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Cornelius IntelliCarb Cold Beverage Dispenser - page 1
INTELLICARB T raining Manual Release Dat e: April 29 , 2004 Publicat ion Number : TP01071 Revision Date: NA Revision: A Visit the IMI Cor nelius we b site at www .cornelius. com fo r all you r Lite rature needs . ® ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 2
INTELLICARB T RAINING MA NUAL The pro ducts, te chnical informa tion, an d instru ction s contai ned in this manu al are s ubject to change without notic e. These inst ructions a re not intend ed to cov er all d etails or varia- tions of t he equi pment, nor to prov ide for e very po ssible conti ngency i n the i nstalla tion, operatio n or mai nte ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 3
InelliCarb Training Manual © 2004, IMI Cornelius Inc. - i - Publication Number: TP01071 T ABLE OF CONTENTS Intr oduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Unit Desc ript ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 4
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - ii - © 2004, IMI Cornelius I nc. Elect ric al Se ctio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 Carbonator Wi ring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Wirin ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 5
InelliCarb Training Manual © 2004, IMI Cornelius Inc. - 1 - Publication Number: TP01071 INTRODUCTION U NIT D ESCRIPTION • Built -in cold c arbonato r produc es bottl e-quali ty drink s every time • No seas onal CO 2 adjustme nts requir ed for c hanges in water tem peratu re • A com plete s ystem fo r simplif ied insta llation • Reduce s se ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 6
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 2 - © 2004, IMI Cornelius I nc. S PECIFICATIONS R EQUIREMENTS • Weight : counter mu st be lev el and abl e to supp ort 45 0 lbs. • Envir onment : Indoor i nstallat ion only • Te m p e r a t u r e : 40 to 100 o F • CO2 : 75 psi at un it • Syru p : 60 ps i., 0.70 - - 0.75 oun ce ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 7
InelliCarb Training Manual © 2004, IMI Cornelius Inc. - 3 - Publication Number: TP01071 I NSTALLATION 1. Loc ate the dispens er indoo rs on a l evel co unter top. A. LE G OPTI ON Unpack th e four (4) legs and insta ll them i nto the threaded h oles prov ided in th e bottom of the unit. Th e install er m ust prov ide flex ibility in the product and ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 8
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 4 - © 2004, IMI Cornelius I nc. Drains Use a 1 - 1/2 ” rigid pi pe (e.g. ABS on P .V .C.) this is to preven t kinking or col lapsing . Make sure to leave a 4 inch air gap be tween the dr ain line an d the fl oor drain. C ORNELIUS I NTELLI C ARB C ARBONATOR A SSEMBLY 1. Ice Drink / D r ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 9
InelliCarb Training Manual © 2004, IMI Cornelius Inc. - 5 - Publication Number: TP01071 C. Initial start-up procedure for carbonated wa ter system: T urn on the CO 2 su pply to th e car- bonator tan k, vent air from carbona tor tank by pulling the tank relie f valve. Turn on water supply to the pump. Co nnect electri cal power t o the pu mp and m ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 10
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 6 - © 2004, IMI Cornelius I nc. Ice Drin k Model ED 150/175 /300 Coldp late Cov er FIGURE 9 Ice Drin k Model E D200/250 Co ldplate C over FIGURE 10 3. T otal Fl ex System for Ice D rink Mo dels ED1 50/175/2 00/250/ 300 T otal Flex Manifold (Insulation Removed) FIGURE 1 1 T otal F lex is ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 11
Intelli Carb Trai ning Manu al © 2004, IMI Cornelius Inc. - 7 - Publication Number: TP01071 6. Check list for proper “f inished” drink carbona tion: A. Fill i ce storage hopper with ic e. B. Water supply must be fr om a contin uous sou rce (no tank supply) . C. Use only filtered water . D. Sup ply wa ter line to t he carbo nator pump must be a ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 12
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 8 - © 2004, IMI Cornelius Inc. MECHANICAL SECTION G ATE R ESTRICTOR P LATE NOTE: Disconnect power to dispenser before instal ling, removing, or adjusting restrictor . FIGURE 12 Adjustment This p late ma y be adju sted a s sho wn to redu ce or increa se the dispe nsing r ate of ice , esp ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 13
Intelli Carb Trai ning Manu al © 2004, IMI Cornelius Inc. - 9 - Publication Number: TP01071 I CE D IVERTER K IT 02394 NOTE: For dispensing Scotsma n, Wilshire, a nd Hoshiz aki compres sed ice c ubes: 1. Dis connect powe r to dispenser. 2. Remo ve Mer chandis er fro m dispenser. 3. Re move ic e chu te and dis card gat e restr ictor . 4. Ins tall ic ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 14
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 10 - © 2004, IMI Cornelius Inc. R EMOVAL AND R EPLACEMENT OF A GITATORS T o Rem ove Agitators For Cleaning (300 sh own) NOTE: All other models have only one agitation Assembly . FIGURE 14 1. Lift agitator and disc from uni t. 2. Remo ve O-Ri ng sta rting at n otch. Warm the O-Ring with ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 15
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 11 - Publication Number: TP01071 POST-MIX V ALVE SECTION S ET - UP I NSTRUCTIONS FIGURE 15 A side w ater lev er kit can be added to a val ve allow ing for dispens ing of water with out sy rup or con centr ate. The side water lev er can be a dded to either a carbona ted dr ink valve or a n ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 16
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 12 - © 2004, IMI Cornelius Inc. NOTE: The notc hed water piston on the Ultra Flow and UFB-1 va lve. results in at leas t one orifice in the sl eeve alw ays open. This eli mi- nates pulsating and smooths water flow at higher flow rates. In operati on the liqui d flows thr ough the kni fe ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 17
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 13 - Publication Number: TP01071 Adjusting Flow Rates Flow rates of the water and syrup a re adjusted based on the des ired r atio. For e xample: i f the de sired ratio is 5:1, then the flow rate of the water is 5 tim es that of th e syru p. If the desi red fini shed dr ink total flow rat ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 18
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 14 - © 2004, IMI Cornelius I nc. Setting Ratios If the ra tio varies and must be adjust ed often, it is pro bably the r esult of a restrict ed syrup system. It is then ti me to cle an and sanitize the syrup tub ing and cooling coils and chec k for oth er problem s such a s syr up pump s ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 19
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 15 - Publication Number: TP01071 SHURFLO S HURFLOW O VERVIEW SHUR flo ’ s Bever age Gas P ump su pplie s syrup under pr essure to a post- mix dispens er , wh ich mixe s the syrup with water to an exac t ratio (br ix). Th e pump i s used in conju nction with non- pressu rized Bag -In- Bo ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 20
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 16 - © 2004, IMI Cornelius I nc. S HURFLOW I NSTALLATION • As in dicated o n the pu mp, the outlet por t is to be mounte d up. • Pumps are to be mounte d at the same lev el or hi gher than the B-I- B. The best choice is to have the pump abov e the B- I-B. • INLET tubing from the B ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 21
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 17 - Publication Number: TP01071 PLUMBING T YPICAL I NSTALLATION FIGURE 21. T ypical Ins tallation ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 22
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 18 - © 2004, IMI Cornelius I nc. P LUMBING L AYOUT FIGURE 22. Plumbing Layo ut Regulator 55-60 psi CO2 Supply B C B A C D E E W ater F ilter BIB Syrup BIB Pump BIB Pump 6-10 Brand Fla vors 3-5 Per Side Carb Water In 3/8" Female Fir Nut 3/8" Barb Conn 1/4" Barb Conn 3/8&qu ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 23
IntelliCa rb Training Manual © 2004, IMI Cornelius Inc. - 19 - Publication Number: TP01071 F LOW D IAGRAM 1 XX (S IX F LAVOR M ODEL ) FIGURE 23. Fl ow Diagra m 1xx (Six F lavor Model) INST A L L FOR NON - -CA RB A S REQUIRED NON - -CA RB WA T E R PLUGGED S1 CHECK VA LV E OPTIONAL FOR DIET DRINKS OR ROOT B EER S5 S Y RU P T ANKS 15- - 50 PSIG PRESS ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 24
IntelliCa rb Training Manual Publication Number: TP0107 1 - 20 - © 2004, IMI Cornelius Inc. F LOW D IAGRAM 1XX (E IGHT F LAVOR M ODELS ) FIGURE 24. Flow Diagram 1XX (E ight Flavor Mo dels) INST A L L FOR NON - - CA RB A S REQUIRED NON - - CA RB WA T E R S8 CHECK VA L V E OPTIONAL FOR DIET DRINKS OR ROOT B EER S4 S5 SYRUP T A NK S 15 - - 50 PSI G S ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 25
IntelliCa rb Training Manual © 2004, IMI Cornelius Inc. - 21 - Publication Number: TP01071 F LOW D IAGRAM 2 XX (E IGHT F LAVOR M ODELS ) FIGURE 25. Flow Diag ram 2xx (Eight Flavor Models) INST ALL FOR NON–CARB AS REQUIRED S6 CHECK VA LV E OPTIONAL FOR DIET DRINKS OR ROOT BEER S1 SYRUP T ANKS 15–50 PSIG S2 S3 PRESSURE REGULA TORS 6 S1 COLD PLA ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 26
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 22 - © 2004, IMI Cornelius I nc. F LOW D IAGRAM 2 XX (T EN F LAVOR M ODEL S ) ) FIGURE 26. Flow Diagram 2xx (T en Flavor Models) S8 S1 S2 S9 S10 CHECK VA LV E PRESSURE REGULA TORS S3 S4 S5 8 S1 5 COLD PLA TE CARBONA TOR PUMP FIL TER OPTIONAL PRESSURE REGULA TOR CO2 CYLINDER F AUCETS POT ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 27
IntelliCa rb Training Manual © 2004, IMI Cornelius Inc. - 23 - Publication Number: TP01071 F LOW D IAGRAM 300 (T WELVE F LAVOR M ODELS ) FIGURE 27. Flo w Diagram 30 0 (T welve Flavo r Models) S8 S3 S2 CHECK VA LV E PRESSURE REGULA TORS S1 S6 S5 10 CARBONA TOR PUMP FIL TER OPTIONAL PRESSURE REGULA TOR CO2 CYLINDER FAUCETS POT ABLE WA TER SUPPLY S4 ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 28
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 24 - © 2004, IMI Cornelius I nc. ELECTRICAL SECTION FIGURE 28 . Electrical Box 1xx Single T ransforme r FIGURE 29. Ele ctrical Box 2xx Sin gle T ransforme r FIGURE 30 . Electrical Box 2XX Dual T ransformer Control Box Single T ransfo rmer Will Power up to Three V alves S imultaneously . ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 29
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 25 - Publication Number: TP01071 C ARBONATOR W IRING D IAGRAM RESET C ONNECTIONS Time Out Selection Pins. 7min/3 min/Disabled (Move Jumper t o Select) ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 30
IntelliCa rb Training Manual Publication Number: TP0107 1 - 26 - © 2004, IMI Cornelius Inc. W IRING D IAGRAM 1 XX (120V) FIGURE 31. W iring Diagra m 1xx (120 V) B L A C K B L A C K KEY SWITCH B L A C K O R A N G E R E D B L A C K R E D W H I T E BLACK WHI TE B L U E G R E E N BLUE RED PINK BLACK BLACK WHIT E BLACK BLACK BLACK PINK B L A C K W H I ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 31
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 27 - Publication Number: TP01071 S CHEMATIC 1 XX FIGURE 32 . Schematic 1xx T’ST AT LI GHT CA P A CI T O R AG I T A T OR M O T OR GAT E SOL EN OID B EVER A G E TRA NSFORM ER MOTOR HEATER OPT I ONA L LI GHT OPT I ONA L ST A R TER OPT I ONA L BALL AS T TI MER L1 L2 OP TI ON AL LOW I CE LE ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 32
IntelliCa rb Training Manual Publication Number: TP0107 1 - 28 - © 2004, IMI Cornelius Inc. W IRING D IAGRAM 2 XX (120V M ODEL ) FIGUR E 33. Wir ing Diagra m 2xx ( 120V Model) Q.C. CONNECTOR R E D B L A C K R E D B L A C K BLACK W H I T E BLACK W H I T E B L A C K Y E L L O W WHIT E WHIT E WHIT E BLACK RED G R E E N BLACK WHIT E R E D W H I T E B ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 33
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 29 - Publication Number: TP01071 W IRING D IAGRAM 2 XX (220/240V M ODELS ) FIGURE 34. W iring Diagram 2xx (220/24 0V Models) BROWN L POWER LINE FIL TER KEY SWITCH TO BEVERAGE V A L VES MOTOR HEA TER AGIT A TOR MOTOR B L A C K B L A C K YELLOW 4 NO NC L1 NC NO COM N L2 2 3 WHITE TO 24V TRA ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 34
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 30 - © 2004, IMI Cornelius I nc. W IRING D IAGRAM 2 XX (220/240V M ODELS ) FIGURE 35. W iring Diagram 2xx (220/24 0V Models) AGIT A TOR MOT OR GA TE SOLENOID OPTIONAL BEVERAGE TRANSFORMER MOTOR HEA TER OPTIONAL LIGHT OPTIONAL ST AR TER OPTIONAL BALLAST TIMER L2 L1 OPTIONAL ICE LEVEL OPT ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 35
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 31 - Publication Number: TP01071 W IRING D IAGRAM 300 (22 0/240V M ODELS ) FIGURE 36. W iring Diagram 300 (220/24 0V Models) YELLOW YELLOW YELLOW YELLOW W H I T E W H I T E W H I T E W H I T E B L A C K R E D B L A C K B L A C K OPTIONAL LIGHT SOCKET KEY SWITCH (OPTIONAL) TO HINGE BRACKET ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 36
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 32 - © 2004, IMI Cornelius I nc. W IRING D IAGRAM 300 (22 0/240V M ODELS ) FIGURE 37. W iring Diagram 300 (220/24 0V Models) DANGER ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SER VICING UNIT . SER VICE INFORMA TION RED BLACK BLACK WHITE BLACK B R N B L U B R N MOTOR HEA TER OPTIONAL ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 37
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 33 - Publication Number: TP01071 S CHEMATIC 300 (120V M ODELS ) FIGURE 38. Sc hematic 300 (12 0V Models) CAP ACITOR BEVERAGE P ANEL OPTIONAL BEVERAGE TRANSFORMER OPTIONAL ICE LEVEL OPTIONAL BEVERAGE V ALVES MOTOR HEA TER OPTIONAL LIGHT GA TE SOLENOID N.O.2 N.C.2 C VEND SWITCH AGIT ATOR MO ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 38
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 34 - © 2004, IMI Cornelius I nc. S CHEMATIC 300 (220/240V M ODE LS ) FIGURE 39 . Schematic 300 (220/2 40V Models) OPTIONAL BEV . TRANSFORMER LINE FIL TER AGIT AT OR MOTOR GA TE SOLENOID OPTIONAL BEV . TRANSFORMER MOTOR HEA TER OPTIONAL LIGHT OPTIONAL ST ARTER OPTIONAL BALLAST N.C1 L N.O ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 39
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 35 - Publication Number: TP01071 T ROUB LESHOOTING SHUR FLO W T ROUBLESHOOTING Pumping Capability For exam ple: The distance syr up can be delivered is limited by i nherent fact ors (restr ictions ) withi n the inle t & outlet si des of the b everage dispensing system. Due to vari anc ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 40
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 36 - © 2004, IMI Cornelius I nc. The chart indi cates that heavy syrup with 1/2 oz./sec [15m L] flow-rat e (per the ill ustration) can be sustained over a hor izontal distance of 500 ft. [152M] when 3/8" I.D. [10mm] tubing is used. Feet : T ake 1% of 500 ft. (500 x 1%) = 5. Which t ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 41
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 37 - Publication Number: TP01071 Pump T roubleshooting DOES NOT OP ERA TE / GAS APPLI ED / DISP ENSER V AL VE OPEN • B-I- B empty o r inl et tubing pinch ed off activati ng va cuum "s old-out" . • Gas regulator over-pres surizing. ( Pump s talled ) • Outle t tube kin ked o ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 42
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 38 - © 2004, IMI Cornelius I nc. D ISPE NSER T ROUBLESHOOTING Should y our unit fail to op erate properly , ch eck that t here is power to th e unit and that the hopper contains ice. If th e unit does n ot dispen se, chec k the following chart un der th e appropri ate sy mptoms to aid i ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 43
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 39 - Publication Number: TP01071 V ALV E T ROUBLESHOOTING Excess Foam Check product temperatur e Check system Remove nozzle below 40 ° Excess Foam Check flow rates Clean Probl em corrected Check system Set flow rate and rat io Problem corrected Correct ? ye s no Clean ? Temp ? above 40 ? ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 44
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 40 - © 2004, IMI Cornelius I nc. Off T as te Remove nozzle Clean no Off T aste Problem corrected Clean ? Check ratio Correct ? Check system Set ratio yes yes no Probl em corrected Probl em: of f tas te ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 45
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 41 - Publication Number: TP01071 V alve Stuck Open Check solenoid visuall y Check for damaged banjos Valv e Stuck Open Check for power at solenoid working ? ye s (solenoid u p) Pr oblem: val ve stuck open Undetermined problem call 800-238-3600 Damage ? Replace banjos no yes Problem co rr ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 46
IntelliCa rb Train ing Ma nual Publication Number: TP0107 1 - 42 - © 2004, IMI Cornelius I nc. No Product Check solenoid visuall y Check system Check vol tage (22-27 AC ) no No Produc t Check swi tc h Problem corrected Powe r ? Working ? yes no Problem: no product Check resistance of c oil 40 ohms ? Check system Replace solenoid Probl em corrected ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 47
IntelliCa rb Train ing Ma nual © 2004, IMI Cornelius Inc. - 43 - Publication Number: TP01071 C ARBONATOR T ROUBLESHOOTING W A RNING: Dis connect elect rical power to the uni t to prevent persona l inju ry before attempting any internal main tenance. O nly qua lified pe rsonnel shoul d servic e the inter nal com ponent s or the elec- trical wir ing ...
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Cornelius IntelliCarb Cold Beverage Dispenser - page 48
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