® INTELLICARB ICE COOLED DISPENSER CB1522 (75lbs), CB2323 (80 & 100lbs), and CB3023 (130lbs) with 8X4 carbonator (80lbs) and 12X4 carbonator (75, 100, & 130lbs), with Flexible manifolding. Installation Manual Release Date: January 29, 2003 Publication Number: 630460204INS Revision Date: July 1, 2005 Revision: D Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
INTELLICARB DRINK DISPENSERS INSTALLATION GUIDE 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 variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment.
TABLE OF CONTENTS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Read and follow all safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recognize safety alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IntelliCarb Drop-In Ice Cooled Installation Guide SAFETY SAFETY INSTRUCTIONS Read and follow all safety instructions Read and follow all safety instructions in this guide and on the machine (decals, labels, and laminated cards). Read and understand all applicable OSHA (Occupation Safety and Health Administration) safety regulations before operating the machine. Recognize safety alerts This is the safety alert symbol.
IntelliCarb Drop-In Ice Cooled Installation Guide SHIPPING AND STORAGE CAUTION — Before shipping, storing, or relocating the Unit, syrup systems must be sanitized and all sanitizing solution must be purged from the syrup systems. All liquids, after sanitizing, must be purged from the unit. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the Unit to freeze resulting in damage to the internal components.
IntelliCarb Drop-In Ice Cooled Installation Guide SYSTEM OVERVIEW DROP-IN PRODUCT OVERVIEW The Drop-In IntelliCarb consists of the following: • Front inlet fittings • 75 lbs., 80 lbs., 100 lbs., and 130 lbs. capacity ice bin • Foamed polyurethane insulation • Key lock switch • 9 3/4 inch cup clearance • Extended drip-tray for cup staging, removable for cleaning • High capacity 11/18 cold plate, 5-2-1 configuration • All fittings are 3/8 inch • Supports UF-1 fast flow (3.0 oz./sec.
IntelliCarb Drop-In Ice Cooled Installation Guide Drop-In Dimensions (CB2323) Counter Top Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 1/4 x 23 1/4 inches Height above counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 inches Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IntelliCarb Drop-In Ice Cooled Installation Guide INSTALLATION CAUTION — Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. INSTALLATION REQUIREMENTS Requirements Summary Weight:...................................................counter must be level and able to support 450 lbs. Environment:.....................................................................................
IntelliCarb Drop-In Ice Cooled Installation Guide DELIVERY INSPECTION AND UNPACKING Inspection Upon delivery inspect the unit for damage or irregularities and immediately report problems to the delivering carrier and file a claim with that carrier. 1. Open loose parts packages and inspect parts. Loose parts Make sure all items are present. Drop-In Part Name P/N Qty.
IntelliCarb Drop-In Ice Cooled Installation Guide INSTALLATION PROCEDURE Back Room Package TUBING NOTE: Tubing, hoses, and cabling can come from underneath or in back of the unit. 1. Run bundled tubing from back room to dispenser location. WATER 1. Install water filter system between booster pump and water pressure regulator. p/n 605620 Pre filter p/n 605625ST Main filter p/n 605600 Polyphosphate feeder (Ice Maker water) NOTE: Recommended shut off valve be installed on outlet side of filter system. 2.
IntelliCarb Drop-In Ice Cooled Installation Guide NOTE: Do not route beverage make up water through polyphosphate feeder. Publication Number: 630460204INS -8- © 2003-2005, IMI Cornelius Inc.
IntelliCarb Drop-In Ice Cooled Installation Guide 4. 5. Connect from water filter system outlet to water regulator assembly and tee to surge tank. 2-wide BIB shelf assembly P/N 561300067 Connect water lines from manifold outlet to water line going to each dispenser. Water connection from filters Water connection to unit(s) 3-wide BIB shelf assembly P/N 561300066 SYRUP 6. Connect syrup lines from bundled tubing to BIB pump outlet fitting.
IntelliCarb Drop-In Ice Cooled Installation Guide 1522-2323-3023 DROP-IN Conversion Instructions for Valves Connected into Manifold 1. 2. 3. 4. 5. 6. 7. Remove the cup rest, front panel, and drip tray. Remove insulation pad, 2 screws, and bracket (as shown below). Pull out the plug fitting and tubing with barb fitting of the desired valve for conversion. Place tubing with barb fitting into desired outlet on the manifold. Replace plug fitting in open outlet.
IntelliCarb Drop-In Ice Cooled Installation Guide Conversion Instructions for 1522 Valve #1 from Carb to Non/Carb 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the cup rest, front panel, and drip tray. Remove insulation pad, 2 screws, and bracket (as shown above on page 10). Pull out a plug fitting from the rear connection of the manifold. Disconnect soda line from valve #1. Assemble straight fitting and oetiker clamp to soda line from valve #1 (as shown on page 10). Assemble soda line from valve #1 to manifold.
IntelliCarb Drop-In Ice Cooled Installation Guide 11. Connect CO2 line from bundled tubing to fixed secondary regulator inlet fitting. Connect tubing from secondary regulator outlet to carbonator tank CO2 inlet. Route CO2 line down center channel raceway with wire harness. CO2 line 12. For 2323 Drop-In install a tee in water line (must be before pump). Run one line to carbonator pump inlet. Connect carbonator pump outlet to “S”. 13. Connect syrup lines. 14.
IntelliCarb Drop-In Ice Cooled Installation Guide SANITIZING PRODUCT COLD PLATE TUBING Preparing the Cleaning Solution: Using a clean tank (tank system) or a five-gallon container (bag-inbox system), prepare a full tank or container of liquid dishwasher detergent by using 70°F (21°C) to 100°F (38°C) potable water and 0.5 oz. (15 ml) of liquid dishwasher detergent (such as Joy, Ivory, ect.) to one gallon of potable water. Shake detergent solution to thoroughly mix the solution.
IntelliCarb Drop-In Ice Cooled Installation Guide STEP 3. SANITIZE COOLING SYSTEMS 1. Using a clean tank (tank system) or a five-gallon container (bag-in-box system), prepare a full tank or container of liquid dishwasher detergent by using 70°F (21°C) to 100°F (38°C) potable water and 0.5 oz. (15 ml) of liquid dishwasher detergent (such as Joy, Ivory, ect.) to one gallon of potable water. Shake detergent solution to thoroughly mix the solution Tank Systems.
IntelliCarb Drop-In Ice Cooled Installation Guide Bag-in-Box Syrup Systems. • Remove all bag valves from bag-in-box syrup containers outlet tubes connectors. • Connect bag-in-box containers into the syrup system. 2. Place waste container under dispensing valves. Dispense from all dispensing valves to permit syrup to purge all potable water from the syrup systems and the dispensing valves. Continue to dispense from the dispensing valves until only syrup is dispensed from the syrup systems and valves.
IntelliCarb Drop-In Ice Cooled Installation Guide Adjust Water-To-Syrup Ratio Separator Water-To-Syrup ratio cup 1. 2. 3. 4. 5. 6. 7. Remove valve cover and install syrup separator over the diffuser and through the nozzle. Hold cup under valve and dispense beverage for a specific time (i.e. 2 seconds). NOTE: Water and syrup must be cold before checking ratios. Adjust carbonated water flow to the desired rate (such as 90 to 110 ml (3 to 3.75 oz.) per second).
WIRING DIAGRAM PROBE VALVE VALVES 24 VAC WATER IN VALVE LOCKOUT SWITCH WATER COM 2 3 4 5 6 7 8 M1 1 M2 2 M3 3 M4 4 M5 5 M6 6 M7 7 M8 8 SL S4 S3 M6 W4 M5 W6 W3 W5 S6 M4 WIRE HARNESS 24 VAC MERCH.
PROBE VALVE VALVES 24 VAC WATER IN VALVE LOCKOUT SWITCH WATER COM PRE-CHILL 3 4 5 6 M1 1 M2 2 M3 3 M4 4 M5 5 M6 6 SL S3 W3 M4 W4 S4 M3 WH OPTIONAL CONNECTION TO HAVE MERCHANDISER CONTROLLED BY KEYSWITCH S2 S1 W2 M6 W1 M5 W6 M2 W5 S6 M1 S5 MANIFOLD RIGHT © 2003-2005, IMI Cornelius Inc.
WIRING DIAGRAM PROBE VALVE VALVES 24 VAC GAS SODA OUT SODA CO-2 WH VALVE WIRE HARNESS BK WATER IN CARBONATOR BK WATER 1 2 3 4 S1 1 M2 2 M3 3 M4 4 WH 5 6 M5 5 M6 6 WIRE HARNESS 24 VAC MERCH.
IntelliCarb Drop-In Ice Cooled Installation Guide IntelliCarb Back Room Plumbing and Settings Publication Number: 630460204INS - 20 - © 2003-2005, IMI Cornelius Inc.
IntelliCarb Drop-In Ice Cooled Installation Guide Removal and Installation of Carbonator Relief Valve Carbonator Removal 1. 2. 3. Remove ice from bin. Disconnect the power to the unit and to the pump and motor. Shut off the CO2 supply that is connected to the Carbonator. 4. 5. 6. Shut off the water supply that is connected to the pump and motor. Remove Cup Rest, Splash Panel, Drip Tray, Sliding Lid and Sanitary Plate.
IntelliCarb Drop-In Ice Cooled Installation Guide Carbonator Installation 1. 2. 3. 4. 5. 6. 7. 8. Clean around Carbonator tank opening removing all silicone, and make sure cavity is clean and dry. Place new Carbonator in place of the old one. Reconnect probe wire harness to pump and motor. Seal top of Carbonator with silicone. Connect the CO2 line from the barbed fitting Carbonator and tighten to 80+/- 10 in pounds (Note: replace white gasket). Reconnect the Carbonator lines to the Carbonator.
IntelliCarb Drop-In Ice Cooled Installation Guide MANIFOLD PARTS BREAKDOWN (1522, 2323, 3023) 5 3 4 2 1 7 8 6 Item No. Part No. Name Qty. 1 620407728 MANIFOLD FLEX 5 POS 2 2 164126000 SCREW SM 08 TA TRPH 16 SS 10 3 620519005 PLUG MANIFOLD 12 4 630201533 BRKT MANIFOLD BLOCK 2 5 77051500 FITG-VAL DOLE ELB 102 DEGREE 8 6 309854000 CLAMP OETR 413 OPEN STPLS #10.5 8 7 630201532 BRKT RETAINER MANIFOLD 2 8 630600024 HOSE .375 B 5.
IntelliCarb Drop-In Ice Cooled Installation Guide CB 1522 INTELLICARB STAINLESS TOWER 75LB WITH 12 X 4 CARBONATOR Item No. Part No. Name Item No. Part No.
IntelliCarb Drop-In Ice Cooled Installation Guide CB 2323 INTELLICARB STAINLESS TOWER 100LB WITH 12 X 4 CARBONATOR 7 8 6 9 2 20 31 1 30 15 10 13 3 4 16 17 14 12 18 11 25 19 5 21 23 24 Item No. Part No. Name Item No. Part No.
IntelliCarb Drop-In Ice Cooled Installation Guide CB 2323 INTELLICARB STAINLESS TOWER 80LB WITH 8 X 4 CARBONATOR 31 30 Item No. Part No. Name 1 630201423 Decorative Frame 2 630000601 Transformer Ass’y, 115/ 24V RMT 75V 3 630001124 Carbonator (8 X 4) 4 167491003 5 Item No.
IntelliCarb Drop-In Ice Cooled Installation Guide CB 3023 INTELLICARB STAINLESS TOWER 130LB WITH 12 X 4 CARBONATOR 29 Item No. Part No. Name 1 630201420 Frame Dec CB3023 2 630000601 Transfrmr 115/24 RMT 75VA 3 630001125 Carbonator Tank Assy 4 167491009 5 Item No.
IntelliCarb Drop-In Ice Cooled Installation Guide TROUBLESHOOTING Trouble Probable Cause ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES NOT INCREASE TO DESIRED WATERTO-SYRUP “RATIO” A. Dispensing Valve syrup flow regulator, syrup tank quick disconnect, or syrup line restricted. B. Syrup tank quick disconnects not secure. C. Syrup tanks secondary CO2 regulator out of adjustment. D. No syrup supply. E. Improper syrup Baume. F.
IntelliCarb Drop-In Ice Cooled Installation Guide Trouble Probable Cause Remedy NOTE: If water supply is dirty, be sure to flush lines and carbonator completely. It may be necessary to remove lines to carbonator tank. Flush tank and all inlet lines to remove any foreign particles or dirt. NO PRODUCT DISPENSED FROM ONE DISPENSING VALVE A. Broken or disconnected wiring. B. Inoperative dispensing valve solenoid coil. C. Inoperative dispensing valve micro switch. A. Repair or connect wiring.
IntelliCarb Drop-In Ice Cooled Installation Guide TROUBLESHOOTING for Carbonator Trouble PUMP RUNS CONTINUOUSLY Probable Cause A. Pump water supply restricted. B. Pump discharge line restricted. C. Inefficient or worn pump. D. Overdrawing. NOISY PUMP Publication Number: 630460204INS A. Bad motor bearings or worn pump shaft. B. Failure of Triac on liquid level control. C. Insufficient water supply. - 30 - Remedy A. Check water filter and pump inlet strainer and clean.
IntelliCarb Drop-In Ice Cooled Installation Guide TROUBLESHOOTING for Carbonator Trouble VALVE DELIVERS CO2 GAS CONTINUOUSLY Probable Cause A. Pump motor will not run. B. Pump water supply restricted. C. Relief valve venting. D. Worn pump. VALVE DELIVERS SODA WATER AND CO2 GAS INTERMITTENLY A. Pump water supply restricted. B. Relief valve venting. C. Inefficient or worn pump. POOR CARBONATION A. Flooded carbonator. B. Water temperature too high (warm). C. Oil in water supply. D.
IntelliCarb Drop-In Ice Cooled Installation Guide TROUBLESHOOTING Trouble DRINK HAS OFF-TASTE OR ODOR (WATER CONTAMINATION) Probable Cause A. Leaking check valves. B. Too much plumbers pipe compound on pipe joints. C. Soda water and beverage lines made of brass or copper. D. High chlorine level. E. Tank corrosion. F. Contaminated CO2 Remedy A. Replace O-Rings in double check valve or replace double check valve. See check valve installation instruction section. B. Remove pipe compound and clean joints.
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