Remcor LOW-PROFILE LARGE RESERVE CARBONATOR Service Manual

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

Installation/Service Manual
LOW-PROFILE LARGE RESERVE
CARBONATOR

IMPORTANT:

It is the responsibility of the Service Person
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.

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.

When installing in an area regulated by the
City of Los Angeles Plumbing and/or
Mechanical Codes, a City of Los Angeles
approved reduced pressure principle
backflow preventer shall be installed on each
potable water supply to each carbonator.

Part No. 319798001
April 4, 1985
Revised: July 9, 2002
Control Code C

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

IMI CORNELIUS INC; 1985–2002

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 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

SELECTING LOCATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PLACING UNIT IN OPERATING LOCATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING PLAIN WATER INLET SUPPLY LINE TO UNIT 8. . . . . . . . . . . . .

CONNECTING CO2 INLET SUPPLY LINE 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING CARBONATED WATER OUTLET LINE 9. . . . . . . . . . . . . . . . . . . .

PERMANENT ELECTRICAL POWER CONNECTION TO UNIT IF REQUIRED

BY LOCAL CODES 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUST CARBONATOR CO2 REGULATOR AND TURN WATER INLET

SUPPLY LINE ON 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Page

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

LUBRICATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING CARBONATOR CO2 REGULATOR 14. . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP YEARLY MAINTENANCE (OR AFTER WATER SYSTEM

DISRUPTIONS) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICING WATER PUMP WATER INLET STRAINER SCREEN 14. . . . . . . . . .

SERVICING LIQUID DUAL CHECK VALVE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THE VENTED DUAL CHECK VALVE ASSEMBLY 17. . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CARBONATOR CO2 GAS CHECK VALVE 17. . . . . . . . . . . . . . . . . . . . .

REPAIR AND REPLACEMENT 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP MOTOR 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATOR TANK LIQUID LEVEL CONTROL MODULE 21. . . . . . . . . . . . . . .

SAFETY THERMOSTAT 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VENTED DUAL CHECK VALVE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

319798001

TABLE OF CONTENTS (cont’d)

TROUBLESHOOTING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATOR PUMP MOTOR WILL NOT OPERATE. 27. . . . . . . . . . . . . . . . . . . . .

CARBONATOR PUMP MOTOR WILL NOT SHUT OFF. 27. . . . . . . . . . . . . . . . . . . .

ERRATIC CYCLING OF CARBONATOR. 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATOR PUMP CAPACITY TOO LOW. 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATOR PUMP MOTOR OPERATES BUT CARBONATOR PUMP

DOES NOT PUMP. 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF FIGURES

FIGURE 1. LOW PROFILE LARGE RESERVE CARBONATOR 4. . . . . . . . . . . . . .

FIGURE 2. CARBONATOR ASSEMBLY COMPONENTS 10. . . . . . . . . . . . . . . . . . .

FIGURE 3. CARBONATOR ASSEMBLY COMPONENTS 15. . . . . . . . . . . . . . . . . . .

FIGURE 4. LIQUID CHECK VALVE ASSEMBLY 16. . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 5. WATER STRAINER SCREEN AND LIQUID DUAL CHECK VALVE 18.

FIGURE 6. CO2 GAS CHECK VALVE 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 7. VENTED DUAL CHECK VALVE LOCATION 23. . . . . . . . . . . . . . . . . . . .

FIGURE 8. WIRING DIAGRAM (UNITS 1624, 416424000, 41642400U,

411624102, AND 496424000) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 9. WIRING DIAGRAM (UNITS 49642400U, AND 496424040) 25. . . . . . . .

Page

LIST OF TABLES

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

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

319798001

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 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.

Maximum CO

Operating Pressure 75–PSI

2

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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2319798001

GENERAL INFORMATION

TO THE USER OF THIS MANUAL

This Manual is a guide for installing and operating this equipment. Refer to Table of Contents for page location
of detailed information pertaining to questions that may arise during installation or operation of this 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

Unit Part Numbers:

115 VAC, 50/60 HZ Unit (Liquid dual check valve) 41642400U
115 VAC, 50/60 HZ Unit (Liquid dual check valve) 416424000
115 VAC, 50/60 HZ Unit (Vented dual check valve) 1624
115 VAC, 50/60 HZ Unit (Vented dual check valve) 411624102
220 VAC, 50 HZ/230 VAC, 60 Hz Unit (Liquid dual check valve) 496424000
230 VAC, 50 HZ Unit (Liquid dual check valve) 496424040
230 VAC, 50 HZ Unit (Liquid dual check valve) 49642400U

3 319798001

Table 1. Design Data (cont’d)

Overall Dimensions:

Width 15-1/2 inches
Height 13 inches
Depth 11-1/4 inches

Weight:

Dry 27 pounds
Shipping 32 pounds

Ambient Operating Temperature 40° F to 100° F

Maximum CO

Electrical Requirements:

115 VAC, 50/60 HZ Unit:

Current Draw 8.1/6.5 Amps
Operating Voltage 115 VAC, 50/60 Hz

230 VAC, 50 HZ Unit

Current Draw 3.3 Amps
Operating Voltage 230 VAC, 50 Hz

Operating Pressure 125-PSI

2

FIGURE 1. LOW PROFILE LARGE RESERVE CARBONATOR

UNIT DESCRIPTION

The carbonator is a compact Unit that may be installed in a remote location from where its carbonated water
outlet is to be connected to post-mix dispenser or system. The purpose of the Unit is to mix plain water and car­bon dioxide (CO2) gas which results in and provides carbonated water for a post-mix dispenser or system. The
Unit consists basically of a water pump, motor, and a carbonated water tank. The water pump has a liquid dual
check valve (Unit Part No. 41642400U, 416424000, 49642400U, 496424000 and 496424040) or a Vented Dual­Check Valve (Unit Part No.1624 and 411624102) on its outlet to prevent carbonated water from back flowing
into the city water system. The Vented-Dual Check Valve vents water and possibly CO2 gas out of a vent port
on failure of the Primary Check Valves. Should such venting occur, the Primary Check Valve should be re­placed. The Unit CO2 inlet has a single check valve to prevent carbonated water back flow into CO2 regulator.

4319798001

THEORY OF OPERATION

A CO2 cylinder delivers CO2 (carbon dioxide) gas through an adjustable CO2 regulator to the carbonator water
tank. At the same time, plain water is pumped into the carbonator water tank by the water pump and is carbon­ated by CO
liquid level sensing device inside the tank signals the liquid level control module which in turn shuts off the water
pump motor and the water pump. As carbonated water is drawn and carbonated water level in the tank drops to
a certain level, the liquid level sensing device inside the water tank signals the liquid level control module that
carbonated water must be replenished which in turn starts the water pump motor and the pump.

gas also entering the tank. When carbonator water tank carbonated water level has been satisfied,

2

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6319798001

INSTALLATION

UNPACKING AND INSPECTION

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

1. After Unit has been unpacked, remove shipping tape and other packing material. Check for obvious dam­age and follow procedure in preceding NOTE if damage is evident.

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

Table 2. Loose-Shipped Parts

Item

No. Part No. Name Qty.

1 178025100 Tapered Gasket, White 1
2 311304000 Tapered Gasket, Black 2

IDENTIFICATION OF LOOSE-SHIPPED PARTS

1. TAPERED GASKET, WHITE (item 1) used to seal connection when connecting regulated CO2 source inlet
line to check valve in carbonator tank CO2 inlet.

2. TAPERED GASKETS, BLACK (item 2) used to seal connections when connecting plain water inlet line to
water pump inlet tee fitting and carbonated water line to carbonator tank carbonated water outlet fitting.

SELECTING LOCATION

Locate the Unit so the following requirements are satisfied.

1. Locate the Unit in a cool area close to a properly grounded electrical outlet with proper electrical require­ments fused at 15-amps (slow-blow). For accessibility, the electrical outlet must not be located behind the
Unit. No other electrical appliance should be connected to this circuit. ALL WIRING MUST CONFORM TO
NATIONAL AND ELECTRICAL CODES.

2. Locate the Unit close to a plain water source line with requirements as outlined in CAUTION note under
CONNECTING PLAIN WATER INLET LINE TO UNIT. Plain water inlet line from plain water source line to
the Unit should be 3/8-inch I.D. (minimum) food-grade plastic.

3. Locate the Unit close to a permanent drain if installing Unit part numbers 1624, 8984, or 411624102. These
Units are equipped with vented Dual-Check Valves which must have their vent tube routed to a permanent
drain.

INSTALLING UNIT

PLACING UNIT IN OPERATING LOCATION

CAUTION: This Unit must not be installed in an unsheltered outdoor location where it will
be exposed to the elements.

7 319798001