Page 2 - INTELLICARB TRAINING MANUAL; Trademarks and copyrights:
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 varia-tions of the equipment, nor to provide for every possible contingency in the installation...
Page 3 - InelliCarb Training Manual; TABLE OF CONTENTS
InelliCarb Training Manual © 2004, IMI Cornelius Inc. - i - Publication Number: TP01071 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Unit Description . . . . . . . . . . . . . . . . . . . . . . ....
Page 4 - IntelliCarb Training Manual
IntelliCarb Training Manual Publication Number: TP01071 - ii - © 2004, IMI Cornelius Inc. Electrical Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Carbonator Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 5 - INTRODUCTION
InelliCarb Training Manual © 2004, IMI Cornelius Inc. - 1 - Publication Number: TP01071 INTRODUCTION U NIT D ESCRIPTION • Built-in cold carbonator produces bottle-quality drinks every time • No seasonal CO 2 adjustments required for changes in water temperature • A complete system for simplified ins...
Page 7 - NSTALLATION; Locate the dispenser indoors on a level counter top.
InelliCarb Training Manual © 2004, IMI Cornelius Inc. - 3 - Publication Number: TP01071 I NSTALLATION 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...
Page 8 - Drains; ORNELIUS; FIGURE 1; Carbonator Time Out Reset Switch; FIGURE 2; tank as supply, tank pressure
IntelliCarb Training Manual Publication Number: TP01071 - 4 - © 2004, IMI Cornelius Inc. 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. C ORNELIUS I NTELLI C ARB C ARBONAT...
Page 9 - Carbonator Relief Valve Locations; supply has been hooked up. Failure to; Ice Drink Model ED175BCH (Lower Front Panel Removed); FIGURE 8
InelliCarb Training Manual © 2004, IMI Cornelius Inc. - 5 - Publication Number: TP01071 C. Initial start-up procedure for carbonated water system: Turn on the CO 2 supply to the car- bonator tank, vent air from carbonator tank by pulling the tank relief valve. Turn on water supply to the pump. Conne...
Page 10 - Ice Drink Model ED200/250 Coldplate Cover; carbonated water circuits.
IntelliCarb Training Manual Publication Number: TP01071 - 6 - © 2004, IMI Cornelius Inc. Ice Drink Model ED150/175/300 Coldplate Cover FIGURE 9 Ice Drink Model ED200/250 Coldplate Cover FIGURE 10 3. Total Flex System for Ice Drink Models ED150/175/200/250/300 Total Flex Manifold (Insulation Removed)...
Page 12 - MECHANICAL SECTION; ATE; Adjustment
IntelliCarb Training Manual Publication Number: TP01071 - 8 - © 2004, IMI Cornelius Inc. MECHANICAL SECTION G ATE R ESTRICTOR P LATE NOTE: Disconnect power to dispenser before installing, removing, or adjusting restrictor. FIGURE 12 Adjustment This plate may be adjusted as shown to reduce or increas...
Page 14 - EMOVAL; To Remove Agitators For Cleaning (300 shown); NOTE: All other models have only one agitation Assembly.; Lift agitator and disc from unit.
IntelliCarb Training Manual Publication Number: TP01071 - 10 - © 2004, IMI Cornelius Inc. R EMOVAL AND R EPLACEMENT OF A GITATORS To Remove Agitators For Cleaning (300 shown) NOTE: All other models have only one agitation Assembly. FIGURE 14 1. Lift agitator and disc from unit. 2. Remove O-Ring star...
Page 15 - POST-MIX VALVE SECTION; UP; Dimensions & Capacities; YSTEM; Water; Water Quality
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 11 - Publication Number: TP01071 POST-MIX VALVE SECTION S ET - UP I NSTRUCTIONS 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...
Page 18 - Setting Ratios; NOTE: Try raising the pressure on the pump before cleaning.; • Take another sample to verify the settings.; NOTE: Valve troubleshooting information is available on page 39.
IntelliCarb Training Manual Publication Number: TP01071 - 14 - © 2004, IMI Cornelius Inc. 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 othe...
Page 19 - SHURFLO; HURFLOW; The pump can be operated on regulated C; NOTE: Shurflow Troubleshooting information available on page 35.
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 15 - Publication Number: TP01071 SHURFLO S HURFLOW O VERVIEW 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...
Page 20 - • As indicated on the pump, the outlet port is to be mounted up.; • INLET; The maximum; must; TART; MAXIMUM; Symptoms of this kind can lead to a misdiagnosis of the
IntelliCarb Training Manual Publication Number: TP01071 - 16 - © 2004, IMI Cornelius Inc. S HURFLOW I NSTALLATION • 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...
Page 21 - PLUMBING; YPICAL; FIGURE 21. Typical Installation
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 17 - Publication Number: TP01071 PLUMBING T YPICAL I NSTALLATION FIGURE 21. Typical Installation
Page 22 - LUMBING; FIGURE 22. Plumbing Layout
IntelliCarb Training Manual Publication Number: TP01071 - 18 - © 2004, IMI Cornelius Inc. P LUMBING L AYOUT FIGURE 22. Plumbing Layout Regulator55-60 psi CO2 Supply B C B A C D E E Water Filter BIB Syrup BIB Pump BIB Pump 6-10 BrandFlavors 3-5 Per Side Carb Water In 3/8" Female Fir Nut 3/8" ...
Page 23 - FIG
Inte lliCarb T ra in ing Ma nual © 2004, I M I Cornelius I n c . - 19 - P ublic at ion Number: T P 01071 F LOW D IAGRAM 1 XX (S IX F LAVO R M OD EL ) FIG U R E 23. Fl ow Diagr a m 1 xx ( S ix F lavo r Mo del) INSTALL FOR NON --CARB AS REQUIRED NON --CARB WATER PLUGGED S1 CHECK VALVE OPTIONAL FOR DIE...
Page 24 - IG
Inte lliCarb T ra in ing Ma nual Publicat ion Num ber: T P 0107 1 - 20 - © 2004, IM I Cornelius I n c. F LOW D IAG R AM 1XX (E IGHT F LAV O R M ODELS ) F IG U R E 24. Flow Dia g ram 1XX (E ight F lavor Mo dels ) INSTALL FOR NON --CARB AS REQUIRED NON --CARB WATER S8 CHECK VALVE OPTIONAL FOR DIET DRI...
Page 25 - LOW; Flav
Inte lliCarb T ra in ing Ma nual © 2004, I M I Cornelius I n c . - 21 - P ublic at ion Number: T P 01071 F LOW D IAGRAM 2 XX (E IGH T F LAVOR M ODELS ) FI G URE 2 5 . Flow Diag ram 2 x x (Eight Flav or M ode ls) INSTALL FORNON–CARB AS REQUIRED S6 CHECKVALVE OPTIONAL FOR DIET DRINKS OR ROOT BEER S1 S...
Page 28 - ELECTRICAL SECTION; FIGURE 28. Electrical Box 1xx Single Transformer
IntelliCarb Training Manual Publication Number: TP01071 - 24 - © 2004, IMI Cornelius Inc. ELECTRICAL SECTION FIGURE 28. Electrical Box 1xx Single Transformer FIGURE 29. Electrical Box 2xx Single Transformer FIGURE 30. Electrical Box 2XX Dual Transformer Control Box Single Transformer Will Power up t...
Page 29 - ARBONATOR
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 25 - Publication Number: TP01071 C ARBONATOR W IRING D IAGRAM RESET C ONNECTIONS Time Out S elec tion Pins . 7min/3 min/Disabled (Mo ve Jumper t o S elec t)
Page 30 - IAGRAM
Inte lliCarb T ra in ing Ma nual Publicat ion Num ber: T P 0107 1 - 26 - © 2004, IM I Cornelius I n c. W IRIN G D IAGRAM 1 XX (120V) FIG U R E 31. W ir ing Diagr a m 1 xx ( 120 V) B LA C K B LA C K KEY SWITCH B LA C K O R A N G E R E D B LA C K R E D W H IT E BLACK WHITE B LU E G R E E N BLUE RED PI...
Page 31 - CHEMATIC; FIGURE 32. Schematic 1xx
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 27 - Publication Number: TP01071 S CHEMATIC 1 XX FIGURE 32. Schematic 1xx T ’ S TA T L IG H T C A PA C ITO R A G ITA TO R M O TO R G A T E S O L E N O ID B E V E R A G E T R A N S F O R M E R M O TO R H E A T E R O P T IO N A L L IG H T O P T ...
Page 33 - IRING
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 29 - Publication Number: TP01071 W IRING D IAGRAM 2 XX (220/240V M ODELS ) FIGURE 34. Wiring Diagram 2xx (220/240V Models) BROWN L POWER LINE FIL TER KEY SWITCH TO BEVERAGE V AL VES MOTOR HEA TER AGIT ATOR MOTOR B L A C K B L A C K YELLOW 4 NO...
Page 36 - SER
IntelliCarb Training Manual Publication Number: TP01071 - 32 - © 2004, IMI Cornelius Inc. W IRING D IAGRAM 300 (220/240V M ODELS ) FIGURE 37. Wiring Diagram 300 (220/240V Models) DANGER ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SER VICING UNIT . SER V ICE INFORMA TION RED BLACK BLACK WHITE BLAC...
Page 39 - TROUBLESHOOTING; SHUR; FLOW; Pumping Capability; • Syrup viscosity and temperature (coldplate,; MAXIMUM HORIZONTAL TUBING; VISCOSITY
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 35 - Publication Number: TP01071 TROUBLESHOOTING SHUR FLOW T ROUBLESHOOTING Pumping Capability For example: The distance syrup can be delivered is limited by inherent factors (restrictions) within the inlet & outlet sides of the beverage d...
Page 40 - in series; Pumps in Series for Long Distances; The frequency of Sanitization is; Factors which also
IntelliCarb Training Manual Publication Number: TP01071 - 36 - © 2004, IMI Cornelius Inc. 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...
Page 41 - Pump Troubleshooting; Operated without fluid for excessive period.
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 37 - Publication Number: TP01071 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) • Out...
Page 42 - ISPENSER; Trouble; A. Short circuit in wiring
IntelliCarb Training Manual Publication Number: TP01071 - 38 - © 2004, IMI Cornelius Inc. D ISPENSER T ROUBLESHOOTING 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 ...
Page 43 - ALVE; Excess Foam
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 39 - Publication Number: TP01071 V ALVE T ROUBLESHOOTING Excess Foam Check product temperature Check system Remove nozzle below 40° Excess Foam Check flow rates Clean Problem corrected Check system Set flow rate and ratio Problem corrected Cor...
Page 44 - Off Taste
IntelliCarb Training Manual Publication Number: TP01071 - 40 - © 2004, IMI Cornelius Inc. Off Taste Remove nozzle Clean no Off Taste Problem corrected Clean ? Check ratio Correct ? Check system Set ratio yes yes no Problem corrected Problem: off taste
Page 45 - Valve Stuck Open
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 41 - Publication Number: TP01071 Valve Stuck Open Check solenoid visually Check for damaged banjos Valve Stuck Open Check for power at solenoid working ? yes (solenoid up) Problem: valve stuck open Undetermined problem call 800-238-3600 Damage...
Page 46 - No Product
IntelliCarb Training Manual Publication Number: TP01071 - 42 - © 2004, IMI Cornelius Inc. No Product Check solenoid visually Check system Check voltage (22-27 AC) no No Product Check switch Problem corrected Power ? Working ? yes no Problem: no product Check resistance of coil 40 ohms ? Check system...
Page 47 - Solid State Carbonator Level Control
IntelliCarb Training Manual © 2004, IMI Cornelius Inc. - 43 - Publication Number: TP01071 C ARBONATOR T ROUBLESHOOTING WARNING: Disconnect electrical power to the unit to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service the internal componen...
