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IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234
Telephone (800) 238-3600 Facsimile (612) 422-3246
Installation Manual
AMBASSADOR PRE-MIX
DISPENSING STATION
Part No. 151468000
September 10, 1964
Revised: February 14, 1991
Control Code A
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 1964–91
PRINTED IN U.S.A
Page 2
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. . . . . . . . . . . . . . . . . . . . . . . . . .
SELECTING LOCATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING UNIT 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT INSTALLATION ON COUNTERTOP 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT INSTALLATION ON EDGE OF COUNTERTOP 9. . . . . . . . . . . . . . . . . . . . . . .
CONNECTING DRIP TRAY DRAIN HOSE 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING DISPENSING VALVES AND KNOBS 9. . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING UNIT PRODUCT INLET LINES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARING UNIT FOR OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL CONNECTION (ONLY ON UNIT WITH LIGHTED SIGN) 11. . . . . . .
OPERATOR INSTRUCTIONS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
OPERATING CONTROLS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSING VALVE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY PRE–OPERATION CHECK 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT TANKS CO2 REGULATORS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING DISPENSED PRODUCT FLOW RATE 13. . . . . . . . . . . . . . . . . . .
REPLENISHING CO2 SUPPLY 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLENISHING PRODUCT SUPPLY 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING AND SANITIZING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY CLEANING OF UNIT 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZING UNIT 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING CO2 SYSTEM GAS CHECK VALVES 14. . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUP REST AND LIGHTED SIGN DOME (IF APPLICABLE) REMOVAL 15. . . . . . .
CUP REST 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTED SIGN DOME 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC INSPECTION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING PRODUCT TANKS CO REGULATORS 15. . . . . . . . . . . . . . . . . . .
ADJUSTING DISPENSED PRODUCT FLOW RATE 15. . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (cont’d)
REPLENISHING CO2 SUPPLY 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLENISHING PRODUCT SUPPLY 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT FLAVOR CHANGE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING AND SANITIZING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY CLEANING OF UNIT 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZING UNIT 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR AND REPLACEMENT 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSING VALVE ASSEMBLY 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTED SIGN (IF APPLICABLE) FLUORESCENT TUBE 20. . . . . . . . . . . . .
LIGHTED SIGN (IF APPLICABLE) STARTER 20. . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTED SIGN (IF APPLICABLE) BALLAST 20. . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING CO2 GAS CHECK VALVES 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NO PRODUCT DISPENSED. 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT
FOAMS IN CUP OR GLASS. 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSED PRODUCT FOAMS AS IT LEAVES DISPENSING VALVE. 23. . . . . .
LIGHTED SIGN NOT OPERATING. 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
LIST OF FIGURES
FIGURE 1. AMBASSADOR PRE-MIX DISPENSING STATION (LIGHTED SIGN
MODEL SHOWN) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. FLOW DIAGRAM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. UNIT INSTALLATION ON COUNTERTOP 10. . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. MOUNTING TEMPLATE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 5. PARTS IDENTIFICATION (LIGHTED SIGN MODEL SHOWN) 16. . . . .
FIGURE 6. DISPENSING VALVE PARTS IDENTIFICATION 18. . . . . . . . . . . . . . . . .
FIGURE 7. CO2 GAS CHECK VALVE 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 8. LIGHTED SIGN WIRING DIAGRAM 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES
TABLE 1. DESIGN DATA 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 2. LOOSE-SHIPPED PARTS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 product systems must be sanitized
and all sanitizing solution must be purged from the product 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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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 Ambassador Four-Flavor
Pre-Mix Dispensing Stations with or without lighted sign, hereafter referred to as units.
UNIT DESCRIPTION
The units (see Figure 1) are compact and lightweight and may be island–mounted or installed on or on edge of
countertop. Units are designed to dispense pre-cooled pre-mix product from either a refrigeration unit or cold
plate (see Figure 2) and consist basically of four dispensing valves attached to front housing, a base with cup
rest, and lighted sign if applicable. Installation of unit, installation of LOOSE–SHIPPED PARTS (see Table 1),
connection of unit to refrigeration unit or cold plate, and adjusting dispensing valve product flow rate is all that is
required for unit operation.
FIGURE 1. AMBASSADOR PRE-MIX DISPENSING STATION (LIGHTED SIGN MODEL SHOWN)
Table 1. Design Data
Part Numbers:
Ambassador Dispensing Station (Without lighted sign) 253169
Ambassador Dispensing Station (With lighted sign) 253209
Overall Dimensions:
Height (With lighted sign) 17-1/2 inches
Height (Without lighted sign) 14-inches
Depth 9-inches
Weight (approximate)
With Lighted Sign 22-pounds
Without Lighted Sign 20-pounds
Ambient Operating Temperature 40° F to 100° F
Electrical Requirements (Unit with lighted sign)
Operating Voltage 115 VAC, 60 Hz
Operating Current 0.2-Amps
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THEORY OF OPERATION
(see Figure 2)
2
cylinder delivers carbon dioxide (CO2) gas through adjustable CO2 regulator to product tanks. When dis-
A CO
pensing valve is opened, CO
applicable cooling unit or cold plate, to dispensing valves resulting in cold dispensed drinks.
2
pressure exerted upon product tanks pushes product from product tanks, through
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PRODUCT COILS (4)
AMBASSADOR DISPENSING STSTION
REFRIGERATION UNIT OR COLDPLATE
5
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CO2 MANIFOLD
CO2 GAS CHECK
VALVE (4)
PRODUCT TANKS PRIMARY
CO2 REGULATOR
CO2 CYLINDER
PRODUCT TANKS (4)
LINE LEGEND
PRODUCT
FIGURE 2. FLOW DIAGRAM
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INSTALLATION
This section covers unpacking and inspection, identification of LOOSE-SHIPPED PARTS, selecting location,
installing unit, preparing unit for operation, and unit operation.
UNPACKING AND INSPECTION
(see Figure 5)
NOTE: The unit was thoroughly inspected before leaving factory and carrier has accepted and signed
for it. Any damage or irregularities should be noted at time of delivery and immediately reported to delivering carrier. Request a written inspection report from Claims Inspector to substantiate any necessary
claim. File claim with 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.
1 140133000 Drain Hose Clamp 1
2 310445000 Drain Hose 1
3 150774000 Wing Nut, 3/8–16 2
4 151140044 Mounting Clamp 2
5 150777000 Hex Nut, Jam, 3/8–16 2
6 150724000 Carriage Bolt, 3/8–16 by by 1/4–in. 2
7 150447000 Flat Washer, Rubber 2
8 151202039 Dispensing Valve 4
9 151741039 Knob, Dispensing Valve 4
10 317904999 Decal, Dispensing Valve Knob (as ordered) 4
11 311245000 Reducer, 7/16–20 Female by 1/2–16 Male 4
12 150807100 Adapter, 7/16–20 Male by 1/2–16 Male 4
13 151103000 Back Panel (customer specify message) 1
14 314080000 Thread Cutting Screw, Phil Pan Hd, Nickel-pltd Steel, No. 6–20 by3/8–in 4
15 160331000 Flat Washer, Nickel-pltd Brass, No. 6, .147 I.D. by .028 thk 4
Part No. Name Qty.
150807200 Adapter, 1/2–16 Male by 1/2–16 Male 4
151692000 Back Panel (customer specify message) 1
IDENTIFICATION OF LOOSE–SHIPPED PARTS
1. DRAIN HOSE (item 2) is to be installed on drip tray and secured with DRAIN HOSE CLAMP (item 1).
2. Dispensing Station to be fastened to countertop using CARRIAGE BOLTS (item 6), FLAT WASHERS,
RUBBER (item 7), HEX NUTS (item 5), MOUNTING CLAMPS (item 4), and WING NUTS (item 3).
3. DISPENSING VALVES (item 9) to be installed on the Dispensing Station.
4. DECALS, DISPENSING VALVES KNOBS (item 10) to be installed on KNOBS, DISPENSING VALVES
(item 9).
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5. KNOBS, DISPENSING VALVES (item 9) to be installed on dispensing valves by pushing knobs down into
place on valves levers.
6. Applicable ADAPTERS (item 12) used to connect product inlet lines from refrigeration unit or cold plate to
unit product inlet lines. REDUCERS (item 11) are provided to make 1/4–inch flare (7/16–20) connections to
unit product inlet lines if desired.
7. Applicable BACK PANEL (item 13) to be installed on unit and secured with FLAT WASHERS (item 15) and
THREAD CUTTING SCREWS (item 14).
SELECTING LOCATION
Units may be island–mounted or installed on or on edge of countertop. Locate unit so following requirements are
satisfied.
1. Unit with lighted sign to be near properly grounded electrical outlet with proper electrical requirements.
2. In a location convenient for the operator, yet can be easily seen by the customer.
3. Easily accessible for service and maintenance.
INSTALLING UNIT
Unit may be installed on countertop with its drip tray drain hose, product inlet lines, and lighted sign power cord
(if applicable) routed through hole cut in countertop or on edge of countertop with drain hose, inlet lines, and
power cord (if applicable) routed over edge of countertop under front of unit. Proceed to applicable installation
procedure.
UNIT INSTALLATION ON COUNTERTOP
(see Figure 3)
1. Place and tape mounting template (see Figure 4) in position on countertop.
2. Drill and cut indicated holes on template in countertop, then remove template.
3. Remove unit cup rest, then lay unit on its side.
4. Install DRAIN HOSE (item 2) on drip tray drain fitting and secure with DRAIN HOSE CLAMP (item 1).
5. Route unit drip tray drain hose, product inlet lines, and lighted sign power cord (if applicable) down through
hole cut in countertop.
6. Place unit in position on countertop with its two mounting holes aligned with two holes drilled in countertop.
7. To comply with National Sanitation Foundation (NSF) requirements, unit base must by sealed with permagum or other sealant material. Proceed as follows to seal unit base.
A. Tilt unit up to expose bottom of base.
B. Liberally apply silastic sealant such as Dow Corning RTV 731 or equivalent on base bottom edges.
NOTE: Do not move unit after positioning or seal from unit base to countertop will be broken.
C. Lower unit into position on countertop with its mounting holes aligned with holes in countertop to com-
plete seal from unit base to countertop.
8. Install FLAT WASHER, RUBBER (item 7) on each CARRIAGE BOLT (item 6), then insert bolts through
holes in unit base and holes drilled in countertop.
9. Install HEX NUTS (item 5) on carriage bolts and tighten nuts against underside of countertop.
10. Secure unit to countertop with MOUNTING CLAMPS (item 4) and WING NUTS (item 3) so arm of each
clamp butts up against underside of countertop when wing nuts are tightened.
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11. Apply additional sealant around bottom of unit base. Seal must have a minimum radius of 1/2–inch to prevent crevices and to insure a complete seal.
UNIT INSTALLATION ON EDGE OF COUNTERTOP
1. Remove cup rest from unit.
2. Place unit on countertop with drip tray extending off countertop and unit inlet lines and lighted sign power
cord (if applicable) routed over edge of countertop.
3. Install DRAIN HOSE (item 2) on drip tray drain fitting and secure with DRAIN HOSE CLAMP (item 1).
4. Install FLAT WASHER, RUBBER (item 7) on each CARRIAGE BOLT (item 6), then insert bolts through
mounting holes in unit base.
5. Install HEX NUTS (item 5) on carriage bolts, then tighten nuts against underside of unit base.
6. Push unit back on countertop so bolts are as close as possible to countertop edge.
7. To comply with National Sanitation Foundation (NSF) requirements, unit base must be sealed to countertop
and all access holes to unit base must be sealed with permagum or other sealant material. Proceed as follows to seal unit base.
A. Tilt unit up to expose bottom of base.
B. Liberally apply silastic sealant such as Dow Corning RTV 731 or equivalent on base bottom edges.
NOTE: Do not move unit after positioning or seal from unit base to countertop will be broken.
C. Lower unit into operating position on countertop to complete seal from unit base to countertop.
8. Secure unit to countertop with MOUNTING CLAMPS (item 4) and WING NUTS (item 3) so arm of each
clamp butts up against underside of countertop when wing nuts are tightened.
9. Apply additional sealant around bottom of unit base. Seal must have a minimum radius of 1/2–inch to prevent crevices and to insure a complete seal.
10. Seal all access holes to unit base with permagum or other sealant material.
CONNECTING DRIP TRAY DRAIN HOSE
NOTE: Drip tray drain hose routed to waste container is not recommended due to sanitation and cleaning problems. Connection of drain hose to a permanent drain is recommended.
1. Preferably, route drip tray drain hose to permanent drain and connect.
2. Install cup rest in drip tray.
INSTALLING DISPENSING VALVES AND KNOBS
1. Install DISPENSING VALVES (item 8) on unit and secure with coupling nuts. Tighten coupling nuts with
spanner wrench.
2. Install DECALS, DISPENSING VALVES KNOBS (item 10) on KNOBS, DISPENSING VALVES (item 9).
3. Install knobs on applicable dispensing valves by pushing knobs down into place on valves levers.
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CARRIAGE BOLT (ITEM 6)
RUBBER WASHER (ITEM 7)
HEX NUT (ITEM 5)
MOUNTING CLAMP (ITEM 4)
WING NUT (ITEM 3)
PRODUCT INLET LINES
DRAIN HOSE (ITEM 2)
LIGHTED SIGN
POWER CORD
(IF APPLICABLE)
FIGURE 3. UNIT INSTALLATION ON COUNTERTOP
BASE
CONNECTING UNIT PRODUCT INLET LINES
(see Figure 2)
All unit product inlet lines internal connections have been made at factory. Perform the following to connect
product inlet lines to unit product inlet lines.
NOTE: REDUCERS (item 11) are provided to make 1/4–inch flare (7/16–20) connections to unit product
inlet lines if desired.
1. Install applicable ADAPTERS (item 12) on ends of unit product inlet lines.
2. Route and label for identification, product inlet lines from refrigeration unit or cold plate to unit.
NOTE: The numbered unit product inlet lines to dispensing valves are labeled to identify dispensing
valve they serve. For example: Line labeled ‘‘1’’ must be connected to system that provides product to
be dispensed from NO. 1 dispensing valve. (NO. 1 dispensing valve is valve on right side when facing
front of unit.)
3. Connect product inlet lines from refrigeration unit or cold plate to applicable labeled unit product inlet lines.
PREPARING UNIT FOR OPERATION
1. Adjust product tanks CO2 regulators as specified.
2. Sanitize product systems as instructed.
3. Connect product tanks into product systems. Check for leaks and tighten or repair any loose connections.
OPERATION
1. Dispense from each dispensing valve until air is bled from systems and product is dispensed.
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2. Check for leaks and tighten or repair any loose connections.
3. Adjust dispensing valve product flow rate as specified.
ELECTRICAL CONNECTION (ONLY ON UNIT WITH LIGHTED SIGN)
WARNING: Lighted sign must be electrically grounded to avoid possible fatal electrical
shock or serious injury to operator. Unit power cord is equipped with a three-prong plug. If a
three-hole (grounded) electrical outlet is not available, use an approved method to ground
lighted sign.
Plug lighted sign power cord into electrical outlet with proper electrical requirements.
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4-IN. DIA.
1 1/4-IN.
1/2-IN. DIA. (2)
2 1/2-IN.
5-IN.
3 1/2-IN.
COUNTERTOP EDGE
FIGURE 4. MOUNTING TEMPLATE
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OPERATOR INSTRUCTIONS
This section covers operators instructions for operating controls, daily pre–operation check, adjustments, replenishing CO
2
and product supplies, cleaning and sanitizing unit, and cleaning gas check valves.
OPERATING CONTROLS
(see Figure 5)
DISPENSING VALVE
Place cup or glass under dispensing valve nozzle. Pull dispensing valve knob forward until cup or glass is full,
then release knob.
DAILY PRE–OPERATION CHECK
1. Make sure primary CO2 regulator assembly 1800-psi gage indicator is not in shaded (‘‘change CO2 cylinder’’) portion of dial. If so, CO
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
cylinder is almost empty and must be replaced.
ADJUSTMENTS
PRODUCT TANKS CO2 REGULATORS
(see Figure 2)
2
Product tanks CO
justed as instructed.
regulators should be checked periodically for proper pressure settings and if necessary, ad-
ADJUSTING DISPENSED PRODUCT FLOW RATE
Product flow rate should be checked periodically and if necessary, adjusted as instructed.
REPLENISHING CO2 SUPPLY
NOTE: When indicator on primary CO2 cylinder regulator assembly 1800-psi gage is in shaded (‘‘change
2
CO
cylinder’’) portion of the dial, CO2 cylinder is almost empty and should be changed.
2
supply should be checked daily and if necessary, replenished as instructed.
CO
REPLENISHING PRODUCT SUPPLY
Product supply should be checked daily and if necessary, replenished as instructed.
CLEANING AND SANITIZING
DAILY CLEANING OF UNIT
Daily cleaning of unit should be performed at end of daily operation as instructed.
13
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Page 17
SANITIZING UNIT
Product systems should be sanitized as instructed every 90-days following Sanitizer Manufacturer’s
recommendations.
CLEANING CO2 SYSTEM GAS CHECK VALVES
(see Figure 2)
2
The CO
and after any CO
system gas check valves must be inspected and serviced at least once a year under normal conditions
2
system servicing or disruption as instructed.
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SERVICE AND MAINTENANCE
This section describes service and maintenance procedures to be performed on the unit.
IMPORTANT: Only qualified personnel should service internal components or lighted sign electrical
wiring.
CUP REST AND LIGHTED SIGN DOME (IF APPLICABLE) REMOVAL
(see Figure 5)
CUP REST
Lift cup rest up and out of drip tray.
LIGHTED SIGN DOME
1. Remove two screws securing end cap on lighted sign, then remove end cap.
2. Remove dome.
PERIODIC INSPECTION
1. Check for loose dispensing valves and tighten as necessary.
2. Check dispensing valves for dripping that indicates leaking and repair as necessary.
3. Make sure lighted sign (if applicable) is operating.
ADJUSTMENTS
ADJUSTING PRODUCT TANKS CO REGULATORS
(see Figure 2)
2
NOTE: To readjust CO
the left (counterclockwise) until pressure gage reads 5–psi lower than new setting will be. Turn adjusting screw to the right (clockwise) until gage registers new setting, then tighten lock nut.
Set product tanks CO
equilibrium pressure for 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. Loosen lock nut on CO
adjusting screw to the right (clockwise) until gage registers desired pressure, then tighten adjusting screw lock
nut.
ADJUSTING DISPENSED PRODUCT FLOW RATE
regulator to lower setting, loosen adjusting screw lock nut, then turn screw to
2
regulators, using Cornelius PRE–MIX COMPUTER slide rule or bottling room chart, at
2
regulator adjusting screw, turn
(see Figure 5)
Rotate dispensing valve compensator adjusting screw to the left (counterclockwise) for higher product flow rate
or to the right (clockwise) for lower product flow rate.
REPLENISHING CO2 SUPPLY
NOTE: When indicator on primary CO2 regulator assembly 1800-psi gage is in shaded (‘‘change CO2 cylinder’’) portion of dial, CO
2
cylinder is almost empty and should be changed.
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DOME
FLORESCENT TUBE
*LIGHTED SIGN
DISPENSING VALVE (4)
CUP REST
END CAP
END CAP
RETAINING SCREW (2)
COMPENSATOR
ADJUSTING
SCREW
BASE
* Lighted sign starter and ballast located underneath unit
FIGURE 5. PARTS IDENTIFICATION (LIGHTED SIGN MODEL SHOWN)
16151468000
Page 20
1. Fully close (clockwise) CO2 cylinder valve.
2. Slowly loosen CO
tor assembly from empty CO
3. Unfasten safety chain and remove empty CO
2
regulator assembly coupling nut allowing CO2 pressure to escape, then remove regula-
2
cylinder.
2
cylinder.
WARNING: To avoid personal injury and/or property damage, always secure CO2 cylinder in
upright position with a safety chain to prevent it from falling over. Should valve become
accidentally damaged or broken off, CO
2
cylinder can cause serious personal injury.
4. Position CO2 cylinder and secure with safety chain.
5. Make sure gasket is in place inside CO
2
regulator assembly coupling nut, then install regulator on CO
cylinder.
6. Open (counterclockwise) CO
2
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).
2
7. Check CO
connections for leaks. Tighten loose connections.
REPLENISHING PRODUCT SUPPLY
1. Remove CO2 disconnect (grey) and liquid disconnect (black) from empty product tank, then remove tank.
2
2. Place full product tank in position, then install CO
product tank.
disconnect (grey) and liquid disconnect (black) on full
2
PRODUCT FLAVOR CHANGE
Sanitize applicable product system as instructed, then install full tank of new flavor product.
CLEANING AND SANITIZING
DAILY CLEANING OF UNIT
1. Remove cup rest from drip tray.
2. Wash out inside of drip tray, then rinse drip tray allowing water to escape through drain hose to waste container or drain.
3. Clean all external surfaces of unit with sponge. Rinse out sponge with clean water, then wring excess water
out of sponge and wipe off external surfaces of unit. Wipe unit dry with a clean soft cloth. DO NOT USE
ABRASIVE TYPE CLEANERS.
4. Install cup rest in drip tray.
SANITIZING UNIT
IMPORTANT: Only qualified personnel should perform sanitizing procedure.
NOTE: An alternate to the preferred sanitizing procedure outlined below would be to remove dispensing
valve, then make necessary connections to circulate sanitizing solution through the product systems.
After systems have been sanitized, dispensing valves may then be disassembled (see Figure 6) and
cleaned before re-installing on Unit.
The product systems should be sanitized every 90-days following Sanitizer Manufacturer’s recommendations.
Use Chlor-Tergent (Oakite Products, Inc.) or equivalent sanitizer. An economic practice would be to arrange any
flavor changeover to coincide with sanitizing operation. Proceed as follows to sanitize product systems.
17 151468000
Page 21
1. Remove quick disconnects from product tanks. Rinse quick disconnects in potable water.
2. Open dispensing valves to relieve pressure on the systems.
3. Remove dispensing valves knobs by pulling knobs up and off valves.
4. Using a spanner wrench, loosen and remove coupling nuts from the dispensing valves, then remove valves
from the Unit.
5. Remove phillips-head screw on end of the dispensing valve (see Figure 6), then remove outer sleeve,
spring, and inner sleeve.
6. Loosen and remove knob lever bonnet securing lever in the valve body, then remove the lever.
7. Slide shaft and seal assembly out through rear of the dispensing valve body.
8. Wash disassembled dispensing valve parts in potable water.
9. Assemble dispensing valves by reversing disassembly procedure steps 5 through 7 preceding.
10. Following Sanitizer Manufacturer’s instructions, fill clean empty product tank with sanitizing solution.
11. Connect sanitizing solution tank into product system to be sanitized.
12. Place waste container under applicable dispensing valve. Open dispensing valve to permit sanitizing solution to purge product out of product system and dispensing valve. Continue to draw from valve until only
sanitizing solution is dispensed.
13. Repeat steps 11 and 12 preceding to purge product from and install sanitizing solution in remaining product
systems.
14. Follow Sanitizer Manufacturer’s application instructions.
15. Remove tank containing sanitizing solution from product system.
WARNING: To avoid possible personal injury or property damage, do not attempt to remove
product tank cover until CO
2
pressure has been released from tank.
16. Install tanks containing product in product systems.
KNOB
KNOB LEVER BONNET
FRICTION WASHER
BALL WASHER
LEVER
INNER SLEEVE
SPRING
O-RING
COMPENSATOR
SHAFT AND
SEAT ASS’Y
PHILLIPS-HEAD SCREW
FIGURE 6. DISPENSING VALVE PARTS IDENTIFICATION
BODY
O-RING
COMPENSATOR ADJUSTING
SCREW
OUTER SLEEVE
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WARNING: Flush sanitizing solution from product systems as instructed. Residual solution
left in systems could create a health hazard.
17. Place waste container under each dispensing valve. Open dispensing valves to permit product to purge
sanitizing solution out of product systems. Continue to dispense from valves until only product is dispensed.
18. Thoroughly rinse out product tank that was used for sanitizing solution to remove all solution residue from
inside tank.
REPAIR AND REPLACEMENT
DISPENSING VALVE ASSEMBLY
Removal.
1. Disconnect product line liquid disconnect from applicable product tank outlet fitting.
2. Open dispensing valve to relieve pressure on system.
3. Remove dispensing valve knob by pulling knob up and off valve.
4. Using spanner wrench, loosen and remove coupling nut from dispensing valve.
Installation.
1. Install dispensing valve on unit by reversing Removal procedure. Tighten coupling nut using spanner
wrench.
2. Install knob on dispensing valve.
QUAD RING
183294000
BALL
183296000
SPRING
183297000
RETAINER
183298000
BODY
183295100
*Quad ring seal must be replaced
each time check valve is serviced.
FIGURE 7. CO2 GAS CHECK VALVE
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Page 23
LIGHTED SIGN (IF APPLICABLE) FLUORESCENT TUBE
(see Figure 5)
Removal.
1. Unplug lighted sign power cord from electrical outlet.
2. Remove two screws securing dome end cap, then remove end cap and dome.
3. Remove fluorescent tube from lamp holders.
Installation.
1. Install new fluorescent tube by reversing Removal procedure.
2. Plug lighted sign power cord into electrical outlet.
LIGHTED SIGN (IF APPLICABLE) STARTER
Removal.
1. Unplug lighted sign power cord from electrical outlet.
2. Remove wing nuts, hex nuts (if applicable), and mounting clamps securing unit to countertop.
3. Tip front of unit up far enough for access to starter located on bottom of unit.
4. Remove starter from socket.
Installation.
1. Install new starter by reversing Removal procedure.
NOTE: To comply with National Sanitation Foundation (NSF) requirements, unit base must be sealed to
countertop and all access holes to unit base must be sealed with permagum or other sealant material
when re-installing unit on countertop.
2. Plug lighted sign power cord into electrical outlet.
LIGHTED SIGN (IF APPLICABLE) BALLAST
Removal.
1. Unplug unit power cord from electrical outlet.
2. Remove wing nuts, hex nuts (if applicable), and mounting clamps securing unit to countertop.
3. Tip front of unit up far enough for access to ballast located on bottom of unit.
4. Remove ballast from unit.
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Page 24
Installation.
1. Install new ballast on unit by reversing Removal procedure.
NOTE: To comply with National Sanitation Foundation (NSF) requirements, unit base must be sealed to
countertop and all access holes to unit base must be sealed with permagum or other sealant material
when reinstalling unit on countertop.
2. Plug lighted sign power cord into electrical outlet.
CLEANING CO2 GAS CHECK VALVES (see Figures 2 and 7)
The CO
after any servicing or disruption of the CO
CHECK VALVES ARE SERVICED.
2
gas check valves must be inspected and serviced at least once a year under normal conditions and
2
system. ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS
21 151468000
Page 25
FLUORESCENT TUBE
STARTER
BALLAST
POWER CORD PLUG
FIGURE 8. LIGHTED SIGN WIRING DIAGRAM
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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.
DISPENSING STATION
supply, then relieve the
2
Trouble
Probable Cause Remedy
NO PRODUCT DISPENSED. A. Quick disconnects not properly
connected to product tanks.
B. No product supply (tank
empty).
2
supply. C. Replenish CO2 supply as
DISPENSED PRODUCT
COMES OUT OF DISPENSING
C. No CO
A. Oil film or soap scum in cup or
glass.
VALVE CLEAR BUT FOAMS IN
CUP OR GLASS.
B. Ice used for finished drink is
sub cooled
NOTE: Crushed ice also causes dispensing problems. When dispensed
product hits sharp edges of the ice, carbonation is released from
product.
DISPENSED PRODUCT
FOAMS AS IT LEAVES
A. Recovery rate of refrigeration
unit or cold plate exceeded.
DISPENSING VALVE.
B. Product tanks CO2 regulator
improperly adjusted.
A. Connect quick disconnects
properly.
B. Replenish product supply as
instructed.
instructed.
A. Use clean cups and glasses.
B. Do not use ice directly from
freezer. Allow ice to become ‘‘wet’’
before using. (Refer to following
NOTE).
A. Allow refrigeration unit to recover
or check cold plate for ice supply.
B. Adjust product tanks CO
2
regulator as instructed.
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.
23 151468000
C. Clean dispensing valve as
instructed.
D. Replace nylon washer. Make sure
it is properly seated.
E. Remove contaminated CO2.
Clean CO
regulator, etc.). Install clean CO
2
system (lines,
2
supply.
Page 27
Trouble RemedyProbable Cause
LIGHTED SIGN (IF APPLICABLE)
LIGHTED SIGN NOT
OPERATING.
A. Lighted sign power cord
unplugged.
B. No power source (blown fuse
or tripped circuit breaker.
C. Fluorescent tube, starter, or
ballast inoperable.
D. Loose, disconnected, or
broken wiring.
A. Plug lighted sign power cord into
electrical outlet.
B. Replace fuse or reset circuit
breaker). (Note: Fuse is not part
of unit.)
C. Replace inoperable part as
instructed.
D. Tighten connections or replace
broken wiring.
151468000
24
Page 28
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 (61) 2 534 2166
D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930
AUSTRIA
D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307
BELGIUM
D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829
BRAZIL
ENGLAND
D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644
D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201
FRANCE
GERMANY
GREECE
HONG
ITALY
NEW
SINGAPORE
SPAIN
USA
D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438
D 488 MESSOGION AVENUE D AGIA PARAS KEVI D 153 42 D A THE NS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491
KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222
D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814
ZEALAND D 20 LANSFORD CRES. D P.O . BOX 19-044 A VONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361
D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604
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 3379
D ONE CORNELIUS PLACE D ANOKA, M INNE SOTA D (612) 421-6120 D FAX (612) 422-3255
LD004
4/21/98
15146800025
Page 29
IMI CORNELIUS INC.
CORPORATE HEADQUARTERS:
One Cornelius Place
Anoka, Minnesota 55303-6234
(612) 421-6120
(800) 238-3600
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