Installation Manual VA 13 CARBONATOR IMPORTANT: Manual Part No

Similar documents
Installation Manual CARBONATOR With Plain-Water Booster

Operator s Manual CHILLER ( CH SERIES) Models: CH750, CH751, and CH951

Operator s Manual CHILLER ( CHILLER SERIES) Models: CH550 and CH 551

Operator s Manual CHILLER ( CH SERIES) Models: CH750, CH751, and CH951

Telephone (800) Facsimile (800)

Installation/Service Manual VANGUARD 245 POST-MIX OVERCOUNTER DISPENSER

ICE/BEVERAGE DISPENSER

ICE/DISPENSER Model D3030

ICE/BEVERAGE DISPENSER

Installation Manual UNIVERSAL C-750 PRE-MIX DISPENSER

Owner / Operator Use and Care Guide I SERIES 224 ICE CUBE MACHINE

VANTAGE. Installation Manual. Release Date: April 16, 2003 Publication Number: INS Revision Date: January 22, 2015 Revision: E

ICE/BEVERAGE DISPENSER

ICE/BEVERAGE DISPENSERS

Owner / Operator Manual Commercial Refrigeration Service, Inc. (866)

CMP ICE MAKER DISPENSER. Installation and Service Manual

Installation/Service Manual SENTRY III-A GLYCOL COOLING UNIT (R-134A REFRIGERANT)

INSTALLATION MANUAL ICE/BEVERAGE DISPENSER MODEL: ENDURO-200/250

INSTALLATION MANUAL ICE/BEVERAGE DISPENSER MODEL: ENDURO VALVE

ICE DISPENSER. Installation/Service Manual

Installation Manual UNDER COUNTER GYLCOL REMOTE COOLING UNIT

TROUBLESHOOTING VANGUARD

ICE/BEVERAGE DISPENSER MODELS: ENDURO-150 (SIX VALVE) INSTALLATION MANUAL

ICE COOLED DISPENSER ALTA 1522 DROP-IN DISPENSER

T-Series Air Conditioner T15 Model

CHILLER. Operator s & Installation Manual

OPERATOR'S MANUAL. IMPORTANT: READ OPERATOR'S MANUAL CAREFULLY Please fill out & return your warranty card! DP80405

CH250 AND CH251 CHILLERS

SPA BLOWER OWNER'S MANUAL XXXX, XXXX, XXXX, XXXX, XXXX, XXXX fax

Owner s Manual Refrigerated Compressed Air Dryers Models F-200, 250, 300 & F350

Sanitaire. Owner s Guide. 10 GALLON Box Extractor SC6088 Series IMPORTANT

Installation & Operating Guide

T-Series Air Conditioner T20 Model

T-Series Air Conditioner T53 Model

T-SERIES Air Conditioner. T43 Model INSTRUCTION MANUAL nvent Rev. I P/N

Installation. 324 Series Built-In Dishwashers U L. Viking Range, LLC 111 Front Street Greenwood, Mississippi USA (662)

Rev. E 2013 Pentair Technical Products P/N Distributed by: McLean Parts

Instruction Manual Item No.: V~, 60Hz

T-SERIES Air Conditioner. T50 Model INSTRUCTION MANUAL nvent Rev. F P/N

PROAIR Air Conditioner. CR23 Model INSTRUCTION MANUAL nvent Rev. D P/N

DELUXE COLLECTION Executive Filtered Water Cooler AQP-WCM-FBOT4

ICE ONLY DISPENSERS MODELS-IOD150, IOD200 AND IOD250 INSTALLATION/SERVICE MANUAL

OWNER S MANUAL FOR AIR ADMIRAL VACUUM/PRESSURE STATION MODELS:

CH750, CH751 & CH951 CHILLERS

Installation & Operating Guide

Installation Instructions. For the 18 Built-In Dishwasher and Front Color Panels

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

General Care and Safety Guide

Owner s Manual Refrigerated Compressed Air Dryers Model F-100

ICE/BEVERAGE DISPENSER

SERVICE/INSTALLATION MANUAL ICE ONLY DISPENSERS MODELS-IOD150, IOD200 AND IOD250

SPECTRACOOL Air Conditioner. N21 Model INSTRUCTION MANUAL nvent Rev. G P/N

K Specifications. Max. Water Volume

VS SERIES NH3 STEAM VAPORIZERS OPERATION MANUAL

K Specifications. Max. Water Volume

Operator Manual Autofill System

Instruction Manual Item No.: V~, 60Hz

T-SERIES Air Conditioner. T20 Model INSTRUCTION MANUAL nvent Rev. C P/N

Viking Installation Guide

B.I.C.A Built-In Coffee Appliance

CHILLERS. Operator s & Installation Manual

CLIMAGUARD Air-to-Air Outdoor Heat Exchangers INSTRUCTION MANUAL. Rev. H 2015 Pentair Equipment Protection P/N

PROAIR Air Conditioner. CR29 Model INSTRUCTION MANUAL nvent Rev. I P/N

T-SERIES Air Conditioner. T29 Model INSTRUCTION MANUAL nvent Rev. I P/N

CHILLER. Operator s & Installation Manual

USER MANUAL SAVE THESE INSTRUCTIONS

INSTALLATION & OPERATING INSTRUCTIONS FOR CEILING MOUNT AIR HANDLERS AC SERIES

WET/DRY VACUUM. QUEST for Continuous Improvement Windsor s Quality Management System is Certified ISO MODEL: T1. Operating Instructions (ENG)

PROAIR Air Conditioner. CR43 Model INSTRUCTION MANUAL nvent Rev. H P/N

Owner s Manual Refrigerated Compressed Air Dryer Model F-50

SAFETY PRECAUTIONS. 2) Before operating machine: - Make sure all safety devices are in place and operate properly.

R Series B & T2 Model

IMAGE V. Parts and Service Manual

Room Air Conditioner Service and Parts Manual

INSTALLATION INSTRUCTIONS

Table of Contents. Specifications... page 2. Installation... page 3. Customizing... page 4. Reversing door swing... page 5

GENESIS Air Conditioners. All Models INSTRUCTION MANUAL nvent Rev. K P/N

OPERATING AND MAINTENANCE MANUAL FOR PLATE HEAT EXCHANGER INDIRECT FIRED WATER HEATER. Electric Heater Company Base Model "BWXP"

CONVEYOR TOASTER MODEL QCS QCS Installation and Operation Instructions 2M-HG0657 Rev. D 6/13/05

Flood Pumper Plus. Water Transfer Machine. Operator and Parts Manual. Model No.: Rev. 00 (11-99)

As part of the V.I.P. family, you are entitled to the best protection by one of the most comprehensive warranties in the industry.

WMHP Series R410a Heat Pump INSTALLATION INSTRUCTIONS

IMPORTANT INSTRUCTIONS

LC Series - Light Commercial Pump Station Installation and Operation Manual

Horizontal/Side Discharge Condensing Units

CELDEK Evaporative Cooler Module Installation, Operation, and Maintenance Manual. CELDEK Evaporative Cooler

CSD-1 CRN Electra Steam, Inc. Instruction Manual for JR06 Steam Generator, JG- and JJ- Models

STARBUCKS UC100 PROGATE

2001 Smith Eastern Corporation

ImPress IRONING STATION

INSTALLATION MANUAL CT-200

55-Gallon Dispenser Package

Refrigerant Recovery Machine. Model No Operating Manual

model NO. LSS GALLON SKID MOUNTED HIGH PRESSURE SPRAYER ASSEMBLY / OPERATION INSTRUCTIONS / PARTS

Disposal Unit (BKSDU) Burger King Shortening. Operation, Service & Parts Manual BURGER KING BKSDU

OWNER S MANUAL FOR ASPIRATION / FILTRATION VACUUM SYSTEM MODELS: 2511 & 2515

SAVE THESE INSTRUCTIONS

Installation Instructions CONVERTIBLE. Post-Mix Dispenser IMI CORNELIUS INC; Manual Part No January 1991 Revised October 6, 1992

Wilbur Curtis Company, Inc.

NON-CYCLING REFRIGERATED AIR/GAS DRYERS QPNC 75 to QPNC 250 OPERATOR S MANUAL

Transcription:

VA 13 CARBONATOR Installation Manual IMPORTANT: It is the responsibility of the Service Person to ensure that the water supply to the dispensing equipment 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 pipe connections and fixtures directly connected to a potable water supply shall be sized, installed, and maintained according to Federal, State, and Local codes. 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. 318511001 EIMI Cornelius Inc.; 1982-1997 Control Code C April 1,1982 Revised: March 11, 1997

TABLE OF CONTENTS Page SAFETY INFORMATION.................................................... 1 RECOGNIZE SAFETY INFORMATION............................... 1 UNDERSTAND SIGNAL WORDS.................................... 1 FOLLOW SAFETY INSTRUCTIONS................................. 1 CO2 (CARBON DIOXIDE) WARNING................................ 1 SHIPPING, STORING, OR RELOCATING UNIT....................... 1 GENERAL INFORMATION.................................................. 3 TO THE USER OF THIS MANUAL....................................... 3 CLAIMS INSTRUCTIONS.............................................. 3 WARRANTY REFERENCE INFORMATION............................... 3 DESIGN DATA........................................................ 3 UNIT DESCRIPTION................................................... 4 THEORY OF OPERATION.............................................. 5 INSTALLATION............................................................ 7 UNPACKING AND INSPECTION........................................ 7 IDENTIFICATION OF LOOSE--SHIPPED PARTS.......................... 7 SELECTING LOCATION................................................ 7 INSTALLING THE UNIT................................................ 7 PLACING UNIT IN OPERATING LOCATION.......................... 7 CONNECTING PLAIN WATER INLET SUPPLY LINE TO UNIT.......... 8 CONNECTING CO2 INLET SUPPLY LINE............................ 9 CONNECTING CARBONATED WATER OUTLET LINE................ 9 PERMANENT ELECTRICAL POWER CONNECTION TO DOMESTIC UNIT IF REQUIRED BY LOCAL CODES......................................... 9 PREPARATION FOR OPERATION....................................... 11 ADJUSTING CARBONATOR CO2 REGULATOR AND TURN PLAIN WATER INLET LINE ON............................................ 11 UNIT OPERATION..................................................... 11 TROUBLESHOOTING...................................................... 15 WATER PUMP MOTOR WILL NOT OPERATE............................. 15 WATER PUMP MOTOR WILL NOT SHUT OFF............................ 15 ERRATIC CYCLING OF CARBONATOR.................................. 16 WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP WATER............................................................... 16 WATER PUMP CAPACITY TOO LOW.................................... 16 WARRANTY.............................................................. 17 LIST OF FIGURES FIGURE 1. VA 13 CARBONATOR........................................ 4 FIGURE 2. CARBONATOR CONNECTIONS.............................. 9 FIGURE 3. CARBONATOR ASSEMBLY COMPONENTS................... 10 FIGURE 4. WIRING DIAGRAM (MODEL NO. 416411000 AND 1621)......... 13 FIGURE 5. WIRING DIAGRAM (MODEL NO. 496411000)................... 13 i 318511001

TABLE OF CONTENTS (cont d) Page LIST OF FIGURES CONT D) FIGURE 6. WIRING DIAGRAM (MODEL NO. 496411020)................... 14 FIGURE 7. WIRING DIAGRAM (MODEL NO. 496411040)................... 14 LIST OF TABLES TABLE 1. DESIGN DATA............................................... 3 TABLE 2. LOOSE-SHIPPED PARTS..................................... 7 318511001 ii

SAFETY INFORMATION Recognize Safety Information This is the safety-alert symbol. When you see this symbol on our machine or in this manual, be alert to the possibility 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 identifies the most serious hazards. Safety signs with signal word DANGER or WARNING are typically near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. DANGER WARNING CAUTION 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. CO 2 (Carbon Dioxide) Warning CO 2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO 2 (carbon dioxide) gas leaks in the entire CO 2 and soft drink system. If a CO 2 gas leak is suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO 2 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation. Shipping, Storing, Or Relocating Unit CAUTION: All water must be purged from the Unit if exposed to freezing temperature. A freezing ambient temperature will cause residual water remaining inside the Unit to freeze resulting in damage to internal components of the Unit. 1 318511002

THIS PAGE LEFT BLANK INTENTIONALLY 318511001 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 location of detailed information pertaining to questions that may arise. A Service Manual (P/N 318511005) for this equipment is available upon request. This 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 damage, 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 damage within 15 days of receipt. WARRANTY REFERENCE INFORMATION Unit Part Number: Serial Number: Install Date: Local Authorized Service Center: Warranty Registration Date (to be filled out by customer) DESIGN DATA Table 1. Design Data Model Numbers 115 VAC Unit (Liquid dual check valve) 416411000 115 VAC Unit (With vented dual check valve) 1621 230 VAC Unit (Liquid dual check valve) 496411000 230 VAC Unit (Liquid dual check valve) 496411020 230 VAC Unit (Liquid dual check valve) 496411040 3 318511001

Overall Dimensions: Width Height Depth Table 1. Design Data (cont d) 6-3/8 inches 15 inches 14 inches Weight: Dry Shipping 28-3/4 pounds 30-1/4 pounds Ambient Operating Temperature 40 F to 100 F Maximum Operating CO 2 Pressure 125 PSI Electrical Requirements: Operating Voltage and Current Draw See Unit Nameplate FIGURE 1. VA 13 CARBONATOR UNIT DESCRIPTION The carbonator is a compact Unit that may be installed in a remote location from where its carbonated water outlet is to be connected to a post-mix dispenser or a system. The purpose of the Unit is to mix plain water and carbon dioxide (CO 2 ) gas which results in and provides carbonated water for a post-mix dispenser or a system. The Unit consists basically of a water pump, motor, and a carbonated water tank. The water pump has a liquid dual check valve (Unit Model No. 416411000, 496411000, 496411020, and 496411040) or a Vented Dual Check Valve (Unit Model No. 1621) on its outlet to prevent carbonated water from back flowing into the city water system. The Vented Dual Check Valve vents water and possibly CO 2 gas out of a vent port on failure of the primary check valves. Should such venting occur, the primary check valve should be replaced. The Unit CO 2 inlet has a single check valve to prevent carbonated water back flow into the CO 2 regulator. 318511001 4

THEORY OF OPERATION A CO 2 cylinder delivers carbon dioxide (CO 2 ) gas through an adjustable CO 2 regulator to the carbonated water tank. At the same time, plain water is pumped into the carbonated water tank by the water pump and is carbonated by CO 2 gas also entering the tank. Carbonated water enters the tank until the weight of the water in the tank forces the tank and balance control mechanism down to activate the level control switches. Activating the level control switches disrupts electrical power to and stops the water pump motor. As carbonated water is dispensed from the tank, the tank becomes lighter allowing the tank and balance control mechanism to rise which again activates the level control switches. Activating the level control switches restores electrical power to the water pump motor allowing the carbonated water tank to be replenished. 5 318511001

THIS PAGE LEFT BLANK INTENTIONALLY 318511001 6

INSTALLATION UNPACKING AND INSPECTION NOTE: This Unit was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it. Any damage or irregularities should be noted at the time of delivery and immediately reported to the delivering carrier. Request a written inspection report from the Claims Inspector to substantiate any necessary claim. File the claim with the delivering carrier, not IMI Cornelius Inc. 1. After unit has been uncrated, remove shipping tape and other packing material. Check for obvious damage and follow procedure in preceding NOTE if damage is evident. 2. Unpack LOOSE--SHIPPED PARTS. Make sure items are present and in good condition. Table 2. Loose-Shipped Parts Item No. Part No. Name Qty. 1 178025100 Tapered Gasket, White 2 2 311304000 Tapered Gasket, Black 1 IDENTIFICATION OF LOOSE -SHIPPED PARTS 1. TAPERED GASKETS, WHITE (item 1) are used to seal connections when connecting lines to fittings labeled CO 2 INLET and CARB WATER OUTLET on the Unit. 2. TAPERED GASKET, BLACK (item 2) is used to seal connection when connecting plain water inlet supply line to the Unit. SELECTING LOCATION Locate unit so following requirements are satisfied. 1. Locate the Unit in a cool area close to a properly grounded electrical outlet with proper electrical requirements fused at 15-amps (slow-blow). No other electrical appliance should be connected to this circuit. For accessibility, the electrical outlet must not be located behind the Unit. ALL WIRING MUST CONFORM TO NATIONAL AND ELECTRICAL CODES. 2. Locate the Unit close to a plain water source line with requirements as outlined in CAUTION note under CONNECTING PLAIN WATER INLET LINE TO UNIT. Plain water inlet line from plain water source line to the Unit should be 3/8-inch I.D. (minimum) food-grade plastic. 3. Locate the Unit close to a permanent drain if installing Unit (P/N 1621) which is equipped with a vented Dual-Check Valve which must have it s vent tube routed to a permanent drain. INSTALLING THE UNIT PLACING UNIT IN OPERATING LOCATION 7 318511001

CAUTION: This Unit must not be installed in an unsheltered outdoor location where it will be exposed to the elements. IMPORTANT: Before putting carbonator into operation, carbonator cover must be removed and packing block must be removed from below the water pump motor. 1. Place carbonator in operating location meeting requirements of SELECTING LOCATION. MAKE SURE CARBONATOR IS SITTING IN LEVEL POSITION FOR PROPER OPERATION. 2. Remove two screws securing the cover assembly on the Unit, then remove the cover. 3. Remove packing block from below the water pump motor. 4. Install cover assembly on the Unit and secure with two screws. 5. Unit Model No. 1621. IMPORTANT: A vented dual-check valve assembly is installed in this carbonator between the water pump outlet and the water inlet to the carbonator tank as shown in Figure 3. The vented dual-check valve assembly vents carbonated water, and possibly CO 2 gas out of a vent port upon failure of the primary check valves. Should such venting occur, the vented dual-check valve assembly must be replaced. CAUTION: Route free end of the vented dual -check valve vent tube to a permanent drain to avoid serious water damage in the event of a check valve failure. Route free end of the vented dual-check valve vent tube, protruding out the end of the carbonator cabinet, to a permanent drain. TO AVOID POSSIBLE BACK-SUCTION FROM THE PERMANENT DRAIN, LOCATE THE END OF THE VENTED DUAL-CHECK VALVE VENT TUBE ABOVE THE DRAIN OR AS REQUIRED BY THE LOCAL PLUMBING CODE. CONNECTING PLAIN WATER INLET SUPPLY LINE TO UNIT CAUTION: Check minimum flow rate and maximum pressure of the plain water inlet supply line. MINIMUM FLOW RATE MUST BE AT LEAST 100-GALLONS PER HOUR. If flow rate is less than 100-gallons per hour, starving of the carbonator water pump will occur. Starving will allow the carbonator water pump to overheat causing the safety thermostat on the water pump outlet to disrupt electrical power to and stop the water pump motor. Overheating could occur if the plain water inlet supply line flow rate drops below 100-gallons per hour. WATER PRESSURE MUST BE 10-PSI LESS THAN THE CO 2 PRESSURE. (Example: operating CO 2 pressure is 80-psi, maximum water pressure can be no more than 70-psi, etc.). Water over pressure (higher than operating pressure) can cause carbonator flooding, malfunction, and leakage through the carbonator tank relief valve. If water is exceeding maximum pressure specifications, a Water Pressure Regulator Kit (P/N 310150000) or equivalent must be installed in the plain water inlet supply line. If fitting connector is not available, tap into the plain water supply line with a 3/8-flare saddle valve (P/N 315664000) or equivalent. NOTE: IMI Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the plain water inlet supply line (see Figure 2). A Cornelius Water Filter (P/N 313860000) and Quick Disconnect Set (P/N 313867000) are recommended. 1. Make sure food grade flexible plastic 3/8-inch I.D. (minimum) plain water inlet line provides adequate water flow rate and pressure as outlined in CAUTION note. 318511001 8

PLAIN WATER INLET CARB (CARBONATED) WATER POWER CORD CO 2 INLET FIGURE 2. CARBONATOR CONNECTIONS Before connecting plain water inlet line to the Unit, open the water line for a period of time to flush out any metal shavings resulting from connecting the water line to the fitting connector or saddle valve. 2. Remove shipping cap from the 3/8-inch flare (5/8-18) male fitting on the Unit labeled WATER INLET. 3. Install TAPERED GASKET (item 2) in the plain water inlet line swivel nut, then connect the water line to the 3/8-flare male fitting labeled WATER INLET on the Unit. CONNECTING CO 2 INLET SUPPLY LINE (see Figure 2) 1. Remove shipping cap from the 1/4--inch flare (7/16-20) male fitting on the Unit stamped CO 2 INLET. 2. Connect CO 2 inlet supply line from the CO 2 regulator to the 1/4-inch flare (7/16-20) male fitting on the Unit labeled CO 2 INLET. Seal connection with TAPERED GASKET, WHITE (item 1). CONNECTING CARBONATED WATER OUTLET LINE (see Figure 1) WARNING: Under no circumstances should copper tubing, copper fittings, or brass fittings be used to connect the Unit carb (carbonated) water outlet to the post-mix dispenser or system. CO 2 gas contact with copper tubing, copper fittings, or brass fittings will cause a health hazard. 1. Remove shipping cap from the 1/4-inch flare (7/16-20) male fitting stamped CARB WATER on the Unit. 2. Extend length of food grade flexible plastic tubing from the Unit carbonated water outlet to the carbonated water inlet of the post-mix dispenser or system, then connect to dispenser or system. 3. Connect food grade flexible plastic tubing to 1/4-inch flare (7/16-20) male fitting labeled CARB WATER on the Unit. Seal connection with TAPERED GASKET, WHITE (item 1). PERMANENT ELECTRICAL POWER CONNECTION TO DOMESTIC UNIT IF REQUIRED BY LOCAL CODES (see applicable Figure 3, 4, or 5) 1. Remove two screws securing the cabinet cover, then remove cover. 9 318511001

2. Loosen two screws securing the motor wiring compartment cover, then remove the cover. 3. Disconnect ground electrical wire from under the ground terminal connection screw located inside the motor wiring compartment. 4. Disconnect the black and white power cord wires inside the motor wiring compartment. 5. Remove power cord and strain relief from the Unit. COVER WATER PUMP MOTOR (ELECTRICAL CONNECTIONS) RETAINING SCREWS (2) RELIEF VALVE CARBONATED WATER TANK LIQUID DUAL CHECK VALVE OR VENTED DUAL -CHECK VALVE WATER PUMP SAFETY THERMOSTAT FIGURE 3. CARBONATOR ASSEMBLY COMPONENTS WARNING: The Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator. The Unit power cord is equipped with a three-prong plug. If a three-hole (grounded) electrical outlet is not available, use an approved method to ground the Unit. 318511001 10

6. Connect 115 VAC, 60 Hz or 220--240 VAC, 50 Hz electrical power from the disconnect switch (not furnished) fused at 15-amps (slow-blow) to the Unit with No. 16 AWG wire in suitable conduit or BX sheath. Install power source green or green/yellow wire under the ground terminal screw located inside the motor wiring compartment. Connect black or brown power cord wire with wire nut and white or blue wire under nut on motor terminal. All WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES. 7. Install motor wiring compartment cover and secure the two cover screws. 8. Install cabinet cover and secure with two screws. PREPARATION FOR OPERATION ADJUSTING CARBONATOR CO 2 REGULATOR AND TURN PLAIN WATER INLET LINE ON CAUTION: Before connecting the CO 2 regulator assembly to the CO 2 cylinder, turn the regulator adjusting screw to the left (counterclockwise) until all tension is relieved from the adjusting screw spring. 1. Open (counterclockwise) CO 2 cylinder valve slightly to allow the lines to slowly fill with CO 2 gas, then open the valve fully to back-seat the valve. (Back-seating the valve prevents leakage around the valve shaft). 2. Adjust the carbonator CO 2 regulator to a nominal 80-psi. 3. Open one of the Post-Mix Dispenser dispensing valves to exhaust trapped air inside the carbonator tank. CAUTION: Never operate the carbonator with the plain water inlet 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. 4. Open the plain water inlet line shutoff valve. UNIT OPERATION NOTE: The carbonator tank liquid levels (pump cut-in and cut-out) were adjusted at the factory and should require no further adjustment. If carbonator tank relief valve opens before the water pump motor cycles off, adjust carbonator tank liquid levels as instructed in Service Manual (P/N 318511004). WARNING: The Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator. The Unit power cord is equipped with a three-prong plug. If a three-hole (grounded) electrical outlet is not available, use an approved method to ground the Unit. 1. Connect electrical power to the Unit. Water pump will start and fill the carbonated water tank with carbonated water. Water pump will stop when tank is full. WARNING: CO 2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO 2 (carbon dioxide) gas leaks in the entire CO 2 and soft drink system. If a CO 2 gas leak is suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO 2 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation. 11 318511001

WARNING: Disconnect electrical power to the carbonator to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring. 2. Check for CO 2, carbonated water, and plain water leaks and if evident, tighten any loose connections. CAUTION: To prevent a fire hazard, no object should be placed or stored on top of the Unit. 318511001 12

SAFETY THERMOSTAT WATER PUMP POWER CORD LEVEL CONTROL SWITCH (2) FIGURE 4. WIRING DIAGRAM (MODEL NO. 416411000 AND 1621) SAFETY THERMOSTAT WATER PUMP POWER CORD LEVEL CONTROL SWITCH (2) FIGURE 5. WIRING DIAGRAM (MODEL NO. 496411000) 13 318511001

WATER PUMP LEVEL CONTROL SWITCH (2) POWER CORD FIGURE 6. WIRING DIAGRAM (MODEL NO. 496411020) WATER PUMP LEVEL CONTROL SWITCH (2) POWER CORD FIGURE 7. WIRING DIAGRAM (MODEL NO. 496411040) 318511001 14

TROUBLESHOOTING WARNING: Disconnect electrical power to the carbonator to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service the internal components or the electrical wiring. If repairs to the carbonated water or the plain water systems must be made, disconnect electrical power to the Unit, then shut off CO 2 and plain water sources. Dispense from dispensing valve until carbonator tank CO 2 pressure has been relieved. Trouble Probable Cause Remedy WATER PUMP MOTOR WILL NOT OPERATE. WATER PUMP MOTOR WILL NOT SHUT OFF. A. Power cord unplugged or circuit breaker open in panel box. A. Plug in power cord or reset circuit breaker. B. Inoperative water pump motor. B. Replace water pump motor as instructed. C. Dirty balance mechanism. C. Clean 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). D. Tighten connections and/or repair open circuit. Check line voltage. E. Check for proper line voltage. Check for restricted pump discharge. F. Replace level control switches as instructed. G. Repair or replace balance mechanism. H. Remove water pump from motor, rotate pump or motor shaft 180 degrees, then recouple pump to motor. I. Water pump damaged. I. Replace water pump as instructed. J. Safety thermostat inoperative (Models 416411000 and 1621). K. Water pressure low or pressure switch inoperative (Model 496411020 only) A. Foreign object restricting tank movement. J. Replace safety thermostat as instructed. K. Restore water pressure or replace pressure switch. A. Remove foreign object. B. Dirty balance mechanism. B. Clean balance mechanism. C. Leak in carbonated water line. C. Tighten or replace line. D. Inoperative level control switches. E. Binding or damaged balance mechanism. D. Replace level control switches as instructed. E. Repair or replace balance mechanism. 15 318511001

Trouble ERRATIC CYCLING OF CARBONATOR. WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP WATER. WATER PUMP CAPACITY TOO LOW. Probable Cause A. Balance mechanism spring obstructed or cocked. Remedy A. Remove obstruction. Make sure spring is perpendicular to spring release and is not twisted. B. Dirty balance mechanism. B. Clean balance mechanism. A. Water pump inlet water strainer screen dirty. A. Clean or replace water strainer screen as instructed. B. Kinked water supply line. B. Straighten water supply line. C. Restriction between water pump outlet and carbonator tank inlet. D. Foreign object in water pump bypass. C. Remove restriction. D. Clean. (Note: Count number of turns bypass screw makes when removing and install same number of turns.) E. Water pump worn out. E. Replace water pump as instructed. A. Water pump inlet water strainer screen dirty. A. Clean or replace water strainer screen as instructed. B. Water supply capacity too low. B. Inlet water supply must be at a minimum of 100-gallons per hour with a maximum water pressure of 70-psi. C. Water filter clogged. C. Replace water filter. D. Inoperative water pump. D. Replace water pump as instructed. 318511001 16

WARRANTY IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire product, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number, serial number and the date of purchase. IMI Cornelius Offices AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166 AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930 BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307 BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829 ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644 FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201 GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438 GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491 HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222 ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814 NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361 SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604 SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379 USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (612) 421-6120 D FAX (612) 422-3255 LD004 4/21/98 17 318511001

IMI CORNELIUS INC. CORPORATE HEADQUARTERS: One Cornelius Place Anoka, Minnesota 55303-6234 (612) 421-6120 (800) 238-3600