Cornelius ICE-COOLED CHEST-A-FIELD DISPENSER Installation Manual

IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234

Telephone [phone] Facsimile [phone]

Installation Manual
ICE-COOLED CHEST-A-FIELD
DISPENSER

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment

EIMI Cornelius Inc; 2004

January 29, 2004Revision: A

160822000INS

TABLE OF CONTENTS

SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RECOGNIZE SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNDERSTAND SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOLLOW SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CO2 (CARBON DIOXIDE) WARNING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIPPING, STORING, OR RELOCATING UNIT 1. . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT DESCRIPTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THEORY OF OPERATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNPACKING AND INSPECTION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION OF LOOSE-SHIPPED PARTS 7. . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING UNIT 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARING UNIT FOR OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATOR’S INSTRUCTIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

OPERATING CONTROLS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSING VALVE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSING VALVE COMPENSATOR ADJUSTING SCREW 11. . . . . . . . . .

DAILY PREOPERATION CHECK 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT TANKS CO2 REGULATOR 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING DISPENSED PRODUCT FLOW RATE 11. . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING PRODUCT SUPPLY 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING ICE SUPPLY 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT FLAVOR CHANGE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CO2 SYSTEM GAS CHECK VALVES 12. . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARING UNIT FOR SHIPPING, RELOCATING, OR STORING 13. . . . . . . . . .

ADJUSTMENTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING PRODUCT TANKS CO2 REGULATOR 13. . . . . . . . . . . . . . . . . . .

ADJUSTING DISPENSED PRODUCT FLOW RATE 13. . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING PRODUCT SUPPLY 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT FLAVOR CHANGE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING ICE SUPPLY 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CO2 SYSTEM GAS CHECK VALVES 18. . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NO PRODUCT DISPENSED. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

160822000INS

TABLE OF CONTENTS (cont’d)

DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT

FOAMS IN CUP. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT FOAMS AS IT LEAVES DISPENSING VALVE. 19. . . . . .

WARRANTY 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF FIGURES

FIGURE 1. ICE-COOLED CHEST-A-FIELD DISPENSER 3. . . . . . . . . . . . . . . . . . .

FIGURE 2. FLOW DIAGRAM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 3. PARTS IDENTIFICATION (FOUR-FLAVOR UNIT SHOWN) 15. . . . . . .

FIGURE 4. CLEANING DISPENSING VALVE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 5. CO2 GAS CHECK VALVE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF TABLES

TABLE 1. DESIGN DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 2. LOOSE-SHIPPED PARTS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

ii160822000INS

SAFETY INFORMATION

Recognize Safety Information

This is the safety-alert symbol. When you see this
symbol on our machine or in this manual, be alert to
the potentially of personal injury.

Follow recommended precautions and safe operating
practices.

Understand Signal Words

A signal word - DANGER, WARNING, OR CAUTION
is used with the safety-alert symbol. DANGER identi-
fies the most serious hazards.

DANGER

Safety signs with signal word DANGER or WARNING
are typically near specific hazards.

General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety mes­sages in this manual.

WARNING

CAUTION

Follow Safety Instructions

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in
good condition. 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 instructions. Keep your machine in
proper working condition. Unauthorized modifications to the machine may impair function and/or safety and
affect the machine life.

CO2 (Carbon Dioxide) Warning

CO2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO2 (carbon dioxide)
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 CO2 gas will experience tremors which are followed rapidly by
loss of consciousness and suffocation.

Shipping, Storing, Or Relocating Unit

CAUTION: Before shipping, storing, or relocating this Unit, the syrup systems must be sanitized and
all sanitizing solution must be purged from the syrup systems. All water must also be purged from
the plain and carbonated water systems. A freezing ambient temperature will cause residual water
remaining inside the Unit to freeze resulting in damage to internal components of the Unit.

1 160822000INS

THIS PAGE LEFT BLANK INTENTIONALLY

2160822000INS

GENERAL DESCRIPTION

IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, and
maintaining this equipment. Refer to Table of Contents for page location of detailed information
pertaining to questions that arise during installation, operation, service and maintenance, or
troubleshooting this equipment.

This section gives the description, theory of operation, and design data for the four-flavor Ice-Cooled
Chest-A-Field Dispenser (see Figure 1) hereafter referred to as Unit.

UNIT DESCRIPTION

The Unit is compact and lightweight and is easily set up on a countertop or may be set up as a portable
dispenser for special events.

Placing Unit on countertop, installation of LOOSE- SHIPPED PARTS, sanitizing cold plate cooling coils before
connecting product tanks, connection of product tanks, and filling Unit with ice is all that is required for
operation.

A 31-1/4 inches high Stand Assembly (P/N 264365069) is available to place the Unit on. Also available is a
Caster Kit (P/N 160367-000) to make the stand portable.

CAUTION: Before shipping, relocating, or storing Unit, cold plate cooling coils must be
sanitized and all sanitizing solution purged from coils and dispensing valves. Ice water and
ice must also be removed from inside Unit. A freezing ambient environment will cause

residual water remaining inside Unit to freeze resulting in damage to internal components.

FIGURE 1. ICE-COOLED CHEST-A-FIELD DISPENSER

3

160822000INS

Table 1. Design Data

Unit Model Number:

Unit With Four Dispensing Valves 264404

Overall Dimensions:

Width 25-1/2 inches
Depth (w/drip tray in place) 21 inches
Height 15 inches

Weights (approximate):

Shipping 68 pounds
Dry (no ice) 63 pounds
Loaded With Ice 100 pounds +

THEORY OF OPERATION

A CO2 cylinder delivers carbon dioxide (CO2) gas through adjustable CO2 regulator to the product tanks. When
dispensing valve is opened, CO2 pressure exerted upon contents of product tank forces product from tank,
through cold plate cooling coil, and to dispensing valve resulting in a cooled dispensed drink. The amount of ice
required to cool the cold plate is determined by how many drinks are being dispensed and product inlet
temperature. Periodically inspect amount of ice on top of cold plate and replenish as necessary.

4160822000INS

5

160822000INS

(ITEM 2)

PRODUCT
TANK (4)

CO2 CYLINDER

PRODUCT TANKS PRIMARY
CO2 REGULATOR ASS’Y

CO2 MANIFOLD

CO2 GAS CHECK
VALVE (4)

DISPENSER

COLD PLATE

DISPENSING

VALVE (4)
LINE LEGEND
PRODUCT
CO

2

4

3

2

1

FIGURE 2. FLOW DIAGRAM

THIS PAGE LEFT BLANK INTENTIONALLY

6160822000INS

INSTALLATION

This section covers unpacking and inspection, identification of LOOSE-SHIPPED PARTS, installation, and Unit
operation.

UNPACKING AND INSPECTION

NOTE: The Unit was thoroughly inspected before leaving the factory and the carrier has accepted and
signed for it. Any damage or irregularities should be noted at time of delivery (or not later than 15 days
from date of delivery) and immediately reported to the delivering carrier. Request a written inspection
report from Claims Inspector to substantiate any necessary claim. File claim with the delivering carrier,
not with IMI Cornelius Inc.

1. After Unit has been unpacked, remove shipping tape and other packing material.

2. Unpack LOOSE-SHIPPED PARTS. Make sure all items are present and in good condition.

Table 2. Loose-Shipped Parts

Item

No. Part No. Name Qty.

1 151741039 Knob,Dispensing Valve 4
2 150807100 Adapter, 7/16-20 male 1/2-16 male 4

176193000 Adapter, 7/16-20 male by 7/16-20 male 4
3 187512000 Drain Hose, ½ I.D. by 40-in. long 1
4 317659029 Drip Tray 1
5 317660000 Cup Rest 1
6 160816039 Drip Tray Hanger 1
7 317906720

317904702
8 160853720 Decal Ice Chest 1

Decal, Set UF/SF F&B 8FL Coke (264404032)
Decal, Set SF/UF/Pre Back Coke (264404035)

2

IDENTIFICATION OF LOOSE-SHIPPED PARTS

1. DECALS, DISPENSING VALVES KNOBS (item 7) to be installed on KNOBS, DISPENSING VALVES (item

1), then knobs are to be installed on dispensing valves.

2. ADAPTERS (item 2) used to connect product tank lines to Unit product inlet lines.

3. DRAIN HOSE (item 3) to be connected to water drain fitting on side of Unit.

4. DRIP TRAY HANGER (item 6) to be hung on front of Unit over dispensing valves.

5. CUP REST (item 5) to be installed on DRIP TRAY (item 4), then drip tray to be installed in drip tray hanger.

INSTALLING UNIT

CAUTION: Do not drop or rough handle Unit. Cold plate could cause severe damage to
bottom of Unit.

1. Place Unit in operating position.

7 160822000INS

2. Route product inlet lines out through notch on top edge of Unit.

3. Wipe Unit interior with a clean damp cloth.

4. Install DECALS, DISPENSING VALVES KNOBS (item 7) on KNOBS, DISPENSING VALVES (item 1),
then install knobs on dispensing valves. Install Decals in flat area on back of chest.

5. Install DRIP TRAY HANGER (item 6) over dispensing valves on front of Unit.

6. Install CUP REST (item 5) in DRIP TRAY (item 4), then install drip tray in drip tray hanger.

7. All Unit product inlet lines internal connections have been made at the factory. Perform the following to
connect product source lines to unit product inlet lines (see Figure 2).

NOTE: The Unit product inlet lines are labeled to identify dispensing valve they serve. For example:
Line labeled ‘‘1’’ is connected to system that provides product to be dispensed from NO. 1 dispensing
valve. (NO. 1 dispensing valve is valve on left side when facing front of Unit).

A. Route, and label for identification, product source lines from product tanks location to Unit.

B. Connect product source lines to Unit product inlet lines using ADAPTERS (item 2).

8. Install product tanks liquid quick disconnects (not provided) on ends of product source lines.

WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder
with safety chain to prevent it from falling over. Should the valve become accidentally
damaged or broken off, CO2 cylinder can cause serious personal injury.

9. Connect DRAIN HOSE (item 3) to water drain fitting on side of Unit. Route drain hose to waste receptacle
or drain.

10. Make up CO2 lines long enough to reach from CO2 regulator assembly to product tanks location.

11. Connect CO2 lines to gas check valves on CO2 regulator assembly CO2 manifold(s). Seal connections with
tapered gaskets.

12. Install product tanks gas quick disconnects (not provided) on other ends of CO2 lines.

PREPARING UNIT FOR OPERATION

1. Set product tanks CO2 regulator, using IMI Cornelius Inc; PRE-MIX COMPUTER slide rule or bottling room
chart, at equilibrium pressure to highest temperature encountered between product tank storage area and
Unit plus 5-psig operating pressure for lines 10-feet in length or less and no vertical lift. Add one pound for
every 10-feet over initial 10-feet of product tank to Unit line length and one pound for every 2-feet of
vertical lift. Add one pound for every product tank on line over three tanks.

IMPORTANT: To prevent off-taste of dispensed product, product systems must be cleaned and
sanitized to remove residue that may be present inside cold plate cooling coils.

2. Sanitize all product systems as instructed.

3. Fill Unit with ice as instructed.

4. Connect full product tanks into systems.

8160822000INS

OPERATION

1. Dispense from each dispensing valve until air is purged from systems and product is dispensed.

2. Check for leaks and tighten any loose connections.

3. Adjust dispensing valves for product flow rate by turning dispensing valve Compensator Adjusting Screw
(Figure 4) to the left (counterclockwise) for higher product flow rate or to the right (clockwise) for lower
product flow rate.

9 160822000INS

THIS PAGE LEFT BLANK INTENTIONALLY

160822000INS 10

OPERATOR’S INSTRUCTIONS

This section covers operators instructions for operating controls, daily preoperation check, adjustments,
replenishing CO
CO2 gas check valves.

CAUTION: Do not drop or rough handle Unit. Cold plate could cause severe damage to
bottom of Unit.

OPERATING CONTROLS

DISPENSING VALVE

(see Figure 3)

Place cup under dispensing valve nozzle. Pull dispensing valve knob forward until cup is full, then release knob.

DISPENSING VALVE COMPENSATOR ADJUSTING SCREW

and product supplies, cleaning and sanitizing, checking cold plate ice supply, and cleaning

2

(see Figure 4)

Dispensing valve compensator adjusting screw (located on side of dispensing valve) is used to adjust product
dispensing flow rate to a lower or higher rate. Adjust as instructed.

DAILY PREOPERATION CHECK

1. Make sure CO2 cylinder regulator assembly 1800-psi gage indicator is not in shaded (“change CO
cylinder’’) portion of dial. If so, CO2 cylinder is almost empty and must be replaced.

2. Sufficient product supply in all product tanks. If not, replenish product supply as instructed.

3. Make sure drip tray is clean and clean cup rest is in place in drip tray.

2

UNIT OPERATION

Place cup under dispensing valve nozzle. Pull dispensing valve knob forward until cup is full, then release knob.

ADJUSTMENTS

PRODUCT TANKS CO2 REGULATOR

(see Figure 2)

Product tanks CO2 regulator should be periodically checked for proper pressure setting and if necessary,
adjusted as instructed.

ADJUSTING DISPENSED PRODUCT FLOW RATE

Dispensed product flow rate should be periodically checked and if necessary, adjusted as instructed.

11 160822000INS

REPLENISHING CO2 SUPPLY

NOTE: When indicator on CO2 cylinder regulator assembly 1800-psi gage is in shaded (‘‘change CO2 cylinder’’)
portion of the dial, CO2 cylinder is almost empty and should be changed. CO2 supply should be checked daily
and if necessary, replenished as instructed.

REPLENISHING PRODUCT SUPPLY

Product supply should be checked daily and if necessary, replenished as instructed.

REPLENISHING ICE SUPPLY

Periodically check and make sure sufficient amount of ice is on cold plate for proper cooling of dispensed
product. Replenish ice supply as instructed.

PRODUCT FLAVOR CHANGE

Sanitize product system as instructed, then install full tank of new flavor product in system.

CLEANING AND SANITIZING

Unit should be thoroughly cleaned and sanitized as instructed every time it is used as a portable (moved from
one location to another). If Unit is used as a semi-portable (left in one location part of the time), it should be
thoroughly cleaned and sanitized every 30-days.

CLEANING CO2 SYSTEM GAS CHECK VALVES

(see Figure 2 and Figure 5)

The CO2 system gas check valves must be inspected and serviced as instructed at least once a year under
normal conditions and after any CO2 system servicing or disruption.

160822000INS 12

SERVICE AND MAINTENANCE

This section describes service and maintenance procedures to be performed on the Unit.

PREPARING UNIT FOR SHIPPING, RELOCATING, OR STORING

CAUTION: Before shipping, relocating, or storing Unit, cold plate cooling coils must be sanitized and all sanitiz­ing solution purged from coils and dispensing valves. Ice water and ice must also be removed from inside Unit.
A freezing ambient environment will cause residual water remaining inside Unit to freeze resulting in damage to
internal components.

ADJUSTMENTS

ADJUSTING PRODUCT TANKS CO2 REGULATOR

(see Figure 2)

Set product tanks CO2 regulator, using Cornelius PRE-MIX COMPUTER slide rule or bottling room chart, at
equilibrium pressure to highest temperature encountered between product tank storage area and Unit plus
5-psig operating pressure for lines 10-feet in length or less and no vertical lift. Add one pound for every 10-feet
over initial 10-feet of product tank to Unit line length and one pound for every 2-feet of vertical lift. Add one
pound for every product tank on line over three tanks.

ADJUSTING DISPENSED PRODUCT FLOW RATE

Turn dispensing valve Compensator Adjusting Screw (Figure 4) to the left (counterclockwise) for higher product
flow rate or to the right (clockwise) for lower pro-duct flow rate.

REPLENISHING CO2 SUPPLY

NOTE: When indicator on CO2 cylinder regulator assembly 1800-psi gage is in shaded (‘‘change CO
cylinder’’) portion of dial, CO2 cylinder is almost empty and should be changed.

1. Fully close (clockwise) CO2 cylinder valve.

2. Slowly loosen CO2 regulator assembly coupling nut allowing CO2 pressure to escape, then remove regula­tor assembly from empty CO2 cylinder.

3. Unfasten safety chain and remove empty CO2 cylinder.

WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder
with safety chain to prevent it from falling over. Should the valve become accidentally
damaged or broken off, CO2 cylinder can cause serious personal injury.

4. Position CO2 cylinder and secure with safety chain.

2

5. Make sure gasket is in place inside CO2 regulator coupling nut, then install regulator on CO2 cylinder.

6. Open (counterclockwise) CO2 cylinder valve slightly to allow lines to slowly fill with gas, then open valve
fully to back-seat valve. (Back-seating valve prevents leakage around valve shaft).

7. Check CO2 connections for leaks. Tighten loose connections.

13

160822000INS

REPLENISHING PRODUCT SUPPLY

1. Remove gas quick disconnect (grey) and liquid quick disconnect (black) from empty product tank, then re­move tank.

2. Place full product tank in position, then connect gas quick disconnect (grey) and liquid quick disconnect
(black) to full product tank.

PRODUCT FLAVOR CHANGE

Sanitize product system as instructed, then install full tank of new flavor product.

REPLENISHING ICE SUPPLY

Periodically check ice supply on cold plate and replenish with clean ice as necessary. MAKE SURE WATER
DRAIN HOLE ON SIDE OF UNIT IS OPEN AND WATER IS DRAINING FROM INSIDE UNIT.

CLEANING AND SANITIZING

IMPORTANT: Only qualified personnel should perform cleaning and sanitizing procedure. Unit should
be thoroughly cleaned and sanitized every time it is used as a portable (moved from one location to
another). If Unit is used as a semiportable (left in one location part of the time), it should be thoroughly
cleaned and sanitized every 30-days. Proceed as follows to clean and sanitize the Unit using
Chlor-Tergent (Oakite Products, Inc.) or equivalent sanitizer.

1. Disconnect product tanks from product systems. Rinse quick disconnects in warm water.

2. Open dispensing valves to relieve pressure on systems.

3. Remove dispensing valves knobs by pulling knobs up and off valves.

4. Using a spanner wrench, loosen and remove coupling nuts from dispensing valves, then remove valves
from unit.

5. Remove phillips-head screw on end of dispensing valve, then remove outer sleeve, spring, and inner
sleeve.

6. Loosen and remove knob lever bonnet securing lever in dispensing valve body, then remove lever.

7. Slide shaft and seat assembly out through rear of dispensing valve body.

8. Wash disassembled dispensing valve parts in plain water.

9. Assemble dispensing valve by reversing disassembly procedure steps 5 through 7 preceding.

10. Disassemble and clean remaining dispensing valves by performing steps 5 through 9 preceding.

11. Remove compensators from inside sleeve and coupling nut assemblies.

12. Wash compensators in plain water, then install compensators in sleeve and coupling nut assemblies.

160822000INS

14

CUP REST

DRIP
TRAY

DRIP TRAY
HANGER

PRODUCT
INLET LINES

DISPENSING
VALVE (4)

FIGURE 3. PARTS IDENTIFICATION (FOUR-FLAVOR UNIT SHOWN)

COLD PLATE

15

WATER
DRAIN
FITTING

ITEM 3

160822000INS

KNOB LEVER BONNET

KNOB

LEVER

INNER
SLEEVE

SPRING
OUTER

SLEEVE

SCREW

FRICTION
WASHER

BALL
WASHER

O-RING

BODY

O-RING

ADJUSTING SCREW

COMPENSATOR

SHAFT AND
SEAT ASS’Y

FIGURE 4. CLEANING DISPENSING VALVE

13. Install dispensing valves on unit. Make sure coupling nuts are tight.

14. Using clean empty product tank, prepare full tank of sanitizing solution by using 70° F to
100° F (max) plain water and .67 oz/gallon of sanitizer. This mixture will provide 200-ppm of chlorine.

15. Shake sanitizing solution tank to thoroughly mix solution, then connect tank to product system to be sani­tized.

16. Place waste container under dispensing valve. Open dispensing valve to permit sanitizing solution to purge
product out of line, coil, and dispensing valve. Continue to draw from valve until only sanitizing solution is
dispensed.

17. Repeat steps 15 and 16 preceding to purge product from, and install sanitizing solution in, remaining sys­tems.

CAUTION: Do not allow sanitizing solution to remain in product systems longer than
recommended contact time. Exceeding contact time will result in damage to stainless steel
components.

18. Allow sanitizing solution to remain in product systems for 10 to 15 minutes (max) contact time.

19. Remove product tank containing sanitizing solution from product system, then connect tanks containing
product into systems.

WARNING: Flush sanitizing solution from product systems as instructed. Residual solution
left in systems could create a health hazard.

20. Place waste container under dispensing valve. Dispense from valve and allow product to purge sanitizing
solution out of product system and until only product is dispensed.

21. Repeat preceding step 20 to purge sanitizing solution out of remaining product systems and until only prod­uct is dispensed.

160822000INS

16

WARNING: To avoid possible personal injury or property damage, do not attempt to
remove product tank cover until CO2 pressure has been released from tank.

22. Thoroughly rinse inside and outside of product tank that was used for sanitizing solution to remove all solu­tion residue.

23. Remove all ice from inside Unit, then rinse cold plate and Unit interior with plain water.

24. Raise end of drain hose from water drain fitting on side of Unit above level of lid.

25. Prepare two gallons of sanitizing solution by using 70° F to 100° F (max) plain water and .67 oz/gallon of
sanitizer. This mixture will provide 200-ppm of chlorine.

26. Pour prepared two gallons of sanitizing solution inside unit on top of cold plate.

QUAD RING
183294000

BALL
183296000

SPRING
183297000

RETAINER
183298000

BODY
183295000

*Quad ring seal must be replaced
each time check valve is serviced.

FIGURE 5. CO2 GAS CHECK VALVE

CAUTION: Do not allow sanitizing solution to remain on top of cold plate longer than
recommended contact time. Exceeding contact time will result in damage to stainless steel
components.

27. Using brush, clean entire inside surface and top of cold plate with sanitizing solution.

28. Allow sanitizing solution to remain inside unit for 10 to 15 minutes (max) contact time.

29. Lower end of drain hose from water drain fitting on side of unit and allow sanitizing solution to drain from
inside unit into waste container.

30. Thoroughly rinse inside of unit and cold plate with plain water to remove all sanitizing solution.

31. Install drain hose on water drain fitting, then fill unit with ice as instructed.

32. Remove cup rest, drip tray, and drip tray holder from Unit.

33. Wash removed items, then rinse with plain water.

34. Wipe entire Unit exterior with clean damp cloth.

17

160822000INS

35. Install cup rest, drip tray, and drip tray holder on Unit.

CLEANING CO2 SYSTEM GAS CHECK VALVES

(see Figures 2 and 5)

The CO2 system gas check valves must be inspected and serviced at least once a year under normal condi­tions and after any servicing or disruption of the CO2 system. ALWAYS REPLACE QUAD RING SEAL EACH
TIME GAS CHECK VALVES ARE SERVICED.

160822000INS

18

TROUBLESHOOTING

IMPORTANT: Only qualified personnel should service internal components or electrical wiring.

WARNING: If repairs are to be made to a product system, remove quick disconnects from
the applicable product tank, then relieve the system pressure before proceeding. If repairs
are to be made to the CO

system, stop dispensing, shut off the CO

2

system pressure before proceeding. If repairs are to be made to the refrigeration system, make sure
electrical power is disconnected from the unit.

Trouble Probable Cause Remedy

supply, then relieve the

2

NO PRODUCT DISPENSED. A. Product tank quick

disconnects not properly
attached.

B. No product supply (tank

empty).

C. No CO2 supply. C. Replenish CO2 supply as

DISPENSED PRODUCT

A. Oil film or soap scum in cup. A. Use clean cups.
COMES OUT OF
DISPENSING VALVE CLEAR
BUT FOAMS IN CUP.

B. Ice used for finished drink is

sub-cooled.

NOTE: Crushed ice also causes dispensing problems. When finished
drink hits sharp edges of ice, carbonation is released from dispensed
drink.

DISPENSED PRODUCT

A. No ice on cold plate. A. Replenish ice supply.
FOAMS AS IT LEAVES
DISPENSING VALVE.

B. Product tanks CO2 regulator

adjusted too high.

A. Attach quick disconnects.

B. Replenish product supply as

instructed.

instructed.

B. Do not use ice directly from

freezer. Allow ice to become ‘‘wet’’
before using. (Refer to following
NOTE).

B. Adjust product tanks CO

2

regulator to proper equilibrium
pressure as instructed, then
replace product supply.

C. Dispensing valve restricted or

dirty.

D. Tapered nylon washer inside

tube swivel nut connection
distorted from being
overtightened restricting
product flow.

E. Oil, water, or dirt in CO

2

supply.

C. Clean dispensing valve as

instructed.

D. Replace nylon washer. Make sure

it is properly seated in swivel nut.

E. Remove contaminated CO2.

Clean CO2 system (lines,
regulators, etc.). Install a clean
CO2 supply.

160822000INS19

WARRANTY

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, serial number and the date of purchase.

IMI CORNELIUS OFFICES

AUSTRALIA D P.O . BOX 4120, MILPERRA DC NSW 1891 D 144 MILPERRA ROAD REVESBY, REVESBY, NSW2212 DAUSTRALIA D (61) 2 9774 4533 D FAX [phone]

5825AUSTRIA
CHAAT, BELGIUM D (32) 3 664 0552 D FA X (32) 3 665 2307ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44)

789

STRASSE

GREECE

(852)

19-044

(65)

3379USA

D AM JUNGFERNBERG 15, D A-2201 D GERASDORF, AUSTRIA D (43) 2246 32 533 D FAX [phone]BELGIUM D BOSKAPELLEI 122 D B-2930 BRAAS-

763 644FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PA RIS , FRANCE D (33) 1 34 28 6200 D FAX [phone]GERMANY D CARL LEVERKUS

15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX [phone]GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS,

D (30) 1 600 1073 D FAX [phone]HONG KONG D 1104 TAI KO TS UI CENTRE D 11-1 5 KOK CHEUNG ST D TAI KO KT SU E, HONG KONG D [phone] D FAX

391 6222ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX [phone]NEW ZEALAND D 606B ROSEBANK ROAD D P. O. BOX

AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FA X (64) 9 8200 361SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FA X

862 5604SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654

D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D [phone] D FAX [phone]

160822000INS 20

THIS PAGE LEFT BLANK INTENTIONALLY

21 160822000INS

IMI CORNELIUS INC.

CORPORATE HEADQUARTERS:

One Cornelius Place
Anoka, Minnesota 55303-6234
[phone]
[phone]