Cornelius Non-Carbonated Post-Mix Beverage Dispenser User's Manual
Contents
1. OPERATIONS Starting And Stopping the Unit E ON OFF switch Key lock switch 1 Push power ON OFF switch to ON to power on the unit 2 Insert key into key lock and turn to the ON to activate valves Dispensing Product To dispense beverage press a cup or glass against the lever or push the button on the valve cover Replenishing Concentrate Supply Bag In Box System 1 Disconnect the concentrate tube from the empty bag in box and remove the empty box 2 Rinse the disconnects in warm water to remove any concentrate residue 3 Install a full bag in box and connect the concentrate tube ADJUSTMENTS Water to Concentrate Ratio Adjustment The ratio adjustment should only be done by a qualified service person Publication Number 859000159INS 6 2003 IMI Cornelius Inc CCD Non Carbonated Impulse Installation amp Operations Manual CLEANING CHECKS Daily Cleaning 1 Remove nozzle assembly and rinse with warm not hot water If possible soak nozzle assembly over night in carbonated water then rinse with warm water Diffuser Nozzle gt 2 Wash external surfaces with mild soap solution rinse with clean water and wipe dry Remove the drip tray wash with mild soap solution rinse and dry NOTE Do not use abrasive or harsh cleaners on the unit Daily Checks 1 Check CO supply 2 Check concentrate supply Sanitizing Concentrate Systems The concentrate systems should be saniti2. CARBONATOR KON CARD MANIFOLD W CO2 IN DUAL A 60 PSI A LIQUID EH ey CHECK VALVE i PLAIN WATER INLET i SYRUP COIL CIRCUIT 2 2 S WTR COIL ge Wee WATER IN 45 PSI MAX L is Y 1 E i al SIRUP C2 MOTUR AARAA SYRUP INLET Internal Carbonator DISPENSING VALVE 6 External Carbonator Publication Number 859000159INS 10 2003 IMI Cornelius Inc eines D Non Carbonated Impulse Installation amp Operations Manual MITE C D N ee WATER WATER FILTER INSTALLATION 2003 IMI Cornelius Inc 11 Publication Number 859000159INS Non Carbonated Impulse Installation amp Operations Manual TROUBLESHOOTING Trouble WATER TO CONCENTRATE RATIO TOO LOW OR TOO HIGH Troubleshooting Dispensing System Probable Cause Dispensing valve concentrate flow regulator not properly adjusted Remedy Adjust Water to Concentrate Ratio as instructed CO gas pressure to concen trate pumps insufficient to oper ate pumps Adjust concentrate pumps CO2 regulator as instructed ADJUSTMENT OF DISPENSING VALVE CONCENTRATE FLOW REGULATOR DOES NOT INCREASE TO DESIRED WATER TO CONCENTRATE RATIO No concentrate supply Replenish concentrate supply as instructed Concentrate supply container not securely connected into concentrate system Securely connect concentrat
3. ONLY CONCENTRATE DIS PENSED Water inlet supply line shutoff valve closed Open water inlet supply line shutoff valve Publication Number 859000159INS 2003 IMI Cornelius Inc Non Carbonated Impulse Installation amp Operations Manual Troubleshooting Refrigeration System COMPRESSOR DOES NOT OPERATE Ice bank sufficient Refrigeration not called for Unit power cord unplugged or control board power switch in OFF position Plug in power cord or place switch in ON position No power source blown fuse or tripped circuit breaker Replace fuse or reset circuit breaker note Fuse or circuit breaker are not part of unit Low voltage at compressor ter minals Voltage must be at least 103 volts at the compressor termi nals when compressor is trying to start Loose disconnected or broken wiring Tighten connections or replace broken wiring Overload protector cut out over heated compressor Con denser fan motor not operating as required Compressor will cool enough to restart Do not overdraw cool ing capacity of unit Refer to CONDENSER FAN MOTOR NOT OPERATING in this sec tion Inoperative overload protector or start relay Replace inoperative part as Inoperative ice bank control Replace ice bank control Inoperative compressor Replace compressor COMPRESSOR WILL NOT STOP AFTER SUFFICIENT I
4. Remove all bag valves from bag in box concentrate containers outlet tubes connectors B Connect bag in box concentrate containers into the concentrate systems 2 Place waste container under dispensing valves Dispense from all dispensing valves to permit con centrate to purge all potable water from the concentrate systems and the dispensing valves Con tinue to dispense from the dispensing valves until only concentrate is dispensed from the concentrate systems and valves 3 Dispose of waste sanitizing solution in a sanitary sewer not in a storm drain then thoroughly rinse the inside and the outside of the container that was used for sanitizing solution to remove all sanitiz ing solution residue Publication Number 859000159INS 8 2003 IMI Cornelius Inc Non Carbonated Impulse Installation amp Operations Manual REFERENCE MATERIAL KLuo d012u0G429 eusaqul
5. on and then the units power switch Check to see that the agitator motor has started After about three minutes the compressor should start If the agitator or compressor do not start call Technical Services Connect Concentrate and Water Lines 1 Route concentrate and plain water lines from the back side of the unit and under the unit to the front Connect them to the appropriate inlet connections NOTE If water supply pressure to the unit is less than 40 psi a water pressure booster is required If water supply pressure to the unit is more than 50 psi a water pressure regulator must be installed in the supply line NOTE A water shutoff valve and water filter in the water supply line are recommended 2 Make the connection behind the splash panel to the marked 3 8 water tubes 3 Connect optional drip tray drain hose if used Be sure the knock out in the drip pan has been removed if drain hose is used 4 Bleed each valve into a bucket until water comes out 5 Besure that all concentrate sources are connected and on Bleed each valve into a bucket until concentrate comes out 6 Reinstall drip tray and position water bath overflow hose in drip tray indent 7 Check the system for gas leaks by pressurizing the system and then turning off the cylinder valve Wait a couple of minutes and check the cylinder gauge to see if the pressure has dropped 8 Check the system for water and concentrate leaks Adjust Water To Concentrate
6. pins on the ice bank control probe The ice bank control module senses this by measuring the differ ence in electrical resistance between the water and the ice When the ice on the evaporator coil becomes thick enough it covers the three stainless steel pins on the ice bank control probe The control module senses there is enough ice and turns the refrigeration compressor and the con denser fan motor off The Unit remains turned off until the ice bank control three stainless steel pins are free of ice Once this happens the ice bank control module starts the refrigeration com pressor and the condenser fan motor Publication Number 859000159INS Non Carbonated Impulse Installation amp Operations Manual Geha NOTE Make sure that the electrical power circuit breaker is switched off or the fuse removed Before connecting electrical power to the unit refer to nameplate to verify the power require ments A Remove the following front merchandiser by removing two screws on the top and lifting up key switch wires hood by removing two screws on the top and lifting up and forward B Remove second valve from the left to facilitate routing of the new cord C First route the new cord up behind the valve panel and through the cutout in the pump deck Use the already attached wire tie fastener on the deck to secure the cord D Connect cord to the receptacle on the refrigeration deck E Turn the circuit breaker
7. CE BANK IS FORMED Inoperative thermistor Replace thermistor Damaged ice bank control wire Repair ice bank control Inoperative control board Replace control board COMPRESSOR OPERATED CONTINUOUSLY BUT DOES NOT FORM SUFFICIENT ICE BANK Cooling capacity is exceeded by overdrawing Reduce amount of drinks drawn per given time Unit located in excessively hot area or air circulation through condenser is restricted Relocate unit or determine and correct condenser coil restric tions Refrigeration system leak Repair refrigeration system NOTE The ice bank freezes from the bottom of the evaporator upward A refrigerant leaks or insufficient charge might show an ice bank at bottom and not at the top of evaporator NOTE If overload protector cuts our compressor condenser fan motor will continue to operate otherwise troubleshooting condenser fan motor problems are the same as COMPRESSOR DOES NOT OPERATE paragraph plus the preceding CONDENSER FAN MOTOR NOT OPERATING Jumper cord loose or discon nected from motor or terminal block Broken wire in cord Tighten connections or replace cord Fan blade obstructed Remove obstruction noperative condenser fan motor Replace condenser fan motor AGITATOR MOTOR NOT OPER ATING Unit power cord or refrigeration system power cord unplugged Plug in power cord 2003 IMI Corneli
8. Cinellus IMPULSE Non Carbonated Post Mix Beverage Dispenser Installation amp Operation Manual Release Date December 16 2003 Publication Number 859000159INS Revision Date NA Revision A www cornelius com Impulse Installation and Operation Manual CGindius gt CONTACT INFORMATION This an abbreviated manual Keep this manual in case there are questions about operating the unit The products technical information and instructions contained in this manual are subject to change with out 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 Appropriate safety precautions should be followed and all local safety and construction requirements should be met To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact IMI Cornelius Inc Internet Corporate Headquarters E One Cornelius Place www cornelius com Anoka MN 55303 6234 E mail U S A tech service 8 cornelius com In the U S A Outside the U S A phone 763 421 6120 phone 763 421 6120 800 238 3600 Trademarks and copyrights Aurora Cornelius Decade Hydro Boost Ol
9. Ratio 1 Remove valve front cover and install concentrate diversion assembly in place of nozzle a E Concen Water flow adjuster on trate diver sion tube en Concentrate adjuster on right Ratio cup 2 Adjust carbonated water flow to the desired rate such as 2 50 oz sec Turn the adjuster 1 4 of a turn at a time and recheck the flow To increase flow turn clockwise 3 Adjust the concentrate to water ratio of each valve using the concentrate adjuster on the left side of each valve Hold cup under valve and dispense beverage for a specific time such as 4 seconds Publication Number 859000159INS 4 2003 IMI Cornelius Inc eines D Non Carbonated Impulse Installation amp Operations Manual Adjusting Flow Rates Flow rates of the water and concentrate 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 concentrate If the desired finished drink flow rate is 3 0 ounces per second then the water flow rate is 2 5 oz sec and the concentrate flow rate is 0 5 oz sec The water at 2 5 oz sec is five times the 0 5 oz sec con centrate flow rate Flow Rates oz sec Based on 5 1 Ratio Concentrate oz sec Finished Drink oz sec Water oz sec 2003 IMI Cornelius Inc 5 Publication Number 859000159INS Non Carbonated Impulse Installation amp Operations Manual Gini gt OPERATIONS
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11. e 18 inches above 6 inches on sides and rear COs sss 75 psi 5 25 bar at unit with internal carbonator Concentrate 60 psi VVater 50 psi maximum Electrical see nameplate on unit for electrical requirements Electrical Requirements Before connecting electrical povver to the unit refer to nameplate to verify povver requirements DANGER To avoid possible serious injury or death the ELCB earth leakage circuit breaker must be installed in electrical circuit of all 50 Hz units WARNING To avoid possible electrical shock the unit must be electrically grounded using the green grounding screw provided inside the electrical contractor box CAUTION The wiring must be properly grounded and connected through a 10 amp disconnect switch slow blow fuse or equivalent HVAC R circuit breaker ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES MAKE SURE UNIT IS PROP ERLY GROUNDED PPP Publication Number 859000159INS 2 2003 IMI Cornelius Inc Non Carbonated Impulse Installation amp Operations Manual INSTALLATION PROCEDURE Counter top Installation NOTE Optional 4 inch legs p n 3184 will elevate the unit 4 inches above counter order 4 legs 1 2 3 Place the unit on a level counter capable of supporting at least 400 pounds Remove drip tray and front access panel Turn power switch off then remove screw located next to the power switch and the scr
12. e supply container into concen trate system Concentrate pumps CO2 regu lator out of adjustment Adjust concentrate pumps CO2 regulator as instructed Dispensing valve syrup flow regulator syrup tank quick dis connect or syrup line restricted Sanitize syrup system as instructed Improper Baume of concen trate Replace concentrate supply Dirty or inoperative concen trate flow regulator Disassemble and clean dis pensing valve concentrate flow regulator Tapered plastic washer inside tube swivel nut connection dis torted from being over tight ened restricting concentrate flow Replace plastic washer Make sure it seats properly ADJUSTMENT OF DISPENSING VALVE CONCENTRATE REGU LATOR DOES NOT DECREASE TO DESIRED WATER TO CON CENTRATE RATIO Dirty or inoperative concen trate flow regulator Disassemble and clean dis pensing valve concentrate flow regulator NO PRODUCT DISPENSED Dispensing valves keyed lock out switch in OFF position Place keyed lock out switch in ON position No electrical power to Unit Plug in Unit power cord or check for blown fuse or tripped circuit breaker Disconnected dispensing valve power cord Connect dispensing valves power cord Disconnected or broken wiring to dispensing valves Connect or replace wiring Inoperative transformer or dis pensing valve solenoids Replace inoperative part
13. e all bag in box concentrate containers concentrate outlet tubes in container containing potable water 1 Flush detergent solution out of the concentrate system and dispensing valve as follows A Place waste container under applicable dispensing valve B Activate the dispensing valve for one minute to purge all detergent solution and flush out the con centrate system 2003 IMI Cornelius Inc 7 Publication Number 859000159INS Non Carbonated Impulse Installation amp Operations Manual Geha gt 2 Connect potable water source to the remaining concentrate systems and flush detergent solution out of the concentrate systems as instructed in step 9 preceding 3 Remove potable water source from the concentrate system STEP 3 Sanitize Concentrate Systems 1 Using five gallon container bag in box system prepare sanitizing solution using 70 F 21 C to1009F 38 C potable water and 0 5 oz 15 ml of non scented household liquid bleach that con tains a 5 2596 sodium hypochlorite concentration to one gallon of potable water This mixture must not exceed 200 PPM of chlorine Stir sanitizing solution to thoroughly mix 2 Bag in Box Concentrate System Place all bag in box concentrate containers concentrate outlet tubes in container containing sanitiz ing solution 3 Sanitize the concentrate system and dispensing valve as follows A Place waste container under applicable dispensing valve B Activate the dispensing
14. ea before attempting to repair the leak Personnel exposed to high concentration of CO gas will experience tremors which are followed rapidly by loss of consciousness and death SYSTEM DIMENSIONS WARNING CO Displaces Oxygen Strict Attention must be observed in the pre Height 27 inches Width 16 inches Depth 26 7 8 inches Shipping Weight 120 pounds approx 2003 IMI Cornelius Inc 1 Publication Number 859000159INS Non Carbonated Impulse Installation amp Operations Manual Geha gt INSTALLATION CAUTION Only trained and certified electrical plumbing and refrigeration techni cians should service this unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES NOTE Water pipe connections and fixtures directly connected to the potable water supply must be sized installed and maintained in accordance with NSF Standard 18 as well as Federal State and Local codes NOTE It is the installer s responsibility to ensure that the water supply is equipped with protec tion against backflow This protection can be an air gap as defined by ANSI ASME A112 1 2 1979 or by an approved vacuum breaker or other approved method INSTALLATION REQUIREMENTS Requirements Summary Weight front or rear counter must be level and able to support 400 Ibs Environment indoor installation only Temperature 40 to 110 F ambient temperature Clearanc
15. ew at top of front panel Next remove front panel disconnect wires to valve key lock switch and peal back magnetic decals from the top Lift off top center section Pull water concentrate and CO lines through counter or wall To comply with NSF International requirements the unit must be sealed to the counter top and all access holes in the unit base must be sealed or the unit can be installed using the optional 4 inch legs P N 3184 Caulk seal the unit to the counter using Dow Corning RTV 731 or equivalent approved sealant Pull plastic wire tie to remove hitch pin from condenser fan motor assembly this pin is only needed during shipping Hitch Pin Wire Tie via 4 Fill the water bath with clean water until it comes out the overflow tube Make sure the overflow tube is not blocked or plugged Use low mineral tap water not distilled or deionized water Fill water bath through hole in top NOTE Water bath must be filled with water before the unit will run GLOBAL ICE BANK CONTROL GIBO THEORY OF OPERATION 2003 IMI Cornelius Inc Once electrical power is supplied to the Unit the agitator motor will start There will be a three minute time delay before the refrigeration compressor and the con denser fan motor will start This three minute time delay will take place each time electrical power to the Unit is interrupted The Unit will continue to operate until ice covers all three stainless steel
16. g the Unit aks 6 DISPENSING PIOduUu i tinkas pare a a E wae A A caw ate St 6 Replenishing Concentrate Supply 4 4444 LL LL LL 6 Adjust Menis edi dees EE a a toga E ARE pl 6 Water to Concentrate Ratio Adjustment u e 6 Cleaning amp Checks Lee skusti Se e Ce eA ee FREUE 6 Daily Cleaning o sacs Sete od su REESE RAE SUE hd Es SES aa et 6 Dally Ene A me oca ks a te Als ak at ra ode te ba 7 Sanitizing Concentrate Systems u e Lu ee 7 REFERENCE MATERIAL aiskiai ks akis eee esse aa dese 9 Wind Daga aa 2 xut ss de Becas a Da a te e 9 TROUBLESHOOTING is dre netas cone ERA r ta 12 2003 IMI Cornelius Inc i Publication Number 859000159INS Impulse Installation and Operation Manual Cen gt Publication Number 859000159INS ii 2003 IMI Cornelius Inc Non Carbonated Impulse Installation amp Operations Manual SAFETY RECOGNIZE SAFETY ALERTS This is the safety alert symbol When you see it in this manual or on the AUTHORIZED SERVICE PERSONNEL CAUTION Only trained and certified electrical plumbing and refrigeration techni cians should service this unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES CO CARBON DIOXIDE WARNING vention of CO gas leaks in the entire CO and soft drink system If a CO gas leak is suspected particularly in a small area immediately ventilate the contaminated ar
17. us Inc Publication Number 859000159INS Non Carbonated Impulse Installation amp Operations Manual No power source Blown fuse or tripped circuit breaker Replace fuse or reset circuit breaker note Fuse or circuit breaker are not part of unit Agitator motor propeller obstructed Remove obstruction Low voltage at compressor ter minals Voltage must be at least 103 volts at the compressor termi nals when compressor is trying to start Loose disconnected or bro ken wiring Tighten connections or replace broken wiring Inoperative agitator motor Replace agitator motor as instructed Publication Number 859000159INS 2003 IMI Cornelius Inc IMI Cornelius Inc One Cornelius Place Anoka MN 55303 1592 U S A
18. valve for one minute to purge all water from and install sanitizing solution in the concentrate system and dispensing valve C Continue to activate the dispensing valve in cycles ON for 15 seconds OFF then ON for 15 seconds Repeat ON and OFF cycles for 15 cycles 4 Repeat step 3 to flush water out of and install sanitizing solution in the remaining concentrate sys tems and dispensing valves 5 Remove sanitizing solution source from the concentrate system 6 Allow sanitizing solution to remain in the concentrate systems for not less than 10 or no more than 15 minutes STEP 4 Water Flush Concentrate Systems WARNING Flush sanitizing solution from the concentrate systems as instructed Residual sanitizing solution left in the concentrate systems could create a health hazard 1 Bag in Box Concentrate System Place all bag in box concentrate containers concentrate outlet tubes in container containing potable water 2 Flush sanitizing solution from the concentrate system and the dispensing valve as follows A Place waste container under applicable dispensing valve B Activate the dispensing valve for one minute to purge all sanitizing solution out of the concentrate system and the dispensing valve 3 Repeat this process for each concentrate curcuit 4 Remove potable water source from the concentrate system STEP 5 Purge Water out of Concentrate Systems Restore Operation 1 Bag in Box Concentrate System A
19. ympus Sitco Spirit UF 1 Vanguard Venture and Vista are registered trademarks of IMI Cornelius Optifill trademark is pending This document contains proprietary information and it may not be reproduced in any way without permis sion from Cornelius Printed in U S A Copyright 2003 All Rights Reserved IMI Cornelius Inc Publication Number 859000159INS ii 2003 IMI Cornelius Inc Genes gt Impulse Installation and Operation Manual TABLE OF CONTENTS SAFETY 542 T acum mae ee 1 Recognize safety alerts License ne ua ERE UP EE CREER C ERIS EE ETE 1 Authorized Service Personnel eee tee eee 1 CO2 Carbon Dioxide Warning iiss ia ira ms a a en ea c eina m s 1 SYSTEM DIMENSIONS 225 i id ii 1 INSTALLATION eis te Botes Ad Sees jek ese ue eee Dt 2 Installation Requirements 2 4 LL LL LL LL LL LL LL LL LL LL LL LL 2 Requirements Summary seda sacs gals a seg Ed de 2 Electrical Requirements 4 444 44 La La La La rns 2 Installation Procedure Qu rh 2 Counter top Installation eene orei e o Ea LL 2 Connect Concentrate and Water Lines ks 4 Adjust Water To Concentrate Ratio 4 a ee 4 Adjusting Flow Rates 11 ES ad a xs doe RE a xm tun SR E 5 OPERATIONS 2 zl o REM di DEA ENE a 6 ODGIGUON ERR Pe eRe ged Pe a area anes Bate Ree ee sea aria 6 Starting And Stoppin
20. zed at least every 120 days and before or after storage Use a non scented liquid household bleach containing a 5 25 sodium hypochlorite concentration per the fol lowing procedure IMPORTANT Only qualified Service Personnel should perform sanitizing procedure on the post mix 1 Rinse bag in box connectors concentrate bag in box systems in warm potable water STEP 1 Wash Concentrate Systems 1 Using a five gallon container bag in box system prepare a full tank or container of liquid dish washer detergent by using 70 F 21 C to 100 F 38 C potable water and 0 5 oz 15 ml of liquid dishwasher detergent to one gallon of potable water Stir detergent solution to thoroughly mix the solution 2 Bag in Box Concentrate Systems A Install bag valves cut from empty bag in box concentrate containers on ends of concentrate containers concentrate outlet tubes connectors B Place all concentrate outlet tubes with bag valves on their ends in container containing deter gent solution 3 Flush the concentrate system and dispensing valve as follows A Place waste container under applicable dispensing valve B Activate the dispensing valve for one minute to purge all concentrate and flush out the concen trate system 4 Repeat the process for each concentrate circuits 5 Remove detergent solution source from the concentrate system STEP 2 Flush Concentrate Systems Fill five gallon container with potable water then plac
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