Cornelius Intellicarb Cold Beverage Dispenser Users Manual
IntelliCarb Cold Beverage Dispenser 007027
Cold Beverage Dispenser to the manual 46ef5bc9-d3bf-4257-81a4-40fdad2f63c4
2015-02-05
: Cornelius Cornelius-Intellicarb-Cold-Beverage-Dispenser-Users-Manual-533838 cornelius-intellicarb-cold-beverage-dispenser-users-manual-533838 cornelius pdf
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® 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. INTELLICARB TRAINING MANUAL The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met, in addition to the information contained in this manual. To inquire about current revisions of this and other documentation or for assistance with any 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. Printed in U.S.A. Copyright © 2004, All Rights Reserved, IMI Cornelius Inc. InelliCarb Training Manual TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Delivery Inspection and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Cornelius IntelliCarb Carbonator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Carbonator Time Out Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Carbonator Relief Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Mechanical Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Gate Restrictor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Ice Diverter Kit 02394 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Removal and Replacement of Agitators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 To Remove Agitators For Cleaning (300 shown) . . . . . . . . . . . . . . . . . . . . . . . .10 Post-Mix Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Set-up Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Dimensions & Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 System Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Adjusting Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Calculating Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Syrup/Concentrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Setting Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Shurflo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Shurflow Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Shurflow Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Plumbing Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Flow Diagram 1xx (Six Flavor Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Flow Diagram 1XX (Eight Flavor Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Flow Diagram 2xx (Eight Flavor Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Flow Diagram 2xx (Ten Flavor Models)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Flow Diagram 300 (Twelve Flavor Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 © 2004, IMI Cornelius Inc. -i- Publication Number: TP01071 IntelliCarb Training Manual Electrical Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Carbonator Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Wiring Diagram 1xx (120V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Schematic 1xx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Wiring Diagram 2xx (120V Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Wiring Diagram 2xx (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Wiring Diagram 2xx (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Wiring Diagram 300 (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Wiring Diagram 300 (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Schematic 300 (120V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Schematic 300 (220/240V Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 SHURflow Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Pumping Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Pumps in Series for Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Pump Sanitizing / Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 DOES NOT OPERATE / GAS APPLIED / DISPENSER VALVE OPEN . . . 37 OPERATES BUT WILL NOT PRIME / DISPENSER VALVE OPEN . . . . . . 37 DOES NOT ACHIEVE SOLD-OUT WITH EMPTY B-I-B . . . . . . . . . . . . . . . 37 AIR IN INLET AND/OR OUTLET TUBING . . . . . . . . . . . . . . . . . . . . . . . . . . 37 STROKES WITH DISPENSER VALVE CLOSED . . . . . . . . . . . . . . . . . . . . 37 FLUID FROM EXHAUST OR VISIBLE WITHIN GAS INLET TUBING . . . . . 37 GAS BLOWING FROM EXHAUST CONTINUOUSLY . . . . . . . . . . . . . . . . . 37 Dispenser Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Valve Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Excess Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Off Taste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 No Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Carbonator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Solid State Carbonator Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Test Solid State Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Publication Number: TP01071 - ii - © 2004, IMI Cornelius Inc. InelliCarb Training Manual INTRODUCTION UNIT DESCRIPTION • Built-in cold carbonator produces bottle-quality drinks every time • No seasonal CO2 adjustments required for changes in water temperature • A complete system for simplified installation • Reduces service frequency and lowers equipment life cost • Generates increased beverage sales and greater consumer satisfaction • Illuminated merchandiser delivers unique, high impact marketing message • Ice used to cool cold plate kept separate from ice dispensed into cups • One piece ABS thermoformed plastic ice storage hopper. Durabide™ design provides durability and ensures all ice in the hopper is dispensable • Unit readily accepts top mount cubers with manual ice fill capability THEORY OF OPERATION The rate of CO2 solubility increases with cold water. IntelliCarb System provides pre–chilled cold water from the cold plate and mix with CO2 in the carbonator tank. The water is introduced into the tank with a high volume 125gph Procon pump and high torque motor. The amount of carbonated water reserve is controlled by a probe mounted in the tank. The probe is called a “liquid level probe”. The liquid level probe senses the water level in the tank. Probe controls the pump “ON” and “OFF” cycle through the electronic board called “liquid level board”. NOTE: The probe works on a 5 M.V. D.C. current that continually reverses direction to prevent probe corrosion. DESCRIPTION The “Enduro IntelliCarb” series of ice dispensers solves your ice and beverage service needs in a sanitary, space saving, economical way. Designed to be automatically filled with ice from a top mounted ice machine or manually filled with ice from any remote ice-making source, these dispensers will dispense cubes (up to 1-1/4 inch in size), cubelets, and hard-chipped or cracked ice. In addition, the units include beverage faucets, a cold plate, an internal carbonator tank and an external pump for the carbonator, and are designed to be supplied direct from syrup tanks with no additional cooling required. 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. -1- Publication Number: TP01071 IntelliCarb Training Manual SPECIFICATIONS Model Descriptions: Ice Storage: Maximum Number of Faucets Available: Built-in Cold Plate: ED150 B=(Beverage) C=(Coldplate) H=(Internal Carb) Z=(No DripTray) 150 Pounds 6 ED175 B=(Beverage) C=(Coldplate) H=(Internal Carb) Z=(No DripTray) 175 Pounds 8 ED200 B=(Beverage) C=(Coldplate) H=(Internal Carb) Z=(No DripTray) 200 Pounds 10 ED250 B=(Beverage) C=(Coldplate) H=(Internal Carb) Z=(No DripTray) 250 Pounds 10 ED300 B=(Beverage) C=(Coldplate) H=(Internal Carb) Z=(No DripTray) 300 Pounds 12 Yes Yes Yes Yes Yes $PSV7RWDO8QLW'UDZ 120/1/60, 3.5 Amps Total Unit Draw 230/1/50, 2.0 Amps Total Unit Draw Electrical: Width 22” Deep 30--11/16” High 35--5/8” Dimensions: Outlet should be within 6 feet of dispenser. Width 24.5” Width 22” Width 24.5” Deep 30–11/16” Deep 30--11/16” Deep 30–11/16” High 39–5/8” High 35–5/8” High 35--5/8” Width 22” Deep 23--1/16” High 35--5/8” CO2 Operating 75--psig (max) Pressure Width 24--1/2” Deep 23--1/16” High 35--5/8” 75--psig (max) Width 22” Deep 23–1/16” High 35–5/8” 75–psig (max) Width 44–3/8” Deep 31–1/2” High 37” Z–Models Z–Models Z--Models 120/1/60, 4.0 Amps Total Unit Draw 230/1/50, 3.0 Amps Total Unit Draw Width 24–1/2” Deep 23–1/16” High 39–5/8” 75–psig (max) Width 44–3/8” Deep 23–1/16” High 37” 75–psig (max) REQUIREMENTS • Weight: counter must be level and able to support 450 lbs. • Environment: Indoor installation only • Temperature: 40 to 100oF • CO2: 75 psi at unit • Syrup: 60 psi., 0.70 -- 0.75 ounces per sec. (0.6 gpm) at unit • Water: 60 psi at pump • Electrical: See name plate DELIVERY INSPECTION AND UNPACKING Upon delivery inspect the unit for damage or irregularities and immediately report problems to the delivering carrier and file a claim with that carrier. • Open loose parts packages and inspect parts. Part No. 710000030 70970 70750 620702201 51774 50335 Publication Number: TP01071 Description Pump and Motor Assy 4”Legs Clamps Brush Drain Pan Drain Line Drain Line Insulation )LWWLQJ6RF[)SW )LWWLQJ0SW[µ%DUE -2- Qty. 1 4 2 1 1 1 1 1 © 2004, IMI Cornelius Inc. InelliCarb Training Manual INSTALLATION 1. Locate the dispenser indoors on a level counter top. A. LEG OPTION Unpack the four (4) legs and install them into the threaded holes provided in the bottom of the unit. The installer must provide flexibility in the product and utility supply to permit shifting the position of the dispenser sufficiently to clean the area beneath it. B. COUNTER MOUNTING If counter mounted the ice drink dispenser must be sealed to the counter. The template drawing indicates where openings can be cut in the counter. Locate the desired position for the dispenser, then mark the outline dimensions on the counter using the template drawings. Cut openings in counter. Apply a continuous bead of NSF International (NSF) silastic sealant (Dow 732 or equal) approximately 1/4--inch inside of the unit outline dimensions and around all openings. Then, position the unit on the counter within the outline dimensions. All excess sealant must be wiped away immediately. 2. The beverage tubes, drain tube and power cord are routed through the large opening in the bottom of the unit. See the mounting template for locating the required clearance opening in the counter for these utility lines. 3. Drip tray assembly: Route the drain tube to an open drain with the end of the tube above the “flood” level of the drain. Use the tubing, fittings, clamps, and insulation provided with the Dispenser to assemble the drain. The completed drain line must pitch continuously downward and contain no “traps” or improper drainage will result. Must have a 4 inch air gap between drain line and drain. NOTE: This equipment must be installed with adequate backflow protection to comply with federal, 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 DISCONNECT SET (P/N 313867000) are recommended. CAUTION: Check the minimum flow rate and the maximum pressure of the plain water inlet supply line. MINUMUM FLOW RATE MUST BE AT LEAST 125--GALLONS PER HOUR. If flow rate is less than 125-gallons per hour, starving of the carbonator water pump will occur. Starving will damage the water pump and could cause the carbonator to time out. INCOMING PLAIN WATER INLET SUPPLY LINE WATER TO PUMP PRESSURE MUST REMAIN A MINIMUM OF 10--PSI BELOW THE CARBONATOR CO2 OPERATING PRESSURE. (Example: Carbonator CO2 operating pressure is 75--PSI and the maximum water pressure can be no more than 65--psi, etc.). Water over pressure (higher than CO2 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, water line must be 1/2” or 3/4” diameter with a shut off valve within 6 feet of the dispenser. 4. Locate the carbonator pump assembly and connect probe wires from Ice/Drink Unit and pump. Connect inlet water to pump and pump outlet to Ice/Drink Unit using 3/8--inch food--grade tubing. NOTE: Locate carbonator assembly within 6 feet of the dispenser. Do not lengthen the control board harness. 5. Connect the beverage system product tubes as indicated in applicable Plumbing Flow Diagram, see page 19. This work should be done by a qualified service person. NOTE: Water pressure for non carbonated beverages must be 60 P.S.I. minimum. NOTE: See applicable Flow Diagram or Decal on the lower front of the unit for the location of syrup and water connections. 6. 7. Clean the hopper interior. Connect the two power cords to a 120 volt, 60 cycle, 3-wire grounded receptacle. For 220--240 Volt International Units, a 3--wire power cord is provided. An adapter plug for the particular country will need to be provided by the Installer. © 2004, IMI Cornelius Inc. -3- Publication Number: TP01071 IntelliCarb Training Manual Drains Use a 1 - 1/2” rigid pipe (e.g. ABS on P.V.C.) this is to prevent kinking or collapsing. Make sure to leave a 4 inch air gap between the drain line and the floor drain. CORNELIUS INTELLICARB CARBONATOR ASSEMBLY 1. Ice Drink / Drop-In Carbonator Pump & Motor Unit Vent to Atmosphere Check Valve 125 G.P.H. ProCon Water Pump Liquid Level Control Box Preset CO2 Regulator (75P.S.I.) High Torque Pump Motor FIGURE 1 Carbonator Time Out Reset Switch The board can be set to turn the carbonator off after three or seven minutes of continuos time. The feature can also be disabled. See the carbonator instruction in this manual. Carbonator Time Out Reset Switch Time Out Selector Pins Liquid Level Control Board FIGURE 2 1. FIGURE 3 Locate carbonator assembly below dispenser no more than 6 feet away. Important: Make sure there is clearance for the liquid level control reset switch on the side of the control box to avoid accidentally tripping the switch. The control board has an internal timer to prevent the pump motor from running continuously. In the event of a water supply interruption or malfunction of the water level probe and/or motor relay circuit. If there is a time-out event, make necessary repairs to what caused the time out, then depress and release the reset switch to put the control board back in service. By moving a jumper on the control you can select either a 7 minute or 3 minute time out or this feature can also be disabled. A. Hook-up a 3/8 ID water supply line 125 G.P.H. minimum (60 psig. max.) to pump inlet. Minimum flowing pressure is 30 psig. Important: Tap for non-carb water supply must be upstream of pump inlet. Do not tap in the pump outlet. B. Hook-up a 3/8 (.375 ID) CO2 supply line (100 psig.) to the inlet of the pre-set CO2 regulator (75 psig.) on the Pump & Motor base. Note: If using a bulk CO2 tank as supply, tank pressure regulator must be set to 100-105 psig. The regulator on the bulk tank should be a secondary. Publication Number: TP01071 -4- © 2004, IMI Cornelius Inc. InelliCarb Training Manual C. Initial start-up procedure for carbonated water system: Turn on the CO2 supply to the carbonator tank, vent air from carbonator tank by pulling the tank relief valve. Turn on water supply to the pump. Connect electrical power to the pump and motor unit. Bleed the air out of the system by energizing a beverage valve until carbonated water is flowing from the valve. NOTE:If the carbonator Pump and Motor does not cycle (turn on and off) properly, check that the probe harness connector and ground lead are secured to the carbonator tank connection points. D. If service is required on Ice Drink units, it will be necessary to lower the beverage valve panel to gain access to the probe and ground connection. Remove the lower front panel (2 screws) from the cabinet and the ice chute cover (“snap” fit). Remove the 6 screws that secure the beverage panel to the cabinet. The panel can now be moved downward due to the flexibility of the beverage tubing to expose the carbonator tank connections. Carbonator Relief Valve Locations The carbonator tank is located behind the splash panel, on the right side of the dispenser. You will need to pull the relief valves to purge air from the system after the CO2 supply has been hooked up. Failure to do this will cause low carbonation volume and popping of the relief valves. Agitator Motor Relief Valve Ring Carbonator Tank Carbonator Tank Relief Valve FIGURE 7 FIGURE 6 2. Dispenser Ice Drink Model ED175BCH (Lower Front Panel Removed) Insulated Cold Plate Cover & Carbonator Tank Assembly Total Flex Manifold (with insulation) Total Flex Manifold (insulation removed) Cold Plate Inlets (3/8 Barb) Carb Tank CO2 Supply Line Carb. Tank Liquid Level Probe Harness FIGURE 8 © 2004, IMI Cornelius Inc. -5- Publication Number: TP01071 IntelliCarb Training Manual Ice Drink Model ED150/175/300 Coldplate Cover Liquid Level Probe Ice Drink Model ED200/250 Coldplate Cover CO2 Check Valve with Ground Stud In-line CO2 Check Valve 3. Ground Plate/Stud Probe FIGURE 10 FIGURE 9 Total Flex System for Ice Drink Models ED150/175/200/250/300 Total Flex Manifold (Insulation Removed) Water Line Plugs Retainer Clip Manifold Block FIGURE 11 Total Flex is a system of water manifold blocks located at the front of the cold plate, adjacent to the cold plate inlets, for easy switch over of carbonated / non-carbonated beverage drinks. The right hand manifold block is for the beverage valves located to the right side of the ice chute, and the left block is for the left bank of valves. Each beverage valve on the dispenser can be set up for either carbonated or non-carbonated drinks. Refer to the unit’s plumbing diagram for the factory carbonated / non-carbonated valve locations. The procedure for switching carbonated / non-carbonated water lines on a beverage valve is as follows: A. Shut off the water supply to the dispenser. Depressurize and drain both the carbonated and noncarbonated water circuits. B. Remove the retainer clip (2 screws) from the manifold block. Switch the plug and water line fitting to their respective carbonated / non-carbonated outlet locations on the block. C. Replace the retainer clip. Turn on the water supply and energize the “switched” valve(s). Check for water leaks. 4. 5. Important: Route the dispenser’s drain line to an open drain with the end of the tube above the flood level of the drain. The drain line must pitch downward and contain no “traps”. Connect both the carbonator pump and motor unit and the dispenser to a grounded electrical supply outlet. Publication Number: TP01071 -6- © 2004, IMI Cornelius Inc. IntelliCarb Training Manual 6. Check list for proper “finished” drink carbonation: A. Fill ice storage hopper with ice. B. Water supply must be from a continuous source (no tank supply). C. Use only filtered water. D. Supply water line to the carbonator pump must be a minimum of .375 ID. E. Syrup supply lines must be a minimum of .265 ID. F. Water inlet pressure range: 45-60 max. static psig. with a minimum flowing pressure of 30 psig. G. Syrup CO2 secondary regulator pressure set to 60 psig. H. CO2 supply must be high quality, food grade. I. Purge all water, carb-water, and product lines of air before brixing valves. J. Important: Brix valves with cold product. Allow at least 15-20 minutes for ice to cool down the coldplate on initial start-up before brixing the valves. K. Dispense at least (2) 12 oz. drinks before taking a carbonation level reading. L. Carbonation tester thermometer must read 32-33oF. for accurate carb-level reading. Store tester in ice water bath during use. M. Hold cup at valve nozzle for drink to be tested. Pour drink slowly down the side wall into the carbtester to avoid agitation during pouring. Press vent valve once on carb-tester after tightening lid. 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. -7- Publication Number: TP01071 IntelliCarb Training Manual MECHANICAL SECTION GATE RESTRICTOR PLATE NOTE: Disconnect power to dispenser before installing, removing, or adjusting restrictor. ADJUSTMENT INSTALL PLATE ON STUDS AS SHOWN FIGURE 12 Adjustment This plate may be adjusted as shown to reduce or increase the dispensing rate of ice, especially desirable when using glasses or other containers with small openings. Adjustment can be made by sliding up or down with nuts loosened, to obtain the desired amount of restriction. Publication Number: TP01071 -8- © 2004, IMI Cornelius Inc. IntelliCarb Training Manual ICE DIVERTER KIT 02394 NOTE: For dispensing Scotsman, Wilshire, and Hoshizaki compressed ice cubes: 1. 2. 3. 4. 5. 6. 7. Disconnect power to dispenser. Remove Merchandiser from dispenser. Remove ice chute and discard gate restrictor. Install ice diverter on gate mounting plate as shown below. Apply RTV to back surface of ice diverter, to seal to gate mounting plate. Reinstall gasket and ice chute. Reinstall merchandiser and energize unit. G AT E MOUNT ING P L AT E S TOR A G E HOP P E R F L A NG E E XT E NDS INTO S TOR A G E HOP P E R T HR OUG H G AT E OP E NING IC E DIV E R T E R IC E C HUT E C OV E R A P P LY R T V TO T HIS S UR FA C E TO S E A L TO HOP P E R G AT E MOUNT ING 10-- 32 WA S HE R GAS K E T P L AT E IC E C HUT E 10-- 32 NUT FIGURE 13 © 2004, IMI Cornelius Inc. -9- Publication Number: TP01071 IntelliCarb Training Manual REMOVAL AND REPLACEMENT OF AGITATORS To Remove Agitators For Cleaning (300 shown) NOTE: All other models have only one agitation Assembly. RIGHT HAND AGITATOR WITH HOLE IN UPRIGHT LEFT HAND AGITATOR O–RING COUNTERCLOCKWISE CLOCKWISE ROTATION ROTATION FRONT (VALVE SIDE) VIEW FROM TOP OF DISPENSER FIGURE 14 1. Lift agitator and disc from unit. 2. Remove O-Ring starting at notch. Warm the O-Ring with water to ease removal. 3. Lift the plastic agitator disc off of the stainless-steel agitator. 4. Replace by reversing steps. NOTE: Refer to Sanitize Procedure in the Owners Instruction for complete cleaning and sanitizing instructions. Publication Number: TP01071 - 10 - © 2004, IMI Cornelius Inc. IntelliCarb Training Manual POST-MIX VALVE SECTION SET-UP INSTRUCTIONS Concentrate valve sleeve has only one hole Syrup valve sleeve has six holes FIGURE 15 A side water lever kit can be added to a valve allowing for dispensing of water without syrup or concentrate. The side water lever can be added to either a carbonated drink valve or a noncarbonated drink valve. Post-mix valves control: Mounting screw Water lever • the ON–OFF of syrup and water, • the flow rates of syrup and water, • the mixing of the two ingredients as they pour into the cup, and • in some instances - dispensed portion. FIGURE 16 Dimensions & Capacities Fast Flow ............................................................................................................... 1 ½ to 3 oz./sec. UFB-1 ......................................................................................................................... 2 to 4 oz./sec. Ultra Flow .............................................................................................................. 3 to 4 ½ oz./sec. Operational temperature range: ......................................................... 10°C (50°F) to 43°C (110° F) Voltage requirements:................................................................................ 22 to 27 VAC (50/60 Hz) Transformer (electronic valves) ........................................................................................80 VA min. Operating Pressure (flowing) ...............................................................................syrup = 20 psi min. .............................................................................................................................water = 35 psi min. Concentrates and juices that contain particulates must be dispensed from a juice valve. A slanted drip tray is necessary when using an Optifill valve. SYSTEM DETAILS Water Water Quality Water quality issues have an affect on dispensing valves. Chloramine, a combination of chlorine and ammonia is responsible for some degradation of rubber components. Chloramine is used in many U. S. water supplies. Its affects can be minimized by installing and maintaining a water filtration system. Ultra pure water affects the sensitivity of the Optifill™ valve. Because ultra pure water has less mineral content, it reduces the conductivity of the water keeping the circuit open and overfilling the beverage container. Water Flow 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. - 11 - Publication Number: TP01071 IntelliCarb Training Manual NOTE: The notched water piston on the Ultra Flow and UFB-1 valve. results in at least one orifice in the sleeve always open. This eliminates pulsating and smooths water flow at higher flow rates. In operation the liquid flows through the knife–edged orifice in the bottom of the piston and then out the orifices in the sleeve. The outlet orifice size in the sleeve is regulated by the position of the piston. In the illustration, the piston is restricting approximately 1/2 of the outlet orifices. Notch in piston FIGURE 17 UFB-1 Flow Module Orifice Sleeve Piston FIGURE 18 Lower Fluid Pressure BUT Larger Orifice Openings Higher Fluid Pressure BUT Smaller Orifice Openings Same Volume Of Syrup/Water Flows From Orifices Knife edge Syrup/Water Flow Higher Fluid Pressure Pushing Against Piston & Spring Lower Fluid Pressure Pushing Against Piston & Spring FIGURE 19 The position of the piston inside the sleeve is determined by the upward pressure of the liquid against the base of the piston and the downward pressure of the spring inside the piston (not shown here). The pressure of the spring is regulated by the adjusting screw. If the pressure of the liquid increases, the flow rate through the knife–edged orifice will increase. The piston is moved upward closing off more of the outlet orifices. The same flow rate is thereby maintained. Publication Number: TP01071 - 12 - © 2004, IMI Cornelius Inc. IntelliCarb Training Manual Adjusting Flow Rates Flow rates of the water and syrup are adjusted based on the desired ratio. For example: if the desired ratio is 5:1, then the flow rate of the water is 5 times that of the syrup. If the desired finished drink total flow rate is 3.0 ounces per second, then the water flow rate is 2.5 oz./ sec and the syrup flow rate is 0.5 oz./sec. (The water at 2.5 oz./sec is five times the 0.5 oz./sec syrup flow rate.) NOTE: Always adjust water within its range. Water Flow Rates At Selected Ratios Water To Syrup Ratio Water at 1.5 oz./ sec. Total Flow Water at 3.0 oz./ sec. Total Flow Water at 3.75 oz./ sec. Total Flow Water at 4.5 oz./ sec. Total Flow 2 to 1 1.00 oz./sec. 2.00 oz./sec. 2.50 oz./sec. 3.00 oz./sec. 3 to 1 1.13 oz./sec. 2.25 oz./sec. 2.81 oz./sec. 3.38 oz./sec. 4 to 1 1.20 oz./sec. 2.40 oz./sec. 3.00 oz./sec. 3.60 oz./sec. 5 to 1 1.25 oz./sec. 2.50 oz./sec. 3.13 oz./sec. 3.75 oz./sec. 6 to 1 1.29 oz./sec. 2.57 oz./sec. 3.21 oz./sec. 3.86 oz./sec. 7 to 1 1.31 oz./sec. 2.63 oz./sec. 3.28 oz./sec. 3.94 oz./sec. Calculating Flow Rates The most frequent ratio is 5:1. The charts above list the breakdown for many ratios and flow rates. It is useful to be able to calculate flow rates when a chart is not available. An example of calculating the water and syrup flow rates given the finished drink flow rate and the water to syrup ratio: Given: 1. Finished Drink Flow Rate = 3.0 oz./sec. 2. Water to Syrup Ratio = 5 to 1 To calculate Water Flow Rate: 1. Calculate the Total Portions = Water Portion + Syrup Portion (example 5 + 1 = 6) 2. Calculate Syrup Flow Rate = Finished Drink Flow Rate ÷ Total Portions (example 3.0 oz./sec ÷ 6 = .5 oz./sec) 3. Calculate Water Flow Rate = Finished Drink Flow Rate – Syrup Flow Rate (example 3.0 oz./sec - .5 oz./sec = 2.5 oz./sec) Prove the calculation is correct by adding water flow rate of 2.5 oz./sec + syrup flow rate of .5 oz./sec = finished drink flow rate of 3.0 oz./sec. Water flowing at 2.5 oz./sec and syrup flowing at .5 oz./sec achieves a ratio of 5:1 and 3.0 oz./sec. flow rate. Syrup/Concentrate Syrup should always be precooled before setting the ratio. Syrup takes a path through the valve parallel to the water path. It is introduced in the block, travels through a syrup flow control, banjo, valve head and out the nozzle. Note, concentrate is not cooled. High sugar syrups are more viscous (thicker) than diet syrups and consequently have more pressure drop within a system. 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. - 13 - Publication Number: TP01071 IntelliCarb Training Manual Setting Ratios If the ratio varies and must be adjusted often, it is probably the result of a restricted syrup system. It is then time to clean and sanitize the syrup tubing and cooling coils and check for other problems such as syrup pumps, etc. NOTE: Try raising the pressure on the pump before cleaning. Set the water flow rate first, then adjust the syrup to the desired ratio. This gives the most accurate valve flow setting possible. Measure the ratio and adjust the syrup flow, if necessary. This will result in uniform flow, better carbonation retention, and improved drink quality. When using a ratio cup always take these precautions to ensure accuracy: • After installing the separator tube, open the valve to fill the syrup tube before starting the ratio test. • Clean the cup thoroughly between tests so there is no carry–over from one test to the next. • 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. Ratio Cup and Syrup Separator FIGURE 20 NOTE: Valve troubleshooting information is available on page 39. Publication Number: TP01071 - 14 - © 2004, IMI Cornelius Inc. IntelliCarb Training Manual SHURFLO SHURFLOW OVERVIEW SHURflo’s Beverage Gas Pump supplies syrup under pressure to a post-mix dispenser, which mixes the syrup with water to an exact ratio (brix). The pump is used in conjunction with non-pressurized Bag-InBox (B-I-B) containers and a bag connector (Q.D.) fitting. The pump can be operated on regulated CO2, nitrogen or compressed filtered air. The compressed gas drives the pump and is not in contact with the syrup. Separate syrup and gas chambers prevent contamination, foaming, and purging of the tubing when the B-I-B has emptied. The pump retains pressure in the outlet line, operating only when syrup is needed. When the dispenser valve is opened, the pump reacts to the pressure drop by operating to maintain pressure in the line. When the dispenser is closed, the incoming gas and output syrup pressures equalize and the pump stops. Actual dynamic line pressure is dependant upon system losses as outlined in the section "Pumping Capability". The automatic "sold-out" feature within the pump ensures consistent syrup delivery right up to the moment the B-I-B is empty. Vacuum produced by the pump evacuates the syrup within the bag. Once the preset vacuum point is achieved and held, incoming gas pressure to the pump is shutoff causing the outlet syrup pressure to drop to zero. When a new B-I-B is installed, the vacuum drops, the pump automatically restarts and pressurizes the system. The SHURflo Beverage Gas Pump ensures quality from the first drink to the last. Beverage Gas Pumps are intended for soda syrups and low viscosity concentrates that do not contain solids. The use of a SHURflo Juice Pump (-09) is recommended for concentrates containing soft solids, classed as round, up to 0.025 in. [0.6 mm] or that are of higher viscosity than soda syrups. When concentrates contain pulp classed as long/stringy, seed particles or are exceptionally viscous, the Particulate Juice Pump (-10) should be used as it can handle soft solids up to 1 /4" [6 mm] cubed. Standard gas pump models are for installations where geographic elevation is less than 5000 ft.[1523M]. For elevations above 5000 ft. specific high altitude models with a reduced sold-out spring rate must be used to compensate for the loss in atmosheric pressure. For further application and model information please contact SHURflo. NOTE: Shurflow Troubleshooting information available on page 35. © 2004, IMI Cornelius Inc. - 15 - Publication Number: TP01071 IntelliCarb Training Manual SHURFLOW INSTALLATION • As indicated on the pump, the outlet port is to be mounted up. • Pumps are to be mounted at the same level or higher than the B-I-B. The best choice is to have the pump above the B-I-B. • INLET tubing from the B-I-B to the pump use; 3/8" I.D. [10mm] minimum, heavy wall (1/8" [3mm]) clear, NSF listed vacuum tubing. Inlet tubing should not have excessive length. Tub- ing that is allowed to drape down can trap air in the B-I-B creating a potential for pump "soldout" problems. The maximum vertical distance from the bottom of the B-I-B to the pump must not exceed 5 ft [1.5 M ]. Maximum inlet tubing length is 10 ft. [3 M ]. • If plumbing multiple B-I-B’s to a pump, B-I-B's should be "Teed" side-by-side horizontally, rather than one on top of the other (vertically). • OUTLET tubing from the pump to the dispenser should be high pressure rated and NSF listed. Consult "Pumping Capability" (see page 2) for appropiate tubing I.D. • Always cut CO2 and outlet tubing at least 2 ft. [.6 M] longer to provide a "service loop" so the B-I-B rack can be moved for cleaning or service. • Use new (clean), 1/4" I.D. [6 mm], flexible, high pressure, braided tubing from the CO2 / air regulator to the pump. NEVER connect a transfer tank "system" in series with a B-I-B system. Syrup contaminants in old components may work their way through the air supply causing premature failure of the gas pump. Gas used to operate pumps MUST be clean and contain no contaminants (syrup, oil, rust, water, etc). Air compressors may be used with proper particle filters and moisture separators. Air storage tanks should be drained regularly. Pumps subjected to contaminated air are not covered by warranty. High concentrations of CO2 can be fatal as it will displace the air from non-ventilated areas. Pumps operated by CO2 must be in ventilated areas. If placed in a confined area (basement, closet, cooler box, etc.), exhaust fans capable of changing the room air on a continuous basis should be used. • All tubing connections must be secured with stainless steel, stepless Oetiker ® clamps. • Cable-tie all tubing securely to prevent kinks or sags that inhibit performance or cause damage to the pump fittings. START-UP PROCEDURE 1. 2. 3. 4. Confirm that all tubing connections are properly clamped, fittings are tight, and tubing is not kinked. Install bag connector to the B-I-B. Adjust gas regulator to about 20 psi. [1.4 bar] allowing the pump to stroke slowly. Operate the valve until all air trapped within the tubing has been purged. Once the air has been purged, adjust the CO2 regulator to the pressure necessary to maintain the desired brix. The most efficient gas usage occurs at 40 psi. [2.8 bar]. MAXIMUM static gas pressure to the pump is 85 psi. [5.8 bar], minimum 20 psi. [1.4 bar]. Flowrates that result in a stroke-rate of more than two strokes per second will decrease pump life. (Consult factory) Pump failure due to "overrunning" is not covered by the limited warranty. To prevent air from entering the system always leave the bag connector attached to the empty B-I-B until a new B-I-B can be installed. Air entered into the system, via air in the bags or vacuum leaks, may cause brix fluctuation, foaming, spitting, non-operation of the vacuum soldout or pump "run-on" with the valve closed. Symptoms of this kind can lead to a misdiagnosis of the pump. Publication Number: TP01071 - 16 - © 2004, IMI Cornelius Inc. IntelliCarb Training Manual PLUMBING TYPICAL INSTALLATION FIGURE 21. Typical Installation © 2004, IMI Cornelius Inc. - 17 - Publication Number: TP01071 IntelliCarb Training Manual PLUMBING LAYOUT Brand Syrup Inlets 3-5 Per Side Carb Water In Plain Water In Carbonator Tank CO2 Inlet Brand Syrup Inlets 3-5 Per Side Connection Legend B B B C B 75 psi Fixed Reg Carb Pump B 3/8" Barb Conn C 1/4" Barb Conn D 3/8" Hose Barb - 3/4" NP E 1/4" Female Flr Nut F Direct Conn to SUR Outlet on BIB Pmp G Direct Conn to CO2 Inlet on BIB Pmp H Syr Inlet BIB Pmp I 3/4" NPT TEE CO2 Supply Regulator 100 psi E A 3/8" Female Fir Nut C E A A Regulator 55-60 psi E D Water Filter I D H BIB Syrup F BIB Pump G F BIB Pump G 6-10 Brand Flavors BIB Syrup H Tubing Legend 3/8" Bev Tubing 1/4" Bev Tubing 3/8" Tycon Tubing FIGURE 22. Plumbing Layout Publication Number: TP01071 - 18 - © 2004, IMI Cornelius Inc. FAUCETS W1, VALVES 1,2, 3,6 W1 6 S6 OPTIONAL PRESSURE REGULATOR POTABLE WATER SUPPLY 5 S5 FILTER W2 4 CARBONATOR PUMP S4 COLDPLATE NON-- CARB WATER INSTALL FOR NON-- CARB AS REQUIRED CHECK VALVE S5 INLET S6 CONNECTIONS S7 S1 S2 CARBONATOR TANK FIGURE 23. Flow Diagram 1xx (Six Flavor Model) - 19 - FAUCETS VIEWED FROM THIS SIDE W2, VALVES 4,5 S3 W2 3 5-- 15 PSIG OPTIONAL FOR DIET DRINKS OR ROOT BEER PLUGGED S3 FLOW DIAGRAM 1XX (SIX FLAVOR MODEL) © 2004, IMI Cornelius Inc. DOUBLE CHECK VALVE 75 PSI 2 S2 W1 1 S1 COLD PLATE S3 S2 S1 S7 SYRUP TANKS 15-- 50 PSIG S6 S5 PRESSURE REGULATORS ITEMS INSIDE BROKEN LINE INCLUDED WITH UNIT IntelliCarb Training Manual Publication Number: TP01071 CO2 CYLINDER S8 W1 OPTIONAL PRESSURE REGULATOR 7 POTABLE WATER SUPPLY S7 FILTER 6 W2 5 CARBONATOR PUMP W2, VALVES 4, 5,6 S5 NON-- CARB WATER CHECK VALVE INSTALL FOR NON-- CARB AS REQUIRED S5 S6 COLDPLATE INLET CONNECTIONS S7 S8 S1 S2 CARBONATOR TANK FAUCETS VIEWED FROM THIS SIDE - 20 - FIGURE 24. Flow Diagram 1XX (Eight Flavor Models) S6 S3 S4 4 S4 W2 5-- 15 PSIG OPTIONAL FOR DIET DRINKS OR ROOT BEER 3 75 PSI S3 2 S2 S4 W1 1 © 2004, IMI Cornelius Inc. S1 S3 S2 S1 SYRUP TANKS 15-- 50 PSIG S8 S7 S6 S5 PRESSURE REGULATORS COLD PLATE CO2 CYLINDER ITEMS INSIDE BROKEN LINE INCLUDED WITH UNIT IntelliCarb Training Manual W1, VALVES 1,2, 3,7,8 8 FLOW DIAGRAM 1XX (EIGHT FLAVOR MODELS) Publication Number: TP01071 DOUBLE CHECK VALVE FAUCETS 8 W1 OPTIONAL PRESSURE REGULATOR W1 VALVES 1,2 3,6,7,8 POTABLE 7 WATER SUPPLY FILTER W2 VALVES 4,5 CARBONATOR INSTALL FOR 6 NON–CARB AS REQUIRED W2 CHECK VALVE S8 Non–Carb Water S7 S6 COLDPLATE INLET CONNECTIONS S5 W2 W1 S4 CARBONATOR TANK - 21 - FIGURE 25. Flow Diagram 2xx (Eight Flavor Models) 5 S3 S2 S1 4 OPTIONAL FOR DIET DRINKS OR ROOT BEER W2 75 PSI 5–15 PSIG 3 FLOW DIAGRAM 2XX (EIGHT FLAVOR MODELS) © 2004, IMI Cornelius Inc. DOUBLE CHECK VALVE FAUCETS 2 W1 Publication Number: TP01071 S1 COLD PLATE ITEMS INSIDE BROKEN LINE INCLUDED WITH UNIT S2 S3 S4 S5 SYRUP TANKS 15–50 PSIG S6 S7 S8 PRESSURE REGULATORS CO2 Cylinder IntelliCarb Training Manual 1 Publication Number: TP01071 - 22 - 1 2 3 4 5 CARBONATOR TANK S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 COLD PLATE W1 W2 W2 W1 ITEMS INSIDE BROKEN LINE INCLUDED WITH UNIT COLDPLATE INLET CONNECTIONS 6 7 8 9 10 FAUCETS S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 OPTIONAL FOR DIET DRINKS OR ROOT BEER 5–15 PSIG W2 VALVES 5,6 W1 VALVES 1,2,3 4,7,8,9,10 S1 S2 S3 S5 SYRUP TANKS 15–50 PSIG S4 S6 S7 CARBONATOR PUMP NON CARB WATER DOUBLE CHECK VALVE S8 CHECK VALVE S9 75 PSI CO2 CYLINDER PRESSURE REGULATORS S10 INSTALL FOR NON–CARB AS REQUIRED OPTIONAL PRESSURE REGULATOR FILTER POTABLE WATER SUPPLY IntelliCarb Training Manual FLOW DIAGRAM 2XX (TEN FLAVOR MODELS)) FAUCETS VIEWED FROM THIS SIDE FIGURE 26. Flow Diagram 2xx (Ten Flavor Models) © 2004, IMI Cornelius Inc. 12 DOUBLE CHECK VALVE COLD PLATE W1 S12 OPTIONAL PRESSURE REGULATOR 11 S11 W2 FILTER 10 S10 COLDPLATE INLET CONNECTIONS FAUCETS VIEWED FROM THIS SIDE - 23 - FIGURE 27. Flow Diagram 300 (Twelve Flavor Models) 9 CARBONATOR PUMP W1 W2 S10 POTABLE WATER SUPPLY INSTALL FOR NON–CARB AS REQUIRED CHECK VALVE NON–CARB WATER S11 S12 S7 S8 S9 W2 TO COLDPLATE SYRUP INLETS S9 8 S8 W1 7 S7 FAUCETS 6 COLD PLATE W1 S6 5 S5 W2 4 CO2 S4 COLDPLATE INLET CONNECTIONS W1 W2 75 PSI S4 S5 S6 S1 S2 S3 OPTIONAL FOR DIET DRINKS OR ROOT BEER 5–15 PSIG S2 S1 S6 S5 S4 S9 S8 S7 S12 S11 S10 Publication Number: TP01071 PRESSURE REGULATORS S3 2 S2 W1 1 S1 CARBONATOR TANK ITEM INSIDE BROKEN LINE INCLUDED WITH UNIT CO2 CYLINDER IntelliCarb Training Manual SYRUP TANKS 15–50 PSIG W2 3 S3 FLOW DIAGRAM 300 (TWELVE FLAVOR MODELS) © 2004, IMI Cornelius Inc. FAUCETS IntelliCarb Training Manual ELECTRICAL SECTION Control Box Single Transformer Will Power up to Three Valves Simultaneously. Transformer FIGURE 28. Electrical Box 1xx Single Transformer FIGURE 29. Electrical Box 2xx Single Transformer One Transformer Powers the Left Bank and the Other Powers the Right Bank. Will Power All Valves Simultaneously. Transformers FIGURE 30. Electrical Box 2XX Dual Transformer Publication Number: TP01071 - 24 - © 2004, IMI Cornelius Inc. IntelliCarb Training Manual RESET CONNECTIONS Time Out Selection Pins. 7min/3 min/Disabled (Move Jumper to Select) CARBONATOR WIRING DIAGRAM © 2004, IMI Cornelius Inc. - 25 - Publication Number: TP01071 TO HINGE DA NG ER! MOTOR HEATER CCW AGITATOR MOTOR GRN TO BEVERAGE FAUCET DISPENSE SWITCH Q.C. CONNECTOR GATE SOLENOID (106VDC) N L WG HR I E T E E N WO BRB BBR BB HR L L L I A AE AE L UL AL U NC DA T C CCD E E EG EK K K K + B L A C K B L U E -- - 26 - FIGURE 31. Wiring Diagram 1xx (120V) GRD 115V SUPPLY EL ECTRIC SHO CK HA ZA RD. DISCO NNECT PO W ER B EFO RE SERVICING UNIT. KEY SWITCH YELLOW WHITE G R E E N BLACK T’STAT YELLOW RED BLUE B L A C K WHITE W H I T E OPTIONAL WHITE BLACK BLACK BLACK BLACK BLACK © 2004, IMI Cornelius Inc. NC NOCOM NC NOCOM R R E E D D B L A C K RED L2 PINK RED W H I T E BLACK PINK OPTIONAL G R E E N WHITE BLACK WHITE BLACK BLACK L1 WHITE BLUE WHITE WHITE BLACK OPTIONAL 1 2 LIGHT WHT ICE LEVEL OPTION IntelliCarb Training Manual WIRING DIAGRAM 1XX (120V) Publication Number: TP01071 SERVICE INFO RM ATIO N IntelliCarb Training Manual SCHEMATIC 1XX G N L TIMER L2 L1 MO TO R H EATER A G ITATO R MO TO R N .O . C VEN D SW ITC H N .C . C A PA C ITO R R EC TIFIER G ATE SO L EN O ID O PTIO N A L B A L L A ST O PTIO N A L L IG H T O PTIO N A L STA R TER B EVER A G E TR A N SFO R MER O PTIO N A L L O W IC E L EVEL T’STAT B EVER A G E VA LVES L IG H T B EVER A G E VA LVES B EVER A G E PA N EL FIGURE 32. Schematic 1xx © 2004, IMI Cornelius Inc. - 27 - Publication Number: TP01071 Q.C. CONNECTOR GRN TO HINGE GATE SOLENOID (106VDC) DANGER! ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SERVICING UNIT. BLUE ICELEVELSIGNAL OPTION KEY SWITCH + B L A C K WB H L I U T E E BLACK WHITE © 2004, IMI Cornelius Inc. OPTIONAL LIGHT SOCKET -- W H I T E R E D G R E E N BLACK BLACK W H I T E B L U E W B B H L L OPTIONAL I U A C T E K LIGHT STARTER E WHITE R E D Y E L L O W MOTOR START R RELAY E D 3 2 BLACK NC 4 W H I T E NC WHITE WHITE BLACK NO COM L2 WHITE AGITATION TIMER NOCOM L1 WHITE BLACK YELLOW OPTIONAL LIGHTBALLAST BLACK B L U E RECTIFIER G R E E N WHITE RED TO BEVERAGE VALVES TO 24V TRANSFORMER DISPENSE SWITCH B YR GWB G BBB R L EE R HL R L L L E A L D E I A E AAA D C L E T C E CCC K O N E K N KKK W BLACK B L U E LIGHT 2 BLUE MOTOR START CAPACITOR B L U E 1 BEVERAGE TRANSFORMER (OPTIONAL) BEVERAGE TRANSFORMER (OPTIONAL) WHITE B L A C K W H I T E B L A C K BLACK BLACK BLACK WHITE OPTIONAL LIGHT SOCKET IntelliCarb Training Manual - 28 - FIGURE 33. Wiring Diagram 2xx (120V Model) N L T’STAT SERVICE INFO RM ATIO N BLK Y B E L L K WIRING DIAGRAM 2XX (120V MODEL) Publication Number: TP01071 MOTOR HEATER AGITATOR MOTOR © 2004, IMI Cornelius Inc. - 29 3 4 W H I T E R E D NC NC GRN BLACK BLACK L1 LT BLUE R E D NO COM NOCOM AGITATION TIMER L2 B L U E J9 J10 LT BLUE WHITE BROWN LT BLUE BLACK WHITE BROWN L O POWER LINE FILTER A D L N WHITE BLACK BLACK WHITE WHITE OPTIONAL LIGHT BALLAST BROWN BROWN B L A C K LINE LAMP L N FIL TER ASY LT BLUE W H I T E BROWN B L A C K BROWN BEVERAGE TRANSFORMER (OPTIONAL) YELLOW POWER SWITCH W H I T E OPTIONAL LIGHT SOCKET B L A C K BEVERAGE TRANSFORMER (OPTIONAL) TO BEVERAGEALVES V BROWN BROWN WHITE OPTIONAL LIGHT SOCKET 2 G RG N RG / NR G Y/ N E Y/ R G L EY N R L E /Y N L E /Y LE L BLUE KEY SWITCH TO 24V TRANSFORMER BLUE ICE LEVEL SIGNAL OPTION LIGHT WHITE MOTOR START RELAY BLACK DISPENSE SWITCH DANGER! ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SERVICING UNIT . SER VICE INFORMATION 2 T’STAT 1 BLACK W H I OPTIONALT LIGHT E STARTER BGBBGY R G B L GGBBB R L RL L RE E R R T RRL L L E UNUANL D N O NNAAA D E/ EC/ L / WB / / CCC Y KYO Y N L YYKKK E EW E UEE L E LL L L E N L MOTOR HEATER TO BEVERAGE PANEL BLACK B L A C K RED BLACK TO HINGE GUSSET B B L L U K E BLK MOTOR ST ART CAPACITOR GRN/YEL GATE SOLENOID Q.C. CONNECTOR AGITATOR MOTOR IntelliCarb Training Manual WIRING DIAGRAM 2XX (220/240V MODELS) FIGURE 34. Wiring Diagram 2xx (220/240V Models) Publication Number: TP01071 IntelliCarb Training Manual WIRING DIAGRAM 2XX (220/240V MODELS) G L N L1 TIMER L2 RECTIFIER MOTOR HEATER AGITATOR MOTOR N.O. C VEND SWITCH N.C. GATE SOLENOID OPTIONAL BALLAST OPTIONAL LIGHT OPTIONAL STARTER OPTIONAL BEVERAGE TRANSFORMER OPTIONAL ICE LEVEL OPTIONAL BEVERAGE VALVES OPTIONAL BEVERAGE VALVES BEVERAGE PANEL FIGURE 35. Wiring Diagram 2xx (220/240V Models) Publication Number: TP01071 - 30 - © 2004, IMI Cornelius Inc. N L © 2004, IMI Cornelius Inc. - 31 - W H I T E G R E E N WO H R I N T E BLACK OPTIONAL LIGHT SOCKET B L A C K GRN LEFT AGITATOR MOTOR (CCW) B L A C K B L U E B L U E B L U E OPTIONAL LIGHT STARTER MOTOR CAPACITOR BLACK G R E E N R E D GRN TO HINGE BRACKET BLUE RED 2 OPTIONAL LIGHT BALLAST BLACK BLACK WHITE PINK BLUE LIGHT G R E E N ICE LEVEL SIGNAL OPTION 1 TO 24V TRANSFORMER B L U E GREEN/YELLOW GATE SOLENOID (DC COIL) T’STAT BLACK B L A C K B L A C K WHITE BLUE YELLOW TO BEVERAGE FAUCET KEY SWITCH (OPTIONAL) DANGER! YELLOW WHITE W H I T E WHITE W H I T E WHITE BLACK R E D BEVERAGE TRANSFORMER (OPTIONAL) YELLOW DISPENSE SWITCH MOTOR HEATER BLUE W H I T E OPTIONAL LIGHT SOCKET B L B A L C R A K E C D K B L A C K RED BLACK B OB R L R L E A N U D C E K RIGHT AGITATOR MOTOR (CW) B L U E MOTOR CAPACITOR BLACK OPTIONAL LIGHT STARTER BG L R UN E/ Y E L BLACK RED BLUE NC NC PINK OPTIONAL LIGHT BALLAST WHITE B L U E 2 J10 NO COM J9 BLACK L1 AGITATION TIMER NO COM BLACK L2 BLACK BLUE BLUE BLACK BLUE LIGHT WHITE BLUE WHITE ICE LEVEL SIGNAL OPTION 1 T’STAT TO 24V TRANSFORMER GATE SOLENOID (DC COIL) ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SERVICING UNIT. SERVICE INFORMATION WHITE RED B L A C K B L A C K TO BEVERAGE FAUCET KEY SWITCH (OPTIONAL) W H I T E BLACK YELLOW W H I T E WHITE W H I T E BLACK BEVERAGE TRANSFORMER (OPTIONAL) YELLOW YELLOW DISPENSE SWITCH MOTOR HEATER R E D W H I T E OPTIONAL LIGHT SOCKET WHITE B L B A L C R A K E C D K B L A C K IntelliCarb Training Manual WIRING DIAGRAM 300 (220/240V MODELS) FIGURE 36. Wiring Diagram 300 (220/240V Models) Publication Number: TP01071 Publication Number: TP01071 N L OPTIONAL LIGHT SOCKET G B B R R L E N U E N GRN LEFT AGITATOR MOTOR (CCW) B L A C K - 32 - BLACK BLACK WO H R I N T E B L U E G R E E N R E D B L U E OPTIONAL LIGHT STARTER B L U E GRN BLACK GATE SOLENOID (DC COIL) BRN MOTOR CAPACITOR TO HINGE BLUE RED OPTIONAL LIGHT BALLAST WHITE LIGHT BLUE TO 24V TRANSFORMER B L U E 2 G R E E N PINK ICE LEVEL SIGNAL OPTION 1 T’STAT BLUE B L A C K B L A C K YELLOW TO BEVERAGE FAUCET KEY SWITCH (OPTIONAL) YELLOW RED BRN W H I T E WHITE WHITE WHITE BLACK R E D BEVERAGE TRANSFORMER (OPTIONAL) YELLOW DISPENSE SWITCH MOTOR HEATER R E D WB O H L R I AN T C E K OPTIONAL LIGHT SOCKET B L A B C L K A C K B L A C K RIGHT AGITATOR MOTOR (CW) BLACK R B E L D U E B L U E RED MOTOR CAPACITOR BLACK BLUE OPTIONAL LIGHT STARTER B L U E BLACK RED GATE SOLENOID (DC COIL) 2 BLUE LIGHT ICE LEVEL SIGNAL OPTION 1 T’STAT WHITE L2 J10 AGITATION TIMER J9 L1 NO COM BLACK NC NO COM NC PINK BLUE BLACK WHITE BLACK WHITE TO 24V TRANSFORMER B L U E OPTIONAL LIGHT BALLAST DANGER ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SERVICING UNIT. SERVICE INFORMATION B L A C K RED TO BEVERAGE FAUCET KEY SWITCH (OPTIONAL) W H I T E YELLOW W H I T E WHITE W H I T E BLACK BEVERAGE TRANSFORMER (OPTIONAL) YELLOW YELLOW DISPENSE SWITCH MOTOR HEATER W H I T E OPTIONAL LIGHT SOCKET WHITE B L B A L C A K C K B L A C K ON/OFF SWITCH B R N B R N IntelliCarb Training Manual WIRING DIAGRAM 300 (220/240V MODELS) FIGURE 37. Wiring Diagram 300 (220/240V Models) © 2004, IMI Cornelius Inc. IntelliCarb Training Manual SCHEMATIC 300 (120V MODELS) G L N TIMER L1 L2 RECTIFIER MOTOR HEATER AGITATOR MOTOR N.O.1 C VEND SWITCH N.C.1 CAPACITOR GATE SOLENOID BALLAST OPTIONAL LIGHT STARTER OPTIONAL BEVERAGE TRANSFORMER OPTIONAL ICE LEVEL OPTIONAL BEVERAGE VALVES BEVERAGE PANEL MOTOR HEATER AGITATOR MOTOR N.O.2 C VEND SWITCH N.C.2 CAPACITOR GATE SOLENOID BALLAST OPTIONAL LIGHT STARTER OPTIONAL BEVERAGE TRANSFORMER OPTIONAL ICE LEVEL BEVERAGE PANEL OPTIONAL BEVERAGE VALVES FIGURE 38. Schematic 300 (120V Models) © 2004, IMI Cornelius Inc. - 33 - Publication Number: TP01071 IntelliCarb Training Manual SCHEMATIC 300 (220/240V MODELS) G N L EMC LINE FILTER E–BOX GD. MOTOR HEATER MOTOR HEATER TIMER L1 L2 RECTIFIER GATE SOLENOID POWER PUSH BUTTON SWITCH N.C1 C VEND SWITCH N.O1 OPTIONAL BALLAST AGITATOR MOTOR OPTIONAL LIGHT OPTIONAL STARTER OPTIONAL BEV. TRANSFORMER BEVERAGE KEYLOCK SWITCH 24V BEV. FAUCETS EMC GATE SOLENOID N.C2 C VEND SWITCH N.O2 OPTIONAL BALLAST AGITATOR MOTOR OPTIONAL LIGHT OPTIONAL STARTER OPTIONAL BEV. TRANSFORMER 24V BEV. FAUCETS FIGURE 39. Schematic 300 (220/240V Models) Publication Number: TP01071 - 34 - © 2004, IMI Cornelius Inc. IntelliCarb Training Manual TROUBLESHOOTING SHURFLOW TROUBLESHOOTING Pumping Capability The distance syrup can be delivered is limited by inherent factors (restrictions) within the inlet & outlet sides of the beverage dispensing system. Due to variances in system configuration and equipment, an accurate determination of pressure drop is difficult. Before deciding on a system’s tubing size, SHURflo recommends estimating system losses by considering the following: • • • • MAXIMUM HORIZONTAL TUBING LENGTHS BY VISCOSITY Distances shown are intended as a guidline only. (cPs.=Centipose) FLO W R AT E /S E C . O Z. D iet S od a S yrup Syrup viscosity and temperature (coldplate, re-circ., etc.). Inside diameter of the inlet/outlet tubing, fittings, bag connector, etc. [10m m ] 1/2" I.D . [13m m ] .5 15 500+ 22.5 500 152+ 500+ 152+ 500+ 152+ 152 500+ 152+ 500+ 152+ 1.0 30 1.5 45 453 138 500+ 152+ 500+ 152+ 212 65 500+ 152+ 500+ 152+ 2.0 60 102 31 500 152 500+ 152+ 2.5 75 64 19 398 121 500 152 3.0 90 32 9 297 90 500 152 3.5 105 -- -- 212 65 500 152 .5 15 500 152 500 152 500+ 152+ 22.5 133 40 500 152 500+ 152+ S od a S yrup 1.0 30 79 24 388 118 500 152 (20 cP s.± 3) 1.5 45 32 9 193 59 500 152 2.0 60 10 3 127 39 366 112 .5 15 129 39 500 152 500+ 152+ .75 22.5 75 23 345 105 500+ 152+ 1.0 30 53 16 239 73 500 152 1.5 45 26 8 127 39 425 129 H eavy Vertical tubing runs will reduce total achievable tubing run length. To estimate the losses within 3/8" I.D . F eet M eter F eet M eter F eet M eter .75 S tan d ard .75 Horizontal & vertical distance of the outlet tubing. the vertical distance. This product is then subtracted from the maximum horizontal distance. The resulting length is the total horizontal/vertical (horz./vert.) tubing run that is [6m m ] (5 cP s.± 3) Total syrup flow rate of valve(s) connected to a pump. the vertical distance, use the chart to the right. Take 1% of the distance in feet [3% if meters]. The resulting number is multiplied by m L 1 /4 " I.D . S od a S yrup (35 cP s.± 3) Distances shown are the results of tests conducted at 70°F [21°C] ambient with a static pressure of 85 psi. [5.8 bar] to the pump. All distances assume a dynamic pressure of 35 psi. [2.38 bar] at the dispenser to maintain brix. obtainable for that flow rate, tubing I.D. and viscosity. For example: FAST FLOW VALVE 1/2 oz./sec. [15 mL] (syrup flow only) GAS IN 3 / 8" I.D. [10mm] TUBING 22 ft. [6.7M] VERTICAL TOTAL TUBING RUN 370 ft. [113M] HEAVY SODA SYRUP 3/ 8 " I.D. [10mm] TUBING (min.) © 2004, IMI Cornelius Inc. - 35 - Publication Number: TP01071 IntelliCarb Training Manual The chart indicates that heavy syrup with 1/2 oz./sec [15mL] flow-rate (per the illustration) can be sustained over a horizontal distance of 500 ft. [152M] when 3/8" I.D. [10mm] tubing is used. Feet: Take 1% of 500 ft. (500 x 1%) = 5. Which then is multiplied by the 22 ft. vertical, (22 x 5) = 110 ft. Subtract this product from the 500 ft. (500 - 110) =390. The results indicate a 390 ft. tubing run (horz./vert.) is possible, while the example only requires a distance of 370 ft. Meters: Take 3% of 152M (152 x 3%) = 4.56. Which then is multiplied by the 6.7M vertical, (4.56 x 6.7) = 30.5M. Subtract this product from the 152M (152-30.5)=121.5. The results indicate a 121.5M tubing run (horz./vert.) is possible, while the example only requires a distance of 113M. NOTE: Had the example above resulted in a value that was equal to, or less than the necessary total tubing run, consider a larger I.D. tubing or installation of a pump(s) in series using a SHURflo Vacuum Regulator. Pumps in Series for Long Distances Long tubing runs or high vertical lift can be achieved by installing pumps in series. Standard SHURflo Beverage pumps are not designed to have positive pressure on the inlet side. The SHURflo Vacuum Regulating Valve (VRV) allows the pump to receive liquid from a pressurized source. By positioning a VRV at the inlet of the secondary pump, incoming pressure is reduced to zero, permitting syrup to be drawn in under vacuum. SHURflo can recommend several other methods to meet the requirements for a particular installation, including Pressurized Inlet Pumps or Accumulators. Contact SHURflo for more information. FIRST PUMP SECOND PUMP GAS IN TO NEXT VRV/PUMP OR DISPENSER B-I-B VRV GAS TO NEXT PUMP Pump Sanitizing / Winterizing Sanitization of the SHURflo Beverage Gas Pump is required. The frequency of Sanitization is dependant on the concentrate type and its manufacturer’s requirements. Factors which also affect the frequency of this procedure are: temperature, concentrate volatility, facility conditions, installation and equipment. The sanitizing procedure fulfills a required 10 minute contact time with a 200 ppm Sodium Hypochlorite solution. Refer to SHURflo Service Bulletin #1025 for the N.S.F. listed sanitizing procedure for the SHURflo pump (only). Pumps that are subjected to freezing (below 32° F [0°C]) must be purged of fluid to prevent damage. Refer to SHURflo Service Bulletin #1025 for complete winterizing procedure. Refer to the equipment manufacturer’s instructions for sanitizing and winterizing procedure for carbonators, dispensers and tubing. Pumps that have been winterized and/or out of service for a period of time should be sanitized prior to being placed back in service. Never apply pressure to the pump’s liquid inlet. Pressurized tanks may damage internal components if used to sanitize or purge fluid from the pump (operating or not). Publication Number: TP01071 - 36 - © 2004, IMI Cornelius Inc. IntelliCarb Training Manual Pump Troubleshooting DOES NOT OPERATE / GAS APPLIED / DISPENSER VALVE OPEN • B-I-B empty or inlet tubing pinched off activating vacuum "sold-out". • Gas regulator over-pressurizing. (Pump stalled) • Outlet tube kinked or restricted. • Operated without fluid for excessive period. (Dry run) • Transfer tube and gas lines contaminated (syrup, rust, oil, etc.) [ensure clean gas supply, change out all contaminated pumps] • Internal damage of control cover. OPERATES BUT WILL NOT PRIME / DISPENSER VALVE OPEN [consult Start-up Procedure for proper priming] • Pump valves have no moisture/dry (add water/syrup to the inlet port with pump stroking slowly). • Vacuum leaks at Q.D., barb fitting clamps, or inlet fitting o-ring. • Debris in valve seats or warped/swollen valves. DOES NOT ACHIEVE SOLD-OUT WITH EMPTY B-I-B • Vacuum leaks at Q.D., barb fitting clamps, or inlet fitting o-ring. • Excessive amount of air in B-I-B from improper packaging. • Air trapped in outlet tubing and/or pump fluid chambers. AIR IN INLET AND/OR OUTLET TUBING • Vacuum leaks at Q.D. o-ring or barb fitting clamps. • Vacuum leaks at inlet fitting; o-ring pinched or missing. • Large amounts of air noticed only in the outlet tubing when pump operates (diaphragm/piston assemblies ruptured). STROKES WITH DISPENSER VALVE CLOSED • Air trapped in outlet tubing and/or pump fluid chambers (open outlet and purge air, check for vacuum leaks, or air in B-I-B). • Debris in outlet valves or warped/swollen valves. FLUID FROM EXHAUST OR VISIBLE WITHIN GAS INLET TUBING • Carbonator check valve. • Ensure clean gas supply. • Diaphragm/piston assemblies ruptured. • [change out all contaminated pumps] 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. - 37 - Publication Number: TP01071 IntelliCarb Training Manual DISPENSER TROUBLESHOOTING Should your unit fail to operate properly, check that there is power to the unit and that the hopper contains ice. If the unit does not dispense, check the following chart under the appropriate symptoms to aid in locating the defect. Trouble BLOWN FUSE OR CIRCUIT BREAKER. GATE DOES NOT OPEN. AGITATOR DOES NOT TURN. GATE DOES NOT OPEN OR IS SLUGGISH. AGITATOR TURNS. ICE DISPENSES CONTINUOUSLY. SLUSHY ICE. WATER IN HOPPER. BEVERAGES DO NOT DISPENSE BEVERAGES TOO SWEET Publication Number: TP01071 Probable Cause A. Short circuit in wiring Remedy A. Repair wiring. B. Inoperable gate solenoid. B. Replace gate solenoid. C. Inoperable agitator motor. A. No power. C. Replace agitator motor. A. Restore power. B. Bent depressor plate (does not actuate switch). B. Replace depressor plate. C. Inoperable dispensing switch. A. Inoperable gate solenoid. C. Replace dispensing switch. A. Replace gate solenoid. B. Excessive pressure against gate slide. B. Adjust gate slide. C. Replace rectifier. C. Inoperable rectifier. A. Stuck or bent depressor plate (does not release switch). A. Replace depressor plate. B. Inoperable dispensing switch. B. Replace dispensing switch. C. Improper switch installation. A. Blocked drain. C. Make sure switch is installed properly. A. Unplug drain. B. Unit not sitting level. B. Level the unit. C. Poor ice quality due to water quality or icemaker problems. C. Correct water quality or repair icemaker. D. Improper use of flaked ice. A. No 24 volts power to faucets. D. Call Service Person. A. Restore 24 volt power to faucets. B. No CO 2 pressure. A. Carbonator not operating. B. Restore CO 2 pressure. A. Repair carbonator. - 38 - © 2004, IMI Cornelius Inc. IntelliCarb Training Manual VALVE TROUBLESHOOTING Excess Foam Excess Foam Problem: excess foam Check product temperature Temp ? Check system above 40° below 40° Remove nozzle Clean ? yes Check flow rates no Correct ? Clean yes Check system no Problem corrected Set flow rate and ratio Problem corrected © 2004, IMI Cornelius Inc. - 39 - Publication Number: TP01071 IntelliCarb Training Manual Off Taste Off Taste Problem: off taste Remove nozzle Clean ? yes Check ratio no Clean Correct ? yes Check system no Problem corrected Set ratio Problem corrected Publication Number: TP01071 - 40 - © 2004, IMI Cornelius Inc. IntelliCarb Training Manual Valve Stuck Open Valve Stuck Open Problem: valve stuck open Check solenoid visually working ? yes (solenoid up) Check for damaged banjos no (solenoid down) Damage ? Check for power at solenoid Power ? no Undetermined problem call 800-238-3600 yes yes Replace dispensing switch Replace banjos Problem corrected Problem corrected no Clean or replace solenoid Problem corrected © 2004, IMI Cornelius Inc. - 41 - Publication Number: TP01071 IntelliCarb Training Manual No Product No Product Problem: no product Check solenoid visually yes Check system Check voltage (22-27 AC) no Check transformer Power ? yes Check resistance of coil Working ? no no Replace switch no yes Check switch 40 ohms ? yes Check system no Problem corrected Replace solenoid Problem corrected Publication Number: TP01071 - 42 - © 2004, IMI Cornelius Inc. IntelliCarb Training Manual CARBONATOR TROUBLESHOOTING WARNING: Disconnect electrical power to the unit to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service the internal components or the electrical wiring. If repairs to the carbonated water or the plain water systems must be made, disconnect electrical power to the Unit, then shut off CO2 and plain water sources. Dispense from dispensing valve until carbonator tank CO2 pressure has been relieved. Trouble CARBONATOR WILL NOT OPERATE. WATER PUMP MOTOR WILL NOT SHUT OFF. ERRATIC CYCLING OF CARBONATOR. WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP WATER. CARBONATOR CARBONATED WATER CAPACITY TOO LOW Probable Cause A. Power cord unplugged or circuit breaker open in panel box. Inoperative carbonator. Remedy A. Plug in power cord or reset circuit breaker. B. Call a qualified Service Person. B. Inoperative carbonator. A. Carbonator internal problem. A. Call a qualified Service Person. A. Carbonator internal problem. A. Call a qualified Service Person. A. Carbonator internal problems or a water supply line problem. A. Call a qualified Service Person. A. Carbonator internal problems or a water supply line problem. A. Call a qualified Service Person. B. Replace water filter. B. Water filter clogged. Solid State Carbonator Level Control MATING CONNECTION GREEN ORANGE RED WIRING HARNESS GROUND TERMINAL PROBE ASS’Y C HI LO SHORT ELECTRODE LONG ELECTRODE CARBONATED LIQUID LEVEL CONTROL CARBONATOR TANK FIGURE 40 NOTE: Carbonators that are equipped with a pump safety thermostat will have a black wire instead of green connected to the C terminal. Test Solid State Level Control 1. Remove all wires and: Carb. motor should run. 2. Jumper C to HI: Carb. motor should stop. Do not remove jumper wire. 3. Jumper LO to C: Motor should remain stopped. 4. Remove 1st jumper from C and HI: Motor should remain stopped. 5. Remove 2nd jumper from C and LO: Motor should start. 2ND JUMP C 1ST JUMP HI ORANGE LO RED FIGURE 41 If level control passes all above test, replace probe. © 2004, IMI Cornelius Inc. - 43 - Publication Number: TP01071 IMI Cornelius Inc. www.cornelius.com 800-238-3600
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