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