Remcor C-1550XR Service Manual

IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234
Telephone [phone] Facsimile [phone]

Service Manual
C-1550XR UNIVERSAL PRE-MIX DISPENSER
(R-404A REFRIGERANT)

Part No. 309989004
January 7, 1986
Revised: January 27, 1999
Control Code A

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

IMI CORNELIUS INC; 1986--99Ó

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT DESCRIPTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

SERVICE AND MAINTENANCE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARING UNIT FOR SHIPPING, RELOCATING, OR STORING 5. . . . . . . . . .

PERIODIC INSPECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING PRODUCT TANK CO2 REGULATORS 5. . . . . . . . . . . . . . . . . . . . . .

ADJUSTING DISPENSED PRODUCT FLOW RATE 6. . . . . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING PRODUCT SUPPLY 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT FLAVOR CHANGE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CONDENSER COIL 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING ICE WATER BATH 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING WATER TANK 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING OF UNIT 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING PRE-MIX SYSTEMS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CO2 GAS CHECK VALVES 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

TROUBLESHOOTING PRODUCT SYSTEM 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NO PRODUCT DISPENSED. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR

BUT FOAMS IN CUP OR GLASS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT FOAMS AS IT LEAVES DISPENSING VALVE. 15. . . . .

TROUBLESHOOTING REFRIGERATION SYSTEM 16. . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR DOES NOT OPERATE. 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR WILL NOT STOP AFTER SUFFICIENT ICE BANK

IS FORMED.. 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM

SUFFICIENT ICE BANK. 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSER FAN MOTOR NOT OPERATING. 17. . . . . . . . . . . . . . . . . . . . . . . . . .

AGITATOR MOTOR NOT OPERATING. 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

309989004

TABLE OF CONTENTS (cont’d)

LIST OF FIGURES

FIGURE 1. UNIVERSAL C-1550XR (FOUR-FLAVOR UNIT SHOWN) 4. . . . . . . . .

FIGURE 2. DISPENSER COMPONENTS (FOUR-FLAVOR UNIT SHOWN) 7. . .

FIGURE 3. PARTS IDENTIFICATION (FOUR-FLAVOR UNIT SHOWN) 8. . . . . . .

FIGURE 4. FLOW DIAGRAM (FOUR-FLAVOR UNIT SHOWN) 9. . . . . . . . . . . . . .

FIGURE 5. CO2 GAS CHECK VALVE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. WIRING DIAGRAM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF TABLES

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

Page

309989004

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, relocating, or storing this Unit, the product coils must be flushed with
potable water, all water must be purged from the product coils, ice bank must be melted, and water
must be drained from the water tank. A freezing ambient environment will cause residual water re­maining inside the Unit to freeze resulting in damage to the Unit internal components.

1 309989004

THIS PAGE LEFT BLANK INTENTIONALLY

2309989004

GENERAL INFORMATION

TO THE USER OF THIS MANUAL

This Manual is a guide for servicing and maintaining this equipment. Refer to Table of Contents for page loca­tion of detailed information pertaining to questions that may arise.

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

Unit Part Numbers:

Universal C-1550XR Four-Flavor 2849749020
Universal C-1550XR Four-Flavor 2849749200
Universal C-1550XR Five-Flavor 2849759200
Universal C-1550XR Five-Flavor (230 VAC, 50 Hz) 4949759020
Universal C-1550XR Five-Flavor (115 VAC, 60 Hz) 2849759020
Universal C-1550XR Five-Flavor (230 VAC, 50 Hz) 4949759200

Overall Dimensions:

Height 42-1/2 inches
Width 21-3/4-inches

Depth (with drip tray) 31-1/2 inches

Weights:

Shipping (1 Carton) 189 pounds
Dry Weight 170 pounds
With Water Tank Full of Water 403 pounds
Ice Bank Weight 100 pounds

Capacities:

Unit Water Bath (no ice bank) approx. 28 gallons

3 309989004

Table 1. Design Data (cont’d)

Dispensing Rate:

12-oz. drinks 8/minute 724 (see NOTE)

NOTE: *Number of 12-oz. drinks that can be dispensed at 40° F or below with 75° F product inlet temperature

and 75° F ambient.

Refrigerant Requirement See Unit Nameplate

Ambient Operating Temperature 40° F to 100° F

Electrical Requirements: See Unit Nameplate

UNIT DESCRIPTION

The Unit (see Figure 1) is equipped with manually operated self-closing dispensing valves. The Unit is equipped
with a handle and wheels which makes it a mobile Unit. The refrigeration system is equipped with a 3/4 H.P.
compressor that is easily accessible for service and maintenance.

THEORY OF OPERATION

(see Figure 4)

A CO2cylinder delivers carbon dioxide (CO2) gas through adjustable CO2regulators to the product tanks. When
dispensing valves are opened, CO2pressure exerted upon the product tanks pushes product from the tanks,
through the Unit cooling coils, and on to the dispensing valves resulting in cold dispensed drinks.

When Unit power cord has been plugged into the electrical outlet and power switch (115 VAC, 60-Hz Units only)
on back of the Unit has been positioned to ‘‘ON’’ (up) position, the compressor, condenser fan motor, and agita­tor motor will start and begin forming an ice bank. When a full ice bank has been formed, the compressor and
condenser fan motor will stop but the agitator motor will continue to operate, circulating ice water bath in water
tank. The water tank ice bank sensing bulb will cycle the compressor and the condenser fan motor on and off as
required to maintain a full ice bank.

FIGURE 1. UNIVERSAL C-1550XR (FOUR-FLA VOR UNIT SHOWN)

4309989004

SERVICE AND MAINTENANCE

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

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

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

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.

IMPORTANT: For the most efficient operation of the Unit, the ambient operating temperature for the
Unit should not exceed 90° F. Satisfactory temperatures may be obtained using blowers, air
conditioning, etc. Check your local codes.

PREPARING UNIT FOR SHIPPING, RELOCATING, OR STORING

CAUTION: Before shipping, relocating, or storing the Unit, the product cooling coils must
be sanitized, all sanitizing solution must be purged from the product coils, the ice bank

must be melted, and all water must be drained from the water tank. A freezing ambient
environment will cause residual water remaining inside the Unit to freeze resulting in damage to
internal components of the Unit.

PERIODIC INSPECTION

1. Check Unit condenser coil (see Figure 3) for accumulation of dust, lint, or grease and if necessary , clean
the coil as instructed. Restriction of air flow through the condenser coil will decrease cooling efficiency of
the Unit.

2. Check area in front, back, sides, and above the Unit for obstructions. These areas must be kept clear at all
times. Listed below are the minimum clearances that must be maintained.

A. Clearance above the Unit ---------------------------------------------------------- 12 inches to nearest obstruction.
B. Clearance back of Unit -------------------------------------------------------------- 12 inches to nearest obstruction.
C. Clearance on sides of Unit ----------------------------------------------------------12 inches to nearest obstruction.
D. Clearance on front of Unit ---------------------------------------------------------- Open

3. Check dispensing valves for dripping that indicates leaking and repair as necessary.

ADJUSTMENTS

ADJUSTING PRODUCT TANK CO2REGULATORS

(see Figure 4)

NOTE: To adjust CO2regulator to provide a lower pressure, 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
adjusting screw to the right (clockwise) until gage registers new setting. Then tighten lock nut.

Set product tank CO2regulators, using Cornelius PRE-MIX COMPUTER slide rule or bottling room chart. Enter
equilibrium pressure for highest temperature encountered between product tank storage area and cooling 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 cooling 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. MAXIMUM UNIT INLET PRESSURE MUST
NOT EXCEED 100 psig. Loosen lock nut on CO2regulator adjusting screw, then turn adjusting screw to the
right (clockwise) until gage registers desired pressure. Tighten adjusting screw lock nut.

ADJUSTING DISPENSED PRODUCT FLOW RATE

(see Figure 2)

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 CO2SUPPLY

NOTE: When indicator on CO2cylinder regulator assembly 1800 psi gage is in shaded (‘‘change CO
cylinder’’) portion of dial, CO2cylinder is almost empty and should be replaced.

CAUTION: Wear protective eyewear to avoid injury from gas-driven particles.

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.

1. Fully close (clockwise) CO2cylinder valve.

2. Slowly loosen CO2regulator assembly coupling nut allowing CO2pressure to escape, then remove regula­tor assembly from empty CO2cylinder.

3. Unfasten safety chain and remove empty CO2cylinder.

WARNING: To avoid personal injury and/or property damage, always secure CO2cylinder
in an upright position with safety chain to prevent it from falling over. Should the shutoff
valve become accidentally broken off, CO2cylinder can cause serious personal injury.

2

4. Position CO2cylinder and secure with safety chain.

5. Make sure gasket is in place inside CO2regulator coupling nut, then install regulator on CO2cylinder.

6. Open (counterclockwise) CO2cylinder 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 CO2connections for leaks.

REPLENISHING PRODUCT SUPPLY

1. Remove inlet (CO2) disconnect (grey) and outlet disconnect (black) from empty product tank, then remove
tank.

2. Place full product tank in position, then connect inlet (CO2) disconnect (grey) and outlet disconnect (black)
to tank.

309989004 6

UNIT PRODUCT

INLET LINES

POWER

CORD

UNIT POWERSWITCH

(115 VAC, 60 HZ UNIT ONL Y)

DRIP TRAY

DRAIN HOSE

PLUG

WATER TANK

OVERFLOW TUBE

WATER TANK

DRAIN HOSE

TOP COVER

DISPENSING

VALVE (4)

CUP REST

DRIP TRAY

COVER RETAINING

SCREW (4)

COMPENSAT ORADJUSTING

SCREW

VALVE TRIM

PANEL

DRIP TRAY

DRAIN HOSE

RETAINING

SCREW (4)

ACCESS GRILLE (4)

AIR INTAKE

FIGURE 2. DISPENSER COMPONENTS (FOUR-FLA VOR UNIT SHOWN)

UNIT PRODUCT

INLET LINES

ELECTRICAL

CONTROL BOX

POWER CORD

TERMINAL

BLOCK

RETAINING

SCREW

ACCESS

GRILLE

UNIT POWERSWITCH

(115 VAC, 60 HZ UNIT ONL Y)

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

309989004 8

CONDENSER

COIL

CONDENSER

FAN MOT OR

COMPRESSOR

1

VALVE (4)

DISPENSING

DISPENSER

PRODUCT COOLING COIL (4)

2

3

4

1

2

3

4

TANK (4)

PRODUCT

FIGURE 4. FLOW DIAGRAM (FOUR-FLAVOR UNIT SHOWN)

MANIFOLD

2

CO

CYLINDER

2

CO

PRESSURE GAGE

2

REGULATOR

PRIMARY CO

PRODUCT TANKS

CYLINDER

2

CO

VALVE (4)

GAS CHECK

LINE LEDGEND

2

CO

PRODUCT

9

309989-000

PRODUCT FLAVOR CHANGE

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

CLEANING CONDENSER COIL

(see Figure 3)

NOTE: Air circulation through the condenser coil, required to cool the coil, is drawn in through grille
on Unit front panel and is exhausted out through grilles on sides and back of the Unit. Restricting air
flow through the condenser coil will decrease cooling efficiency of the Unit.

Area in front, sides, and back of the Unit must be kept free of obstructions at all times which would
prevent air flow in and out of the Unit.

An excessive accumulation of dust, lint, and grease on the condenser coil will restrict air flow through the coil
which will decrease cooling efficiency of the Unit. The Unit condenser coil should be periodically cleaned by per­forming the following:

1. Unplug Unit power cord from electrical outlet.

2. Remove four screws securing air intake grille on the Unit front panel, then remove the grille.

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

4. Install air intake grille on the Unit and secure with four screws.

5. Plug Unit power cord into electrical outlet.

CHECKING ICE WATER BATH

A “gurgle’ heard from the Unit, indicates water level in the water tank is low and more water should be added for
maximum product cooling. Before adding more water to the water tank, the ice water bath and the ice bank
should be checked for cleanliness and the water tank components checked for excessive mineral deposit
build-up.

1. Unplug Unit power cord from electrical outlet.

2. Remove four screws securing the Unit top cover, then remove cover.

3. Check condition of the ice water bath and the ice bank. The ice water bath should be clear and the ice
bank should be free of foreign particles.

4. Check agitator motor shaft and ice bank sensing bulb for excessive mineral deposit build-up.

5. If cleaning of water tank is necessary, refer to CLEANING WATER TANK in this section for cleaning
procedure.

6. Make sure end of water tank overflow tube is placed in a waste container. Fill water tank with clean water­until water starts flowing from overflow tube into the waste container. USE A LOW-MINERAL-CONTENT
WATER WHERE A LOCAL WATER PROBLEM EXIST.

7. Install Unit top cover and secure with four screws.

8. Plug Unit power cord into electrical outlet. After water has stopped dripping from the water tank overflow
tube, remove tube from the waste container and place back inside the Unit.

CLEANING WATER T ANK

NOTE: The ice water bath should be changed as often as necessary to keep the water tank clean. A
convenient time to perform this operation is at the time the Unit is being sanitized. To save time, water
can be drained from the water tank while the Unit is being sanitized.

309989004 10

1. Unplug Unit power cord from electrical outlet.

2. Remove screws securing the Unit top cover, then remove cover.

3. Remove four screws securing either the side or the back access grille, then remove the grille.

4. Route water tank drain hose out hole in back of the Unit to a waste container or to a drain.

5. Remove plug from end of the drain hose and allow water to drain from the water tank.

NOTE: If ice bank is clear and contains no foreign particles, it does not have to be melted down. Skip
steps 6 and 7 and proceed with step 8 .

6. If ice bank is dirty , allow it to melt. Hot water may be used to speed up melting.

CAUTION: Never use an ice pick or other instrument to remove ice from the evaporator coil.
Such practice can result in a punctured refrigerant circuit or damage to the water tank.

7. Wash inside of the water tank with a mild soap solution.

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

9. Rinse all parts and flush water tank with clean water.

10. Install plug in end of the water tank drain hose, then place drain hose back inside the Unit.

11. Place end of the Unit water tank overflow tube in a waste container.

12. Fill water tank with clean water until water starts flowing from the overflow tube into the waste container.
USE A LOW-MINERAL-CONTENT WATER WHERE A LOCAL WATER PROBLEM EXIST.

13. Install Unit top cover and secure with four screws.

14. Plug Unit power cord into electrical outlet. Make sure compressor, condenser fan motor, and agitator motor
are operating.

15. After water has stopped dripping from the water tank overflow tube, remove tube from the waste container,
then place tube back inside the Unit.

16. Install access grille on the Unit and secure with screws.

CLEANING AND SANITIZING

DAILY CLEANING OF UNIT

NOTE: A drip tray that does not have a drain hose routed to a waste container or a permanent drain
must be removed from the Unit and be thoroughly cleaned. A drip tray that has a drip tray drain hose
routed to a waste container or a permanent drain may be cleaned in place on the Unit as follows.

17. Remove cup rest from the drip tray.

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

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

20. 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 of the Unit. Wipe Unit dry with a clean
soft cloth. DO NOT USE ABRASIVE-TYPE CLEANERS.

30998900411

SANITIZING PRE-MIX SYSTEMS

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

The pre-mix product systems should be sanitized every 90-days using a non-scented household liquid bleach
such as Hi-Lex or Chlorox containing a 5.25% sodium hypochlorite concentration. Proceed as follows to sanitize
the pre-mix product systems.

1. Disconnect product tanks from the product systems.

2. Rinse product tanks quick disconnects with warm potable water.

3. Using a clean empty product tank, prepare a full tank of non-scented liquid dishwasher detergent solution
by using 70° F (21° C) to 100° F (38° C) potable water and 0.5 oz. (15 ml) of liquid dishwasher detergent
(such as Joy, Ivory, etc.) to one gallon of potable water. Shake tank containing detergent solution to thor­oughly mix the solution.

4. Connect tank containing detergent solution into one of the product systems.

5. Place waste container under the applicable dispensing valve.

6. Activate the dispensing valve to permit detergent solution to purge product out of the line, coil, and the dis­pensing valve. Continue to dispense until only detergent solution is dispensed from the dispensing valve.

7. Connect tank containing detergent solution into remaining product systems and flush product out of sys­tems as instructed in steps 5 and 6 preceding.

8. Using a clean product tank, prepare sanitizing solution using 70° F (21° C) to 100° F (38° C) potable water
and 0.5 oz. (15 ml) of household liquid bleach such as non-scented Hi-Lex or Chlorox that contains a

5.25 % sodium hypochlorite concentration to one gallon of potable water. This mixture must not exceed
200 PPM of chlorine. Shake tank containing sanitizing solution to thoroughly mix the solution.

9. Connect tank containing sanitizing solution into one of the product systems.

10. Place waste container under the applicable dispensing valve.

11. Activate the dispensing valve for one minute to purge detergent solution from and install sanitizing solution
in the product system.

12. Continue activating the dispensing valve in cycles (“ON” for 15--seconds, “OFF”, then “ON” for
15-seconds). Repeat “ON” and “OFF” cycles for 15 cycles.

13. Repeat steps 9 through 11 preceding to purge detergent solution from the remaining product systems.

14. Allow sanitizing solution to remain in the product system for not less than 10-minutes or for no more than
15-minutes.

15. Connect product tank containing potable water into the product system to be flushed.

WARNING: Flush sanitizing solution from the system(s) as instructed. Residual sanitizing
solution left in the product system(s) could create a health hazard.

16. Place waste container under applicable dispensing valve.

17. Activate the dispensing valve for one minute to purge all sanitizing solution out of the product system.

18. Continue activating the dispensing valve in cycles (“ON” for 15--seconds, “OFF”, then “ON” for
15-seconds). Repeat “ON” and “OFF” cycles for 15 cycles.

19. Repeat steps 15 through 18 preceding to purge sanitizing solution from the remaining product systems.

309989004 12

20. Remove product tank containing flush water from the product system, then connect a clean empty product
tank into the system.

21. Place waste container under applicable dispensing valve.

22. Activate the dispensing valve to purge all water from the product system.

23. Repeat steps 20 and 22 preceding to purge all water from the remaining product systems.

24. 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 CO2GAS CHECK VAL VES

(see Figures 4 and 5)
The primary CO2regulator assembly CO2gas check valves must be inspected and serviced at least once a

year under normal conditions and after any servicing or disruption of the CO2system. ALWAYS REPLACE

QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED.

QUAD RING
183294000

BALL
183296000

SPRING
183297000

RETAINER
183298000

BODY
183295100

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

FIGURE 5. CO2GAS CHECK VALVE

30998900413

FIGURE 6. WIRING DIAGRAM

309989004 14

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 CO2system, stop dispensing, shut off the CO2supply , then relieve
the system pressure before proceeding. If repairs are to be made to the refrigeration system, make
sure electrical power is disconnected from the Unit.

TROUBLESHOOTING PRODUCT SYSTEM

Trouble Probable Cause Remedy

NO PRODUCT DISPENSED. A. Product tank quick

disconnects not attached
properly .

B. No product supply (product

tank empty).

C. No CO2supply . C. Replenish CO2supply as

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

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

DISPENSED PRODUCT
FOAMS AS IT LEAVES
DISPENSING VALVE.

A. Oil film or soap scum in cup or

glass.

B. Ice used for finished drink is

sub-cooled.

A. Recovery rate of unit

exceeded (ice bank depleted).

B. Product tanks CO2regulator

adjusted too high.

A. Attach quick disconnects

securely .

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 ice bank to recover.

B. Adjust product tanks CO

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

2

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

supply .

15 309989004

2

C. Sanitize product system as

instructed.

D. Replace nylon washer. Make sure

it is properly seated.

E. Remove contaminated CO2.

Clean CO2system (lines,
regulators, etc.). Install clean CO
supply .

2

Trouble RemedyProbable Cause

TROUBLESHOOTING REFRIGERATION SYSTEM

COMPRESSOR DOES NOT
OPERATE.

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

B. Unit power cord unplugged or

Unit power switch in ‘‘OFF’’

B. Plug in power cord or place power

switch in ‘‘ON’’ (up) position.

(down) position.

C. No power source (blown fuse

or tripped circuit breaker).

C. Replace fuse or reset circuit

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

D. Low voltage at compressor

terminals.

D. Voltage must be at least 103 volts

(115 VAC Unit) or 208 (230 VAC
Unit) at compressor terminals
when compressor is trying to
start.

E. Loose, disconnected, or

broken wiring.

F. Overload protector cut out;

over--heated compressor.
Condenser fan motor not
operating as required.

E. Tighten connections or replace

broken wiring.

F. Compressor will cool enough to

restart. Do not overdraw cooling
capacity of Unit. Refer to
‘‘CONDENSER FAN MOTOR
NOT OPERATING’’ in this
section.

COMPRESSOR WILL NOT
STOP AFTER SUFFICIENT
ICE BANK IS FORMED.
(NOTE--ICE BANK SHOULD
JUST COVER CONTROL
BULB).

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 cap tube

A. Replace ice bank control.

kinked or broken.

B. Ice bank control stuck in

B. Replace ice bank control.

closed position.
A. Cooling capacity is exceeded

by over--drawing.

B. Unit located in excessively hot

area or air circulation through

A. Reduce amount of drinks drawn

per given time.

B. Relocate Unit or determine and

correct condenser coil restriction.

condenser coil is restricted.
C. Refrigeration system leak. C. Repair refrigeration system.

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 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
OPERA TE’’ paragraph plus the following:

16309989004

Trouble RemedyProbable Cause

CONDENSER FAN MOTOR
NOT OPERATING.

CONDENSER FAN MOTOR
NOT OPERATING. (cont’d)

AGITATOR MOTOR NOT
OPERATING.

A. Jumper cord loose or

disconnected from motor or
terminal block. Broken wire in
cord.

B. Fan blade obstructed. B. Remove obstructions.

C. Inoperative condenser fan

motor.

A. Unit power cord or agitator

motor power cord
disconnected or Unit power
switch in ‘‘OFF’’ position.

B. No power source (blown fuse

or tripped circuit breaker).

C. Agitator motor propeller

obstructed.

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

A. Tighten connections or replace

cord.

C. Replace condenser fan motor.

A. Plug in power cords or place Unit

power switch in ‘‘ON’’ position.

B. Replace fuse or reset circuit

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

C. Remove obstruction.

(115 VAC Unit) or 208 (230 VAC
Unit) at compressor terminals
when compressor is trying to
start.

E. Loose, disconnected, or

broken wiring.

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

E. Tighten connections or replace

broken wiring.

instructed.

17 309989004

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 W ilshireprod­uct, 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 ITAOCARA 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

18309989004

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309989004

IMI CORNELIUS INC.

CORPORATE HEADQUARTERS:

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