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®
INTELLICARB
Training Manual
Release Date: April 29, 2004
Publication Number: TP01071
Revision Date: NA
Revision: A
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
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INTELLICARB TRAINING MANUAL The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or varia- tions of the equipment, nor to provide for every possible contingency in the installation, 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, an
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InelliCarb Training Manual TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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IntelliCarb Training Manual Electrical Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Carbonator Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Wiring Diagram 1xx (120V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Schematic 1xx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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InelliCarb Training Manual INTRODUCTION UNIT DESCRIPTION • Built-in cold carbonator produces bottle-quality drinks every time • No seasonal CO adjustments required for changes in water temperature 2 • A complete system for simplified installation • Reduces service frequency and lowers equipment life cost • Generates increased beverage sales and greater consumer satisfaction • Illuminated merchandiser delivers unique, high impact marketing message • Ice used to cool cold pla
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IntelliCarb Training Manual SPECIFICATIONS ED150 ED175 ED200 ED250 ED300 B=(Beverage) B=(Beverage) B=(Beverage) B=(Beverage) B=(Beverage) C=(Coldplate) C=(Coldplate) C=(Coldplate) C=(Coldplate) C=(Coldplate) Model H=(Internal H=(Internal H=(Internal H=(Internal H=(Internal Descriptions: Carb) Carb) Carb) Carb) Carb) Z=(No DripTray) Z=(No DripTray) Z=(No DripTray) Z=(No DripTray) Z=(No DripTray) 150 Pounds 175 Pounds 200 Pounds 250 Pounds 300 Pounds Ice Storage: 6 8 10 10 12 Maximum Number of
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InelliCarb Training Manual INSTALLATION 1. Locate the dispenser indoors on a level counter top. A. LEG OPTION Unpack the four (4) legs and install them into the threaded holes provided in the bottom of the unit. The installer must provide flexibility in the product and utility supply to permit shifting the position of the dispenser sufficiently to clean the area beneath it. B. COUNTER MOUNTING If counter mounted the ice drink dispenser must be sealed to the counter. The template drawing in
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IntelliCarb Training Manual Drains Use a 1 - 1/2” rigid pipe (e.g. ABS on P.V.C.) this is to prevent kinking or collapsing. Make sure to leave a 4 inch air gap between the drain line and the floor drain. CORNELIUS INTELLICARB CARBONATOR ASSEMBLY 1. Ice Drink / Drop-In Carbonator Pump & Motor Unit Vent to Atmosphere Check Valve 125 G.P.H. ProCon Water Pump Liquid Level Control Box Preset CO2 Regulator (75P.S.I.) High Torque Pump Motor FIGURE 1 Carbonator Time Out Reset Switch The board can be se
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InelliCarb Training Manual C. Initial start-up procedure for carbonated water system: Turn on the CO supply to the car- 2 bonator tank, vent air from carbonator tank by pulling the tank relief valve. Turn on water supply to the pump. Connect electrical power to the pump and motor unit. Bleed the air out of the system by energizing a beverage valve until carbonated water is flowing from the valve. NOTE:If the carbonator Pump and Motor does not cycle (turn on and off) properly, check that the
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IntelliCarb Training Manual Ice Drink Model ED150/175/300 Coldplate Cover Ice Drink Model ED200/250 Coldplate Cover Liquid Level Probe In-line CO Check Valve Probe Ground Plate/Stud CO Check Valve with Ground Stud 2 2 FIGURE 10 FIGURE 9 3. Total Flex System for Ice Drink Models ED150/175/200/250/300 Total Flex Manifold (Insulation Removed) Water Line Plugs Retainer Clip Manifold Block FIGURE 11 Total Flex is a system of water manifold blocks located at the front of the cold plate, adjacent to th
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IntelliCarb Training Manual 6. Check list for proper “finished” drink carbonation: A. Fill ice storage hopper with ice. B. Water supply must be from a continuous source (no tank supply). C. Use only filtered water. D. Supply water line to the carbonator pump must be a minimum of .375 ID. E. Syrup supply lines must be a minimum of .265 ID. F. Water inlet pressure range: 45-60 max. static psig. with a minimum flowing pressure of 30 psig. G. Syrup CO secondary regulator pressure set to 60 p
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IntelliCarb Training Manual MECHANICAL SECTION GATE RESTRICTOR PLATE NOTE: Disconnect power to dispenser before installing, removing, or adjusting restrictor. ADJUSTMENT INSTALL PLATE ON STUDS AS SHOWN FIGURE 12 Adjustment This plate may be adjusted as shown to reduce or increase the dispensing rate of ice, especially desirable when using glasses or other containers with small openings. Adjustment can be made by sliding up or down with nuts loosened, to obtain the desired amount of restrictio
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IntelliCarb Training Manual ICE DIVERTER KIT 02394 NOTE: For dispensing Scotsman, Wilshire, and Hoshizaki compressed ice cubes: 1. Disconnect power to dispenser. 2. Remove Merchandiser from dispenser. 3. Remove ice chute and discard gate restrictor. 4. Install ice diverter on gate mounting plate as shown below. 5. Apply RTV to back surface of ice diverter, to seal to gate mounting plate. 6. Reinstall gasket and ice chute. 7. Reinstall merchandiser and energize unit. GATE MOUNTING PLATE STORAGE
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IntelliCarb Training Manual REMOVAL AND REPLACEMENT OF AGITATORS To Remove Agitators For Cleaning (300 shown) NOTE: All other models have only one agitation Assembly. RIGHT HAND AGITATOR LEFT HAND WITH HOLE IN UPRIGHT AGITATOR O–RING COUNTERCLOCKWISE CLOCKWISE ROTATION ROTATION FRONT (VALVE SIDE) VIEW FROM TOP OF DISPENSER FIGURE 14 1. Lift agitator and disc from unit. 2. Remove O-Ring starting at notch. Warm the O-Ring with water to ease removal. 3. Lift the plastic agitator disc off of the st
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IntelliCarb Training Manual POST-MIX VALVE SECTION SET-UP INSTRUCTIONS Concentrate valve sleeve Syrup valve sleeve has only one hole has six holes FIGURE 15 A side water lever kit can be added to a valve allowing for dispensing of water without syrup or concentrate. The side Mounting screw water lever can be added to either a carbonated drink valve or a noncarbonated drink valve. Water Post-mix valves control: lever • the ON–OFF of syrup and water, • the flow rates of syrup and water,
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IntelliCarb Training Manual NOTE: The notched water piston on the Ultra Flow and UFB-1 valve. results in at least one orifice in the sleeve always open. This elimi- Notch in nates pulsating and smooths water flow at higher flow rates. piston In operation the liquid flows through the knife–edged orifice in the bottom FIGURE 17 of the piston and then out the orifices in the sleeve. The outlet orifice size in the sleeve is regulated by the position of the piston. In the illustration, the pist
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IntelliCarb Training Manual Adjusting Flow Rates Flow rates of the water and syrup 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 syrup. If the desired finished drink total flow rate is 3.0 ounces per second, then the water flow rate is 2.5 oz./ sec and the syrup flow rate is 0.5 oz./sec. (The water at 2.5 oz./sec is five times the 0.5 oz./sec syrup flow rate.) NOTE: Always adjust water within its ran
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IntelliCarb Training Manual Setting Ratios If the ratio varies and must be adjusted often, it is probably the result of a restricted syrup system. It is then time to clean and sanitize the syrup tubing and cooling coils and check for other problems such as syrup pumps, etc. NOTE: Try raising the pressure on the pump before cleaning. Set the water flow rate first, then adjust the syrup to the desired ratio. This gives the most accurate valve flow setting possible. Measure the ratio and adjust
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IntelliCarb Training Manual SHURFLO SHURFLOW OVERVIEW SHURflo’s Beverage Gas Pump supplies syrup under pressure to a post-mix dispenser, which mixes the syrup with water to an exact ratio (brix). The pump is used in conjunction with non-pressurized Bag-In- Box (B-I-B) containers and a bag connector (Q.D.) fitting. The pump can be operated on regulated CO2, nitrogen or compressed filtered air. The compressed gas drives the pump and is not in contact with the syrup. Separate syrup and gas chamb
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IntelliCarb Training Manual SHURFLOW INSTALLATION As indicated on the pump, the outlet port is to be mounted up. Pumps are to be mounted at the same level or higher than the B-I-B. The best choice is to have the pump above the B-I-B. INLET tubing from the B-I-B to the pump use; 3/8" I.D. [10mm] minimum, heavy wall (1/8" [3mm]) clear, NSF listed vacuum tubing. Inlet tubing should not have excessive length. Tub- ing that is allowed to drape down can trap air in the B-I-B creating
