamps, and insulation provided with the Dispenser to assemble the drain. The completed drain line must pitch continuously downward and contain no “traps” or improper drainage will result. Must have a 4 inch air gap between drain line and drain.

NOTE: This equipment must be installed with adequate backflow protection to comply with federal, state, and local codes.

InelliCarb Training Manual

NOTE: IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the plain water inlet supply line. A Cornelius Water Filter (P/N 313860000) and QUICK DISCONNECT SET (P/N 313867000) are recommended.

CAUTION: Check the minimum flow rate and the maximum pressure of the plain water inlet supply line. MINUMUM FLOW RATE MUST BE AT LEAST 125--GALLONS PER HOUR. If flow rate is less than 125-

-gallons per hour, starving of the carbonator water pump will occur. Starving will damage the water pump and could cause the carbonator to time out. INCOMING PLAIN WATER INLET SUPPLY LINE WATER TO PUMP PRESSURE MUST REMAIN A MINIMUM OF 10--PSI BELOW THE CARBONATOR C

OPERATING PRESSURE. (Example: Carbonator CO2 operating pressure is 75--PSI and the maximum water pressure can be no more than 65--psi, etc.). Water over pressure (higher than C

O2 operating pres-

sure) can cause carbonator flooding, malfunction, and leakage through the carbonator relief valve. If water is exceeding maximum pressure specifications, a Water Pressure Regulator Kit (P/N 310150000) or equivalent must be installed in the plain water inlet supply line. If fitting connector is not available, water line must be 1/2” or 3/4” diameter with a shut off valve within 6 feet of the dispenser.

4. Locate the carbonator pump assembly and connect probe wires from Ice/Drink Unit and pump. Con-

nect inlet water to pump and pump outlet to Ice/Drink Unit using 3/8--inch food--grade tubing.

NOTE: Locate carbonator assembly within 6 feet of the dispenser. Do not lengthen the control board harness.

5. Connect the beverage system product tubes as indicated in applicable Plumbing Flow Diagram, see

page 19. This work should be done by a qualified service person.

NOTE: Water pressure for non carbonated beverages must be 60 P.S.I. minimum.

NOTE: See applicable Flow Diagram or Decal on the lower front of the unit for the location of syrup and water connections.

6. Clean the hopper interior.

7. Connect the two power cords to a 120 volt, 60 cycle, 3-wire grounded receptacle. For 220--240 Volt

International Units, a 3--wire power cord is provided. An adapter plug for the particular country will need to be provided by the Installer.

IntelliCarb Training Manual

Drains

Use a 1 - 1/2” rigid pipe (e.g. ABS on P.V.C.) this is to prevent kinking or collapsing. Make sure to leave a 4 inch air gap between the drain line and the floor drain.

CORNELIUS INTELLICARB CARBONATOR ASSEMBLY

1. Ice Drink / Drop-In Carbonator Pump & Motor Unit

Vent to Atmosphere Check Valve

Liquid Level Control Box

Preset CO2 Regulator (75P.S.I.)

Carbonator Time Out Reset Switch

The board can be set to turn the carbonator off after three or seven minutes of continuos time. The feature can also be disabled. See the carbonator instruction in this manual.

FIGURE 2 FIGURE 3

1. Locate carbonator assembly below dispenser no more than 6 feet away. Important: Make sure there is clearance for the liquid level control reset switch on the side of the control box to avoid accidentally tripping the switch. The control board has an internal timer to prevent the

pump motor from running continuously. In the event of a water supply interruption or malfunction of the water level probe and/or motor relay circuit. If there is a time-out event, make necessary repairs to what caused the time out, then depress and release the reset switch to put the control board back in service. By moving a jumper on the control you can select either a 7 minute or 3 minute time out or this feature can also be disabled.

A. Hook-up a 3/8 ID water supply line 125 G.P.H. minimum (60 psig. max.) to pump inlet. Minimum

flowing pressure is 30 psig. Important: Tap for non-carb water supply must be upstream of

pump inlet. Do not tap in the pump outlet.

B. Hook-up a 3/8 (.375 ID) CO

psig.) on the Pump & Motor base. Note: If using a bulk CO

regulator must be set to 100-105 psig. The regulator on the bulk tank should be a secondary.

supply line (100 psig.) to the inlet of the pre-set CO2 regulator (75

FIGURE 1

Carbonator Time Out Reset Switch

Time Out

Selector Pins

Liquid Level

Control Board

125 G.P.H. ProCon Water Pump

High Torque Pump Motor

tank as supply, tank pressure

C. Initial start-up procedure for carbonated water system: Turn on the CO2 supply to the car-

bonator tank, vent air from carbonator tank by pulling the tank relief valve. Turn on water supply to the pump. Connect electrical power to the pump and motor unit. Bleed the air out of the system by energizing a beverage valve until carbonated water is flowing from the valve.

NOTE:If the carbonator Pump and Motor does not cycle (turn on and off) properly, check that the probe harness connector and ground lead are secured to the carbonator tank connection points.

D. If service is required on Ice Drink units, it will be necessary to lower the beverage valve panel to

gain access to the probe and ground connection. Remove the lower front panel (2 screws) from the cabinet and the ice chute cover (“snap” fit). Remove the 6 screws that secure the beverage panel to the cabinet. The panel can now be moved downward due to the flexibility of the beverage tubing to expose the carbonator tank connections.

Carbonator Relief Valve Locations

The carbonator tank is located behind the splash panel, on the right side of the dispenser. You will need to pull the relief valves to purge air from the system after the CO

do this will cause low carbonation volume and popping of the relief valves.

Relief

Valve Ring

Agitator

Motor

Carbonator

Tan k

Carbonator

Tank Relief

Valve

InelliCarb Training Manual

supply has been hooked up. Failure to

2. Dispenser

Total Flex Manifold

(with insulation)

Cold Plate Inlets

(3/8 Barb)

Carb. Tank Liquid

Level Probe Harness

FIGURE 6

FIGURE 7

Ice Drink Model ED175BCH (Lower Front Panel Removed)

FIGURE 8

Insulated Cold Plate Cover & Carbonator Tank Assembly

Total Flex Manifold (insulation removed)

Carb Tank CO2 Supply Line

IntelliCarb Training Manual

Ice Drink Model ED150/175/300 Coldplate Cover

Liquid Level Probe

CO2 Check Valve with Ground Stud

FIGURE 9

Ice Drink Model ED200/250 Coldplate Cover

In-line CO2 Check Valve

3. Total Flex System for Ice Drink Models ED150/175/200/250/300

Total Flex Manifold (Insulation Removed)

Water Line

Retainer Clip

Probe

FIGURE 10

Ground Plate/Stud

Plugs

Manifold Block

FIGURE 11

Total Flex is a system of water manifold blocks located at the front of the cold plate, adjacent to the cold plate inlets, for easy switch over of carbonated / non-carbonated beverage drinks. The right hand manifold block is for the beverage valves located to the right side of the ice chute, and the left block is for the left bank of valves. Each beverage valve on the dispenser can be set up for either carbonated or non-carbonated drinks. Refer to the unit’s plumbing diagram for the factory carbonated / non-carbonated valve locations. The procedure for switching carbonated / non-carbonated water lines on a beverage valve is as follows:

A. Shut off the water supply to the dispenser. Depressurize and drain both the carbonated and non-

carbonated water circuits.

B. Remove the retainer clip (2 screws) from the manifold block. Switch the plug and water line fitting

to their respective carbonated / non-carbonated outlet locations on the block.

C. Replace the retainer clip. Turn on the water supply and energize the “switched” valve(s). Check

for water leaks.

4. Important: Route the dispenser’s drain line to an open drain with the end of the tube above the flood level of the drain. The drain line must pitch downward and contain no “traps”.

5. Connect both the carbonator pump and motor unit and the dispenser to a grounded

electrical sup-

ply outlet.

IntelliCarb Training Manual

6. Check list for proper “finished” drink carbonation:

A. Fill ice storage hopper with ice. B. Water supply must be from a continuous source (no tank supply). C. Use only filtered water. D. Supply water line to the carbonator pump must be a minimum of .375 ID. E. Syrup supply lines must be a minimum of .265 ID. F. Water inlet pressure range: 45-60 max. static psig. with a minimum flowing pressure of 30 psig. G. Syrup CO

H. CO

secondary regulator pressure set to 60 psig.

supply must be high quality, food grade.

I. Purge all water, carb-water, and product lines of air before brixing valves. J. Important: Brix valves with cold product. Allow at least 15-20 minutes for ice to cool down the

coldplate on initial start-up before brixing the valves.

K. Dispense at least (2) 12 oz. drinks before taking a carbonation level reading. L. Carbonation tester thermometer must read 32-33

F. for accurate carb-level reading. Store tester

in ice water bath during use.

M. Hold cup at valve nozzle for drink to be tested. Pour drink slowly down the side wall into the carb-

tester to avoid agitation during pouring. Press vent valve once on carb-tester after tightening lid.

N. Shake carb-tester in vertical motion until peak pressure reading is obtained. Use Pepsi chart for

carbonation level reading.

NOTE: Carbonator troubleshooting procedure located on page 43.

IntelliCarb Training Manual

MECHANICAL SECTION

GATE RESTRICTOR PLATE

NOTE: Disconnect power to dispenser before installing, removing, or adjusting restrictor.

ADJUSTMENT

Adjustment

This plate may be adjusted as shown to reduce or increase the dispensing rate of ice, especially desirable when using glasses or other containers with small openings. Adjustment can be made by sliding up or down with nuts loosened, to obtain the desired amount of restriction.

INSTALL PLATE

ON STUDS AS

SHOWN

FIGURE 12

ICE DIVERTER KIT 02394

NOTE: For dispensing Scotsman, Wilshire, and Hoshizaki compressed ice cubes:

1. Disconnect power to dispenser.

2. Remove Merchandiser from dispenser.

3. Remove ice chute and discard gate restrictor.

4. Install ice diverter on gate mounting plate as shown below.

5. Apply RTV to back surface of ice diverter, to seal to gate mounting plate.

6. Reinstall gasket and ice chute.

7. Reinstall merchandiser and energize unit.

IntelliCarb Training Manual

IC E C H UT E

COVE R

10--32 WA S HE R

GATE MOUNTING P LATE

IC E DIV E R T E R

IC E C H UT E

GASKET

STORAGE HOPPER

FLANGE E XTENDS

INTO S TORA GE HOP-

PER THROUGH GATE

OPE NING

APPLY RTV TO

THIS SUR FACE TO

SEAL TO HOPPER

GATE MOUNTING

PLATE

10--32 NU T

FIGURE 13

IntelliCarb Training Manual

REMOVAL AND REPLACEMENT OF AGITATORS

To Remove Agitators For Cleaning (300 shown)

NOTE: All other models have only one agitation Assembly.

COUNTERCLOCKWISE

ROTATION

LEFT HAND

AGITATOR

O–RING

FRONT (VALVE SIDE) VIEW FROM TOP OF DISPENSER

RIGHT HAND AGITATOR WITH HOLE IN UPRIGHT

CLOCKWISE

ROTATION

FIGURE 14

1. Lift agitator and disc from unit.

2. Remove O-Ring starting at notch. Warm the O-Ring with water to ease removal.

3. Lift the plastic agitator disc off of the stainless-steel agitator.

4. Replace by reversing steps.

NOTE: Refer to Sanitize Procedure in the Owners Instruction for complete cleaning and sanitiz-

instructions.

ing

POST-MIX VALVE SECTION

SET-UP INSTRUCTIONS

IntelliCarb Training Manual

Concentrate valve sleeve

has only one hole

A side water lever kit can be added to a valve allowing for dispensing of water without syrup or concentrate. The side water lever can be added to either a carbonated drink valve or a noncarbonated drink valve.

Post-mix valves control:

• the ON–OFF of syrup and water,

• the flow rates of syrup and water,

• the mixing of the two ingredients as they pour into the

cup, and

• in some instances - dispensed portion.

Dimensions & Capacities

Fast Flow ............................................................................................................... 1 ½ to 3 oz./sec.

UFB-1 ......................................................................................................................... 2 to 4 oz./sec.

Ultra Flow .............................................................................................................. 3 to 4 ½ oz./sec.

Operational temperature range: ......................................................... 10°C (50°F) to 43°C (110° F)

Voltage requirements:................................................................................ 22 to 27 VAC (50/60 Hz)

Syrup valve sleeve has six holes

FIGURE 15

Mounting

screw

Water

lever

FIGURE 16

Transformer (electronic valves) ........................................................................................80 VA min.

Operating Pressure (flowing)...............................................................................syrup = 20 psi min.

.............................................................................................................................water = 35 psi min.

Concentrates and juices that contain particulates must be dispensed from a juice valve. A slanted drip tray is necessary when using an Optifill valve.

SYSTEM DETAILS

Water

Water Quality

Water quality issues have an affect on dispensing valves. Chloramine, a combination of chlorine and ammonia is responsible for some degradation of rubber components. Chloramine is used in many U. S. water supplies. Its affects can be minimized by installing and maintaining a water filtration system.

Ultra pure water affects the sensitivity of the Optifill™ valve. Because ultra pure water has less mineral content, it reduces the conductivity of the water keeping the circuit open and overfilling the beverage container.

Water Flow

The size of the orifice in the piston varies depending on whether the piston is used for syrup or water, and whether it is high flow or ultra flow valve.

+ 33 hidden pages

Cornelius Cold Beverage Dispenser User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual