Cornelius CB1522 User manual

®
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 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, and mechanical equipment. It is assumed that appropriate safety
precautions are taken and that all local safety and construction requirements are being
met, in addition to the information contained in this manual.
To inquire about current revisions of this and other documentation or for assistance with
any Cornelius product contact:
www.cornelius.com
800-238-3600
Trademarks and copyrights:
Aurora, Cornelius, FlavorFusion, Hydro Boost, Optifill, Pinnacle, and Vanguard are regis-
tered trademarks of IMI Cornelius Inc.
This document contains proprietary information and it may not be
reproduced in any way without permission from Cornelius.
Printed in U.S.A.
Copyright © 2005, All Rights Reserved, IMI Cornelius, Inc.

TABLE OF CONTENTS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Read and follow all safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Recognize safety alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Different types of alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Qualified Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drop-In Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drop-In Dimensions (CB1522) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drop-In Dimensions (CB2323) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drop-In Accessories —Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Custom Compact Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drop-in Dimensions (CB3023) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Requirements Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Delivery Inspection and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Back Room Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1522-2323-3023 Drop-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conversion Instructions for Valves Connected into Manifold . . . . . . . . . . . . . . 10
Conversion Instructions for 1522 Valve #1 from Carb to Non/Carb . . . . . . . . . 11
Drop-In Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjust Water-To-Syrup Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cold Plate Plumbing & Wiring Diagram for CB2323 & CB3023 8 Valve . . . . . . 17
Cold Plate Plumbing & Wiring Diagram for CB2323 6 valve . . . . . . . . . . . . . . . 18
Cold Plate Plumbing & Wiring Diagram for CB1522 6 Valve . . . . . . . . . . . . . . 19
IntelliCarb Back Room Plumbing and Settings . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal and Installation of Carbonator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Carbonator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Carbonator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Manifold Parts Breakdown (1522, 2323, 3023) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CB 1522 IntelliCarb Stainless Tower 75lb with 12 x 4 Carbonator . . . . . . . . . . . . . 24
CB 2323 IntelliCarb Stainless Tower 100lb with 12 x 4 Carbonator . . . . . . . . . . . . 25
CB 2323 IntelliCarb Stainless Tower 80lb with 8 x 4 Carbonator . . . . . . . . . . . . . . 26
CB 3023 IntelliCarb Stainless Tower 130lb with 12 x 4 Carbonator . . . . . . . . . . . . 27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

IntelliCarb Drop-In Ice Cooled Installation Guide
© 2003-2005, IMI Cornelius Inc. - 1 - Publication Number: 630460204INS
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 regula-
tions before operating the machine.
Different types of alerts
There are three types of safety alerts:
DANGER —Indicates an immediate hazardous situation which if not avoided WILL result in seri-
ous injury, death, or equipment damage.
WARNING —Indicates a potentially hazardous situation which, if not avoided, COULD result in
serious injury, death, or equipment damage.
CAUTION —Indicates a potentially hazardous situation which, if not avoided, MAY result in
minor or moderate injury or equipment damage.
SAFETY TIPS
•Carefully read all safety messages in this guide and safety signs on the machine.
•Keep safety signs in good condition and 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 proper training.
•Keep your machine in proper working condition and do not allow unauthorized modifications to the
machine.
QUALIFIED SERVICE PERSONNEL
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.
CO2(CARBON DIOXIDE) WARNING
WARNING —CO2Displaces Oxygen. Strict Attention must be observed in the prevention of
CO2gas leaks in the entire CO2and soft drink system. If a CO2gas 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 CO2gas will experience tremors which are followed
rapidly by loss of consciousness.
Recognize safety alerts
This is the safety alert symbol. When you see it in this guide or on the machine be
alert to the potential of personal injury, or damage to the machine.

IntelliCarb Drop-In Ice Cooled Installation Guide
Publication Number: 630460204INS - 2 - © 2003-2005, IMI Cornelius Inc.
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
© 2003-2005, IMI Cornelius Inc. - 3 - Publication Number: 630460204INS
SYSTEM OVERVIEW
DROP-INPRODUCT 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.), UF-1 Ultra flow (4.5 oz./sec.), and UFB 2.0 - 4.0 valves
•Improved ability to clean outlet line area
•Lighted and non-lighted merchandiser options
•Optional cabinet stand for free standing installations.
SPECIFICATIONS
Drop-In Dimensions (CB1522)
Counter Top Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1/4 x 23 1/4 inches
Height above counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 inches
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 inches
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 inches
Shipping weight (approx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 pounds
Drop-in Unit

IntelliCarb Drop-In Ice Cooled Installation Guide
Publication Number: 630460204INS - 4 - © 2003-2005, IMI Cornelius Inc.
Drop-In Dimensions (CB2323)
Counter Top Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 1/4 x 23 1/4 inches
Height above counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 inches
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches
Shipping weight (approx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 pounds
Drop-In Accessories — Optional
Lighted marquee merchandiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166208004
Cabinet stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165492000
Custom Compact Dimensions
Counter Top Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 1/4 x 23 1/4 inches
Height above counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 inches
Height of Merchandiser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 inches
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches
Shipping weight (approx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 pounds
Drop-in Dimensions (CB3023)
Counter Top Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 1/4 x 23 1/4 inches
Height above counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 inches
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 inches
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 inches
Shipping weight (approx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285 pounds

IntelliCarb Drop-In Ice Cooled Installation Guide
© 2003-2005, IMI Cornelius Inc. - 5 - Publication Number: 630460204INS
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:..................................................................................... indoor installation only
Temperature:................................................................... 40 to 100°F ambient temperature
CO2:................................................................................................................. 75 psi at unit
Syrup: ....................................................................... 60 psi. min,.70 –.75 ounces per sec.,
...............................not to exceed 3.75 oz/sec Finished Product Flow Rate (.6 gpm) at unit
Water pressure: ....................................................................................60 psi max. at pump
Electrical: ..................................................................................................... see name plate
Water volume........................................................................................................... 125 gph
Product supply beverage tubing ............................................................................ .375 min.

IntelliCarb Drop-In Ice Cooled Installation Guide
Publication Number: 630460204INS - 6 - © 2003-2005, IMI Cornelius Inc.
DELIVERY INSPECTION AND UNPACKING
Inspection
Upon delivery inspect the unit for damage or irregularities and immediately report problems to the deliver-
ing carrier and file a claim with that carrier.
1. Open loose parts packages and inspect parts.
Make sure all items are present.
Part Name
Drop-In
P/N Qty.
Pump &motor assy. 629087457 1
4" legs n/a n/a
Clamps Oetiker n/a
Drain pan drain line 167090002 1
Cold plate drain line 167467072 1
Merchandiser assy. 166167010 1
Transformer 630000601 1
Ftg-3/4 Soc x 3/4 fpt n/a n/a
Ftg-3/4 mptx1" barb n/a n/a
Loose
parts

IntelliCarb Drop-In Ice Cooled Installation Guide
© 2003-2005, IMI Cornelius Inc. - 7 - Publication Number: 630460204INS
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.
NOTE: Recommended shut off valve be installed on outlet side of filter system.
2. Run water line from source to inlet connection on booster pump.
3. Connect water line from booster pump outlet to water filter system inlet.
p/n 605620
Pre filter
p/n 605625ST
Main filter
p/n 605600
Polyphosphate feeder (Ice
Maker water)

IntelliCarb Drop-In Ice Cooled Installation Guide
Publication Number: 630460204INS - 8 - © 2003-2005, IMI Cornelius Inc.
NOTE: Do not route beverage make up water through polyphosphate feeder.

IntelliCarb Drop-In Ice Cooled Installation Guide
© 2003-2005, IMI Cornelius Inc. - 9 - Publication Number: 630460204INS
4. Connect from water filter system outlet to
water regulator assembly and tee to surge
tank.
5. Connect water lines from manifold outlet to
water line going to each dispenser.
SYRUP
6. Connect syrup lines from bundled tubing to BIB
pump outlet fitting.
HIGH PRESSURE CYLINDER CO2
1. Connect primary regulator manifold to high pres-
sure cylinder CO2source and connect tubing to
the secondary regulator mounted on the side of
BIB rack.
2. Connect one CO2line from the bundled tubing to the primary regulator manifold on CO2source to
supply each dispenser.
BULK CO2 TA N K
1. Connect bulk CO2 tank to the secondary regulator mounted on the side of BIB rack. DO NOT USE
PRIMARY REGULATOR WITH BULK CO2TANKS.
2-wide BIB
shelf assembly
P/N 561300067
3-wide BIB
shelf assembly
P/N 561300066
Water
connection
from filters
Water
connection
to unit(s)
BIB
pumps
Secondary
regulator

IntelliCarb Drop-In Ice Cooled Installation Guide
Publication Number: 630460204INS - 10 - © 2003-2005, IMI Cornelius Inc.
1522-2323-3023 DROP-IN
Conversion Instructions for Valves Connected into Manifold
1. Remove the cup rest, front panel, and drip tray.
2. Remove insulation pad, 2 screws, and bracket (as shown below).
3. Pull out the plug fitting and tubing with barb fitting of the desired valve for conversion.
4. Place tubing with barb fitting into desired outlet on the manifold.
5. Replace plug fitting in open outlet.
6. Reassemble bracket, 2 screws, and insulation pad.
7. Reassemble drip tray, front panel, and cup rest.
PLUG FITTING
BRACKET
TUBING WITH
BARB FITTING
SCREW
REAR CONNECTION
NON-CARB WATER
OPTION
FRONT CONNECTION
CARBONATED WATER
OPTION
MANIFOLD
OETIKER CLAMP

IntelliCarb Drop-In Ice Cooled Installation Guide
© 2003-2005, IMI Cornelius Inc. - 11 - Publication Number: 630460204INS
Conversion Instructions for 1522 Valve #1 from Carb to Non/Carb
1. Remove the cup rest, front panel, and drip tray.
2. Remove insulation pad, 2 screws, and bracket (as shown above on page 10).
3. Pull out a plug fitting from the rear connection of the manifold.
4. Disconnect soda line from valve #1.
5. Assemble straight fitting and oetiker clamp to soda line from valve #1 (as shown on page 10).
6. Assemble soda line from valve #1 to manifold.
7. Assemble hose plug and clamp oetiker to soda line valve #1 (as shown on page 10).
8. Reassemble bracket, 2 screws, and insulation pad.
9. Reassemble drip tray, front panel, and cup rest.
Drop-In Installation
1. Install dispenser in counter following standard procedures.
2. 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.
3. 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.
4. Liberally apply a sealant, such as Dow Corning RTV 731 or equivalent, to the unit flange bottom sur-
face.
5. Lower the unit into position to complete the seal of the rim to the counter top. Apply additional seal-
ant around the rim to ensure a complete seal.
NOTE: Do not move the unit after positioning or the seal will be broken.
6. Remove any excess sealant.
NOTE: For non-electrical valves, skip the next step.
7. Mount the Transformer power supply under the counter, in a position to allow access to the electrical
outlet and to allow the 24V power cord to reach the dispenser.
8. Install the drain hose to the ice bin drain fitting and route the drain hose to a permanent drain.
9. Mount secondary CO2regulator, carbonator pump with motor, and valve transformer in a conve-
nient location, no more than 7 feet from the unit.
10. Connect carbonator motor 3 wire plug to the tower 3 wire harness.
Connect the tower 2 wire harness to the transformer.
Carbonator
motor and
pump
assembly
Valve
transformer
Secondary
regulator

IntelliCarb Drop-In Ice Cooled Installation Guide
Publication Number: 630460204INS - 12 - © 2003-2005, IMI Cornelius Inc.
11. Connect CO2line from bundled tubing to fixed sec-
ondary regulator inlet fitting.
Connect tubing from secondary regulator outlet to
carbonator tank CO2inlet.
Route CO2line down center channel raceway with
wire harness.
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. Connect fittings and drain hoses to ice bin and drip tray drains.
Run separate hoses all the way to the drain. Allow a 3”air gap
between the drain and the end of the hose. All connections
must comply with local plumbing and health codes.
15. Turn water supply on.
Plug in water booster pump (on BIB rack).
After the booster pump cycles off, check that water pressure
regulator is set at 60 psi.
16. Turn CO2source on. Set secondary regulator for BIB pumps
(located on side of rack) at 60 psi min. Bleed carbonator.
17. Fill bin with ice.
18. Plug in Pump Motor and valve transformer.
The carbonator tank should fill in 7 to 12 seconds.
Open each valve until carbonated water comes out.
19. Connect syrup lines to bag-in-boxes.
Bleed syrup from each valve.
Free-Standing Dispenser
1. Install the 6”legs to the dispenser cabinet if they are to be used.
2. Place the dispenser in the location selected. Be sure the dispenser is level. This is important to
ensure that the bin drains properly.
3. Mount the Transformer power supply in a convenient location to allow access to the electrical outlet
and to allow the 24V power cord to reach the dispenser.
4. Install the drain hose to the ice bin drain fitting and route the drain hose to a permanent drain.
CO2line
2323 Drop-In
W1
Water
pressure
regulator
Water
manifold
assembly

IntelliCarb Drop-In Ice Cooled Installation Guide
© 2003-2005, IMI Cornelius Inc. - 13 - Publication Number: 630460204INS
SANITIZING PRODUCT COLD PLATE TUBING
Preparing the Cleaning Solution: 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.
Preparing the Sanitizing Solution: Using a clean tank (tank system) or a five-gallon container (bag-in-
box system), prepare sanitizing solution using 70°F (21°C) to 100°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.
STEP 1. WASH PRODUCT/SYRUP 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.
•Observe and note CO2 pressure settings on the tanks CO2 regulator, then re-adjust CO2 regula-
tor to 60 to 80-psi. Pressurize the tank containing detergent solution to 60 to 80-psi.
•Connect detergent solution tank, pressurized at 60 to 80-psi, into one of the tubing systems.
Bag-in Box Systems.
•Install bag valves (cut empty bag-in-box syrup containers) on ends of syrup containers syrup out-
let tubes connectors.
•Place all syrup outlet tubes, with bag valves on their ends, in container containing detergent
solution.
2. Flush the syrup system and dispensing valve as follows:
•Place waste container under applicable dispensing valve.
•Activate the dispensing valve for one minute to purge all syrup and flush out the syrup system.
•Continue to activate the dispensing valve in cycles (“ON”for 15-seconds, “OFF”, then “ON”for
15-seconds). Repeat “ON”and “OFF”cycles 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.
•Flush detergent solution out of syrup system and dispensing valve as follows:
•Place waste container under applicable dispensing valve.
•Activate the dispensing valve for one minute to purge all detergent solution and flush out of the
syrup system.
•Continue to activate the dispensing valve in cycles (“ON”for 15-seconds, “OFF”, then “ON”for
15-seconds).
3. Connect potable water source to remaining syrup systems and flush detergent solution out of syrup
systems as instructed in step A preceding.
4. Remove potable water source from the syrup system.

IntelliCarb Drop-In Ice Cooled Installation Guide
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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.
•Connect sanitizing solution tank, pressurized at 60 to 80-psi, into one of the tubing systems.
Bag-in-Box Syrup System.
•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:
•Place waste container under applicable dispensing valve.
•Activate the dispensing valve for one minute to purge all water from and install sanitizing solution
in the syrup system and dispensing valve.
•Continue to activate the dispensing valve in cycles (“ON”for 15-seconds, “OFF”, then “ON”for
15-seconds). Repeat “ON”and “OFF”cycles for 15-cycles.
3. Repeat steps to flush water out of and install sanitizing solution in the remaining syrup systems and
dispensing valves.
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-min-
utes (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.
•Connect tank containing potable water, pressurized at 60 to 80-psi, into one of the systems.
Bag-in-Box Syrup Systems.
•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:
•Place waste container under applicable dispensing valve.
•Activate the dispensing valve for one minute to purge all sanitizing solution out of the syrup sys-
tem and the dispensing valve.
•Continue to activate the dispensing valve in cycles (“ON”for 15-seconds, “OFF”, then “ON”for
15-seconds). Repeat “ON”and “OFF”cycles for 15-cycles.
3. Repeat preceding steps to purge sanitizing solution out of the remaining syrup systems and dis-
pensing valves.
4. Remove potable water source from the syrup system.
STEP 5. PURGE WATER (RESTORE OPERATION)
Tank Systems.
1. Noting tanks CO2 regulator pressure setting observed in step 4 preceding, readjust CO2 regulator to
the observed pressure setting.
•Connect tanks containing the product into the system.

IntelliCarb Drop-In Ice Cooled Installation Guide
© 2003-2005, IMI Cornelius Inc. - 15 - Publication Number: 630460204INS
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 dis-
pense 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 CO2 pressure has been released from the tank.
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 solu-
tion residue.
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 solution.
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 manufacture’s direc-
tions 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.
Post-Mix 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
hookup.
Pre-Mix units must have a pre-mix supply connected to each inlet for each valve supplied. Refer to
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 and 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 CO2 regulators as indicated in the following chart:
4. Operate each valve until product is flowing.
5. Fill the bin with 32°F ice. DO NOT use ice taken directly from the freezer.
6. Adjust the brix (water-to-syrup ratio) for post-mix valves.
Post-Mix
Regulator Pressure Setting
Primary (Carbonator) feed line to Carb secondary regulator 90-120 PSI
Secondary, Sugared Syrup Tank 55 PSI min.
Secondary, Diet Syrup Tank 8-12 PSI
Secondary, B-I-B 60 PSI min

IntelliCarb Drop-In Ice Cooled Installation Guide
Publication Number: 630460204INS - 16 - © 2003-2005, IMI Cornelius Inc.
Adjust Water-To-Syrup Ratio
1. Remove valve cover and install syrup separator over the diffuser and through the nozzle.
2. Hold cup under valve and dispense beverage for a specific time (i.e. 2 seconds).
3. NOTE: Water and syrup must be cold before checking ratios.
4. Adjust carbonated water flow to the desired rate (such as 90 to 110 ml (3 to 3.75 oz.) per second).
Turn the flow adjuster 1/4 of a turn at a time and recheck the flow.
To increase reading turn clockwise.
5. Set syrup flow adjuster to get the desired ratio.
6. Test the valve and adjust until a consistent ratio is delivered three consecutive times.
7. Repeat procedure for other valves.
Valve Type
Manufacturer Maximum Operating
Pressure
Portion Control
Cornelius 130 psi
Flowmatic 100 psi
Pushbutton
Cornelius 130 psi
Flowmatic 100 psi
Lever Type
Cornelius 130 psi
Flowmatic 100 psi
Autofill Lever
Cornelius 130 psi
Flowmatic 100 psi
Non-Electric
Cornelius 130 psi
Separator
Water-To-Syrup
ratio cup