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

1. Place carbonator in operating location meeting requirements of SELECTING LOCATION. MAKE SURE
CARBONATOR IS SITTING IN LEVEL POSITION FOR PROPER OPERATION.

2. Unit Part No. 1624, and 411624102.

IMPORTANT: A vented dual-check valve assembly is installed in the carbonator between the water
pump outlet and the water inlet to the carbonator tank as shown in Figure 2. The vented dual-check
valve assembly vents carbonated water, and possibly CO

gas out of a vent port upon failure of the

2

primary check valves. Should such venting occur, the vented dual-check valve assembly must be
replaced.

CAUTION: Route free end of the vented dual-check valve vent tube to a permanent drain to
avoid serious water damage in the event of a check valve failure.

Route free end of the vented dual-check valve vent tube to a permanent drain. TO AVOID POSSIBLE BACK­SUCTION FROM THE PERMANENT DRAIN, LOCATE THE END OF THE VENTED DUAL-CHECK VALVE
VENT TUBE ABOVE THE DRAIN OR AS REQUIRED BY THE LOCAL PLUMBING CODE.

CONNECTING PLAIN WATER INLET SUPPLY LINE TO UNIT

(see Figure 2)

NOTE: IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the
plain water inlet supply line. A Cornelius Water Filter (P/N 313860000) and QUICK DISCONNECT SET
(P/N 313867000) are recommended.

CAUTION: Check minimum flow rate and maximum pressure of the plain water inlet supply
line. MINIMUM FLOW RATE MUST BE AT LEAST 100-GALLONS PER HOUR. If flow rate is

less than 100-gallons per hour, starving of the carbonator water pump will occur. Starving
will allow the carbonator water pump to overheat causing the safety thermostat on the pump outlet
to stop the water pump motor. Overheating could occur if the plain water inlet supply line flow rate
drops below 100-gallons per hour. INCOMING PLAIN WATER INLET SUPPLY LINE WATER
PRESSURE MUST REMAIN A MINIMUM OF 10-PSI BELOW THE the CARBONATOR CO

2

OPERATING PRESSURE. (Example: Carbonator CO2 operating pressure is 80-psi and the
maximum water pressure can be no more than 70-psi, etc.)Water over pressure (higher than CO

2

operating pressure) can cause carbonator flooding, malfunction, and leakage through the
carbonator relief valve. If water is exceeding maximum pressure specifications, a Water Pressure
Regulator Kit (P/N 310150000) or equivalent must be installed in the plain water inlet supply line. If
fitting connector is not available, tap into the plain water supply line with a 3/8-flare saddle valve
(P/N 315664000) or equivalent.

1. Make sure food grade flexible plastic plain water inlet supply line provides adequate water flow rate and
pressure as outlined in CAUTION note.

2. Before connecting plain water inlet supply line to Unit, open water line for a period of time to flush out any
metal shavings resulting from connecting water line to fitting connector or saddle valve.

3. Remove shipping cap from 3/8-inch flare (5/8-18) male fitting on tee fitting in water pump inlet port.

4. Install TAPERED GASKET, BLACK (item 2) in plain water inlet supply line swivel nut, then connect water
line to tee fitting in water pump inlet port.

CONNECTING CO2 INLET SUPPLY LINE

(see Figure 2)

1. Remove shipping cap from CO2 inlet 1/4-inch flare (7/16-20) male fitting on top of the carbonator water
tank.

8319798001

2. Connect CO2 inlet supply line, from CO2 regulator, to CO2 inlet fitting on top of the carbonator water tank.

CONNECTING CARBONATED WATER OUTLET LINE

(see Figure 2)

WARNING: Under no circumstances should copper tubing, copper fittings, or brass fittings
be used to connect Unit carbonated water outlet to post-mix dispenser or system. CO2 gas
contact with copper tubing, copper fittings, or brass fittings will cause a health hazard.

1. Remove cap nut from one of the carbonated water 3/8-inch flare (5/8-18) outlet fittings on the carbonator
water tank.

2. Make up carbonated water line by extending length of food grade flexible plastic tubing from the Unit car­bonated water outlet to the carbonated water inlet of a post-mix dispenser or system.

3. Connect carbonated water line to post-mix dispenser or system carbonated water inlet.

4. Connect other end of carbonated water line to 3/8-inch flare (5/8-18) water outlet fitting on carbonator wa­ter tank. Seal connection with TAPERED GASKET, BLACK (item 2).

PERMANENT ELECTRICAL POWER CONNECTION TO UNIT IF REQUIRED
BY LOCAL CODES

(see Figure 2 and 8)

1. Remove screws securing the control box cover, then remove the cover.

2. Disconnect power cord ground electrical wire from under ground terminal connection hex nut located inside
the control box.

3. Disconnect applicable black or brown and white or blue electrical wires from terminals on the control
module.

4. Remove the power cord and strain relief from the control box.

WARNING: This Unit must be electrically grounded to avoid possible fatal electrical shock
or serious injury to operator. A ground terminal is provided inside control box to connect
ground wire which electrically grounds Unit.

5. Connect 115 VAC, 50/60 Hz or 220–240 VAC, 50/60 Hz electrical power from disconnect switch (not fur­nished) fused at 15-Amps to Unit with No. 16 AWG wire in suitable conduit or BX sheath. Make sure power
source ground wire is installed under ground terminal hex nut located inside the control box as shown in
Figure 8. ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES.

6. Install control box cover and secure with screws.

PREPARATION FOR OPERATION

CAUTION: To prevent a fire hazard, no object should be placed or stored on top of the Unit.

9 319798001

CAUTION

THIS WATER TUBE IS NOT A HANDLE LIFT­ING BY THIS TUBE CAN RESULT IN WATER
LEAKS AND FLOODING.

VENTED DUAL

CHECK VALVE OR

LIQUID DUAL

CHECK VALVE

SAFETY

THERMOSTAT

COVER

RETAINING SCREW (2)

CONTROL

BOX

CO2 GAS

CHECK VALVE

LIQUID LEVEL

SENSING DEVICE

RELIEF VALVE

CARBONATOR TANK

WATER

PUMP

POWER

CORD

WATER PUMP

MOTOR

FIGURE 2. CARBONATOR ASSEMBLY COMPONENTS

10319798001

ADJUST CARBONATOR CO2 REGULATOR AND TURN WATER INLET SUPPLY LINE ON

CAUTION: Before connecting CO2 regulator assembly to CO2 cylinder, turn regulator
adjusting screw to the left (counterclockwise) until all tension is relieved from adjusting
screw spring.

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

2. Adjust carbonator CO2 regulator to a nominal 80-psi.

3. Open one of the post-mix system dispensing valves to exhaust trapped air inside the carbonator tank.

CAUTION: Never operate the carbonator with the water inlet supply line shutoff valve
closed. ‘‘Dry running’’ the water pump will burn out the pump. A pump damaged in this
manner is not covered by warranty.

4. Open water inlet supply line shutoff valve.

UNIT OPERATION

WARNING: The Unit must be electrically grounded to avoid possible fatal electrical shock
or serious injury to the operator. The 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 the Unit.

1. Connect electrical power to the Unit. The water pump will start and fill the carbonator tank with carbonated
water. The water pump will stop when the carbonator tank is full.

2. Check for water and CO2 leaks and tighten any loose connections.

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12319798001

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 electrical wiring.

WARNING: Disconnect electrical power to the carbonator to prevent personnel injury
before attempting any internal maintenance.

CAUTION: Never operate the carbonator with the water inlet supply line shutoff valve
closed. ‘‘Dry running’’ the water pump will burn out the pump. A pump damaged in this
manner is not covered by warranty.

WARNING: Strict attention must be observed in the prevention of CO2 (carbon dioxide) gas
leaks in the entire CO2 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 concentrations of CO2 gas will experience tremors which are
followed rapidly by loss of consciousness and suffocation.

CAUTION: To prevent a fire hazard, no object should be placed or stored on top of the Unit.

PREPARING UNIT FOR SHIPPING, STORING, OR RELOCATING

IMPORTANT: All water must be purged from the Unit if exposed to a freezing temperature. A freezing
ambient will cause residual water inside the Unit to freeze resulting in damage to internal components.
Damage of this type will void the warranty. Perform the following procedure to purge water from the
Unit.

1. Disconnect electrical power from the Unit.

2. Close water inlet supply line shutoff valve.

3. Disconnect water inlet supply line from the Unit.

4. Dispense from one of the dispensing valves until all carbonated water has been dispensed from the carbo­nator water tank.

5. Shut off CO2 supply to the Unit, then disconnect CO2 inlet supply line.

6. Connect filtered dry compressed air (50-psi max) to the Unit water inlet. DO NOT USE CO2 GAS WHICH
COULD CAUSE A HEALTH HAZARD.

7. Dispense from one of the dispensing valves until all residual water has been blown from the Unit and lines.

8. Disconnect filtered dry compressed air from the Unit water inlet.

9. Disconnect carbonated water outlet line from the Unit.

10. The Unit is now ready for shipping or relocating.

13 319798001

LUBRICATION

The water pump motor bearings must be oiled periodically. Refer to oiling instructions on the motor. DO NOT
OVER OIL.

ADJUSTING CARBONATOR CO2 REGULATOR

NOTE: To readjust the CO2 regulator to a lower setting, loosen the adjusting screw lock nut, then turn
the screw to the left (counterclockwise) until the pressure gage reads 5-psi lower than the new setting
will be. Turn the adjusting screw to the right (clockwise) until the gage registers new setting, then
tighten the lock nut.

Loosen the CO
right (clockwise) until the regulator gage reads nominal 80-psig, then tighten the lock nut. DO NOT EXCEED
125-PSIG.

regulator adjusting screw lock nut. Turn the carbonator CO2 regulator adjusting screw to the

2

W ATER PUMP YEARLY MAINTENANCE (OR AFTER WATER SYSTEM
DISRUPTIONS)

WARNING: The carbonator water pump water inlet strainer screen and the liquid dual check
valve (Unit Model No. 416424000, 41642400U, 496424000, 49642400U and 496424040) must

be inspected and serviced 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. If the system has a Vented Dual–Check Valve
(Unit Model No. 1624, and 411624102), clean the carbonator water pump water inlet strainer screen
and flush the system. A carbonator water pump with no screen or a defective screen in the strainer
would allow foreign particles to foul the double-check valve. CO2 gas could then back flow into the
water system and create a health hazard in the water system.

SERVICING WATER PUMP WATER INLET STRAINER SCREEN

(see Figure 5)

1. Disconnect electrical power from the Unit.

2. Close the Unit water inlet supply line shutoff valve.

3. Note pressure setting on the carbonator CO2 regulator. Loosen the lock nut and turn the CO2 regulator ad­justing screw to the left (counterclockwise) until the regulator gage reads 0-psi.

4. Remove quick disconnect from outlet side of the soft drink tank.

5. Place container under the applicable dispensing valve of syrup system soft drink tank was disconnected
from. Open dispensing the valve and dispense carbonated water until the carbonator tank CO2 pressure
has been released.

6. Loosen the screen retainer, then pull the screen retainer and strainer screen from the water pump.

7. Pull strainer screen from the screen retainer. Clean any sediment from the screen retainer and the water
pump screen retainer port.

8. Inspect the strainer screen for holes, restrictions, corrosion, and other damage. Discard damaged strainer
screen.

14319798001

CAUTION

THIS WATER TUBE IS NOT A HANDLE LIFT­ING BY THIS TUBE CAN RESULT IN WATER
LEAKS AND FLOODING.

VENTED DUAL

CHECK VALVE OR

LIQUID DUAL

CHECK VALVE

SAFETY

THERMOSTAT

COVER

RETAIING SCREW (2)

CONTROL

BOX

CO2 GAS

CHECK VALVE

LIQUID LEVEL

SENSING DEVICE

RELIEF VALVE

CARBONATOR W ATER

TANK

WATER

PUMP

POWER

CORD

WATER PUMP

MOTOR

FIGURE 3. CARBONATOR ASSEMBLY COMPONENTS

15 319798001

9. Check O-Ring on the screen retainer. Replace worn or damaged O-Ring (P/N 315349000).

NOTE: A strainer screen should always be used, otherwise particles could foul the liquid double check
valve.

10. Install good or new strainer screen (P/N 315348000) in the screen retainer, then screw the retainer into the
water pump and tighten securely.

11. Service liquid double check valve (refer to next paragraph, SERVICING LIQUID DUAL CHECK VALVE).

SERVICING LIQUID DUAL CHECK VALVE

(see Figure 3 and 5)

1. Service the water strainer screen as instructed in previous paragraph, SERVICING WATER PUMP
STRAINER SCREEN before servicing the liquid dual check valve.

2. Disconnect the water tank inlet line from the water tank inlet and from the liquid dual check valve assembly
outlet. Remove the check valve assembly from the water pump outlet port.

3. Disassemble each check valve as shown in Figure 4.

4. Wipe each part with clean lint-free cloth. Inspect each part, especially the ball for burrs, nicks, corrosion,
deterioration, and other damage. Discard the ball seat and any damaged or suspicious parts and replace
with new parts during reassemble.

5. Reassemble check valves as shown in Figure 4. ALWAYS INSTALL NEW BALL SEAT (O-RING) ITEM 2
AND FLAT WASHER (ITEM 1).

4

INDEX

3

1

4

3

1

2

NO.

1 *560000480 FLA T WASHER

312419000 BALL

4 560000481 SPRING

2 *560000432 BALL SEAT (O-RING)

* INSTALL NEW BALL SEAT (ITEM 2) AND FLAT WASHER (ITEM 1)
AT EACH SERVICING

NOTE: Make sure when assembling the

PART
NO.

NAME

check valves together, the FLAT WASHER

2

(item 1) is in place inside female end of the
check valve.

FIGURE 4. LIQUID CHECK VALVE ASSEMBLY

6. Assemble the check valves together. DO NOT OVERTIGHTEN.

7. Install the liquid dual check valve assembly in the water pump outlet port.

8. Connect the water tank water inlet line between the water tank water inlet and the liquid dual check valve
assembly outlet. DO NOT OVER TIGHTEN.

16319798001

9. Turn the carbonator CO2 regulator adjusting screw to the right (clockwise) until the gage indicates pressure
setting noted in step 3 of SERVICING WATER PUMP WATER STRAINER SCREEN. Tighten the adjusting
screw lock nut.

10. Open the Unit water inlet supply line shutoff valve.

11. Connect electrical power to the Unit. The water pump will start and fill the carbonator water tank. Check for
water leaks and tighten any loose connections.

12. Install quick disconnect on the soft drink tank outlet.

THE VENTED DUAL CHECK VALVE ASSEMBLY

(see Figure 5)
A vented dual check valve assembly is installed in the carbonator between the water pump outlet and the water

inlet to the carbonator water tank as shown in Figure 7. The vented dual check valve assembly vents carbon­ated water, and possibly CO2 gas out of a vent port upon failure of the primary check valves. Should such vent-

ing occur, the vented dual check valve assembly must be replaced.

CLEANING CARBONATOR CO2 GAS CHECK VALVE

(see Figures 3 and 6)
The carbonator tank CO2 gas check valve must be inspected and serviced at least once a year under normal

conditions and after any servicing or disruption of the CO2 system. ALWAYS REPLACE QUAD RING SEAL
EACH TIME GAS CHECK VALVE IS SERVICED. Proceed as follows:

1. Disconnect electrical power from the Unit.

2. Note pressure setting on the carbonator CO2 regulator.

3. Loosen the CO2 regulator adjusting screw lock nut, then turn the screw to the left (counterclockwise) until
the pressure gage reads 0-psi.

4. Relieve CO2 pressure from the carbonator water tank by pulling up on the pressure relief valve plastic cap
on top of the water tank.

5. Disconnect the CO2 inlet line from the CO2 check valve inlet, then remove the CO2 check valve from the
carbonator water tank.

6. Disassemble check valve as shown in Figure 6.

7. Wipe each part with a clean lint-free cloth. Inspect each part, especially the ball for burrs, nicks, corrosion,
deterioration, and other damage.

8. Reassemble the check valve as shown in Figure 6. ALWAYS INSTALL NEW QUAD RING SEAL.

9. Install CO2 check valve in the carbonator water tank inlet fitting. MAKE SURE THE SHORTEST
THREADED END OF THE CHECK VALVE IS SCREWED INTO THE CARBONATOR WATER TANK
INLET FITTING FOR PROPER VALVE OPERATION.

10. Connect CO2 inlet line to CO2 check valve.

11. Turn the carbonator CO2 regulator adjusting screw to the right (clockwise) until the pressure gage registers
pressure noted in step 2 preceding, then tighten the adjusting screw lock nut.

12. Connect electrical power to the carbonator.

17 319798001

WATER LINE TO TANK

WHITE TAPERED

VENTED DUAL
CHECK VALVE

GASKET

LIQUID DUAL

CHECK VALVE

SAFETY THERMOSTAT

WATER PUMP

WATER STRAINER

SCREEN (P/N 315348000)

O-RING (P/N 315349000)

SCREEN RETAINER

PUMP-TO-MOTOR

COUPLING

FIGURE 5. WATER STRAINER SCREEN AND LIQUID DUAL CHECK 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 6. CO2 GAS CHECK VALVE

18319798001

REPAIR AND REPLACEMENT

WATER PUMP

(see Figures 3 and 5)

Removal.

1. Disconnect electrical power from the Unit.

2. Close the CO2 cylinder shutoff valve, then close the shutoff valve in the water inlet supply line.

3. Pull up on the carbonator water tank relief valve plastic cap to release CO2 pressure from the water tank.

4. Disconnect the water inlet supply line from the water pump water inlet fitting. Be careful not to lose the
black tapered gasket inside the swivel nut.

5. Disconnect the water tank water inlet line from the water tank inlet fitting and the liquid dual check valve
assembly outlet or the vented dual check valve assembly outlet.

6. Remove the liquid dual check valve assembly or the vented dual check valve assembly from the water
pump outlet port.

7. Note position of the safety thermostat on the water pump outlet, then remove the thermostat from the
pump.

8. Remove fitting from the water pump inlet port.

9. Loosen screw on the pump-to-motor coupling enough to remove the water pump from the motor.

Installation.

1. Disassemble and clean the liquid dual check valve assembly as instructed in steps 3 through 6 of
SERVICING LIQUID DUAL CHECK VALVE.

2. Install the new water pump by reversing the Removal procedure and use the following instructions.
A. Make sure pipe thread sealing compound is used on the fittings threads when installing the liquid dual

check valve assembly or the vented dual check valve assembly and fitting in the inlet and outlet ports
of the new water pump.

B. Make sure drive tang on the water pump and slot in the pump motor shaft are properly lubricated and

aligned when installing the water pump on the motor.

3. Open the CO2 cylinder shutoff valve, then open the Unit water inlet supply line shutoff valve.

4. Connect electrical power to the Unit.

5. Dispense carbonated water from one of the dispensing valves to make the Unit cycle on. Check for water
leaks and tighten or repair any loose connections.

19 319798001

WATER PUMP MOTOR

(see Figures 3 and 5)

Removal.

1. Disconnect electrical power from the Unit.

2. Loosen screw on the pump-to-motor coupling to disconnect the water pump from the motor, then remove
pump from the motor.

3. Remove screws securing the control box cover, then remove the cover.

4. Disconnect the black and white pump motor electrical wires from the L1 and L2 terminals on the control
module.

5. Tag the pump motor electrical wires for identification, then disconnect wires from the motor terminals.

6. Remove conduit fitting securing the control box to the pump motor, then remove the control box from the
motor and lay off to one side.

7. Remove screw and clamp securing the water pump motor to the base, then remove old motor.

Installation.

1. Install new pump motor by reversing the Removal procedure.

2. Make sure tang on the water pump and slot in the pump motor shaft are properly lubricated and aligned
when installing the water pump on the motor.

3. Make sure all wiring is correct (see Figure 8).

4. Install the control box cover and secure with screws.

5. Connect electrical power to the Unit.

CARBONATOR TANK LIQUID LEVEL SENSING DEVICE
(see Figure 3)

Removal.

1. Disconnect electrical power from the Unit.

2. Close the Unit water inlet supply line shutoff valve.

3. Note pressure setting on the carbonator CO2 regulator, then loosen the lock nut and turn the CO2 regulator
adjusting screw to the left (counterclockwise) until the regulator gage reads 0-psi.

4. Remove quick disconnect from outlet side of the soft drink tank.

5. Place container under the applicable dispensing valve of the syrup system the soft drink tank was discon­nected from. Open the dispensing valve and dispense carbonated water until the carbonator water tank
CO2 pressure has been released.

6. Disconnect electrical polarized plug from the liquid level sensing device electrical connector.

7. Remove the threaded liquid level sensing device from the carbonator water tank.

20319798001

Installation.

1. Install new liquid level sensing device in the carbonator water tank by reversing the Removal procedure.

2. Connect the electrical polarized plug to the new liquid level sensing device electrical connector.

3. Restore the carbonator CO

4. Open the Unit water inlet supply line shutoff valve.

5. Connect electrical power to the Unit.

regulator to the pressure noted in step 3 of Removal.

2

CARBONATOR TANK LIQUID LEVEL CONTROL MODULE

(see Figure 3)

Removal.

1. Disconnect electrical power from the Unit.

2. Remove screws securing the control box cover, then remove the cover.

3. Remove screws securing the liquid level control module inside the control box.

4. Label the electrical wires connected to the liquid level control module for identification, then disconnect
wires from the module.

Installation.

1. Install new liquid level control module by reversing the Removal procedure.

2. Make sure electrical wires are correctly connected to the control module (see Figure 8).

3. Install the control box cover and secure with screws.

4. Connect electrical power to the Unit.

SAFETY THERMOSTAT

(see Figure 3)

Removal.

1. Disconnect electrical power from the Unit.

2. Remove screws securing the control box cover, then remove the cover.

3. Disconnect safety thermostat wires from the control module terminals.

4. Pull safety thermostat wires out of the control box.

5. Note position of the safety thermostat on the water pump outlet, then remove the thermostat.

21 319798001

Installation.

1. Install new safety thermostat by reversing the Removal procedure.

2. Make sure the safety thermostat electrical wires are properly connected (see Figure 8).

3. Install the control box cover and secure with screws.

4. Connect electrical power to the Unit.

VENTED DUAL CHECK VALVE

(see Figure 5)

Removal.

1. Disconnect electrical power from the unit.

2. Close the CO2 cylinder shutoff valve then close shutoff valve in the water inlet supply line.

3. Pull up on the carbonator water tank relief valve plastic cap to release CO2 pressure from the tank.

4. Disconnect water tank inlet line from the vented dual check valve assembly.

5. Remove vent line from the vented dual check valve assembly.

6. Remove the vented dual check valve assembly from the water pump outlet port.

Installation.

1. Install new vented dual check valve in the water pump outlet port. (be sure flow direction arrow points up).

2. Using tapered gasket connect water line from the water tank to the top of the vented dual check valve.
Tighten fittings.

3. Attach vent line to the vented dual check valve.

4. Open CO2 cylinder shutoff valve, then open water inlet supply line shutoff valve.

5. Check carefully for leaks and repair if evident.

6. Connect electrical power to the Unit.

7. Allow the Unit to cycle several times while observing for correct operation.

22319798001

WATER

SOURCE

VENTED DUAL

CHECK VALVE ASS’Y

CARBONATOR ASS’Y (PARTIAL)

SHUTOFF

VALVE

VENT PORT

FILTER

CARBONATOR

TANK

VENT TUBE

TO PERMANENT

DRAIN

FIGURE 7. VENTED DUAL CHECK VALVE LOCATION

WATER PUMP

23 319798001

WATER PUMP

MOTOR

LIQUID LEVEL

SENSING DEVICE

SAFETY THERMOSTAT

(P/N 317989-000)

G

CONTROL

BOX

*LIQUID LEVEL CONTROL

MODULE

* Actual location of “HI”, “LO”, “C”, and “LOAD” terminals may
vary on different brands of control modules.

FIGURE 8. WIRING DIAGRAM (UNITS 1624, 416424000, 41642400U, 411624102, and 496424000)

319798001

24

LIQUID LEVEL

SENSING DEVICE

WATER PUMP

MOTOR

SAFETY THERMOSTAT

(P/N 317989-000)

CONTROL

BOX

*LIQUID LEVEL CONTROL

MODULE

* Actual location of “HI”, “LO”, “C”, and “LOAD” terminals may
vary on different brands of control modules.

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

25

319798001

THIS PAGE LEFT BLANK INTENTIONALLY

26319798001

TROUBLESHOOTING

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

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

system, stop dispensing, shut off the CO

2

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

Trouble Probable Cause Remedy

supply, then relieve the

2

CARBONATOR PUMP
MOTOR WILL NOT OPERATE.

A. Unit power cord unplugged or

circuit breaker open in panel

A. Plug in Unit power cord or reset

circuit breaker.

box.

B. Inoperable pump motor. B. Replace pump motor as

instructed.

C. Overheated motor cut off by

thermal overload protector.

C. Check for proper line voltage.

Check for restricted pump
discharge.

D. Inoperative liquid level control

module.

E. Liquid level sensing device

inside carbonator tank

D. Replace liquid level control

module as instructed.

E. Replace sensing device as

instructed.

inoperable.

F. Loose electrical connection

and/or open electrical circuit.

G. Carbonator pump binding (new

or replacement pumps only).

F. Tighten connection and/or repair

open circuit. Check line voltage.

G. Remove carbonator pump from

motor, rotate pump or motor shaft
180 degrees, then recouple pump
to motor.

H. Carbonator pump damaged. H. Replace carbonator pump as

instructed.

CARBONATOR PUMP
MOTOR WILL NOT SHUT
OFF.

ERRATIC CYCLING OF
CARBONATOR.

A. Liquid level sensing device

inside carbonator tank
inoperable.

B. Loose electrical connection

and/or open electrical circuit.

C. Inoperable liquid level control

module.

D. Leak in carbonated water

system.

A. Liquid level sensing device

inside carbonator tank
inoperable.

B. Liquid level control module

inoperable.

27 319798001

A. Replace sensing device as

instructed.

B. Tighten connection and/or repair

open circuit.

C. Replace liquid level control

module as instructed.

D. Repair carbonated water system.

A. Replace sensing device as

instructed.

B. Replace liquid level control

module as instructed.

Trouble RemedyProbable Cause

CARBONATOR PUMP
CAPACITY TOO LOW.

CARBONATOR PUMP
MOTOR OPERATES BUT
CARBONATOR PUMP DOES
NOT PUMP.

A. Pump inlet water strainer

screen dirty.

B. Kinked plain water inlet supply

line.

C. Foreign object in pump

bypass.

D. Water pump worn out. D. Replace water pump as

E. Water filter clogged. E. Replace water filter.
A. Water pump inlet water

strainer screen dirty.

B. Water supply too low or turned

off.

C. Water filter clogged. C. Replace water filter.
D. Inoperative water pump. D. Replace water pump as

A. Clean or replace water strainer

screen as instructed.

B. Straighten plain water inlet supply

line.

C. Clean. (Note: Count number of

turns bypass screw makes when
removing and install same
number of turns).

instructed.

A. Clean or replace water strainer

screen as instructed.

B. Inlet water supply must be a

minimum of 100-gallons per hour
with a maximum water pressure
of 70-psi.

instructed.

28319798001

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]

D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX [phone]

AUSTRIA

D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX [phone]

BELGIUM

D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX [phone]

BRAZIL
ENGLAND

D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX [phone]

D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX [phone]

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 [phone]

D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHE NS, GREECE D (30) 1 600 1073 D FAX [phone]

KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D [phone] D FAX [phone]

D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, IT ALY D (39) 39 608 0817 D FAX [phone]

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]

D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX [phone]

D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SP AIN D (34) 3 640 2839 D FAX [phone]

D ONE CORNELIUS PLACE D ANOKA, MI NNESOTA D [phone] D FAX [phone]

LD004

4/21/98

31979800129

IMI CORNELIUS INC.

CORPORATE HEADQUARTERS:

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