Low Profile Large Reserve Carbonator Service Manual
Contents
1. A VENTED DUAL CHECK VALVE ASS Y O p TIN CARBONATOR ASS Y PARTIAL op NG i x c TT SHUTOFF VALVE n 1 VENT PORT FILTER CARBONATOR TANK VENT TUBE AREAS EE ex TO PERMANENT WATER PUMP DRAIN FIGURE 6 VENTED DUAL CHECK VALVE LOCATION 319798006 18 WATER PUMP d MOTOR SAFETY THERMOSTAT P N 317989 000 CONTROL BOX GRN OR GRN YEL c O Em Er er NA Jaba 456 LIQUID LEVEL S N L SENSING DEVICE OR OR 1 RED ORN LIQUID LEVEL CONTROL MODULE BLK WHT 2 Ei gt GRN OR BLK Actual location of HI LO and LOAD terminals may vary on different brands of control modules FIGURE 7 WIRING DIAGRAM MODELS 1624 416424000 41642400U 411624102 AND 496424000 19 319798000 WATER PUMP Pd MOTOR SAFETY THERMOSTAT P N 317989 000 CONTROL all Bi Hr Er T WHT Z OR Q BLU BLK OR BRN2. PUMP TO MOTOR COUPLING FIGURE 4 WATER STRAINER SCREEN AND LIQUID DUAL CHECK VALVE QUAD RING E id 183294000 BALL C a 183296000 SPRING Se 183297000 ge RETAINER 183298000 BODY e 183295100 Quad ring seal must be replaced each time check valve is serviced FIGURE 5 GAS CHECK VALVE 13 319798006 REPAIR AND REPLACEMENT WATER PUMP see Figures 2 and 4 Removal Disconnect electrical power from the Unit 2 Close the CO cylinder shutoff valve then close the shutoff valve in the water inlet supply line 3 Pull up on the carbonator water tank relief valve plastic cap to release CO pressure from the water tank 4 Disconnect the water inlet supply line from the water pump water inlet fitting Be careful not to lose the black tapered gasket inside the swivel nut 5 Disconnect the water tank water inlet line from the water tank inlet fitting and the liquid dual check valve assembly outlet or the vented dual check valve assembly outlet 6 Remove the liquid dual check valve assembly or the vented dual check valve assembly from the water pump outlet port 7 Note position of the safety thermostat on the water pump outlet then remove the thermostat from the pump 8 Remove fitting from the water pump inlet port 9 Loosen screw on the pump to motor coupling enough to remove the water pump from the motor Installation 1 Disassemble and clean the liquid dual check valve assembly as inst
3. 13 WATERCPUMP icu babe tira ds 13 WATER PUMP MOTOR 14 CARBONATOR TANK LIQUID LEVEL CONTROL MODULE 15 SAFETY THERMOSTAT dema aaea 2 ar ei 15 VENTED DUAL CHECK VALVE 16 TROUBLESHOOTING Kimi kid usi iii ins ar ran 21 CARBONATOR PUMP MOTOR WILL NOT OPERATE 21 CARBONATOR PUMP MOTOR WILL NOT SHUT OFF 21 ERRATIC CYCLING OF CARBONATOR 21 CARBONATOR PUMP CAPACITY TOO LOW 22 CARBONATOR PUMP MOTOR OPERATES BUT CARBONATOR PUMP DOES NOTPUMP suni i a cack EE e recu ec cce BEAM ca ea v er 22 WARRANTY ner oer cx wur a apa NR a pe rately asa De NOR 23 LIST OF FIGURES FIGURE 1 LOW PROFILE LARGE RESERVE CARBONATOR 4 FIGURE 2 CARBONATOR ASSEMBLY COMPONENTS 9 FIGURE 3 LIQUID CHECK VALVE ASSEMBLY 10 FIGURE 4 WATER STRAINER SCREEN AND LIQUID DUAL CHECK VALVE 12 FIGURE 5 CO2 GAS CHECK VALVE 12 319798006 TABLE OF CONTENTS cont d Page LIST OF FIGURES CONT D FIGURE 6 VENTED DUAL CHECK VALVE LOCATION 17 FIGURE 7 WIRING DIAGRAM MODELS 1624 416424000 41642400U 411624102 AND 496424000 18 FIGURE 8 WIRING DIAGRAM MODEL NO 8984 49642400U AND 4964240
4. 3 Loosen the CO regulator adjusting screw lock nut then turn the screw to the left counterclockwise until the pressure gage reads O psi 4 Relieve pressure from the carbonator water tank by pulling up on the pressure relief valve plastic cap on top of the water tank 5 Disconnect the inlet line from the CO check valve inlet then remove the CO check valve from the carbonator water tank 6 Disassemble check valve as shown in Figure 5 7 Wipe each part with a clean lint free cloth Inspect each part especially the ball for burrs nicks corrosion deterioration and other damage 8 Reassemble the check valve as shown in Figure 5 ALWAYS INSTALL NEW QUAD RING SEAL 9 Install check valve in the carbonator water tank inlet fitting MAKE SURE THE SHORTEST THREADED END OF THE CHECK VALVE IS SCREWED INTO THE CARBONATOR WATER TANK INLET FITTING FOR PROPER VALVE OPERATION 10 Connect CO inlet line to check valve 11 Turn the carbonator CO regulator adjusting screw to the right clockwise until the pressure gage registers pressure noted in step 2 preceding then tighten the adjusting screw lock nut 12 Connect electrical power to the carbonator 319798006 12 a WATER LINE TO TANK WHITE TAPERED LIQUID DUAL a CHECK VALVE VENTED DUAL SAFETY THERMOSTAT CHECK VALVE MW WATER PUMP WATER STRAINER SCREEN P N 315348000 gt O RING P N 315349000 SCREEN
5. 5 Place container under the applicable dispensing valve of syrup system soft drink tank was disconnected from Open dispensing the valve and dispense carbonated water until the carbonator tank CO pressure has been released 6 Loosen the screen retainer then pull the screen retainer and strainer screen from the water pump 7 Pull strainer screen from the screen retainer Clean any sediment from the screen retainer and the water pump screen retainer port 8 Inspect the strainer screen for holes restrictions corrosion and other damage Discard damaged strainer Screen 9 319798006 A CAUTION THIS WATER TUBE IS NOT A HANDLE LIFT ING BY THIS TUBE CAN RESULT IN WATER LEAKS AND FLOODING GAS LIQUID LEVEL CHECK VALVE SENSING DEVICE VENTED DUAL CHECK VALVE OR CONTROL RELIEF VALVE LIQUID DUAL BOX CARBONATOR WATER TANK SOS CI EN SAFETY THERMOSTAT ES SU COVER RETAIING SCREW 2 S N S WATER PUMP POWER CORD WATER PUMP MOTOR FIGURE 2 CARBONATOR ASSEMBLY COMPONENTS 319798006 10 9 Check O Ring on the screen retainer Replace worn or damaged O Ring P N 315349000 NOTE A strainer screen should always be used otherwise particles could foul the liquid double check valve 10 11 Install good or new strainer screen P N 315348000 in the screen retainer then screw the retainer into the water pump and tighten securely Service liquid double chec
6. po 9 Install new safety thermostat by reversing the Removal procedure Make sure the safety thermostat electrical wires are properly connected see Figure 7 Install the control box cover and secure with screws Connect electrical power to the Unit VENTED DUAL CHECK VALVE see Figure 4 Removal o a Disconnect electrical power from the unit Close the CO cylinder shutoff valve then close shutoff valve in the water inlet supply line Pull up on the carbonator water tank relief valve plastic cap to release CO pressure from the tank Disconnect water tank inlet line from the vented dual check valve assembly Remove vent line from the vented dual check valve assembly Remove the vented dual check valve assembly from the water pump outlet port Installation sb 5 Install new vented dual check valve in the water pump outlet port be sure flow direction arrow points up Using tapered gasket connect water line from the water tank to the top of the vented dual check valve Tighten fittings Attach vent line to the vented dual check valve Open CO cylinder shutoff valve then open water inlet supply line shutoff valve Check carefully for leaks and repair if evident Connect electrical power to the Unit Allow the Unit to cycle several times while observing for correct operation 17 319798006
7. COELHO e RIO DE JANEIRO BRAZIL e 55 21 591 7150 e FAX 55 21 593 1829 ENGLAND e TYTHING ROAD ALCESTER e WARWICKSHIRE B49 6 EU ENGLAND e 44 789 763 101 e FAX 44 789 763 644 FRANCE 71 ROUTE DE ST DENIS e F 95170 DEUIL LA BARRE PARIS FRANCE 33 34 28 6200 e FAX 33 1 34 28 6201 GERMANY e CARL LEVERKUS STRASSE 15 e D 4018 LANGENFELD GERMANY e 49 2173 7930 e FAX 49 2173 77 438 GREECE e 488 MESSOGION AVENUE e AGIA PARASKEVI e 153 42 e ATHENS GREECE 30 1 600 1073 e FAX 30 1 601 2491 HONG KONG 1104 TAIKOTSUI CENTRE 11 15 KOK CHEUNG ST TAIKOKTSUE HONG KONG 852 789 9882 e FAX 852 391 6222 ITALY e VIA PELLIZZARI 11 e 1 20059 e VIMARCATE ITALY e 39 39 608 0817 e FAX 39 39 608 0814 NEW ZEALAND e 20 LANSFORD CRES e P O BOX 19 044 AVONDALE e AUCKLAND 7 NEW ZEALAND e 64 9 8200 357 e FAX 64 9 8200 361 SINGAPORE e 16 TUAS STREET e SINGAPORE 2263 e 65 862 5542 e FAX 65 862 5604 SPAIN e POLIGONO INDUSTRAIL e RIERA DEL FONOLLAR E 08830 SANT BOI DE LLOBREGAT BARCELONA SPAIN 34 3 640 2839 e FAX 34 3 654 3379 USA e ONE CORNELIUS PLACE ANOKA MINNESOTA 612 421 6120 e FAX 612 422 3255 LD004 4 21 98 23 319798006 IMI CORNELIUS INC AA CORPORATE HEADQUARTERS One Cornelius Place Anoka Minnesota 55303 6234 612 421 6120 800 238 3600
8. LIQUID LEVEL OR SENSING DEVICE S L2 I al aT Bee Peles N LIQUID LEVEL CONTROL ORN MODULE GRN OR BLK Actual location of HI LO and LOAD terminals may vary on different brands of control modules FIGURE 8 WIRING DIAGRAM MODEL NO 8984 49642400U AND 496424040 19 319798006 THIS PAGE LEFT BLANK INTENTIONALLY 319798006 20 TROUBLESHOOTING IMPORTANT Only qualified personnel should service internal components or electrical wiring the applicable product tank then relieve the system pressure before proceeding If repairs N WARNING If repairs are to be made to a product system remove quick disconnects from are to be made to the CO system stop dispensing shut off the CO supply then relieve the System pressure before proceeding If repairs are to be made to the refrigeration system make sure electrical power is disconnected from the unit Trouble CARBONATOR PUMP MOTOR WILL NOT OPERATE CARBONATOR PUMP MOTOR WILL NOT SHUT OFF ERRATIC CYCLING OF CARBONATOR Probable Cause Unit power cord unplugged or circuit breaker open in panel box Inoperable pump motor Overheated motor cut off by thermal overload protector Inoperative liquid level control module Liquid level sensing device inside carbonator tank inoperable Loose electrical conn
9. 40 554 a ORs RN aA eee ce tee 19 LIST OF TABLES 3 TABLE 1 DESIGN DATA 319798006 ji 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 possibility of personal injury Follow recommended precautions and safe operating practices 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 A WA G are typically near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety mes A CAUTI 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 Carbon Dioxide Warning CO Displaces Oxygen Strict Attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire and so
10. CGCirelis gt REMCOR CORNELIUS INC One Cornelius Place 8 Anoka MN 55303 6234 Telephone 800 238 3600 Facsimile 612 422 3246 LOW PROFILE LARGE RESERVE CARBONATOR Service Manual IMPORTANT It is the responsibility of the Service Person 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 laws When installing in an area regulated by the City of Los Angeles Plumbing and or Mechanical Codes a City of Los Angeles approved reduced pressure principle backflow preventer shall be installed on each potable water supply to each carbonator THIS MANUAL IS NOW OBSOLETE SERVICE INFORMATION WAS INCOR PORATED INTO THE INSTALLATION SERVICE MANUAL 319798001 LARRY POTTS WAS INFORMED Part No 319798006 April 4 1985 Revised March 11 1997 5 17 00 Control Code B THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment IMI CORNELIUS INC 1998 PRINTED IN U S A TABLE OF CONTENTS Page SAFETY 1 RECOGNI
11. MANUAL 319798001 LARRY POTTS WAS INFORMED 5 17 00 THIS PAGE LEFT BLANK INTENTIONALLY 7 319798006 SERVICE AND MAINTENANCE This section describes service and maintenance procedures to be performed on the Unit IMPORTANT Only qualified personnel should service internal components or electrical wiring WARNING Disconnect electrical power to the carbonator to prevent personnel injury before attempting any internal maintenance closed Dry running the water pump will burn out the pump A pump damaged in this manner is not covered by warranty WARNING Strict attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire CO soft drink system If a gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the CAUTION Never operate the carbonator with the water inlet supply line shutoff valve leak Personnel exposed to high concentrations of CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation CAUTION To prevent a fire hazard no object should be placed or stored on top of the Unit PREPARING UNIT FOR SHIPPING STORING OR RELOCATING IMPORTANT All water must be purged from the Unit if exposed to a freezing temperature A freezing ambient will cause residual water inside the Unit to freeze resulting in damage to internal components Damage of this type wi
12. ZE SAFETY 1 UNDERSTAND SIGNAL 5 1 FOLLOW SAFETY INSTRUCTIONS 1 CO2 CARBON DIOXIDE WARNING 1 SHIPPING STORING OR RELOCATING UNIT 1 GENERAL INFORMATION 3 TO THE USER OF THIS MANUAL 3 CLAIMS INSTRUCTIONS 3 WARRANTY REFERENCE INFORMATION 3 DESIGN DATA comas a a dica 3 UNIT DESCRIPTION 2m nis CONTRE 4 THEORY OF OPERATION 5 SERVICE AND MAINTENANCE 7 PREPARING UNIT FOR SHIPPING STORING OR RELOCATING 7 LUBRICATION sesso en rte ee oeste SM aae Rer 8 ADJUSTING CARBONATOR CO2 REGULATOR 8 WATER PUMP YEARLY MAINTENANCE OR AFTER WATER SYSTEM exce re rs REIR ties RA aaa RR aa 8 SERVICING WATER PUMP WATER INLET STRAINER SCREEN 8 SERVICING LIQUID DUAL CHECK VALVE 10 THE VENTED DUAL CHECK VALVE ASSEMBLY 11 CLEANING CARBONATOR CO2 GAS CHECK VALVE 11 REPAIR AND REPLACEMENT
13. arbonated water from back flowing into the city water system The Vented Dual Check Valve vents water and possibly CO gas out of a vent port on failure of the Primary Check Valves Should such venting occur the Vented Dual Check Valve should be replaced The Unit inlet has a single check valve to prevent carbonated water back flow into CO regulator 319798006 4 THEORY OF OPERATION A CO cylinder delivers CO carbon dioxide gas through an adjustable CO regulator to the carbonator water tank At the same time plain water is pumped into the carbonator water tank by the water pump and is carbon ated by CO gas also entering the tank When carbonator water tank carbonated water level has been satisfied liquid level sensing device inside the tank signals the liquid level control module which in turn shuts off the water pump motor and the water pump As carbonated water is drawn and carbonated water level in the tank drops to a certain level the liquid level sensing device inside the water tank signals the liquid level control module that carbonated water must be replenished which in turn starts the water pump motor and the pump 5 319798006 This manual is now obsolete Service Information from this manual has been incorporated into the Installation Manual which is now an Installation Service Manual 319798001 5 10 00 THIS MANUAL IS NOW OBSOLETE SERVICE INFORMATION WAS INCOR PORATED INTO THE INSTALLATION SERVICE
14. arbonator water tank by reversing the Removal procedure Connect the electrical polarized plug to the new liquid level sensing device electrical connector Restore the carbonator CO regulator to the pressure noted in step of Removal Open the Unit water inlet supply line shutoff valve Connect electrical power to the Unit CARBONATOR TANK LIQUID LEVEL CONTROL MODULE see Figure 2 Removal Po Disconnect electrical power from the Unit Remove screws securing the control box cover then remove the cover Remove screws securing the liquid level control module inside the control box Label the electrical wires connected to the liquid level control module for identification then disconnect wires from the module Installation ur Install new liquid level control module by reversing the Removal procedure Make sure electrical wires are correctly connected to the control module see Figure 7 Install the control box cover and secure with screws Connect electrical power to the Unit SAFETY THERMOSTAT see Figure 2 Removal Disconnect electrical power from the Unit Remove screws securing the control box cover then remove the cover Disconnect safety thermostat wires from the control module terminals Pull safety thermostat wires out of the control box Note position of the safety thermostat on the water pump outlet then remove the thermostat 319798006 16 Installation
15. dual check valve assembly outlet DO NOT OVER TIGHTEN 11 319798006 9 Turn the carbonator regulator adjusting screw to the right clockwise until the gage indicates pressure setting noted in step 3 of SERVICING WATER PUMP WATER STRAINER SCREEN Tighten the adjusting Screw lock nut 10 Open the Unit water inlet supply line shutoff valve 11 Connect electrical power to the Unit The water pump will start and fill the carbonator water tank Check for water leaks and tighten any loose connections 12 Install quick disconnect on the soft drink tank outlet THE VENTED DUAL CHECK VALVE ASSEMBLY see Figure 4 A vented dual check valve assembly is installed in the carbonator between the water pump outlet and the water inlet to the carbonator water tank as shown in Figure 6 The vented dual check valve assembly vents carbon ated water and possibly CO gas out of a vent port upon failure of the primary check valves Should such vent ing occur the vented dual check valve assembly must be replaced CLEANING CARBONATOR GAS CHECK VALVE see Figures 2 and 5 The carbonator tank gas check valve must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the system ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK VALVE IS SERVICED Proceed as follows 1 Disconnect electrical power from the Unit 2 Note pressure setting on the carbonator CO regulator
16. ection and or open electrical circuit Carbonator pump binding new or replacement pumps only Carbonator pump damaged Liquid level sensing device inside carbonator tank inoperable Loose electrical connection and or open electrical circuit Inoperable liquid level control module Leak in carbonated water system Liquid level sensing device inside carbonator tank inoperable Liquid level control module inoperable 21 Remedy Plug in Unit power cord or reset circuit breaker Replace pump motor as instructed Check for proper line voltage Check for restricted pump discharge Replace liquid level control module as instructed Replace sensing device as instructed Tighten connection and or repair open circuit Check line voltage Remove carbonator pump from motor rotate pump or motor shaft 180 degrees then recouple pump to motor Replace carbonator pump as instructed Replace sensing device as instructed Tighten connection and or repair open circuit Replace liquid level control module as instructed Repair carbonated water system Replace sensing device as instructed Replace liquid level control module as instructed 319798006 Trouble CARBONATOR PUMP CAPACITY TOO LOW CARBONATOR PUMP MOTOR OPERATES BUT CARBONATOR PUMP DOES NOT PUMP 319798006 Probable Cause Pump inlet water strainer Screen dirty Kinked plain water inlet supply line Foreign ob
17. ft drink system If a gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Person nel exposed to high concentration of CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation Shipping Storing Or Relocating Unit CAUTION All water must be purged from the Unit if exposed to freezing temperature A freezing am bient temperature will cause residual water remaining inside the Unit to freeze resulting in damage to internal components of the Unit 1 319798006 THIS PAGE LEFT BLANK INTENTIONALLY 319798006 2 GENERAL INFORMATION TO THE USER OF THIS MANUAL be exposed to the elements CAUTION This Unit must not be installed in an unsheltered outdoor location where it will This Manual is a guide for performing service and maintenance procedures on this equipment Refer to Table of Contents for page location of detailed service and maintenance procedures A Parts Manual P N 319798003 for this equipment is available upon request This Unit must be serviced by a qualified Service Person This Unit contains no user serviceable parts CLAIMS INSTRUCTIONS Claims In the event of shortage notify the carrier as well as IMI Cornelius immediately In the event of dam age notify the carrier IMI Cornelius is not responsible for damage occurring in transit but will gladly render assistance necessary to pur
18. ject in pump bypass Water pump worn out Water filter clogged Water pump inlet water strainer screen dirty Water supply too low or turned off Water filter clogged Inoperative water pump 22 Remedy Clean or replace water strainer Screen as instructed Straighten plain water inlet supply line Clean Note Count number of turns bypass screw makes when removing and install same number of turns Replace water pump as instructed Replace water filter Clean or replace water strainer Screen as instructed Inlet water supply must be a minimum of 100 gallons per hour with a maximum water pressure of 70 psi Replace water filter Replace water pump as instructed WARRANTY IMI Cornelius Inc warrants that all equipment and parts are free from defects in material and workmanship un der normal use and service For a copy of the warranty applicable to your Cornelius Remcor or Wilshire prod uct in your country please write fax or telephone the IMI Cornelius office nearest you Please provide the equipment model number serial number and the date of purchase IMI Cornelius Offices AUSTRALIA e P O 210 e RIVERWOOD e NSW 2210 AUSTRALIA e 61 2 533 3122 e FAX 61 2 534 2166 AUSTRIA e AM LANGEN FELDE 32 e A 1222 e VIENNA AUSTRIA e 43 1 233 520 e FAX 43 1 2335 2930 BELGIUM e BOSKAPELLEI 122 e B 2930 BRAASCHAAT BELGIUM e 32 3 664 0552 e FAX 32 3 665 2307 BRAZIL e RUA ITAOCARA 97 e TOMAS
19. k valve refer to next paragraph SERVICING LIQUID DUAL CHECK VALVE SERVICING LIQUID DUAL CHECK VALVE see Figure 2 and 4 1 Service the water strainer screen as instructed in previous paragraph SERVICING WATER PUMP STRAINER SCREEN before servicing the liquid dual check valve Disconnect the water tank inlet line from the water tank inlet and from the liquid dual check valve assembly outlet Remove the check valve assembly from the water pump outlet port Disassemble each check valve as shown in Figure 3 Wipe each part with clean lint free cloth Inspect each part especially the ball for burrs nicks corrosion deterioration and other damage Discard the ball seat and any damaged or suspicious parts and replace with new parts during reassemble Reassemble check valves as shown in Figure 3 ALWAYS INSTALL NEW BALL SEAT O RING ITEM 2 AND FLAT WASHER ITEM 1 560000480 FLAT WASHER 312419000 BALL 560000481 SPRING 560000432 BALL SEAT O RING INSTALL NEW BALL SEAT ITEM 2 AND FLAT WASHER ITEM 1 AT EACH SERVICING NOTE Make sure when assembling the check valves together the FLAT WASHER item 1 is in place inside female end of the check valve FIGURE 3 LIQUID CHECK VALVE ASSEMBLY Assemble the check valves together DO NOT OVERTIGHTEN Install the liquid dual check valve assembly in the water pump outlet port Connect the water tank water inlet line between the water tank water inlet and the liquid
20. ll void the warranty Perform the following procedure to purge water from the Unit 1 2 3 4 e Disconnect electrical power from the Unit Close water inlet supply line shutoff valve Disconnect water inlet supply line from the Unit Dispense from one of the dispensing valves until all carbonated water has been dispensed from the carbo nator water tank Shut off supply to the Unit then disconnect inlet supply line Connect filtered dry compressed air 50 psi max to the Unit water inlet DO NOT USE GAS WHICH COULD CAUSE A HEALTH HAZARD Dispense from one of the dispensing valves until all residual water has been blown from the Unit and lines Disconnect filtered dry compressed air from the Unit water inlet Disconnect carbonated water outlet line from the Unit The Unit is now ready for shipping or relocating 319798006 8 LUBRICATION The water pump motor bearings must be oiled periodically Refer to oiling instructions on the motor DO NOT OVER OIL ADJUSTING CARBONATOR CO REGULATOR NOTE To readjust the regulator to a lower setting loosen the adjusting screw lock nut then turn the screw to the left counterclockwise until the pressure gage reads 5 psi lower than the new setting will be Turn the adjusting screw to the right clockwise until the gage registers new setting then tighten the lock nut Loosen the CO regulator adjusting screw lock nut Turn the carbonator regula
21. ontrol box from the motor and lay off to one side 7 Remove screw and clamp securing the water pump motor to the base then remove old motor Installation 1 Install new pump motor by reversing the Removal procedure 2 Make sure tang on the water pump and slot in the pump motor shaft are properly lubricated and aligned when installing the water pump on the motor 3 Make sure all wiring is correct see Figure 7 4 Install the control box cover and secure with screws 5 Connect electrical power to the Unit CARBONATOR TANK LIQUID LEVEL SENSING DEVICE see Figure 2 Removal Disconnect electrical power from the Unit Close the Unit water inlet supply line shutoff valve Note pressure setting on the carbonator CO regulator then loosen the lock nut and turn the regulator adjusting screw to the left counterclockwise until the regulator gage reads 0 Remove quick disconnect from outlet side of the soft drink tank Place container under the applicable dispensing valve of the syrup system the soft drink tank was discon nected from Open the dispensing valve and dispense carbonated water until the carbonator water tank CO pressure has been released Disconnect electrical polarized plug from the liquid level sensing device electrical connector Remove the threaded liquid level sensing device from the carbonator water tank 15 319798006 Installation Install new liquid level sensing device the c
22. ructed in steps 3 through 6 of SERVICING LIQUID DUAL CHECK VALVE 2 Install the new water pump by reversing the Removal procedure and use the following instructions A Make sure pipe thread sealing compound is used on the fittings threads when installing the liquid dual check valve assembly or the vented dual check valve assembly and fitting in the inlet and outlet ports of the new water pump B Make sure drive tang on the water pump and slot in the pump motor shaft are properly lubricated and aligned when installing the water pump on the motor 3 Open the CO cylinder shutoff valve then open the Unit water inlet supply line shutoff valve 4 Connect electrical power to the Unit 5 Dispense carbonated water from one of the dispensing valves to make the Unit cycle on Check for water leaks and tighten or repair any loose connections 319798006 14 WATER PUMP MOTOR see Figures 2 and 4 Removal Disconnect electrical power from the Unit 2 Loosen screw on the pump to motor coupling to disconnect the water pump from the motor then remove pump from the motor 3 Remove screws securing the control box cover then remove the cover 4 Disconnect the black and white pump motor electrical wires from the L1 and L2 terminals on the control module 5 Tag the pump motor electrical wires for identification then disconnect wires from the motor terminals 6 Remove conduit fitting securing the control box to the pump motor then remove the c
23. sue your claim Merchandise must be inspected for concealed dam age within 15 days of receipt WARRANTY REFERENCE INFORMATION Warranty Registration Date to be filled out by customer Unit Part Number Serial Number Install Date Service Center DESIGN DATA Table 1 Design Data pH nit Part Numbers 41642400 41642400 21162410 49642400 49642404 230 VAC 50 Hz Unit Liquid dual check valve 49642400 A A AAA 3 319798006 Table 1 Design Data cont d verall Dimensions Width Height Depth Weight Dry Shipping Ambient Operating Temperature Maximum CO Operating Pressure lectrical Requirements 115 VAC 50 60 Hz Unit Current Draw Operating Voltage 230 VAC 50 Hz Unit Current Draw Operating Voltage FIGURE 1 LOW PROFILE LARGE RESERVE CARBONATOR UNIT DESCRIPTION The carbonator is a compact Unit that may be installed in a remote location from where its carbonated water outlet is to be connected to a post mix dispenser or system The purpose of the Unit is to mix plain water and carbon dioxide CO gt gas which results in and provides carbonated water for a post mix dispenser or system The Unit consists basically of a water pump motor and a carbonator water tank The water pump has a liquid dual check valve Unit Part No 41642400U 416424000 49642400U 496424000 and 496424040 or a Vented Dual Check Valve Unit Part No 1624 8984 and 411624102 on its outlet to prevent c
24. tor adjusting screw to the right clockwise until the regulator gage reads nominal 80 psig then tighten the lock nut DO NOT EXCEED 125 PSIG WATER PUMP YEARLY MAINTENANCE OR AFTER WATER SYSTEM DISRUPTIONS WARNING The carbonator water pump water inlet strainer screen and the liquid dual check valve Unit Model No 416424000 41642400U 496424000 49642400U and 496424040 must be inspected and serviced at least once a year under normal circumstances and after any disruptions plumbing work earthquake etc to the water supply system that might cause turbulent erratic flow of water through the system If the system has a Vented Dual Check Valve Unit Model No 1624 8984 and 411624102 clean the carbonator water pump water inlet strainer Screen and flush the system A carbonator water pump with no screen or a defective screen in the strainer would allow foreign particles to foul the double check valve CO gas could then back flow into the water system and create a health hazard in the water system SERVICING WATER PUMP WATER INLET STRAINER SCREEN see Figure 4 1 Disconnect electrical power from the Unit 2 Close the Unit water inlet supply line shutoff valve 3 Note pressure setting on the carbonator regulator Loosen the lock nut and turn the CO regulator ad justing screw to the left counterclockwise until the regulator gage reads 0 4 Remove quick disconnect from outlet side of the soft drink tank
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