Cornelius Impulse XL User manual

Impulse XL
Post-mix Beverage Dispenser
Operator’s Manual
890519401
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© 2010, IMI Cornelius Inc.
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SAFETY
Safety Instructions
Read And Follow All Safety Instructions
Recognize Safety Alerts
Different Types Of Alerts
Safety Tips
Authorized Service Personnel
CO2(Carbon Dioxide) Warning
Shipping And Storage
GENERAL INFORMATION
General Description
Unit Description
Speci!cations
Dimensions
Part Numbers
Capacity
Accessories
Theory of Operation
INSTALLATION
Delivery Inspection and Unpacking
Inspection
Unpacking
Installation Requirements
Requirements Summary
Electrical Requirements
Environmental Requirements
Installation Procedure
Counter-top Installation
Connect Syrup, Water, And Carbonated Water Lines
Check For Leaks
Reinstall Panels
Adjust Water-To-Syrup Ratio
Adjust Flow Rates
Electronic Control Board Function
Ice Bank Control
Carbonator Control
LED Diagnostics
OPERATIONS
Operations
Starting And Stopping The Unit
Dispensing Product
Replenishing Syrup Supply
Adjustments
Water-to-syrup Ratio Adjustment
TABLE OF CONTENTS

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Cleaning & Checks
Daily Cleaning
Daily Checks
Sanitizing Syrup Systems
Sanitizing Syrup Tank Systems
Sanitizing Bag-In-Box Syrup System
Double Liquid Check Valve Inspection & Cleaning
Condenser Cleaning
Service
Preventative Maintenance
Preventative Maintenance Summary
Sanitizing
Double Liquid Check Valve Inspection & Cleaning
Check For Leaks
Check Ratio
Clean Condenser
Clean BIB Connectors
Adjustments
CO2Connection
Primary And Secondary Co2 Regulator Settings
Trouble shooting
Component Service
Carbonator Pump Replacement
Pump Motor Replacement
Agitator Motor Replacement
Controller Board Replacement
Condenser Fan Motor Replacement
Power Cord Replacement
Illustrated Parts List (Intellicarb)
Reference Material
Wiring Diagram
Plumbing Diagram - Internal Carbonator

© 2010, IMI Cornelius Inc.
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GENERAL INFORMATION
GENERAL DESCRIPTION
This manual is a guide for installing, operating, and maintaining this equip-
ment. This section gives the Unit Description, Theory of Operation, and
Design Data for Impulse Post-Mix Beverage Over counter Dispenser. This
Unit must be installed and serviced by a quali!ed Service Person. This
Unit Contains no User serviceable parts.
WARRANTY REFERENCE INFORMATION
UNIT DESCRIPTION
The Raja over the counter, post-mix, beverage dispenser is large-cooling-capacity,
easy-to-maintain, and can be ordered with or without a built-in carbonator. Syrup
pump kits are available for the units.
• Raja — 6 valve
Raja units may be island mounted or installed on a front or rear
counter. The 2/3 H.P. refrigeration deck is easily removed for service and
maintenance. Adjustable water "ow regulators and syrup "ow regulators,
located on dispensing valves, are easily accessible.
Key Lock
Switch
ON/OFF
Switches
Removable
Refrigeration
Deck
Removable
Drip Tray
Warranty Registration Date
(to be !lled out by customer)
Unit Part Number:
Serial Number:
Install Date:
Lacal Authorized Serviced Center:

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SPECIFICATIONS
Dimensions
Part Numbers
50 Hz Model, 230 VAC see nameplate
Capacity
Assuming: – a 3 oz./sec. (85g / sec.) dispensing rate
– a 90°F (32 °C) ambient temperature
– two 12-oz. (340g) drinks per minute
– drinks dispensed at 40° F (5 °C) or below
Capacities by unit are:
Raja unit, 230 volt, 50 Hz, 250 drinks continuously
The Raja over the counter, post-mix, beverage dispenser offers the following
features:
• Key-lock switch • 6 valves on Raja unit
• Built-in carbonator (optional)
• Syrup pump kit (optional) • Removable refrigeration deck (s)
• Removable drip tray
Height 27.6 inches 700 mm
Width 18.3 inches 464 mm
Depth 29.1 inches 740 mm
Shipping Weight (approx.) 176.2 pounds 80(no water) kg
Water Bath Size 15 gal (US) 57 l
Ice Bank Size 40.0 lb 18.0 kg

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A CO2cylinder delivers carbon dioxide (CO2) gas through adjustable CO2
regulators to the applicable syrup tanks or bag in box syrup pumps and also
the integral (built in) carbonator. Plain water enters the integral carbonator
carbonated water tank and is carbonated by CO2gas pressure also entering
the water tank. When dispensing valve is opened, CO2gas pressure exerted
upon the applicable syrup tank contents or bag in box syrup pump pushes
syrup from the syrup supply, through the Unit syrup cooling coil, and on to the
dispensing valve.
Carbonated water is pushed from the integral carbonator carbonated water
tank by CO2gas head pressure and is pushed through the carbonated water
manifold to the dispensing valve. Syrup and carbonated water meet simultane
ously at the dispensing valve resulting in a carbonated drink being dispensed.
A still (non carbonated) drink is dispensed in the same manner as the carbon
ated drink except plain water is substituted for carbonated water.
HEORY OFOPERA ION
NO E: HE UNI IS FAC ORY SE O DISPENSE NON-CARBONA ED
WA ER AND CARBONA ED WA ER AS PER CUS OMER’S REQUIRE-
MEN . I IS AVAILABLE O DISPENSE A MOS 3 NON-CARBONA ED
WA ERS WI H CARBONA ED WA ER DISPENSING FROM HE REMAIN-
ING VALVE(S). NON-CARBONA ED WA ER DISPENSING VALVE(S) MAY
BE CONVER ED O ALSO DISPENSE CARBONA ED DRINK(S).

2010, IMI Cornelius Inc.
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OTE

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INSTALLATION
LOOSE PARTS
Name Quantity
Cup rest 1
Drip tray 1
Drain hose 1
Hose clamp 1
1
Service Manual
DELIVERY INSPECTION AND UNPACKING
Inspection
Upon delivery inspect the unit for damage or irregularities and immediately
report problems to the delivering carrier and !le a claim with that carrier.
Unpacking
Remove shipping tape and other packing material.
Unpack the loose parts and make sure all items are present.
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It is the responsibility of the Installer to ensure that the water supply to the dispensing equipment is
provided with protection against backflow by an air gap as defined in ANSI A112. 1.2-1979; or
an approved vacuum breaker or other such method as proved effective by test. and must comply
with all federal, State, and Local codes.
Failure to comply could result in serious injury,death or damage to the
equipment.
Water pipe connection and fixtures directly connected to potable water supply shall be sized,
intalled and maintained according to Federal,State and Local laws.
Warning

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NSTALLAT ON REQU RMENTS
Requirements Summary
Weight............counter must be level and able to support 510 lbs. (200 kg)
Environment...indoor installation only
Temperature...50 ° F to 110° F (10° C 43° C) ambient temperature
CO2............... 75 psi (5 bar)
Syrup............. 60 psi (4 bar)
Water..............30~43 psi (2~3 bar) maximum
Electrical.........see nameplate on unit for electrical requirements
Electrical Requirements
Before connecting electrical power to the unit refer to nameplate
to verify power requirements.
DANGER
FA LURE TO COMPLY COULD RESULT N SER OUS NJURY,DEATH OR DAMAGE TO THE EQU PMENT.
FA LURE TO COMPLY COULD RESULT N SER OUS NJURY,DEATH OR DAMAGE TO THE EQU PMENT.
FA LURE TO COMPLY COULD RESULT N SER OUS NJURY,DEATH OR DAMAGE TO THE EQU PMENT 
— To avoid possible serious injury or death the ELCB
(earth leakage circuit breaker) must be installed in electrical
circuit of all 50 Hz units.
WARN NG — To avoid possible electrical shock the unit must be
electrically grounded using the green grounding screw provided
inside the electrical contactor box.
CAUT ON — 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 PROPERLY GROUNDED.
Environmental Requirements
Ambient (room) temperature MUST NOT EXCEED 110° F (43° C)
Temperatures in excess of 110° F (43° C) will void the factory
warranty and may eventually result in refrigeration system failure.
CAUT ON — To avoid overheating and damaging to the unit,
and voiding the warranty, there must be at least 8 inch (0.2 m)
of clearance on all sides and 18 inch (0.45 m) on the top of the unit.
CAUT ON — This unit is designed for indoor installation only
(in non harsh environments).
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AUTION —If the unit is exposed to freezing temperature,
water in the unit will freeze and may damage the unit.
AUTION
—
Never put any liquid vessel or water cup onto the Top Cover ,
INSTALLATION PRO EDURE
ounter-top Installation
1. Place the unit on a level counter capable of supporting at least
510 pounds ( 200 kg ).
2. Remove two mounted screws from the top and Lift Top cover off.
AUTION — Make sure that the power to the unit is disconnected
(unplugged) before removing the covers.
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Remove Two Screws
Before Remove Top cover
avoid spillage into the top vents.
The appliance is not suitable for installation in an area where
a water jet could be used.

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counter top and all access holes in the unit base must be sealed,
Caulk/seal the unit to the counter using Dow Corning RTV 731 or
equivalent approved sealant.
4. Fill the water bath with clean water around the carbonator tank or bend
back the insulation on the non carbonated unit until it comes out the
over!ow tube. Make sure the over!ow tube is not blocked or plugged.
Use low mineral tap water, not distilled or deionized water.
NOTE W ater bath must be "lled with water before the unit will run.
GLOBAL ICE BANK CONTROL (GIBO) THEORY OF OPERATION
Once electrical power is supplied to the Unit,
the agitator motor will start. There will be a
three-minute time delay before the refrig
eration compressor and the condenser 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 pins on the
ice bank control probe. The ice bank control
module senses this by measuring the di ffer
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 condenser
fan motor off.
The Unit remains turned o ff until the ice bank
control three stainless-steel pins are free of
ice. Once this happens, the ice bank control
module starts the refrigeration compressor
and the condenser fan moto r.
3. Pull water, syrup, and CO lines through counter or wall. To comply
with NSF International requirements the unit must be sealed to the
Fill Waterbath by Hosetube
through Hole in top

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5. Make sure that the electrical power
circuit breaker is switched off or the
fuse removed.
NOTE -- Before connecting electrical
power to the unit, refer to nameplate
to verify the power requirements.
A. Remove the following:
– Top cover by removing
screws on the top and lifting
up
– key switch wires
B. First route the new cord up behind
the valve panel and through the
cutout in the deck. Use the
already attached wire tie/fastener
on the deck to secure the cord.
C. Connect cord to the receptacle on
the refrigeration deck.
D. Turn the circuit breaker 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.
Cord
Fastener
Plug cord into
Receptacle
Power
Switch

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onnect Syrup, Water, and arbonated Water Lines
1. Route syrup 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.
CO2
Plain Water
Inlet
NOTE
W ater pipe connections and !xtures 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 laws and regulations.
NOTE
It is the installer’s responsibility to ensure that the water supply
is equipped with protection against back "ow . This protection
can be an air gap as de!ned by ANSI/ASME A112.1.2 1979,
or by an approved vacuum breaker or other approved method.
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 shutof f valve and water !lter in the water supply line
are recommended.
Syrup Inlets
Over Flow Line

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2. The unit has a built-in carbonator, connect the water line to the
pump.
Water Line Connected
to Pump
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. If the unit has a built-in carbonator,
connect the CO2lines. Be
sure the water and CO2are on.
CO2should be set at 75 psi
(5.25 bar) maximum. Higher CO2
pressure will result in LOWER
carbonation.
CO2Inlet Carbonator
Bleed the air out of the carbonator (hold with wrench) Bleed Valve
by pulling up on the metal ring on
the bleed valve. Bleed each valve into a bucket until water comes out
for 2-3 seconds.

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OTE The CO2 inlet !tting is sealed inside the carbonator with an
O-ring. This !tting rotates freely and must be held by a second
wrench while securing the CO 2 inlet line.
5. If remote carbonator is used, be sure it is on. Bleed each valve into a
bucket until carbonated water comes out.
6. Be sure that all syrup sources are connected and on. Bleed each valve
into a bucket until syrup comes out.
7. Reinstall drip tray and position water bath over"ow hose in drip tray
indent.
8. Check the system for gas leaks by pressurizing the system and then
turning off the cylinder valve. W ait a couple of minutes and check the
cylinder gauge to see if the pressure has dropped.
9. Check the system for water and syrup leaks.
Check for Leaks
1. Bleed air from the lines by activating dispensing valves.
2. Remove air from carbonator (if unit has built-in carbonator) by
opening safety relief valve until water escapes.
3. Check the system for gas leaks by pressurizing the system and
then turning off the cylinder valve. W ait a couple of minutes and
check the cylinder gauge to see if the pressure has dropped.
4. Check the system for water and syrup leaks.
Reinstall Panels
1. Reinstall top and front vented panels as well as the front stainless
steel panel.

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djust Water-To-Syrup Ratio
1. Remove valve front cover and install syrup diversion assembly in
place of nozzle.
Water Flow Syrup
Adjuster on Syrup Diversion
Left Adjuster on Tube
Right
Ratio Cup
2. Adjust carbonated water !ow to the desired rate (such as 2.50 oz. / sec.)
(70g / sec.). T urn the adjuster 1/4 of a turn at a time and recheck the !o w.
T o increase !ow turn clockwise.
3. Adjust the syrup to water ratio of each valve using the syrup adjuster
on the left side of each valve. Hold cup under valve and dispense
beverage for a speci"c time (such as 4 seconds).
djusting 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 !ow rate of the water is 5
times that of the syrup.
If the desired "nished drink !ow rate is 3.0 ounces per second, then the
water !ow rate is 2.5 oz./sec. (70 g / sec.) and the syrup !ow rate is
0.5 oz./sec. (14 g / sec.) (The water at 2.5 oz./sec. (70 g / sec.) is "ve times
the 0.5 oz./sec. (14 g / sec.) syrup !ow rate.)

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Flow Rates Based on 5:1 Ratio
Finished Drink oz./sec. Water oz./sec. Syrup oz./sec.
1.5 (42 g/sec.) 1.25 (35 g/sec.) .25 (7 g/sec.)
2.0 (56 g/sec.) 1.67 (47 g/sec.) .33 (9.4 g/sec.)
2.5 (70 g/sec.) 2.08 (60 g/sec.) .42 (12 g/sec.)
3.0 (85 g/sec.) 2.5 (70 g/sec.) .50 (14 g/sec.)
3.5 (99 g/sec.) 2.92 (83 g/sec.) .58 (16.5 g/sec.)
4.0 (113 g/sec.) 3.33 (95 g/sec.) .67 (19 g/sec.)
4.5 (128 g/sec.) 3.75 (105 g/sec.) .75 (21 g/sec.)
Electronic Control Board Function
An integrated circuit board and microprocessor are used to control the
electrical functions of the Raja beverage dispenser. Functional
features of the control board include:
• Ice bank control with compressor start-up protection
• Carbonator control with continuous run protection
• LED diagnostics
Inputs to the control board include line power, the ice bank position
sensor, and carbonator water level sensor. Switched outputs from the
circuit board include the compressor, agitator motor, condenser fan
motor, and carbonator pump (refer to electrical diagram in reference
section).
Ice Bank Control
The ice bank control operates the compressor and condenser fan motor
to control the size of the ice bank. The control board will not restart the
compressor until after the compressor has been off for at least 3 minutes
to allow the refrigeration system pressures to equalize.