Cornelius VANTAGE POST-MIX DISPENSER User Manual

Service/Maintenance
Manual

IMPORTANT:

TO THE INSTALLER.
It is the responsibility of the

Installer to ensure that the water
supply to the dispensing
equipment is provided with
protection against backflow by an
air gap as defined in ANSI/ASME
A112. 1.2-1979; or an approved
vacuum breaker or other such
method as proved effective by
test.

VANTAGE POST-MIX DISPENSER

Water pipe connections and
fixtures directly connected to a
potable water supply shall be
sized, installed, and maintained
according to Federal, State, and
Local laws.

Part No. 312031004
January 26, 1996
Revised: March 3, 1998
Control Code C

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must

IMI CORNELIUS INC; 1998Ó

PRINTED IN U.S.A

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 INFORMATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TO THE USER OF THIS MANUAL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLAIMS INSTRUCTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY REFERENCE INFORMATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESIGN DATA 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

UNIT WITH INTEGRAL (BUILT-IN) COLD CARBONATOR 4. . . . . . . . . . . . . .

UNIT REQUIRING REMOTE CARBONATOR 4. . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND MAINTENANCE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARING UNIT FOR SHIPPING OR RELOCATING 7. . . . . . . . . . . . . . . . . . . . .

HOOD AND FRONT ACCESS PANEL REMOVAL 7. . . . . . . . . . . . . . . . . . . . . . . . . .

HOOD REMOVAL 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT ACCESS PANEL REMOVAL 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC INSPECTION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CO2 REGULATORS ADJUSTMENTS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING DISPENSING VALVES WATER FLOW RATE 10. . . . . . . . . . . . .

ADJUSTING WATER-TO-SYRUP “RATIO” (BRIX) OF DISPENSED

PRODUCT 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

DAILY CLEANING OF UNIT 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING POST-MIX SYRUP SYSTEMS 12. . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING DROP-IN REFRIGERATION ASSEMBLY CONDENSER COIL 15. . . .

CHECKING ICE WATER BATH 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING WATER TANK 16.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATOR WATER PUMP YEARLY MAINTENANCE OR AFTER

WATER SYSTEM DISRUPTIONS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE CARBONATOR 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTEGRAL (BUILT-IN) CARBONATOR 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Page

TROUBLESHOOTING UNIT 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER-TO-SYRUP ‘‘RATIO’’ TOO LOW OR TOO HIGH. 19. . . . . . . . . . . . . . .

ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES

NOT INCREASE TO DESIRED WATER-TO-SYRUP ‘‘RATIO’’ 19. . . . . . . . . . .

ADJUSTMENT OF DISPENSING VALVE SYRUP REGULATOR DOES NOT

DECREASE TO DESIRED WATER-TO-SYRUP ‘‘RATIO’’. 20. . . . . . . . . . . . . .

DISPENSED PRODUCT CARBONATION TOO LOW. 20. . . . . . . . . . . . . . . . . .

i 312031004

TABLE OF CONTENTS (cont’d)

DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR

BUT FOAMS IN CUP OR GLASS. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT PRODUCES FOAM AS IT LEAVES

DISPENSING VALVE. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NO PRODUCT DISPENSED FROM ALL DISPENSING VALVES 21. . . . . . . .

ONLY CARBONATED WATER DISPENSED. 21. . . . . . . . . . . . . . . . . . . . . . . . . .

ONLY SYRUP DISPENSED. 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING REFRIGERATION SYSTEM 21. . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR DOES NOT OPERATE. 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR WILL NOT STOP AFTER SUFFICIENT ICE BANK IS

PRODUCED. 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM

SUFFICIENT ICE BANK. 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSER FAN MOTOR NOT OPERATING. 22. . . . . . . . . . . . . . . . . . . . . . .

AGITATOR MOTOR NOT OPERATING. 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF FIGURES

Page

FIGURE 1. VANTAGE POST--MIX DISPENSER (FIVE-FLAVOR UNIT SHOWN) 4
FIGURE 2. PLUMBING DIAGRAM (FIVE-FLAVOR UNIT WITH INTEGRAL

CARBONATOR SHOWN) 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 3. PLUMBING DIAGRAM (FIVE-FLAVOR UNIT W/INTEGRAL CARB AND
ONE NON-CARB

DRINK SHOWN) 5. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

FIGURE 4. PLUMBING DIAGRAM (FOUR-FLAVOR UNIT REQUIRING

REMOTE CARBONATOR) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 5. PLUMBING DIAGRAM (FIVE-FLAVOR UNIT REQUIRING

REMOTE CARBONATOR) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. PARTS IDENTIFICATION (FIVE-FLAVOR UNIT WITH INTEGRAL

CARBONATOR SHOWN) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 7. PARTS IDENTIFICATION (FIVE-FLAVOR UNIT REQUIRING REMOTE

CARBONATOR SHOWN) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 8. UF-1 DISPENSING VALVE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 9. WIRING DIAGRAM 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF TABLES

TABLE 1. DESIGN DATA 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

312031004

ii

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 identi­fies 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

CO2Displaces Oxygen. Strict Attention must be observed in the prevention of CO2(carbon dioxide)
gas leaks in the entire CO2and soft drink system. If a CO2gas 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 CO2gas 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.

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2

THIS PAGE LEFT BLANK INTENTIONALLY

3

312031004

GENERAL INFORMATION

TO THE USER OF THIS MANUAL

This is a Service and Maintenance Manual for the four and five-flavor Vantage Post-Mix Dispensers with integral
(built-in) cold carbonators (see figure 2 or 3) or the four and five-flavor Dispensers requiring connection to re­mote carbonators (see figures 4 or 5).These Dispensers will hereafter be referred to as Units. Retain this manu­al as part of your equipment.

This Unit must be installed and serviced by a qualified Service Person. This Unit contains no User serviceable
parts.

CLAIMS INSTRUCTIONS

Claims: In the event of shortage, notify the carrier as well as IMI Cornelius immediately. In the event of dam-
age, notify the carrier. IMI Cornelius is not responsible for damage occurring in transit, but will gladly
render assistance necessary to pursue your claim. Merchandise must be inspected for concealed dam­age within 15 days of receipt.

WARRANTY REFERENCE INFORMATION

Warranty Registration Date

(to be filled out by customer)
Unit Part Number:
Serial Number:
Install Date:
Local Authorized

Service Center:

DESIGN DATA

Table 1. Design Data

Part Number See Unit nameplate

Dimensions:

Height 18-1/2 inches
Width 15-inches
Depth 26-inches

Maximum Plain Water Pressure (Integral Carbonator Units Only) 45-psi (see NOTE)

Maximum Carbonator CO2Pressure (Integral Carbonator Units Only) 60-psi

Voltage/Amps See Unit nameplate

Operating Temperature 40° F to 100° F

NOTE: The plain water source water pressure must not exceed 45-psi. If water pressure exceeds
45-psi, a water pressure regulator must be used to regulate the water pressure.

312031004

4

5

31203100431203100

4

6

CARB WATER

INLET

SYRUP

INLET

CARB WATER

COOLING COIL

SYRUP

COOLING COIL (4)

1

DISPENSING

VALVE (4)

2

3

CARB WATER

INLET

CARB WATER

COOLING COIL

CARB WATER

MANIFOLD

4

FIGURE 4. PLUMBING DIAGRAM (FOUR-FLAVOR UNIT REQUIRING REMOTE CARBONATOR)

SERVICE AND MAINTENANCE

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

IMPORTANT: Only qualified Service Personnel should service the internal components or electrical
wiring.

DANGER: To avoid possible fatal electrical shock or serious injury to the operator, it
is required that a GFCI (ground fault circuit interrupt) be installed in the electrical circuit for
the domestic Units. It is required that an ELCB (earth leakage circuit breaker) be installed in

the electrical circuit for the export Units.

WARNING: Disconnect electrical power from the Unit to prevent personal injury before
attempting any internal maintenance. Only qualified personnel should service the internal
components or electrical wiring.

PREPARING UNIT FOR SHIPPING OR RELOCATING

CAUTION: This Unit is intended for indoor installation only. Do not install this Unit in an
outdoor environment which would expose it to the outside elements.

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
environment will cause residual water in the Unit to freeze resulting in damage to internal
components.

HOOD AND FRONT ACCESS PANEL REMOVAL

(see applicable Figure 6 or 7)

HOOD REMOVAL

CAUTION: Do not place or store anything on top of the Unit.

Remove screw securing hood, then lift hood straight up off the Unit.

IMPORTANT: Circulating air, required to cool the refrigeration assembly condenser coil, is drawn in
through grille on top of the hood and is exhausted out through grille on back of the lower housing
assembly .

FRONT ACCESS PANEL REMOVAL

Remove two screws securing the front access panel, then remove the panel.

PERIODIC INSPECTION

1. Clean the drop-in refrigeration assembly condenser coil every 30-days as instructed. Cleaning the
condenser coil should be performed by a qualified Service Person. DO NOT place objects on top of the

hood or on back side of the Unit. Restricting circulating air in and out of the Unit will cause the refrigeration
system to overheat.

HOOD

HOOD RETAINING

SCREW

FRONT ACCESS

PANEL

FRONT ACCESS

PANEL RETAINING

SCREW (2)

DOUBLE LIQUID

INSULATION PAD

WATER TANK

OVERFLOW TUBE

115/24 VAC

TRANSFORMER

DROP-IN

REFRIGERATION ASS’Y

CHECK VALVE

CONDENSER

COIL

AGITATOR

MOTOR

CONTROL

BOX

CUP REST

DRIP TRAY

SYRUP INLET

TUBE (5)

CO2CHECK VALVE

DISPENSING

VALVE (5)

WATER TANK

DRAIN HOSE

CARBONAT OR

WATER TANK

FIGURE 6. PARTS IDENTIFICA TION (FIVE-FLAVOR UNIT WITH INTEGRAL CARBONA TOR SHOWN)

8312031004

HOOD

HOOD RETAINING

SCREW

FRONT ACCESS

PANEL

FRONT ACCESS

PANEL RETAINING

SCREW (2)

REFRIGERATION ASS’Y

WATER TANK

OVERFLOW TUBE

115/24 VAC

TRANSFORMER

DROP-IN

CONDENSER

COIL

AGITATOR

MOTOR

CONTROL

BOX

CUP REST

DRIP TRAY

SYRUP INLET

TUBE (5)

DISPENSING

VALVE (5)

CARB WATER INLET TUBE

WATER TANK

DRAIN HOSE

2. Check the dispensing valves for dripping that indicates leakage and repair as necessary .

ADJUSTMENTS

CO2REGULATORS ADJUSTMENTS

WARNING: CO2displaces oxygen. Strict attention must be observed in the prevention of
CO2(carbon dioxide) gas leaks in the entire CO2and soft drink system. If a CO2gas 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 CO2gas will experience
tremors which are followed rapidly by loss of consciousness and suffocation.

NOTE: To readjust CO2regulator to a lower setting, loosen adjusting screw lock nut, then turn screw to
the left (counterclockwise) until pressure gage reads 5 psi lower than new setting will be. Turn the
adjusting screw to the right (clockwise) until the gage registers new setting, then tighten the lock nut.

Adjusting Carbonator CO2Regulator.
UNIT WITH INTEGRAL (BUILT-IN) COLD CARBONATOR
Adjust CO2regulator for the Unit integral (built-in) carbonator at 60-psi maximum.
UNIT REQUIRING REMOTE CARBONATOR
Adjust CO2regulator for the remote carbonator to CO2pressure specified in manual provided with the

carbonator.

Adjusting Syrup Source CO2Regulator.

SUGAR SYRUP TANKS CO2REGULATOR
Adjust syrup tanks CO2regulator to a minimum of 45-psi.

SYRUP PUMPS (BAG-IN-BOX SYSTEM)
Adjust the syrup pumps CO2regulator to 70-psi. DO NOT EXCEED MAXIMUM CO2PRESSURE SPECIFIED

ON THE SYRUP PUMPS.

ADJUSTING DISPENSING VALVES WATER FLOW RATE

(see Figure 8)

1. Remove cover from the dispensing valve by lifting the front cover up 1/4 inch and pulling forward.

2. Install syrup diversion tube assembly on the dispensing valve by pushing rubber end of the syrup diversion
tube onto the syrup outlet of the inner nozzle.

3. Measure the water flow rate by dispensing water into a graduated cup for a set period of time.

NOTE: Adjusting screw stops are built into the valve to prevent leakage when the screws are adjusted
too far clockwise. Stop adjusting clockwise when turning resistance increases. Turn the screw
counterclockwise 1--1/2 turns after the stop are contacted.

4. Turn the water flow regulator adjusting screw to the left (counterclockwise) to decrease the water flow rate
or turn the adjusting screw to the right (clockwise) to increase the water flow rate, then recheck the flow
rate. Adjustments should be no more than 1/4 turn at a time.

5. Remove syrup diversion tube from the dispensing valve, then install cover on the dispensing valve.

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WATER FLOW

REGULAT OR

INNER NOZZLE

SYRUP FLOW

REGULAT OR

Counterclockwise

to Decrease

Clockwise

to Increase

NOZZLE

SYRUP DIVERSION

TUBE

RATIO CUP

FIGURE 8. UF-1 DISPENSING VALVE

ADJUSTING WATER-TO-SYRUP “RATIO” (BRIX) OF DISPENSED PRODUCT

(see Figure 8)

NOTE: Make sure the dispensing valve water flow rate is as desired before adjusting the valve for
Water-to-Syrup ‘‘Ratio’’ (Brix) of the dispensed product.

Adjust Water--to--Syrup “Ratio” (Brix) of the dispensed product by using ratio cup (P/N 311100000) and syrup
diversion tube assembly (P/N 319540000) as follows:

1. Remove cover from the dispensing valve by lifting front cover up 1/4 inch and pulling forward.

2. Install syrup diversion tube assembly on the dispensing valve by pushing the rubber end of the syrup
diversion tube onto the syrup outlet of the inner nozzle.

Notice: Refer to syrup manufacturer’s recommendations on syrup package for water-to-syrup ratio.

3. Dispense enough to fill syrup diversion tube with syrup.

4. Hold large chamber of the ratio cup under the dispensing valve nozzle. Place free end of the syrup
diversion tube into the syrup chamber marked for the proper ratio. Dispense approximately 6 ounces of
water into the ratio cup. Water and syrup levels should be even in cup.

Note: Adjusting screw stops are built into the valve to prevent leakage when the screws are adjusted
clockwise too much. Stop adjusting clockwise when turning resistance increases. Turn the screw
counterclockwise 1--1/2 turns after the stop are contacted.

5. Adjusting Syrup Flow Regulator -- If water and syrup levels are uneven in the ratio cup, adjust by
turning the dispensing valve syrup flow regulator adjusting screw labeled SYRUP as follows.

A. For less syrup, turn the adjusting screw counterclockwise no more than 1/4 turn at a time.
B. For more syrup, turn the adjusting screw clockwise no more than 1/4 turn at a time.

6. Repeat water-to-syrup ratio test and adjust syrup flow regulator as many times as necessary until proper
ratio of dispensed drink is achieved.

7. Remove syrup diversion tube assembly from dispensing valve.

8. Install dispensing valve front cover.

CLEANING AND SANITIZING

DAILY CLEANING OF UNIT

1. Remove cup rest from the drip tray .

2. Wash drip tray in place on the Unit, then rinse drip tray with hot water allowing water to drain out through
the drain hose.

3. Wash cup rest, then rinse the cup rest with clean water. Install cup rest in the drip tray.

4. Clean all external surfaces of the Unit with a sponge. Rinse out the sponge with clean water, then wring
excess water out of the sponge and wipe off all external surfaces on the Unit. Wipe Unit dry with a clean
soft cloth. DO NOT USE ABRASIVE CLEANERS.

5. Remove nozzle and syrup diffusers from the dispensing valves. Place nozzles and syrup diffusers in
sanitizing solution.

6. Wash the nozzles and syrup diffusers in sanitizing solution, then rinse them with potable water.

7. Re-install nozzles and syrup diffusers back on the dispensing valves.

SANITIZING POST-MIX SYRUP SYSTEMS

IMPORTANT: Only qualified Service Personnel should perform sanitizing procedure on the post-mix
syrup systems.

The post-mix syrup systems should be sanitized every 90-days using a non-scented household liquid bleach
containing a 5.25 % sodium hypochlorite concentration. Proceed as follows to sanitize the post-mix syrup
systems.

1. Disconnect syrup supplies from syrup systems.

2. Rinse quick disconnects (syrup tanks systems) or bag-in-box connectors (syrup bag-in-box systems) in
warm potable water.

STEP 1. WASH SYRUP SYSTEMS

3. Using a clean syrup tank (syrup 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 to one gallon of potable water. Stir detergent solution to
thoroughly mix the solution.

4. Syrup Tank Systems.
A. Observe and note CO2pressure setting on the syrup tanks CO2regulator, then re-adjust CO

regulator to 60 to 80-psi. Pressurize syrup tank containing detergent solution to 60 to 80-psi.

B. Connect detergent solution tank, pressurized at 60 to 80-psi, into one of the syrup systems.

12312031004

2

Bag-in Box Syrup Systems.

C. Install bag valves, cut from empty bag-in-box syrup containers, on ends of syrup containers syrup

outlet tubes connectors.

D. Place all syrup outlet tubes, with bag valves on their ends, in container containing detergent solution.

5. Flush the syrup system and dispensing valve as follows:
A. Place waste container under applicable dispensing valve.
B

B. Activate the dispensing valve for one minute to purge all water from and install sanitizing solution in

the syrup system and dispensing valve.

C. Continue to activate the dispensing valve in cycle

14312031004

25. Dispose of waste sanitizing solution in a sanitary sewer, not in a storm drain, then thoroughly rinse the
inside and the outside of the container that was used for sanitizing solution to remove all sanitizing solution
residue.

CLEANING DROP -IN REFRIGERATION ASSEMBLY CONDENSER COIL

(see applicable Figure 6 or 7)

CAUTION: The refrigeration assembly condenser coil must be cleaned every 30-days.
Excessive accumulation of dust, lint, and grease on the condenser coil will restrict air flow

through the coil and cause the refrigeration system to overheat. Operating the refrigeration
system in an overheated condition will eventually lead to compressor failure and will automatically
void the factory warranty .

Clean the drop-in refrigeration assembly coil as follows:

1. Unplug Unit power cord from the electrical outlet.

2. Remove screw securing the hood, then lift the hood straight up to remove.

3. Vacuum or use a soft brush to clean the condenser coil. If available, use low-pressure compressed air.

4. Clean dust and dirt from around top of the drop-in refrigeration assembly.

5. Install hood on the Unit and secure with screw.

6. Plug Unit power cord into electrical outlet. The refrigeration system will start after a 2-minute time delay.

CHECKING ICE WATER BATH

(see Figure 6)
A ‘‘gurgle’’ heard from the Unit indicates water level in the water tank is low and more water should be added for

maximum cooling. Before adding more water, check the ice water bath for cleanliness and check the water tank
coils for excessive mineral deposit build-up.

1. Unplug Unit power cord from electrical outlet.

2. Remove screw securing the hood, then lift the hood straight up to remove.

3. Lift insulation pad covering front section of the water tank for visual inspection of the ice water bath and
the ice bank.

4. Using a flashlight, inspect the ice water bath and ice bank for cleanliness.

CLEANING WATER TANK

(see Figure 6)

1. Unplug the Unit power cord from electrical outlet.

2. Close shutoff valve in plain water source line connected to the Unit.

3. Remove two screws securing the Unit front access panel, then remove the panel.

4. Extend the water tank drain hose (located on front of Unit) to a waste container or floor drain. Remove plug
from end of the drain hose and allow the water tank to drain.

5. Remove screw securing the hood, then lift the hood straight up to remove from the Unit.

6. Unit With Integral (Built-In) Cold Carbonator. (see Figures 2 and 6)
A. Disconnect plain water source line from Unit double liquid check valve assembly inlet.
B. Disconnect carbonator water pump plain water outlet line from carbonated water tank plain water inlet

line.

7. Unplug the drop-in refrigeration assembly and electric dispensing valve power cords at connectors on front
of the Unit.

CAUTION: The ice bank around the drop-in refrigeration assembly evaporator coils must be
completely melted before attempting to lift the drop-in refrigeration assembly up and out of

the Unit lower cabinet assembly. Attempting to lift the drop-in refrigeration assembly and
ice bank together up out of the Unit lower housing assembly may cause damage to the evaporator
coils.

CAUTION: Never use an ice pick or other instrument to remove ice from the drop-in

refrigeration assembly evaporator coils. Such practice can result in a punctured

refrigeration circuit.

8. Allow the ice bank around the drop-in refrigeration assembly evaporator coils to completely melt. Hot water
may be used to speed up the melting process.

9. Very carefully, lift the drop-in refrigeration assembly up and out of the Unit lower housing assembly..

10. Use a fiber brush and carefully clean mineral deposit build-up from the agitator motor shaft and the ice
bank sensing bulb.

11. Wash inside of the water tank and the drop-in refrigeration assembly evaporator coils, then rinse with clean
water.

12. Install plug in end of the water tank drain hose.

13. Very carefully, install drop-in refrigeration assembly in Unit lower housing assembly by reversing the
removal procedure.

14. Unit With Integral (Built-In) Cold Carbonator. (see Figures 2 and 6)
A. Connect carbonator water pump plain water outlet line to carbonated water tank plain water inlet line.
B. Connect plain water source line to Unit double liquid check valve assembly inlet.

15. Fill the water tank with clean water until water runs out of the water tank overflow hose. USE

LOW-MINERAL-CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS.

16. Plug Unit power cord into electrical outlet. The refrigeration system will start after a 2-minute time delay.

16312031004

17. Dispense from one of the dispensing valves to make the carbonator cycle on and off.

18. Check for water leaks and repair if leaks are found.

19. Install Unit hood and secure with screw.

20. Install Unit front access panel and secure with two screws.

CARBONATOR WATER PUMP YEARL Y MAINTENANCE OR AFTER WATER
SYSTEM DISRUPTIONS

REMOTE CARBONATOR

The remote carbonator water pump water inlet strainer screen and the double liquid check valve must be
inspected and cleaned at least once a year under normal circumstances and after any water system disruption
(plumbing work, earthquake, etc.). Refer to manual provided with the remote carbonator for servicing procedure.

INTEGRAL (BUILT-IN) CARBONATOR

(see Figures 2 and 6)

Replacing Double Liquid Check Valve.

WARNING: The carbonator water pump double liquid check valve assembly must be
replaced at least once a year under normal circumstances, and after any disruptions

(plumbing work, earthquake, etc.) to the water supply system that might cause turbulent
(erratic) flow of water through the system. Foreign particles fouling the double liquid check valve
could cause CO2gas to back flow into the water system and create a health hazard in the water
system.

The carbonator water pump double liquid check valve assembly must be replaced at least once a year under
normal circumstances and after any water system disruption (plumbing work, earthquake, etc.) to the water
supply system.

Replacing CO2Gas Check Valve.

(see Figures 2 and 6)
The CO2gas check valve must be replaced at least once a year under normal circumstances and after any

servicing or disruption of the CO2system.

FIGURE 9. WIRING DIAGRAM

18312031004

TROUBLESHOOTING

IMPORTANT: Only a qualified Service Person should service internal components or electrical wiring.

DANGER: Disconnect electrical power to the Unit to prevent personal injury before

attempting any electrical repairs to the internal components. If repairs are to be made to

one of the syrup systems, disconnect syrup supply from the system, then bleed system
pressure before proceeding. If repairs will be made to the CO2or the carbonated water system,
disconnect electrical power to the carbonator, shut off CO2and plain water supplies, then bleed
systems pressures before proceeding.

TROUBLESHOOTING UNIT

Trouble Probable Cause Remedy

WATER-TO-SYRUP ‘‘RATIO’’
TOO LOW OR TOO HIGH.

ADJUSTMENT OF
DISPENSING VALVE SYRUP
FLOW REGULATOR DOES
NOT INCREASE TO DESIRED
WATER-TO-SYRUP ‘‘RATIO’’

A. Dispensing valve syrup flow

regulator not properly
adjusted.

B. Syrup Tanks System.

CO2gas pressure to syrup
tanks insufficient to push syrup
out of tank.

Bag-In-Box System.

CO2gas pressure to syrup
pumps insufficient to operate
pumps.

A. No syrup supply. A. Replenish syrup supply.

B. Syrup Tanks system.

Syrup tanks CO2regulator out
of adjustment.

Syrup Bag-In-Box System.

Syrup pumps CO2regulator
out of adjustment.

A. Adjust Water-to-Syrup ‘‘Ratio’’ as

instructed.

B. Adjust CO2regulator for syrup

tanks as instructed.

Adjust syrup pumps CO2regulator
as instructed.

B. Adjust CO2regulator for syrup

tanks as instructed.

Adjust syrup pumps CO2regulator
as instructed.

C. Dispensing valve syrup flow

control or syrup line restricted.
D. Improper syrup Baume. D. Replace syrup supply.
E. Inoperative dispensing valve

syrup flow control.
F. Tapered gasket inside tube

swivel nut connection distorted

from being overtightened

restricting syrup flow.

19 312031004

C. Sanitize syrup system as

instructed.

E. Repair dispensing valve syrup

flow control.

F. Replace tapered gasket. Make

sure it is properly seated.

Trouble RemedyProbable Cause

ADJUSTMENT OF
DISPENSING VALVE SYRUP
REGULATOR DOES NOT
DECREASE TO DESIRED
WATER-TO-SYRUP ‘‘RATIO’’.

DISPENSED PRODUCT
CARBONATION TOO LOW.

DISPENSED PRODUCT
COMES OUT OF
DISPENSING VALVE CLEAR
BUT FOAMS IN CUP OR
GLASS.

A. Dirty or inoperative dispensing

valve syrup flow control.

A. Disassemble and clean

dispensing valve syrup flow
regulator.

A. Carbonator CO2regulator out

of adjustment for existing

A. Adjust carbonator CO2regulator

as instructed.
water conditions or
temperature.

B. Air in carbonated water tank. B. Vent air out of carbonated water

tank by dispensing from

dispensing valve to make

carbonator water pump motor

cycle on.

C. Water, oil, or dirt, in CO

supply .

2

C. Remove contaminated CO2.

Clean CO2system (lines,

regulator, etc.) using a mild

detergent. Install a clean CO

2

supply .

A. Oil film or soap scum in cup

A. Use clean cups and glasses.

or glass.

B. Ice used for finished drink

is subcooled.

B. Do not use ice dir

20312031004

Trouble RemedyProbable Cause

DISPENSED PRODUCT
PRODUCES FOAM AS IT
LEAVES DISPENSING VALVE.
(cont’d)

NO PRODUCT DISPENSED
FROM ALL DISPENSING
VALVES

ONLY CARBONATED WATER
DISPENSED.

F. Dirty water supply. F. Check water filter. Replace

cartridge (see NOTE).

NOTE: If water supply is dirty, be sure to flush lines and
carbonator carbonated water tank completely. It may be necessary
to remove lines to the carbonated water tank, invert the tank, then
flush tank and all inlet lines to remove any foreign particles or dirt.

A. No electrical power to Unit. A. Plug in Unit power cord or check

for blown power fuse or tripped
circuit breaker. (Note: Fuse or
circuit breaker are not part of
Unit.)

B. Disconnected dispensing

valves power cord.

C. Disconnected or broken wiring

B. Connect dispensing valves power

cord.

C. Connect or replace wiring.

to dispensing valveS.

D. Inoperative 115 /24 VAC

D. Replace transformer.

transformer.

A. Out of syrup A. Replenish syrup supply as

instructed.
B. Inoperable dispensing valve. B. Repair dispensing valve.
C. Dispensing valve syrup flow

control not properly adjusted.

D. Dispensing valve syrup flow

control or syrup lines
restricted.

ONLY SYRUP DISPENSED. A. Plain water inlet supply line

shutoff valve closed.

B. Carbonator not operating. B. Repair carbonator.

TROUBLESHOOTING REFRIGERATION SYSTEM

COMPRESSOR DOES NOT

A. Ice bank sufficient. A. Refrigeration not called for.

OPERATE.

B. Ice bank control board has

2-minute time delay.

C. Unit power cord unplugged or

drop-in refrigeration assembly
power cord unplugged.

D. No power source (blown fuse

or tripped circuit breaker).

C. Adjust dispensing valve syrup

flow control (Water-to-Syrup

‘‘Ratio’’) as instructed.

D. Sanitize syrup system as

instructed.

A. Open plain water inlet supply line

shutoff valve.

B. Wait 2-minutes for compressor to

start.

C. Plug in Unit power cord or plug in

refrigeration assembly power

cord.

D. Replace fuse or reset circuit

breaker. (Note: Fuse or circuit

breaker are not part of Unit.)
E. Low voltage. E. Voltage must be at least 103 volts

at compressor terminal when

compressor is trying to start.
F. Loose, disconnected, or

broken wiring.

F. Tighten connections or replace

broken wiring.

21 312031004

Trouble RemedyProbable Cause

COMPRESSOR DOES NOT
OPERATE.(CONT’D)

COMPRESSOR WILL NOT
STOP AFTER SUFFICIENT
ICE BANK IS PRODUCED.

COMPRESSOR OPERATES
CONTINUOUSLY BUT DOES
NOT FORM SUFFICIENT ICE
BANK.

G. Inoperative overload protector

G. Replace inoperative part.

or start relay.
H. Inoperative ice bank control. H. Replace ice bank control.
I. Inoperative compressor. I. Replace compressor.
A. Ice bank control probe

A. Replace ice bank probe.

damaged.

B. Ice bank control board

B. Replace ice bank control board.

inoperative.
A. Cooling capacity is exceeded

by over-drawing.

B. Unit located in excessively hot

area or air circulation through

condenser coil is restricted.

A. Reduce amount of drinks drawn

per given time.

B. Relocate Unit or check and if

necessary , clean condenser coil
as instructed.

NOTE: Ice bank freezes from bottom of evaporator upward. A

refrigerant leak or insufficient charge might show an ice bank at

bottom and not at the top of evaporator.

NOTE: If overload protector cuts out compressor, condenser fan

motor will continue to operate; otherwise; troubleshooting

condenser fan motor problems is same as for ‘‘COMPRESSOR

DOES NOT OPERATE’’ paragraph plus the following:

CONDENSER FAN MOTOR
NOT OPERATING.

AGITATOR MOTOR NOT
OPERATING.

A. Jumper cord loose or

disconnected from motor or

A. Tighten connections or

replace cord.
terminal block. Broken wire in
cord.

B. Inoperative condenser

B. Replace condenser fan motor.

fan motor.

A. Unit power cord or

A. Connect power cord(s).
refrigeration assembly power
cord unplugged.

B. No power source (blown fuse

or tripped circuit breaker).

B. Replace fuse or reset circuit

breaker. (Note: Fuse or circuit
breaker are not part of Unit.)

C. Agitator motor propeller

C. Remove obstruction.
obstructed.

D. Low voltage. D. Voltage must be at least 103 VAC

at compressor terminals when
compressor is trying to start.

E. Loose, disconnected, or

broken wiring.

E. Tighten connections or replace

broken wiring.

F. Inoperative agitator motor. F. Replace agitator motor.

22312031004

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, Remcor or Wilshire
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. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX [phone]
AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX [phone]
BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX [phone]
BRAZIL D RUA IT AOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX [phone]
ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX [phone]
FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX [phone]
GERMANY D CARL LEVERKUS STRASSE 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, GREECE D (30) 1 600 1073 D FAX [phone]
HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D [phone] D FAX [phone]
ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX [phone]
NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX [phone]
SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX [phone]
SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX [phone]
USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D [phone] D FAX [phone]

LD004

4/21/98

31203100423

IMI CORNELIUS INC.

CORPORATE HEADQUARTERS:

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