Related Manuals for Cornelius IntelliCarb Cold Beverage Dispenser
Summary of Contents for Cornelius IntelliCarb Cold Beverage Dispenser
- Page 1 ® INTELLICARB Training Manual Release Date: April 29, 2004 Publication Number: TP01071 Revision Date: NA Revision: A Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
- Page 2 Cornelius product contact: www.cornelius.com 800-238-3600 Trademarks and copyrights: Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olympus, and Vista are registered trademarks of IMI Cornelius Inc. Optifill trademark is pending. This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius.
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Page 3: Table Of Contents
Drains ............4 Cornelius IntelliCarb Carbonator Assembly ....... .4 Carbonator Time Out Reset Switch . - Page 4 Test Solid State Level Control ........43 Publication Number: TP01071 - ii - © 2004, IMI Cornelius Inc.
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Page 5: Introduction
IMPORTANT: For dispensing compressed or extruded style ice, an Ice Diverter Kit must be installed on the dispenser, see FIGURE 13 on page 9. © 2004, IMI Cornelius Inc. INTRODUCTION in the carbonator tank. The water is introduced into the tank with a... -
Page 6: Specifications
230/1/50, 3.0 Amps Total Unit Draw Width 24.5” Width 44–3/8” Deep 30–11/16” Deep 31–1/2” High 39–5/8” High 37” Z–Models Width 24–1/2” Width 44–3/8” Deep 23–1/16” Deep 23–1/16” High 39–5/8” High 37” 75–psig (max) 75–psig (max) Qty. © 2004, IMI Cornelius Inc. -
Page 7: Installation
NOTE: This equipment must be installed with adequate backflow protection to comply with fed- eral, state, and local codes. 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 DISCON- NECT SET (P/N 313867000) are recommended. -
Page 8: Drains
(100 psig.) to the inlet of the pre-set CO - 4 - Vent to Atmosphere Check Valve 125 G.P.H. ProCon Water Pump High Torque Pump Motor FIGURE 3 regulator (75 tank as supply, tank pressure © 2004, IMI Cornelius Inc. -
Page 9: Carbonator Relief Valve Locations
Ice Drink Model ED175BCH (Lower Front Panel Removed) Total Flex Manifold (with insulation) Cold Plate Inlets (3/8 Barb) Carb. Tank Liquid Level Probe Harness © 2004, IMI Cornelius Inc. InelliCarb Training Manual supply has been hooked up. Failure to Agitator Motor Carbonator Tank... - Page 10 Connect both the carbonator pump and motor unit and the dispenser to a grounded electrical sup- ply outlet. Publication Number: TP01071 Ice Drink Model ED200/250 Coldplate Cover In-line CO Check Valve Probe FIGURE 10 FIGURE 11 - 6 - Ground Plate/Stud Plugs Manifold Block © 2004, IMI Cornelius Inc.
- Page 11 N. Shake carb-tester in vertical motion until peak pressure reading is obtained. Use Pepsi chart for carbonation level reading. NOTE: Carbonator troubleshooting procedure located on page 43. © 2004, IMI Cornelius Inc. IntelliCarb Training Manual F. for accurate carb-level reading. Store tester...
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Page 12: Mechanical Section
Adjustment can be made by sliding up or down with nuts loosened, to obtain the desired amount of restriction. Publication Number: TP01071 ADJUSTMENT INSTALL PLATE ON STUDS AS SHOWN FIGURE 12 - 8 - © 2004, IMI Cornelius Inc. -
Page 13: Ice Diverter Kit 02394
C OV E R 10- - 32 WA S HE R 10- - 32 NUT © 2004, IMI Cornelius Inc. G AT E MOUNT ING P L AT E IC E DIV E R T E R G A S K E T... -
Page 14: Removal And Replacement Of Agitators
NOTE: Refer to Sanitize Procedure in the Owners Instruction for complete cleaning and sanitiz- ing instructions. Publication Number: TP01071 GITATORS RIGHT HAND AGITATOR LEFT HAND WITH HOLE IN UPRIGHT AGITATOR O–RING FRONT (VALVE SIDE) VIEW FROM TOP OF DISPENSER FIGURE 14 - 10 - CLOCKWISE ROTATION © 2004, IMI Cornelius Inc. -
Page 15: Post-Mix Valve Section
The size of the orifice in the piston varies depending on whether the piston is used for syrup or water, and whether it is high flow or ultra flow valve. © 2004, IMI Cornelius Inc. IntelliCarb Training Manual Syrup valve sleeve... - Page 16 Higher Fluid Pressure BUT Smaller Orifice Openings Same Volume Of Syrup/Water Flows From Orifices Higher Fluid Pressure Pushing Against Piston & Spring FIGURE 19 - 12 - Notch in piston FIGURE 17 UFB-1 Flow Module © 2004, IMI Cornelius Inc.
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Page 17: Adjusting Flow Rates
This pressure drop results in less flow at the valve and therefore a slower fill time. Increasing the pump pressure will help overcome the pressure drop caused by high sugar syrups. © 2004, IMI Cornelius Inc. Water Flow Rates At Selected Ratios Water at 3.0 oz./ Water at 3.75 oz./... -
Page 18: Setting Ratios
Fill the cup to approximately 3/4 full and use approximately the same quantity for each test to ensure accurate settings. • Take another sample to verify the settings. NOTE: Valve troubleshooting information is available on page 39. Publication Number: TP01071 Ratio Cup and Syrup Separator FIGURE 20 - 14 - © 2004, IMI Cornelius Inc. -
Page 19: Shurflo
For further application and model information please contact SHURflo. NOTE: Shurflow Troubleshooting information available on page 35. © 2004, IMI Cornelius Inc. SHURFLO 2, nitrogen or compressed filtered air. The compressed gas... -
Page 20: Shurflow Installation
Symptoms of this kind can lead to a misdiagnosis of the - 16 - minimum, heavy wall [10mm] (1/8" [3 M horizontally, side-by-side / air (syrup, oil, rust, ), exhaust fans capable of changing clamps. ® [2.8 bar MAXIMUM [1.4 bar © 2004, IMI Cornelius Inc. must... -
Page 21: Plumbing
IntelliCarb Training Manual PLUMBING YPICAL NSTALLATION FIGURE 21. Typical Installation © 2004, IMI Cornelius Inc. - 17 - Publication Number: TP01071... -
Page 22: Plumbing Layout
Inlet on BIB Pmp Syr Inlet BIB Pmp 3/4" NPT TEE CO2 Supply Regulator 100 psi BIB Pump BIB Pump FIGURE 22. Plumbing Layout - 18 - Tubing Legend 3/8" Bev Tubing 1/4" Bev Tubing 3/8" Tycon Tubing © 2004, IMI Cornelius Inc. -
Page 23: Flow Diagram 1Xx (Six Flavor Model)
FAUCETS VALVES 1,2, VALVES 4,5 COLDPLATE INLET CONNECTIONS OPTIONAL FOR DIET DRINKS OR ROOT BEER 5- - 15 PSIG PLUGGED COLD PLATE ITEMS INSIDE BROKEN LINE INCLUDED WITH UNIT DOUBLE CHECK VALVE OPTIONAL PRESSURE REGULATOR CARBONATOR INSTALL FOR PUMP NON- - CARB AS REQUIRED CHECK NON- - CARB... -
Page 24: Flow Diagram 1Xx (Eight Flavor Models)
FAUCETS VALVES 1,2, 3,7,8 VALVES 4, COLDPLATE INLET CONNECTIONS OPTIONAL FOR DIET DRINKS OR ROOT BEER 5- - 15 PSIG COLD PLATE ITEMS INSIDE BROKEN LINE INCLUDED WITH UNIT DOUBLE CHECK VALVE OPTIONAL PRESSURE REGULATOR FILTER CARBONATOR INSTALL FOR PUMP NON- - CARB AS REQUIRED CHECK... -
Page 25: Flow Diagram 2Xx (Eight Flavor Models)
FAUCETS VALVES 1,2 3,6,7,8 VALVES 4,5 COLDPLATE INLET CONNECTIONS 5–15 PSIG COLD PLATE ITEMS INSIDE BROKEN LINE INCLUDED WITH UNIT DOUBLE CHECK VALVE OPTIONAL PRESSURE REGULATOR CARBONATOR CHECK VALVE Non–Carb Water OPTIONAL FOR DIET DRINKS OR ROOT BEER SYRUP TANKS 15–50 PSIG POTABLE WATER... -
Page 26: Flow Diagram 2Xx (Ten Flavor Models))
IntelliCarb Training Manual IAGRAM FIGURE 26. Flow Diagram 2xx (Ten Flavor Models) Publication Number: TP01071 LAVOR ODELS CARBONATOR TANK FAUCETS VIEWED FROM THIS SIDE - 22 - © 2004, IMI Cornelius Inc. -
Page 27: Flow Diagram 300 (Twelve Flavor Models)
FAUCETS COLD PLATE COLDPLATE INLET CONNECTIONS FAUCETS COLD PLATE COLDPLATE INLET CONNECTIONS ITEM INSIDE BROKEN LINE CARBONATOR TANK INCLUDED WITH UNIT DOUBLE CHECK VALVE CARBONATOR PUMP CHECK VALVE NON–CARB WATER TO COLDPLATE SYRUP INLETS OPTIONAL FOR DIET DRINKS OR ROOT BEER 5–15 PSIG SYRUP TANKS... -
Page 28: Electrical Section
FIGURE 29. Electrical Box 2xx Single Transformer One Transformer Powers the Left Bank and the Other Powers the Right Bank. Transformers Will Power All Valves Simultaneously. FIGURE 30. Electrical Box 2XX Dual Transformer Publication Number: TP01071 - 24 - © 2004, IMI Cornelius Inc. -
Page 29: Carbonator Wiring Diagram
IntelliCarb Training Manual ARBONATOR IRING IAGRAM © 2004, IMI Cornelius Inc. - 25 - Publication Number: TP01071... -
Page 30: Wiring Diagram 1Xx (120V)
TO HINGE MOTOR AGITATOR HEATER MOTOR DISPENSE SWITCH Q.C. CONNECTOR 115V SUPPLY BLACK WHITE BLACK BLACK BLACK OPTIONAL SERVICE INFO RM ATIO N DA NG ER! EL ECTRIC SHO CK HA ZA RD. DISCO NNECT PO W ER B EFO RE SERVICING UNIT. GATE SOLENOID (106VDC) -
Page 31: Schematic 1Xx
VEN D SW ITC H O PTIO N A L B A L L A ST B EVER A G E VA LVES © 2004, IMI Cornelius Inc. TIMER MO TO R H EATER A G ITATO R MO TO R N .O . -
Page 32: Wiring Diagram 2Xx (120V Model)
MOTOR HEATER AGITATOR MOTOR Q.C. CONNECTOR TO HINGE DISPENS GATE SWITCH SOLENOID (106VDC) BLACK MOTOR START CAPACITOR RECTIFIER OPTIONAL LIGHT STARTER BLACK WHITE OPTIONAL LIGHT SOCKET SERVICE INFO RM ATIO N DANGER! ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SERVICING UNIT. BLACK WHITE BLACK... -
Page 33: Wiring Diagram 2Xx (220/240V Models)
IntelliCarb Training Manual (220/240V M IRING IAGRAM ODELS FIGURE 34. Wiring Diagram 2xx (220/240V Models) © 2004, IMI Cornelius Inc. - 29 - Publication Number: TP01071... -
Page 34: Wiring Diagram 2Xx (220/240V Models)
FIGURE 35. Wiring Diagram 2xx (220/240V Models) Publication Number: TP01071 ODELS TIMER RECTIFIER MOTOR HEATER AGITATOR MOTOR N.O. N.C. GATE SOLENOID OPTIONAL LIGHT OPTIONAL STARTER OPTIONAL BEVERAGE TRANSFORMER OPTIONAL ICE LEVEL OPTIONAL BEVERAGE VALVES BEVERAGE PANEL - 30 - © 2004, IMI Cornelius Inc. -
Page 35: Wiring Diagram 300 (220/240V Models)
IntelliCarb Training Manual 300 (220/240V M IRING IAGRAM ODELS FIGURE 36. Wiring Diagram 300 (220/240V Models) © 2004, IMI Cornelius Inc. - 31 - Publication Number: TP01071... -
Page 36: Wiring Diagram 300 (220/240V Models)
IntelliCarb Training Manual 300 (220/240V M IRING IAGRAM ODELS FIGURE 37. Wiring Diagram 300 (220/240V Models) Publication Number: TP01071 - 32 - © 2004, IMI Cornelius Inc. -
Page 37: Schematic 300 (120V Models)
300 (120V M CHEMATIC VEND SWITCH BALLAST OPTIONAL BEVERAGE VALVES BEVERAGE PANEL VEND SWITCH © 2004, IMI Cornelius Inc. ODELS TIMER RECTIFIER MOTOR HEATER AGITATOR MOTOR N.O.1 N.C.1 CAPACITOR GATE SOLENOID OPTIONAL LIGHT STARTER OPTIONAL BEVERAGE TRANSFORMER OPTIONAL ICE LEVEL... -
Page 38: Schematic 300 (220/240V Models)
SOLENOID N.C1 N.O1 AGITATOR MOTOR OPTIONAL LIGHT OPTIONAL STARTER OPTIONAL BEV. TRANSFORMER BEVERAGE KEYLOCK SWITCH BEV. FAUCETS GATE SOLENOID N.C2 N.O2 AGITATOR MOTOR OPTIONAL LIGHT OPTIONAL STARTER OPTIONAL BEV. TRANSFORMER BEV. FAUCETS - 34 - © 2004, IMI Cornelius Inc. -
Page 39: Troubleshooting
For example: GAS IN HEAVY SODA SYRUP " I.D. [10mm] TUBING © 2004, IMI Cornelius Inc. within (restrictions) Distances shown are intended as a guidline only. FLO W R AT E . 75 1. 0 D i et 1. 5... -
Page 40: Pumps In Series For Long Distances
(4.56 x tubing run in series p(s) TO NEXT SECOND VRV/PUMP PUMP DISPENSER GAS TO NEXT PUMP The frequency of Sanitization is Factors which also ). Pumps that are subjected to (operating or not © 2004, IMI Cornelius Inc. -
Page 41: Pump Troubleshooting
GAS BLOWING FROM EXHAUST CONTINUOUSLY • Control cover subjected to contaminated gas supply or damaged (ensure clean gas supply, change out all contaminated pumps). © 2004, IMI Cornelius Inc. (Pump stalled) (Dry run) (syrup, rust, oil, etc.) [ensure clean gas supply, change... -
Page 42: Dispenser Troubleshooting
B. Level the unit. C. Correct water quality or repair ice- maker. D. Call Service Person. A. Restore 24 volt power to faucets. pressure. B. Restore CO A. Repair carbonator. - 38 - Remedy pressure. © 2004, IMI Cornelius Inc. -
Page 43: Valve Troubleshooting
Check product temperature Temp below 40° Remove nozzle Clean Clean Problem corrected © 2004, IMI Cornelius Inc. Check above 40° system Check flow rates Correct Set flow rate and ratio Problem corrected - 39 - IntelliCarb Training Manual... -
Page 44: Off Taste
IntelliCarb Training Manual Off Taste Off Taste Problem: off taste Remove nozzle Clean Problem corrected Publication Number: TP01071 Check ratio Correct Clean Set ratio Problem corrected - 40 - Check system © 2004, IMI Cornelius Inc. -
Page 45: Valve Stuck Open
Check solenoid visually working no (solenoid down) Check for power at solenoid Power Clean or replace solenoid Problem corrected © 2004, IMI Cornelius Inc. Check for yes (solenoid up) damaged banjos Damage Replace Replace dispensing banjos switch Problem Problem corrected... -
Page 46: No Product
Problem: no product Check solenoid visually Check Working system Check Check voltage transformer (22-27 AC) Check Power resistance of coil Check 40 ohms switch Problem Replace corrected solenoid Problem corrected - 42 - Check system © 2004, IMI Cornelius Inc. -
Page 47: Carbonator Troubleshooting
Motor should remain stopped. Remove 2nd jumper from C and LO: Motor should start. If level control passes all above test, replace probe. © 2004, IMI Cornelius Inc. and plain water sources. Dispense from dispensing valve until pressure has been relieved. Probable Cause... - Page 48 IMI Cornelius Inc. www.cornelius.com 800-238-3600...