Service Manual Carbonator with Plain Water Booster
Contents
1. Shipping Storing Or Relocating Unit CAUTION All water must be purged from the Unit if exposed to freezing temperature A freezing am bient temperature will cause residual water remaining inside the Unit to freeze resulting in damage to internal components of the Unit 1 319642004 THIS PAGE LEFT BLANK INTENTIONALLY 319642004 2 GENERAL INFORMATION TO THE USER OF THIS MANUAL This Manual is a guide for servicing and maintaining this equipment Refer to Table of Contents for page loca tion of detailed information pertaining to questions that may arise A Parts Manual P N 319642003 for this equipment is available upon request Thie Unit must be serviced by a qualified Service Person This Unit contains no User serviceable parts CLAIMS INSTRUCTIONS Claims In the event of shortage notify the carrier as well as IMI Cornelius immediately In the event of dam age notify the carrier IMI Cornelius is not responsible for damage occurring in transit but will gladly render assistance necessary to pursue your claim Merchandise must be inspected for concealed dam age within 15 days of receipt WARRANTY REFERENCE INFORMATION Warranty Registration Date to be filled out by customer Unit Part Number Serial Number Install Date Local Authorized Service Center DESIGN DATA 41641700 49641700 49641702 49641704 Co ee Width 3 8 i Height 18 1 4 inches Depth 14 inches 3 319642004 Weight Dr2. Close the water inlet supply line shutoff valve 3 Note pressure setting on the carbonator CO regulator then loosen the lock nut and turn the CO regulator adjusting screw to the left counterclockwise until regulator gage reads 0 psi 4 Remove screws securing the cover assembly on the unit then remove the cover see Figure 4 5 Pull up on the carbonated water tank relief valve to release CO pressure from inside the tank 6 Loosen screen retainer then pull the screen retainer and the strainer screen from the water pump 7 Pull strainer screen from the screen retainer Clean any sediment from the screen retainer and water pump screen retainer port 8 Inspect the strainer screen for holes restrictions corrosion and other damage Discard damaged strainer screen 9 Check the O Ring on the screen retainer Replace worn or damaged O Ring P N 315349000 NOTE A strainer screen should always be used otherwise particles could foul the double liquid check valve 10 Install good or new strainer screen P N 315348000 in the screen retainer then screw the retainer into the water pump and tighten securely 11 Install Unit cover and secure with screws 12 Service the double liquid check valve refer to next paragraph SERVICING DOUBLE LIQUID CHECK VALVE SERVICING DOUBLE LIQUID CHECK VALVE see Figure 4 and 5 1 Refer to steps 1 through 5 in SERVICING WATER PUMP WATER INLET STRAINER SCREEN to prepare the carbonator for servicing
3. CONTROL SWITCHES 5 Connect electrical power to the Unit and allow the carbonated water tank to fill with water After the water pump motor cycles off disconnect electrical power from the Unit 6 Repeat steps 3 4 and 5 preceding until the correct switch adjustment is achieved 7 Connect electrical power to the Unit and allow carbonated water tank to fill with water 8 Using a container graduated in ounces open the Post Mix Dispenser dispensing valve and dispense until the water pump motor cycles on then immediately close the dispensing valve The total volume dispensed differential should be 8 to 20 ounces 9 Install cover assembly on the Unit and secure with screws WATER PUMP YEARLY MAINTENANCE OR AFTER WATER SYSTEM DISRUPTIONS WARNING The carbonator water pump waiter inlet strainer screen and the double liquid check valve must be inspected and serviced at least once a year under normal circumstances and after any disruptions plumbing work earthquake etc to the water supply system that might cause a turbulent erratic flow of water through the system A carbonator water pump with no screen or a defective screen in the strainer would allow foreign particles to foul the double liquid check valve gas could then back flow into the water system and create a health hazard in the water system 9 319642004 SERVICING WATER PUMP WATER INLET STRAINER SCREEN 1 Disconnect electrical power from the Unit 2
4. Unit Check for water leaks and tighten any loose connections Install upper and lower covers on the Unit and secure with screws WATER PRESSURE REGULATOR see Figure 3 Removal e AD SOV m 10 12 13 14 Disconnect electrical power from the Unit Close plain water inlet supply line shutoff valve Note pressure setting on the carbonator CO regulator then loosen lock nut and turn the CO regulator adjusting screw to the left counterclockwise until the regulator gage reads 0 Remove screws securing the cover assembly on the Unit then remove the cover Pull up on carbonated water tank relief valve to release CO pressure from inside the tank Remove screws securing lower access cover to the Unit then remove cover Disconnect water line swivel nut connector from the water pump outlet Be careful not to lose tapered gas ket from inside the water line swivel nut Disconnect water tank water line swivel nut connector from the double liquid check valve outlet Be careful not to lose tapered gasket from inside the water line swivel nut Disconnect Unit plain water outlet line from the bulkhead connector Be careful not to lose tapered gasket from inside the water out line swivel nut Loosen large nut securing the Unit plain water outlet bulkhead fitting in the cabinet then remove the nut Swing the water solenoid valve pressure regulator out far enough to disconnect electrical wires from the solenoid th
5. it s double liquid check valve Remove four screws securing lower access cover on the Unit then remove cover Disconnect water tank inlet line from the double liquid check valve assembly outlet Remove the double liquid check valve assembly from elbow in the water solenoid valve outlet Retain the white tapered gasket inside the inlet female end of the double liquid check valve assembly Disassemble each check valve as shown in Figure 5 Wipe each part with clean lint free cloth Inspect each part especially ball for burrs nicks corrosion deteri oration and other damage Discard the ball seat and any damaged or suspicious parts and replace with new parts during reassembly Reassemble check valves as shown in Figure 5 ALWAYS INSTALL NEW BALL SEAT QUAD RING P N 312418000 NOTE Make sure when assembling check valves together check valve female end with white tapered gasket inside is on inlet side of the double liquid check valve assembly 8 Assemble check valves together DO NOT OVER TIGHTEN 319642004 10 9 Make sure white tapered gasket is in place inside female end of the double liguid check valve assembly then install check valve assembly on elbow in the water solenoid valve outlet 10 Connect water tank inlet line to the double liquid check valve assembly outlet DO NOT OVER TIGHTEN 11 Turn carbonator regulator adjusting screw to the right clockwise until gage indicates pressure setting noted in step 3
6. of SERVICING WATER PUMP WATER INLET STRAINER SCREEN Tighten adjusting screw lock nut 12 Open the Unit water inlet supply line shutoff valve 13 Connect electrical power to the Unit The water pump will start and fill the carbonated water tank Pull up on the carbonated water tank relief valve to release trapped air from inside the tank 14 Check for water leaks and tighten any loose connections 15 Install lower access cover on the Unit and secure with four screws REPAIR AND REPLACEMENT LEVEL CONTROL SWITCH S see Figure 3 NOTE If level control switch s are determined to be at fault it will be necessary to test each switch individually for proper operation and replace switch s as necessary Removal 1 Disconnect electrical power from the Unit 2 Remove screws securing cover on the Unit then remove cover 3 Tag level control switches electrical wires for identification then disconnect electrical wires from switches 4 Remove two screws securing level control switches then remove switches from the Unit 5 Individually check each level control switch for proper operation Installation 1 Install new switch s by reversing removal procedure 2 Make sure electrical wiring is correct see applicable Figure 6 7 or 8 SAFETY THERMOSTAT see Figure 3 and 4 IMPORTANT If necessary to replace the safety thermostat use only Replacement Safety Thermostat Kit P N 318040088 with special additional instal
7. pump motor then remove cover 4 Disconnect safety thermostat electrical wire from electrical wire inside motor wiring compartment and termi nal on level control switches 5 Note position of safety thermostat on the water pump outlet then remove thermostat from the pump 6 Disconnect thermostat electrical wire from motor wiring compartment and wiring harness to level control switch then remove old thermostat from inside the Unit Installation 1 Install new safety thermostat by reversing removal procedure 2 Make sure electrical wiring is correct see applicable Figure 6 7 or 8 WATER PUMP see Figure 3 Removal 1 Disconnect electrical power from the Unit 2 Close the CO cylinder shutoff valve then close the water inlet supply line shutoff valve 3 Remove screws securing cover on the Unit then remove the cover 4 Pull up on carbonated water tank relief valve to release CO pressure from inside the tank 5 Disconnect water inlet line from the water pump inlet Be careful not to lose black tapered gasket from in side the water inlet line swivel nut 6 Disconnect water outlet line from the water pump outlet Be careful not to lose the white tapered gasket from inside the water outlet line swivel nut 7 Note position of safety thermostat on the water pump outlet then remove thermostat from the pump 8 Loosen screw on the pump to motor coupling enough to remove pump from the motor then remove pump 9 Remove elb
8. AX 43 1 2335 2930 BELGIUM BOSKAPELLEI 122 B 2930 BRAASCHAAT BELGIUM 32 3 664 0552 FAX 32 3 665 2307 BRAZIL RUA ITAOCARA 97 TOMAS COELHO RIO DE JANEIRO BRAZIL 55 21 591 7150 FAX 55 21 593 1829 ENGLAND TYTHING ROAD ALCESTER WARWICKSHIRE B49 6 EU ENGLAND 44 789 763 101 FAX 44 789 763 644 FRANCE 71 ROUTE DE ST DENIS F 95170 DEUIL LA BARRE PARIS FRANCE 33 1 34 28 6200 FAX 33 1 34 28 6201 GERMANY CARL LEVERKUS STRASSE 15 D 4018 LANGENFELD WEST GERMANY 49 2173 7930 FAX 49 2173 77 438 GREECE 488 MESSOGION AVENUE AGIA PARASKEVI 153 42 ATHENS GREECE 30 1 600 1073 FAX 30 1 601 2491 HONG KONG 1104 TAIKOTSUI CENTRE 11 15 KOK CHEUNG ST TAIKOKTSUE HONG KONG 852 789 9882 FAX 852 391 6222 ITALY VIA PELLIZZARI 11 1 20059 VIMARCATE ITALY 39 39 608 0817 FAX 39 39 608 0814 NEW ZEALAND 20 LANSFORD CRES P O BOX 19 044 AVONDALE AUCKLAND 7 NEW ZEALAND 64 9 8200 357 FAX 64 9 8200 361 SINGAPORE 16 TUAS STREET SINGAPORE 2263 65 862 5542 FAX 65 862 5604 SPAIN POLIGONO INDUSTRAIL RIERA DEL FONOLLAR E 08830 SANT BOI DE LLOBREGAT BARCELONA SPAIN 34 3 640 2839 FAX 34 3 654 3379 USA ONE CORNELIUS PLACE ANOKA MINNESOTA 612 421 6120 FAX 612 422 3255 25 319642004 IMI CORNELIUS INC AA CORPORAT
9. E HEADQUARTERS One Cornelius Place Anoka Minnesota 55303 6234 612 421 6120 800 238 3600
10. IS MANUAL CLAIMS WARRANTY REFERENCE INFORMATION DESIGN DATA Liit yi ite ein ii THEORY OF OPERATION SERVICE AND MAINTENANCE PREPARING UNIT FOR SHIPPING OR RELOCATING LUBRICATION x e tee ra lt Be ee Deere ADJUSTMENTS ee DEI er ea en ecke PLAIN WATER PRESSURE CARBONATOR CO2 REGULATOR ADJUSTING CARBONATED WATER TANK LIQUID LEVELS WATER PUMP YEARLY MAINTENANCE OR AFTER WATER SYSTEM DISRUPTIONS 2 panai up ident mo ren E a nM ELE SERVICING WATER PUMP WATER INLET STRAINER SCREEN SERVICING DOUBLE LIQUID CHECK VALVE REPAIR AND REPLACEMENT LEVEL CONTROL SWITCH S o n anoa nn SAFETY THERMOSTAT WATER PUMP TEE WATER PUMP MOTOR RELA OA MAC ds o Gs Led Lud beue A WATER SOLENOID VALVE WATER PRESSURE REGULATOR TROUBLESHOOTING WATER PUMP MOTOR WILL NOT OPERATE WATER PUMP MOTOR WILL NOT SH
11. N BLUE BLUE TRANSFORMER is MICRO SWITCH NO 3 DISPENSING VALVE 427 SOLENOID COIL bes MICRO SWITCH p 24 VAC TWO CONDUCTOR CORD CONNECTED TO NO 3 DISPENSING VALVE FA L SOLENOID COIL T NO 4 DISPENSING VALVE SOLENOID COIL m DISPENSING STATION 496417020 REV J FIGURE 8 WIRING DIAGRAM MODEL NO 496417020 21 319642004 H y 1 BRN Sr I 2d TEL E Och WHT d 14 om YEL Ly C NC BROWN BLACK BLUE GREEN YELLOW TRANSFORMER MICRO SWITCH 230V 24V x M t NO 3 DISPENSING VALVE Psi SOLENOID COIL CI MICRO SWITCH 24 VAC TWO CONDUCTOR CORD CONNECTED TO NO 3 DISPENSING VALVE SOLENOID COIL 4 DISPENSING VALVE SOLENOID COIL x A AA J DISPENSING STATION FIGURE 9 WIRING DIAGRAM MODEL NO 496417040 319642005 22 TROUBLESHOOTING IMPORTANT Only qualified personnel should service internal components or electrical wiring the applicable product tank then relieve the system pressure before proceeding If repairs N WARNING If repairs are to be made to a product system remove quick disco
12. OU L CARBONATOR with plain water booster Service Manual It is the responsibility of the Service Person to ensure that the water supply to the dispensing eguipment is provided with protection against backflow by an air gap as defined in ANSI ASME A112 1 2 1979 or an approved vacuum breaker or other such method as proved effective by test Water connections fixtures directly connected to a potable water supply shall be sized installed and maintained according to Federal State and Local laws O e When installing in an area regulated by the City of Los Angeles Plumbing and or Mechanical Codes a City of Los Angeles approved reduced pressure principle backflow preventer shall be installed on each potable water supply to each carbonator Manual Part No 319642004 IMI Cornelius Inc 1984 97 Control Code B March 27 1984 Revised March 11 1997 TABLE OF CONTENTS SAFETY RECOGNIZE SAFETY INFORMATION UNDERSTAND SIGNAL WORDS FOLLOW SAFETY INSTRUCTIONS CO2 CARBON DIOXIDE WARNING SHIPPING STORING OR RELOCATING UNIT GENERAL INFORMATION TO THE USER OF TH
13. UT OFF ERRATIC CYCLING OF CARBONATOR WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP WATER Capit iet WATER PUMP CAPACITY TOO LOW NO PLAIN WATER DISPENSED WHEN DISPENSING VALVE IS OPENED WARRANTY Sue asa eta aaa la a URN a aa aa CD atn 0 000 WHA gt gt ON N 23 319642004 TABLE OF CONTENTS cont d Page LIST OF FIGURES FIGURE 1 CARBONATOR WITH PLAIN WATER BOOSTER 5 FIGURE 2 LEVEL CONTROL SWITCHES 9 FIGURE 3 CARBONATOR ASSEMBLY COMPONENTS 12 FIGURE 4 WATER STRAINER SCREEN AND DOUBLE CHECK VALVE 13 FIGURE 5 CHECK VALVE ASSEMBLY 13 FIGURE 6 WIRING DIAGRAM MODEL NO 416417000 19 496417000 REVIA petere dareu keinen kode on 20 FIGURE 7 WIRING DIAGRAM MODEL NO 496417000 20 496417020 REV scons Anais ed donee os 21 FIGURE 8 WIRING DIAGRAM MODEL NO 496417020 21 FIGURE 9 WIRING DIAGRAM MODEL NO 496417040 22 LIST OF TABLES TABLE DESIGN DATA 00 rada Grin kee ae a nad ae RC du 3 319642004 T SAFETY INFORMATION Recognize Safety Information This is the safety alert symbol When you see this symbol on our machine or in this man
14. Y LEVEL SWITCH TRANSFORMER r MICRO SWITCH 115V 24V OR E E NO 3 DISPENSING VALVE at SOLENOID COIL 230 24V TOM E MICRO SWITCH 24 VAC TWO CONDUCTOR CORD p CONNECTED TO NO 3 DISPENSING VALVE SOLENOID COIL NO 4 DISPENSING VALVE SOLENOID COIL joe A ea i DISPENSING STATION FIGURE 6 WIRING DIAGRAM MODEL NO 416417000 19 319642004 24 VOLT CONNECTOR CORD WATER SOLENOID SAFETY THERMOSTAT WATER PUMP MOTOR STRAIN RELIEF E er CARBONATOR 7 BRN SOL vo 22 YEL 2H 4 51 ee 2 ER 1 RELAY TR 3 C BS _ YEL POWER CORD pue ne NC a M e LEVEL SWITCH PLACK BROWN BLUE YELLOW GREEN TRANSFORMER p MICRO SWITCH 115V 24V el OR _ Ee 230 24V NO 3 DISPENSING VALVE zx SOLENOID COIL pie MICRO SWITCH 24 VAC TWO CONDUCTOR CORD a CONNECTED TO NO 3 DISPENSING VALVE SOLENOID COIL NO 4 DISPENSING VALVE SOLENOID COIL FEB ns UN T 1 DISPENSING STATION 496417000 REV R FIGURE 7 WIRING DIAGRAM MODEL NO 496417000 319642004 20 BLK YELLOW GREE
15. d Clean balance mechanism Replace thermostat Correct water supply refer to manual for water supply requirements Clean or replace water strainer screen as instructed Straighten water supply line Remove restriction or replace water solenoid Clean Note Count number of turns bypass screw makes when removing and install same number of turns Replace water pump as instructed Clean or replace water strainer screen as instructed Inlet water supply must be at a minimum of 100 gallons per hour not to exceed water pressure of 30 psi Replace water filter Replace water pump as instructed Replace micro switch or coil Repair connection or repair or replace service cord Replace relay as instructed IMI CORNELIUS INC One Cornelius Place Anoka MN 55303 6234 Telephone 800 238 3600 Facsimile 612 422 3232 WARRANTY IMI Cornelius Inc warrants that all equipment and parts are free from defects in material and work manship under normal use and service For a copy of the warranty applicable to your Cornelius prod uct in your country please write fax or telephone the IMI Cornelius office nearest you Please provide the equipment model number and the date of purchase IMI Cornelius Offices AUSTRALIA P O 210 RIVERWOOD NSW 2210 AUSTRALIA 61 2 533 3122 FAX 61 2 534 2166 AUSTRIA AM LANGEN FELDE 32 A 1222 VIENNA AUSTRIA 43 1 233 520 F
16. ect electrical power from the Unit Close the water inlet supply line shutoff valve 2 3 Disconnect the plain water inlet supply line from the Unit 4 Disconnect the plain water outlet line from the Unit 5 Dispense from the dispensing valve until all carbonated water has been dispensed from the carbonated water tank Shut off CO gt supply to the Unit then disconnect CO gt inlet supply line from the Unit 7 Connect filtered dry compressed air 50 psi max to the Unit plain water inlet DO NOT USE GAS WHICH COULD CAUSE A HEALTH HAZARD Connecting compressed air to the Unit plain water inlet will blow residual water out of the water pump through the Unit plain water outlet 8 Disconnect compressed air from the Unit plain water inlet 9 Remove four screws securing the lower access cover on the Unit then remove the cover 10 Disconnect the water line swivel nut connector from outlet end of the double liguid check valve and allow water to drain out of the line 11 Remove the double liguid check valve from elbow in the water solenoid valve outlet Allow water to drain out of the double liguid check valve and the solenoid valve 12 Install the double liguid check valve on the water solenoid valve then connect water line to the double liquid check valve outlet 7 319642004 13 Install the Unit lower access cover and secure with four screws 14 Disconnect the carbonated water outlet line from the Unit 15 The Un
17. en disconnect the wires Remove water solenoid valve pressure regulator assembly from inside the cabinet Remove double liquid check valve from the water solenoid valve Be careful not to lose tapered gasket from inside the double liquid check valve inlet Remove water pressure regulator from tee fitting in the water solenoid valve inlet Remove fittings from old water pressure regulator inlet and outlet 17 319642004 installation 1 Install new water pressure regulator by reversing removal procedure MAKE SURE PIPE THREAD SEAL ING COMPOUND IS USED TO SEAL PIPE THREAD CONNECTIONS WHEN INSTALLING NEW REG ULATOR Restore pressure to the carbonator as noted in step 3 of removal procedure Open plain water shutoff valve Connect electrical power to the Unit Check for water leaks and tighten any loose connections Qus Install upper and lower covers on the Unit and secure with screws 319642004 18 24 VOLT CONNECTOR CORD WATER SOLENOID SAFETY THERMOSTAT WATER PUMP MOTOR STRAIN RELIEF B _ 5 y CARBONATOR V 1 BRN T A L i YEL E 31 dg E n ad RELAY 13 YEL POWER CORD BLACK OR BLUE WHITE OR BROWN GREEN OR YELLOW GREEN BLACK O Fa JN 55 E
18. it is now ready for shipping or relocating LUBRICATION The water pump motor bearings must be oiled periodically Refer to oiling instructions on the pump motor DO NOT OVER OIL ADJUSTMENTS PLAIN WATER PRESSURE REGULATOR NOTE The plain water outlet line water pressure regulator is factory set at 50 psig and should require no further adjustment If further adjustment is necessary turn the water pressure regulator handle to the right clockwise for higher psi or to the left counterclockwise for lower psi CARBONATOR REGULATOR NOTE To readjust the regulator to a lower setting loosen the adjusting screw lock nut then turn the screw to the left counterclockwise until pressure gage reads 5 psi lower than the new setting will be Turn the adjusting screw to the right clockwise until the gage registers the new setting then tight en the lock nut Loosen the CO regulator adjusting screw lock nut Turn the carbonator CO regulator adjusting screw to the right clockwise until the regulator gage reads a nominal 80 psig then tighten the lock nut DO NOT EXCEED 125 PSIG ADJUSTING CARBONATED WATER TANK LIQUID LEVELS see Figures 2 and 3 The carbonated water tank liquid levels pump cut in and cut out were adjusted at the factory and should require no further adjustments If an incorrect adjustment is suspected check and make neces sary adjustments as follows 1 Remove screws securing cover assembly on the U
19. lation instructions included with the kit 11 319642004 COVER RETAINING SCREWS 4 MOTOR WIRING WATER PUMP MOTOR COMPARTMENT COVER 0 SAFETY x THERMOSTAT j RELIEF VALVE CLAMPS 2 2 2 CARBONATED SQ S WATER O O Q A ZA TANK c 22 Zw pe 2 Z 2 gt 6 BALANCE CONTROL XX ZA 5 mw 2 7 WATER PUMP LEVEL CONTROL l A SWITCH S Las WATER PRESSURE REGULATOR Pd SR WATER SOLENOID VALVE RETAINING SCREW 2 RELAY 24 VAC LOWER ACCESS COVER RETAINING SCREW 4 DOUBLE LIQUID CHECK VALVE LOWER ACCESS COVER FIGURE 3 CARBONATOR ASSEMBLY COMPONENTS 319642004 12 WATER PUMP MOTOR L PUMP TO MOTOR COUPLING SAFETY THERMOSTAT P N 318040000 WATER STRAINER SCREEN P N 315348000 TAPERED GASKET WATER SOLENOID VALVE WATER LINE TOTANK L DOUBLE CHECK VALVE FIGURE 4 WATER STRAINER SCREEN AND DOUBLE CHECK VALVE a mero ame ya NO PARTNO 27796000 O 2 312415000 Flat Washer Stainless Steel 0 i 312418000 Ball Seat quad ring SE 212705000 6 17965000 INSTALL NEW BALL SEAT AT EACH SERVICING FIGURE 5 CHECK VALVE ASSEMBLY 13 319642004 Removal Disconnect electrical power from Unit 2 Remove screws securing cover on Unit then remove cover 3 Loosen two screws securing the wiring compartment cover on the water
20. motor shaft 180 degrees then recouple pump to motor Replace water pump as instructed Replace safety thermostat as instructed Remove foreign object Clean balance mechanism Tighten or replace line Replace level control switches as instructed Repair or replace balance mechanism 319642004 Trouble ERRATIC CYCLING OF CARBONATOR WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP WATER WATER PUMP CAPACITY TOO LOW NO PLAIN WATER DISPENSED WHEN DISPENSING VALVE IS OPENED 319642004 Probable Cause Balance mechanism spring obstructed or cocked Dirty balance mechanism Erratic safety thermostat Erratic water inlet supply to carbonator causing safety thermostat to interrupt electrical supply to water pump motor Water pump inlet water strainer screen dirty Kinked water supply line Restriction between water pump outlet and carbonator tank inlet or water solenoid not operating Foreign object in water pump bypass Water pump worn out Water pump inlet water strainer screen dirty Water supply capacity too low Water filter clogged Water pump worn out Inoperative dispensing valve micro switch or solenoid coil Poor electrical connection or broken 24 VAC service cord from dispensing valve to carbonator Inoperative carbonator 24 VAC relay 24 Remedy Remove obstructions Make sure spring is perpendicular to spring release and is not twiste
21. mp motor 319642004 COVER PLAIN WATER INLET CO INLET CARBONATED WATER OUTLET H POWER CORD BT E 6 S z SS lt PLAIN WATER OUTLET 24 VAC TWO CONDUCTOR CORD TO BE CONNECTED TO DISPENSING VALVE THAT WILL DISPENSE A STILL NON CARBONATED DRINK FIGURE 1 CARBONATOR WITH PLAIN WATER BOOSTER 5 319642004 THIS PAGE LEFT BLANK INTENTIONALLY 319642004 6 SERVICE AND MAINTENANCE This section describes service and maintenance procedures to be performed on the Unit IMPORTANT Only qualified personnel should service internal components or electrical wiring CAUTION This Unit must not be installed in an unsheltered outdoor location where it will be exposed to the elements CAUTION Never operate the carbonator with the water inlet supply line shutoff valve closed Dry running the water pump will burn out the pump A pump damaged in this manner is not covered by warranty CAUTION To prevent a fire hazard no object should be placed or stored on top of the Unit PREPARING UNIT FOR SHIPPING OR RELOCATING IMPORTANT All water must be purged from the Unit if exposed to a freezing temperature A freezing ambient will cause residual water inside the Unit to freeze resulting in damage to the internal components Damage of this type will void the Factory warranty Perform the following procedure to purge water from the Unit 1 Disconn
22. nit then remove the cover 2 With carbonated water tank full of water and water pump motor cycled off disconnect electrical power from Unit 3 Using container graduated in ounces open the dispensing valve and completely drain the carbonated wa ter tank Total carbonated water dispensed should be 40 to 60 ounces WARNING To avoid possible electrical shock which may cause serious injury or death make sure electrical power is disconnected from the Unit before attempting to adjust the level control switches 319642004 8 4 Under 40 ounces of carbonated water dispensed If total amount of carbonated water dispensed is under 40 ounces loosen screw securing the switch ad justment bracket and move the bracket up slightly Moving the bracket up allows weight of more water in the carbonated tank to push the tank further down before activating the level control switches which shuts off the water pump motor Tighten screw after adjustment Over 60 ounces of carbonated water dispensed If total measurement of carbonated water dispensed is over 60 ounces loosen screw securing the switch adjustment bracket and move the bracket down slightly Moving the bracket down allows weight of less wa ter in the carbonated water tank to activate the level control switches which shuts off the water pump motor Tighten screw after adjustment SWITCH ADJUSTMENT BRACKET SWITCH ACTUATOR 2 LEVEL CONTROL SWITCH 2 FIGURE 2 LEVEL
23. nnects from are to be made to the CO system stop dispensing shut off the CO supply then relieve the system pressure before proceeding If repairs are to be made to the refrigeration system make sure electrical power is disconnected from the unit Trouble WATER PUMP MOTOR WILL NOT OPERATE WATER PUMP MOTOR WILL NOT SHUT OFF Probable Cause A Power cord unplugged or circuit breaker open in panel box B Inoperative water pump motor C Dirty balance mechanism D Loose connections and or open electrical circuit E Overheated motor cut off by thermal overload protector F Inoperative level control switches G Binding or damaged balance mechanism H Water pump binding new or replacement pumps only Water pump damaged Safety thermostat inoperative A Foreign object restricting tank movement B Dirty balance mechanism Leak in carbonated water line D Inoperative level control switches E Binding or damaged balance mechanism 23 Remedy Plug in power cord or reset circuit breaker Replace water pump motor as instructed Clean balance mechanism Tighten connections and or repair open circuit Check line voltage Check for proper line voltage Check for restricted pump discharge or water solenoid not opening Replace level control switches as instructed Repair or replace balance mechanism Remove water pump from motor rotate pump or
24. ow fittings from the water pump inlet and outlet ports Installation Install new water pump by reversing Removal procedure and using the following instructions A Make sure pipe thread sealing compound is used on elbows fittings threads then install eloows in new water pump inlet and outlet ports 319642004 14 B Make sure drive tang on pump and slot in pump motor shaft are properly lubricated and aligned then install pump on the motor C Make sure tapered gaskets are inside water pump water inlet and outlet lines swivel nuts then con nect lines to pump Open CO cylinder valve then open water inlet supply line shutoff valve Connect electrical power to the Unit Check Unit for leaks during operation Tighten any loose connections Qu spe c0 m Install cover on Unit and secure with screws WATER PUMP MOTOR see Figure 3 Removal 1 Disconnect electrical power from the Unit 2 Remove screws securing cover on the Unit then remove the cover 3 Loosen screw on water pump to motor coupling enough to remove pump from motor then remove the pump 4 Loosen two screws securing the wiring compartment cover on the water pump motor then remove the cover 5 Tag electrical wires for identification then disconnect wires from terminals on the motor 6 Remove four screws securing the motor then remove the motor from inside the Unit Installation 1 Install the new pump motor by reversing removal procedure 2 Make su
25. re drive tang on the pump and slot in the pump motor shaft are properly lubricated and aligned then install pump on the motor 3 Make sure all wiring is correct See applicable Figure 6 7 or 8 RELAY 24 VAC See Figure 3 Removal 1 Disconnect electrical power from the Unit 2 Remove four screws securing lower access cover on the Unit then remove the cover 3 Tag electrical wires for identification then disconnect wires from the relay see Figure NO TAG 15 319642004 4 Remove two screws securing relay to the Unit then remove old relay Installation Install new relay by reversing removal procedure 2 Make sure electrical wiring is correct see Figure NO TAG 3 Install lower access panel and secure with four screws 4 Connect electrical power to the Unit WATER SOLENOID VALVE see Figure 3 Removal 10 11 12 13 14 15 Disconnect electrical power from the Unit Close plain water inlet supply line shutoff valve Note pressure setting on the carbonator CO regulator then loosen lock nut and turn regulator adjust ing screw to the left counterclockwise until regulator gage reads 0 Remove screws securing cover on the Unit then remove cover Pull up on carbonated water tank relief valve to release CO pressure from inside the tank Remove screws securing lower access covers to the Unit then remove the cover Disconnect water line swivel nu
26. t connector from the water pump outlet Be careful not to lose tapered gas ket from inside the water line swivel nut Disconnect water tank water line swivel nut connector from the double liquid check valve outlet Be careful not to lose tapered gasket from inside the swivel nut Disconnect Unit plain water outlet line from the bulkhead connector Be careful not to lose tapered gasket from inside the water outlet line swivel nut Loosen large nut securing the Unit plain water outlet bulkhead fitting in the cabinet then remove the nut Swing water solenoid valve pressure regulator out far enough to disconnect electrical wires from the sole noid then disconnect the wires Remove water solenoid valve pressure regulator assembly from inside the cabinet Remove double liquid check valve from the water solenoid valve Be careful not to lose tapered gasket from inside the double liquid check valves inlet Remove elbow fitting from the water solenoid valve outlet Remove water solenoid valve from tee fitting connected to the water pressure pressure regulator 319642004 16 Installation o wo Install new water solenoid valve by reversing removal procedure MAKE SURE PIPE THREAD SEALING COMPOUND IS USED TO SEAL PIPE THREAD CONNECTIONS WHEN INSTALLING THE NEW WATER SOLENOID VALVE Restore pressure to the carbonator as noted in step of removal procedure Open plain water shutoff valve Connect electrical power to the
27. ual be alert to the potentially of personal injury Follow recommended precautions and safe operating practices Understand Signal Words A signal word DANGER WARNING OR CAUTION is used with the safety alert symbol DANGER identi fies the most serious hazards Safety signs with signal word DANGER or WARNING A WA R N i N G are typically near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety mes A CAUTI O N sages in this manual Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs Keep safety signs in good condition Replace missing or damaged safety signs Learn how to operate the machine and how to use the controls properly Do not let anyone operate the machine without instructions Keep your machine in proper working condition Unauthorized modifications to the machine may impair function and or safety and affect the machine life Carbon Dioxide Warning CO Displaces Oxygen Strict Attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire CO and soft drink system If a gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Person nel exposed to high concentration of CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation
28. y Shipping mbient Operating Temperature Maximum Operating Pressure lectrical Requirements Model No 416417000 Operating Voltage Current Draw Table 1 Design Data cont d Model No 496417000 496417020 and 496417040 Operating Voltage Current Draw THEORY OF OPERATION 38 pounds 40 F to 100 125 PS 6 5 Amps 220 230 VAC 50 60 Hz 3 3 Amps 115 VAC 60 Hz A CO cylinder delivers carbon dioxide CO gt gas through a regulator to the carbonator tank When carbo nator tank calls for water an electrical circuit is completed through the level control switches which opens the water solenoid valve and also starts the water pump motor Plain water is pumped through the water solenoid valve into the carbonator tank which is carbonated by CO which is also entering the tank When carbonator tank is full the weight of the water in the tank forces the tank and the balance control mechanism down activat ing the level control switches which stops the water pump motor and also closes the water solenoid valve When still non carbonated drink dispensing valve is activated it sends an electrical signal to start the carbona tor water pump motor The carbonator water pump provides pressurized plain water to the dispensing valve which dispenses a still non carbonated drink When the dispensing valve lever is released the electrical signal to the carbonator water pump motor is cut off which stops the water pu
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