Cornelius Beverage Dispenser Drop In and Free Standing Ice Cooled Dispensers User Manual

Telephone(800) 238-3600  
INSTALLATION INSTRUCTION  
THIS INSTALLATION INSTRUCTION APPLIES TO ALL MODELS OF  
DROP-IN AND FREE-STANDING ICE COOLED DISPENSERS.  
UNPACKING AND INSPECTION  
The 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 delivery carrier.  
Request a written inspection report from Claims Inspector to substantiate any necessary claim.  
Claims must be filed with the delivery carrier.  
SELECTING A LOCATION  
CAUTION: Water pipe connections and fixtures directly connected to a potable water  
supply shall be sized, installed and maintained according to federal, state and local laws.  
The dispenser must be located near a permanent drain to route and connect unit ice bin and drip tray drain  
hoses. All drains and connections to such drains must meet local plumbing codes.  
Units with electrically operated valves must be located near a properly grounded electrical outlet. Circuit should  
be fused and no other electrical appliance should be connected to the circuit. ALL ELECTRICAL WIRING  
MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES.  
INSTALLING THE DISPENSER  
Drop-In Dispenser  
1. Use the Template supplied to mark the location of the hole to be cut into the counter top. Cut the hole as  
marked and remove the material.  
2. Apply the double stick tape (if supplied with the loose shipped parts).  
Note: To comply with the National Sanitation Foundation (NSF) requirements, the unit must be sealed  
to the counter top.  
3. Liberally apply a sealant, such as Dow Corning RTV 731 or equivalent, to the unit flange bottom surface.  
4. Lower the unit into position to complete the seal of the rim to the counter top. Apply additional sealant  
around the rim to ensure a complete seal.  
Note: Do not move the unit after positioning or the seal will be broken.  
10/4/94  
EIMI Cornelius Inc; 1994–2003  
Revised 10/8/03  
1
166239001  
Rev. Level1  
 
C. Continue to activate the dispensing valve in cycles (ONfor 15-seconds, OFF, then ONfor  
15-seconds). Repeat ONand OFFcycles for 15-cycles.  
3. Connect detergent solution to remaining syrup systems and flush syrup out of syrup systems as instructed  
in step 2 preceding.  
4. Remove detergent solution source from the syrup system.  
STEP 2. FLUSH COOLING SYSTEMS  
Tank Systems.  
1. Connect tank containing potable water, pressurized at 60 to 80-psi, into one of the tubing systems.  
Bag-in-Box Syrup System.  
2. Fill five-gallon container with potable water, then place all bag-in-box syrup containers syrup outlet tubes in  
container containing potable water.  
A. Flush detergent solution out of syrup system and dispensing valve as follows:  
B. Place waste container under applicable dispensing valve.  
C. Activate the dispensing valve for one minute to purge all detergent solution and flush out of the syrup  
system.  
D. Continue to activate the dispensing valve in cycles (ONfor 15-seconds, OFF, then ONfor  
15-seconds). Repeat ONand OFFcycles for 15-cycles.  
3. Connect potable water source to remaining syrup systems and flush detergent solution out of syrup sys-  
tems as instructed in step A preceding.  
4. Remove potable water source from the syrup system.  
STEP 3. SANITIZE COOLING SYSTEMS  
1. Using a clean tank (tanks system) or a five-gallon container (bag-in-box system), prepare sanitizing solu-  
tion using 70° F (21° C) to100° F (38° C) potable water and 0.5 oz. (15 ml) of household liquid bleach such  
as non-scented Hi-Lex or Chlorox that contains a 5.25 % sodium hypochlorite concentration to one gallon  
of potable water.This mixture must not exceed 200 PPM of chlorine. Shake sanitizing solution to thoroughly  
mix.  
Tank Systems.  
A. Connect sanitizing solution tank, pressurized at 60 to 80-psi, into one of the tubing systems.  
Bag-in-Box Syrup System.  
B. Place all bag-in-box syrup containers syrup outlet tubes in container containing sanitizing solution.  
2. Sanitize the syrup 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 water from and install sanitizing solution in  
the syrup system and dispensing valve.  
C. Continue to activate the dispensing valve in cycles (ONfor 15-seconds, OFF, then ONfor  
15-seconds). Repeat ONand OFFcycles for 15-cycles.  
3. Repeat steps to flush water out of and install sanitizing solution in the remaining syrup systems and dis-  
pensing valves.  
10/4/94  
EIMI Cornelius Inc; 19942003  
3
Revised 10/8/03  
166239001  
Rev. Level 1  
 
4. Remove sanitizing solution source from the syrup system.  
5. Allow sanitizing solution to remain in the syrup systems for not less than 10 or no more than 15-minutes  
(max.) contact time.  
STEP 4. WATER FLUSH SYSTEMS  
WARNING: Flush sanitizing solution from the systems as instructed. Residual sanitizing  
solution left in the systems could create a health hazard.  
1. Fill tank (tank system) or a five-gallon container (bag-in-box system) with potable water.  
Tank Systems.  
A. Connect tank containing potable water, pressurized at 60 to 80-psi, into one of the systems.  
Bag-in-Box Syrup System.  
B. Place all bag-in-box syrup containers syrup outlet tubes in container containing potable water.  
2. Flush sanitizing solution from the syrup 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 syrup system  
and the dispensing valve.  
C. Continue to activate the dispensing valve in cycles (ONfor 15-seconds, OFF, then ONfor  
15-seconds). Repeat ONand OFFcycles for 15-cycles.  
3. Repeat preceding steps to purge sanitizing solution out of the remaining syrup systems and  
dispensing valves.  
4. Remove potable water source from the syrup system.  
STEP 5. PURGE WATER (RESTORE OPERATION)  
Tank Systems.  
1. Noting tanks CO regulator pressure setting observed in step 4 preceding, readjust CO regulator to the  
2
2
observed pressure setting,  
A. Connect tanks containing the product onto the system.  
Bag-in-Box Syrup System.  
B. Remove all bag valves from bag-in-box syrup containers outlet tubes connectors.  
C. Connect bag-in-box syrup containers into the syrup systems.  
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.  
WARNING: To avoid possible personal injury or property damage, do not attempt to  
remove the syrup tank cover until CO pressure has been released from the tank.  
2
3. Dispose of waste sanitizing solution in sanitary sewer, not in storm drain, then thoroughly rinse inside and  
outside of the container that was used for sanitizing solution to remove all sanitizing solution residue.  
10/4/94  
Revised 10/8/03  
EIMI Cornelius Inc; 19942003  
4
166239001  
Rev. Level 1  
 
CLEANING THE ICE BIN  
1. Prepare a mild detergent soap solution in 100)F potable water.  
2. Using a nylon (not wire) bristle brush, clean the cold plate and the interior of the ice bin with the soap solu-  
tion.  
3. Rinse the cold plate and interior bin surfaces with clean potable water.  
4. Using a mechanical spray bottle, prepare a sanitizing solution according to the manufacturers directions  
and spray the entire interior bin surfaces. Allow to air dry.  
CONNECTING PRODUCT TO THE DISPENSER  
Note: All inlet connections are clearly marked with a label adjacent to the inlet connections.  
Note: Always leak check all connections.  
PostMix units must have syrup, carbonated water and plain water connected. The number of syrups will  
depend on the number of valves on the dispenser. Refer to the plumbing diagram for details of the hook-  
up.  
Pre-Mix units must have a pre-mix supply connected to each inlet for each valve to be supplied. Refer to  
the plumbing diagram for details of the hook-up.  
Note: A plumbing diagram when supplied with the unit, can be found in the dispensing tower.  
PREPARING FOR OPERATION  
On Units Without Electrically Operated Valves, Skip Steps 1 & 2 Below  
1. Plug transformer into electrical outlet. The 24V supply must be connected in the dispensing tower.  
2. Turn the key-switch to the ON position. The ice-bin lid must be closed to allow the valves to operate.  
3. Adjust the CO regulators as indicated in the following chart:  
2
Post-Mix  
Regulator  
Pressure Setting  
90 120 PSI  
55 PSI  
Primary (Carbonator)  
Secondary, Sugared Syrup Tank  
Secondary, Diet Syrup Tank  
Secondary, BIB  
8 12 PSI  
60 PSI  
Pre-Mix  
Basic pressure shown is based on ambient temperature of 72)F. Use a  
Cornelius Pre-Mix slide rule for exact calculations.  
Basic Pressure  
47 PSI  
For each 10 ft. of horizontal tubing  
between tank and dispenser  
Add 1 PSI  
For each 2 ft. of elevation  
Add 1 PSI  
Add 1 PSI  
For each tank per flavor over  
3 tanks  
4. Operate each valve until product is flowing.  
10/4/94  
Revised 10/8/03  
EIMI Cornelius Inc; 19942003  
5
166239001  
Rev. Level 1  
 
5. Fill the bin with 32)F ice. DO NOT use ice taken directly from a freezer.  
6. Adjust the brix (water-to-syrup ratio) for post-mix valves.  
7. Set the flow rate for pre-mix valves.  
DRINK DISPENSER VALVES  
IMI CORNELIUS INC.  
MASON CITY IA.  
DRINK DISPENSERS  
VALVE TYPE  
MANUFACTURER  
PORTION CONTROL  
CORNELIUS  
LANCER  
MAXIMUM OPERATING PRESSURE  
130 psi  
100psi  
100psi  
130psi  
FLOWMATIC  
McCANN  
PUSH BUTTON  
CORNELIUS  
LANCER  
130psi  
100psi  
100psi  
130psi  
FLOWMATIC  
McCANN  
LEVER TYPE  
CORNELIUS  
LANCER  
130psi  
100psi  
100psi  
130psi  
FLOWMATIC  
McCANN  
AUTOFILL LEVER  
CORNELIUS  
LANCER  
130psi  
100psi  
100psi  
130psi  
FLOWMATIC  
McCANN  
NON–ELECTRIC  
CORNELIUS  
LANCER  
130psi  
100psi  
PREMIX TYPE  
CORNELIUS  
130psi  
10/4/94  
Revised 10/8/03  
EIMI Cornelius Inc; 19942003  
6
166239001  
Rev. Level 1  
 
TROUBLESHOOTING  
TROUBLESHOOTING  
Trouble  
Probable Cause  
Remedy  
ADJUSTMENT OF  
A. Dispensing valve syrup flow  
regulator, syrup tank quick  
disconnect, or syrup line  
restricted.  
A. Sanitize syrup system as  
instructed.  
DISPENSING VALVE SYRUP  
FLOW REGULATOR DOES  
NOT INCREASE TO DESIRED  
WATER-TO-SYRUP ‘‘RATIO’’  
B. Syrup tank quick disconnects  
not secure.  
B. Secure quick disconnects.  
C. Syrup tanks secondary CO  
C. Adjust syrup tanks secondary  
2
regulator out of adjustment.  
CO regulator as instructed.  
2
D. No syrup supply.  
D. Replenish syrup supply.  
E. Replace syrup supply.  
E. Improper syrup Baume.  
F. Dirty or inoperative piston or  
spring in dispensing valve  
syrup flow regulator.  
F. Disassemble and clean  
dispensing valve syrup flow  
regulator.  
G. Tapered nylon washer inside  
tube swivel nut connector  
distorted from being  
G. Replace nylon washer and make  
sure it seats properly.  
overtightened.  
ADJUSTMENT OF  
A. Dirty or inoperative piston or  
spring in dispensing valve  
syrup flow regulator.  
A. Disassemble and clean  
dispensing valve syrup flow  
regulator.  
DISPENSING VALVE SYRUP  
FLOW REGULATOR DOES  
NOT DECREASE TO  
DESIRED WATER-TO-SYRUP  
‘‘RATIO’’  
DISPENSED PRODUCT  
CARBONATION TOO LOW  
A. Carbonator primary CO  
A. Adjust carbonator primary CO  
regulator (Reference manual  
provided with carbonator).  
2
2
regulator out of adjustment for  
existing water conditions or  
temperature.  
B. Air in carbonator tank.  
B. Vent air out of carbonator tank  
through relief valve. Actuate  
dispensing valve carbonated  
water lever to make carbonator  
pump cycle on.  
C. Water, oil, or dirt, in CO  
supply.  
C. Remove contaminated CO .  
2
2
Clean CO system (lines,  
2
regulators, etc.) using a mild  
detergent. Install a clean CO  
supply.  
2
10/4/94  
Revised 10/8/03  
EIMI Cornelius Inc; 19942003  
7
166239001  
Rev. Level 1  
 
Trouble  
Probable Cause  
Remedy  
DISPENSED PRODUCT  
COMES OUT OF  
A. Oil film or soap scum in cup or A. Use clean cup or glass.  
glass.  
DISPENSING VALVE CLEAR  
BUT FOAMS IN CUP OR  
GLASS  
B. Ice used for finished drink is  
sub-cooled.  
B. Do not use ice directly from  
freezer. Allow ice to become ‘‘wet’’  
before using. (Refer to following  
NOTE).  
NOTE: Crushed ice in the glass also causes dispensing problems. When finished drink hits sharp  
edges of ice, carbonation is released from dispensed drink.  
C. Carbonator CO regulator  
C. Reduce carbonator CO regulator  
2
2
pressure too high for existing  
water conditions or  
temperature.  
pressure setting. Reference  
manual provided with carbonator.  
D. Syrup over-carbonated with  
D. Remove syrup tanks quick  
CO as indicated by bubbles in  
disconnects. Relieve tank CO  
2
2
inlet syrup lines leading to  
unit.  
pressure, shake tank vigorously,  
then relieve tank CO pressure as  
2
many times as necessary to  
remove over-carbonation.  
E. Warm Product - No ice in bin,  
bridged ice on cold plate or  
plugged drain.  
E. Replenish ice, break ice up to  
eliminate bridging, unplug the  
drain.  
NOTE: If water supply is dirty, be sure to flush lines and carbonator completely. It may be necessary to  
remove lines to carbonator tank. Invert and 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. A. Repair or connect wiring.  
B. Inoperative dispensing valve  
solenoid coil.  
B. Replace solenoid coil as  
instructed.  
C. Inoperative dispensing valve  
micro switch.  
C. Replace micro switch as  
instructed.  
ONLY CARBONATED WATER A. Quick disconnects not secure  
A. Secure quick disconnects on  
syrup tanks.  
DISPENSED  
on syrup tanks.  
B. Out of syrup.  
B. Replenish syrup supply as  
instructed.  
C. B-I-B connectors not properly  
connected.  
C. Properly attach the connectors.  
D. Syrup secondary CO  
D. Adjust syrup tanks secondary  
2
regulator not properly  
adjusted.  
CO regulator as instructed.  
2
E. Inoperable dispensing valve.  
E. Repair dispensing valve.  
F. Dispensing valve syrup flow  
regulator not properly  
adjusted.  
F. Adjust dispensing valve syrup  
flow regulator (Water-to-Syrup  
‘‘Ratio’’) as instructed.  
10/4/94  
Revised 10/8/03  
EIMI Cornelius Inc; 19942003  
8
166239001  
Rev. Level 1  
 
Trouble  
Probable Cause  
Remedy  
ONLY CARBONATED WATER G. Dispensing valve syrup flow  
G. Sanitize syrup system as  
instructed.  
DISPENSED, Continued  
regulator, syrup tank quick  
disconnect, or syrup lines  
restricted.  
ONLY SYRUP DISPENSED  
A. Plain water inlet supply line  
shutoff valve closed.  
A. Open plain water inlet supply line  
shutoff valve.  
B. Carbonator power cord  
unplugged from electrical  
outlet.  
B. Plug carbonator power cord into  
electrical outlet.  
C. Carbonator primary CO  
regulator not properly  
adjusted.  
C. Adjust carbonator primary CO  
regulator (Reference manual  
provided with carbonator).  
2
2
10/4/94  
Revised 10/8/03  
EIMI Cornelius Inc; 19942003  
9
166239001  
Rev. Level 1  
 

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