Cornelius Enduro-300 IntelliCarb User manual

IMPORTANT:
TO THE INSTALLER.
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/ASME A112.1.2-1979;
or an approved vacuum
breaker or other such
method as proved effective
by test.
Water pipe connections
and fixtures directly
connected to a potable
water supply shall be
sized, installed, and
maintained according to
Federal, State, and Local
Codes.
Operator’s Manual
ICE/BEVERAGE DISPENSER
Model: Enduro–300 IntelliCarb
PRINTED IN U.S.A
IMI CORNELIUS INC; 2001–2006
IMI CORNELIUS INC
www.cornelius.com
Part No. 620919505
Revision Date: January 26, 2006
December 11, 2001
Revision: F
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
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TABLE OF CONTENTS
Page
SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOGNIZE SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDERSTAND SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOLLOW SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO2 (CARBON DIOXIDE) WARNING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIPPING, STORING, OR RELOCATING UNIT 1. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY (OR AS REQUIRED) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING CO2 SUPPLY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING FOR CO2 AND WATER LEAK 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEEKLY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MONTHLY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING CARBONATED WATER TANK RELIEF VALVE 3. . . . . . . . . . . . . . . .
WATER PUMP MOTOR LUBRICATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
YEARLY WATER PUMP MAINTENANCE (OR AFTER WATER SYSTEM
DISRUPTION) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING CO2 GAS CHECK VALVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
START-UP & OPERATING INSTRUCTIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICE DRINK DISPENSER 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBONATOR PUMP 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING INSTRUCTIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSER 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING EXTERIOR SURFACES 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING INTERIOR SURFACES 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGE SYSTEM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COLD PLATE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSING VALVES 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT TUBING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZE SYRUP LINES, B-I-B SYSTEMS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLENISHING CO2 SUPPLY 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND REPLACEMENT OF AGITATORS 8. . . . . . . . . . . . . . . . . . . . . . . . .
TO REMOVE AGITATORS FOR CLEANING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOWN FUSE OR CIRCUIT BREAKER 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GATE DOES NOT OPEN. AGITATOR DOES NOT TURN. 9. . . . . . . . . . . . . . . . . .
GATE DOES NOT OPEN OR IS SLUGGISH. AGITATOR TURNS. 9. . . . . . . . . . .
ICE DISPENSES CONTINUOUSLY. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SLUSHY ICE. WATER IN HOPPER. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES DO NOT DISPENSE 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES TOO SWEET 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES TOO SWEET (CONT’D) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES NOT SWEET ENOUGH 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES NOT COLD (UNITS WITH BUILT–IN COLD PLATE) 10. . . . . . . . . . .
CARBONATOR PUMP MOTOR WILL NOT OPERATE. 10. . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (cont’d)
Page
CARBONATOR PUMP MOTOR WILL NOT SHUT OFF. 10. . . . . . . . . . . . . . . . . . . .
ERRATIC CYCLING OF CARBONATOR. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBONATOR PUMP CAPACITY TOO LOW. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBONATOR PUMP MOTOR OPERATES BUT CARBONATOR PUMP
DOES NOT PUMP. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES
FIGURE 1. AGITATORS REPLACEMENT 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. CABINET SECTION EXPLODED VIEW 13. . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. GATE SOLENOID ASSEMBLY 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. Z–STYLE COLD PLATE DRAIN 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 5. CARBONATOR ASS’Y 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 6. ELECTRICAL BOX ASSEMBLY 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7. PUMP AND MOTOR ASSEMBLY 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 8. WATER MANIFOLD ASSEMBLY 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5
SAFETY INFORMATION
Recognize Safety Information
This is the safety-alert symbol. When you see this
symbol on our machine or in this manual, be alert to
the potentially of personal injury.
Follow recommended precautions and safe operating
practices.
CAUTION
DANGER
Understand Signal Words
A signal word - DANGER, WARNING, OR CAUTION
is used with the safety-alert symbol. DANGER identi-
fies the most serious hazards.
Safety signs with signal word DANGER or WARNING
are typically near specific hazards. WARNING
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety mes-
sages in this manual.
Follow Safety Instructions
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in
good condition. 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 instructions. Keep your machine in
proper working condition. Unauthorized modifications to the machine may impair function and/or safety and
affect the machine life.
CO2(Carbon Dioxide) Warning
CO2Displaces Oxygen. Strict Attention must be observed in the prevention of CO2(carbon dioxide)
gas 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 and suffocation.
Maximum CO2Operating Pressure 75–PSI
CAUTION: Before shipping, storing, or relocating this Unit, the syrup systems must be sanitized and
all sanitizing solution must be purged from the syrup systems. All water must also be purged from
the plain and carbonated water systems. A freezing ambient temperature will cause residual water
remaining inside the Unit to freeze resulting in damage to internal components of the Unit.
Shipping, Storing, Or Relocating Unit
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MAINTENANCE
The following dispenser maintenance should be performed at the intervals indicated:
DAILY (or as required)
Remove foreign material from vending area drip tray to prevent drain blockage.
CHECKING CO2SUPPLY
Make sure CO2cylinder regulator assembly 1800–psi gage indicator is not in shaded (“change CO2cylinder”)
portion of the dial. If so, the CO2cylinder is almost empty and must be replaced.
CHECKING FOR CO2AND WATER LEAK
Check the Unit for CO2and water leaks and if found, call a qualified Service Person to repair as necessary.
WEEKLY
(or as required)
Clean vending area. Check for proper water drainage from the vending area drip tray.
MONTHLY
Clean and sanitize the hopper interior and beverage system, if applicable (see CLEANING INSTRUCTIONS).
CHECKING CARBONATED WATER TANK RELIEF VALVE
The relief valve on bottom of the carbonated water tank under the coldplate cover should be periodically
checked for proper operation by briefly pulling up on the relief valve ring.
WATER PUMP MOTOR LUBRICATION
The water pump motor bearings must be lubricated periodically. Call a qualified Service Person to perform the
bearings lubrication procedure.
YEARLY WATER PUMP MAINTENANCE (OR AFTER WATER SYSTEM
DISRUPTION)
The water pump water strainer screen and the liquid dual check valve must be inspected and cleaned at least
once a year under normal cicumstances and after any water system disruption (plumbing work, earthquake,
etc.). Call a qualified Service Person to inspect and clean the strainer screen and the liquid dual check valve.
CLEANING CO2GAS CHECK VALVE
The CO2gas check valve, located on the carbonated water tank, must be inspected and serviced at least once a
year under normal conditions and after any CO2system servicing disruption.Call a qualified Service Person to
inspect and clean the CO2gas check valve.
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620919505
START-UP & OPERATING INSTRUCTIONS
ICE DRINK DISPENSER
Fill the hopper with ice. Dispense several large cups of ice (approximately 20 to 30 seconds total dispensing
time) to allow ice to fill the cold plate cabinet. Add ice to the hopper as necessary to refill, then replace the re-
place the lid. Allow 10 to 15 minutes for the cold plate to cool down. Repeat this procedure whenever the dis-
penser has run out of ice. Start up the beverage system and adjust faucets to the proper brix. Contact your local
syrup distributor for complete information on the beverage system.
In normal operation, pushing the ice dispenser mechanism will cause ice to flow from the ice chute. Ice flow will
continue until the dispenser mechanism is released. Dispensing of any faucet will provide beverage of the ap-
propriate flavor.
CAUTION: Use caution to avoid spilling ice when filling dispenser. Clean up immediately any
spilled ice from filling or operating the unit. To prevent contamination of ice, the lid must be
installed on the unit at all times.
If the dispenser fails to dispense ice or beverage see troubleshooting guide.
CARBONATOR PUMP
1. Turn water on until the tank is full.
2. Turn the pump on (it should not run).
3. Turn CO2on.Operate one of the dispensing valves and cycle the carbonator a couple of times.
CLEANING INSTRUCTIONS
WARNING: Disconnect Power Before Cleaning! Do not use metal scrapers, sharp objects or
abrasives on the ice storage hopper, top cover and the agitator disk, as damage may result.
Do not use solvents or other cleaning agents, as they may attack the plastic material.
Soap solution - Use a mixture of mild detergent and warm (100°F) potable water.
Sanitizing solution - Dissolve 2 packets (4 oz) Stera Sheen Green Label into 2 gallons of warm (80–100 deg F)
water to insure 200 ppm of available chlorine.
DISPENSER
CLEANING EXTERIOR SURFACES
Important: Perform the following daily.
1. Remove cup rest from drip tray.
2. Wash the drip tray with soap solution. Rinse drip tray with clean water and allow solution to run down the
drain.
3. Wash cup rest with soap solution and rinse in clean water. Install the cup rest in the drip tray.
4. Clean all exterior surfaces of Unit with soap solution, then rinse with clean water.
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CLEANING INTERIOR SURFACES
CAUTION: When pouring liquid into the hopper, do not exceed the rate of 1/2–gallon
per minute.
Important: Perform the following at least once a month.
1. Remove agitator assembly (see Figure1).
2. Using a nylon bristle brush or sponge, clean the interior of the hopper, top cover and agitator assembly with
soap solution. Thoroughly rinse the hopper, cover and agitator surfaces with clean potable water.
3. Reassemble agitator assembly. Take special care to ensure that the thumbscrew is tight.
4. Using a mechanical spray bottle filled with sanitizing solution, spray the entire interior and agitator assem-
bly. Allow to air dry.
5. Remove merchandiser and ice chute cover from unit.
6. With a nylon bristle brush or sponge, clean the inside of the ice chute, gasket, and cover with soap solution
and rinse thoroughly to remove all traces of detergent.
7. Reassemble ice chute assembly.
8. Using a mechanical spray bottle filled with sanitizing solution, spray the inside of the ice chute. Allow to air
dry.
9. Reinstall merchandiser.
BEVERAGE SYSTEM
(IF APPLICABLE)
WARNING: Disconnect Power Before Cleaning! Do not use metal scrapers, sharp objects or
abrasives on the ice storage hopper, top cover and the agitator disk, as damage may result.
Do not use solvents or other cleaning agents, as they may attack the plastic material.
Soap solution - Use a mixture of mild detergent and warm (100°F) potable water.
Sanitizing solution - Dissolve 2 packets (4 oz) Stera Sheen Green Label into 2 gallons of warm (80–100 deg F)
water to insure 200 ppm of available chlorine.
Cleaning tank - Fill clean, empty tank with a mixture of mild detergent and five (5) gallons of warm
potable water (120°F).
CAUTION: When pouring liquid into the hopper, do not exceed the rate of 1/2–gallon
per minute.
COLD PLATE
1. Remove splash panel.
2. Remove or move the plastic cold plate cover to expose the cold plate.
3. Locate and remove any debris from the drain trough. Check that the drain holes are not clogged.
4. Pour small amount of soap solution through cold plate openings in hopper.
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620919505
5. Using a cloth, wash down the surfaces of the cold plate and plastic cover with soap solution.
6. Install and properly position the cover on the cold plate.
7. Install the splash panel in the reverse order it was removed.
8. Rinse cold plate surface by pouring potable water through hopper openings.
DISPENSING VALVES
Refer to addendum supplied with the unit that is applicable to the manufacturer of the valves installed
on the unit.
PRODUCT TUBING
Only trained and qualified persons should perform these cleaning and sanitizing procedures.
Sanitize tank systems, Post-Mix and Pre-Mix as follows:
1. Remove all the quick disconnects from all the tanks. Fill a suitable pail or bucket with soap solution.
2. Submerge all disconnects (gas and liquid) in the soap solution and then clean them using a nylon bristle
brush. (Do not use a wire brush). Rinse with clean water.
3. Prepare sanitizing solution and using a mechanical spray bottle, spray the disconnects.
Allow to air dry.
4. Using a clean, empty tank, prepare five (5) gallons of the sanitizing solution. Rinse the tank disconnects
with approximately 9 oz. of the sanitizing solution. Close the tank.
5. Prepare cleaning tank by filling clean five (5) gallon tank with a mixture of mild detergent and potable water
(120_F).
6. Connect a gas disconnect to the tank and then apply one of the product tubes to the cleaning tank. Oper-
ate the appropriate valve until liquid dispensed is free of any syrup.
7. Disconnect cleaning tank and hook up sanitizing tank to syrup line and CO2system.
8. Energize beverage faucet until chlorine sanitizing solution is dispensed through the faucet. Flush at least
two (2) cups of liquid to ensure that the sanitizing solution has filled the entire length of the syrup tubing.
9. Allow sanitizer to remain in lines for fifteen (15) minutes.
10. Repeat the step above, applying a different product tube each time until all tubes are filled with the sanitiz-
ing solution.
11. For post-mix valves, remove the nozzle and syrup diffuser and clean them in a mild soap solution.
Rinse with clean water and reassemble the nozzle and syrup diffuser on the valve.
12. For pre-mix valves, disconnect all product tubes from the tank of sanitizing solution and then open the
valves to allow the pressure to be relieved. Remove the valves from the dispenser, disassemble and wash
thoroughly in a mild soap solution.
13. Rinse the parts in clean water, reassemble the valve and reconnect it to the dispenser.
14. Discard the tank of sanitizing solution and reconnect the product (syrup or pre-mix) tanks. Operate the
valves until all sanitizer has been flushed from the system and only product (syrup or pre-mix) is flowing.
Sanitize syrup lines, B-I-B Systems
1. Remove all the quick disconnects from all the B-I-B containers.
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2. Fill a suitable pail or bucket with soap solution.
3. Submerge all disconnects (gas and liquid) in the soap solution and then clean them using a nylon bristle
brush. (Do not use a wire brush). Rinse with clean water.
4. Using a plastic pail, prepare approximately five (5) gallons of sanitizing solution.
5. Rinse the B-I-B disconnects in the sanitizing solution.
6. Sanitizing fittings must be attached to each B-I-B disconnect. If these fittings are not available, the fittings
from empty B-I-B bags can be cut from the bags and used. These fittings open the disconnect so the sani-
tizing solution can be drawn through the disconnect.
7. Place all the B-I-B disconnects into the pail of sanitizing solution. Operate all the valves until the sanitizing
solution is flowing from the valve. Allow sanitizer to remain in lines for fifteen (15) minutes.
8. Remove the nozzle and syrup diffuser from each valve and clean them in a soap solution. Rinse with clean
water and reassemble the nozzle and syrup diffuser to the valve.
9. Remove the sanitizing fittings from the B-I-B disconnects and connect the disconnects to the appropriate
B-I-B container. Operate the valves until all sanitizer has been flushed from the system and syrup is flow-
ing freely.
REPLENISHING CO2SUPPLY
NOTE: When indicator on the 1800–psi gage is in the shaded (“change CO2cylinder”) portion of the dial,
CO2 cylinder is almost empty and should be changed.
1. Fully close (clockwise) the CO2cylinder valve.
2. Slowly loosen the CO2regulator assembly coupling nut allowing CO2pressure to escape, then remove the
regulator assembly from the empty CO2cylinder.
3. Unfasten safety chain and remove the empty CO2cylinder.
WARNING: To avoid personnel injury and/or property damage, always secure the CO2
cylinder with a safety chain to prevent it from falling over. Should the valve become
accidently damaged or broken off, a CO2cylinder can cause serious personnel injury.
4. Position the full CO2cylinder and secure with a safety chain.
5. Make sure gasket is in place inside the CO2regulator assembly coupling nut , then install the regulator as-
sembly on the CO2cylinder.
6. Open (counterclockwise) the CO2cylinder valve slightly to allow the lines to slowly fill with gas, then open
the valve fully to back–seat the valve (back–seating the valve prevents gas leakage around the valve
shaft).
7. Check CO2connections for leaks. Tighten any loose connections.
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