CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234

Telephone (800) 238-3600 Facsimile (763) 422-3246

Installation Manual
CARBONATOR
With Plain-Water Booster

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 codes.

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.

Publication Number: 319642005

Revision Date: May 05, 2014
Revision: E

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION

This Manual must be read and understood before installing or operating this equipment

© 1984–2014 CORNELIUS INC;

 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
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TO THE USER OF THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CLAIMS INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WARRANTY REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DESIGN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
IDENTIFICATION OF LOOSE–SHIPPED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SELECTING LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONNECTING PLAIN WATER INLET SUPPLY LINE . . . . . . . . . . . . . . . . . . . 8
CONNECTING CO2 INLET SUPPLY LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONNECTING CARBONATED WATER OUTLET LINE . . . . . . . . . . . . . . . . . 8
CONNECTING PLAIN WATER OUTLET LINE . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONNECTING UNIT 24 VAC TWO–CONDUCTOR CORD TO ELECTRIC
DISPENSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PERMANENT ELECTRICAL POWER CONNECTION TO DOMESTIC
UNIT IF REQUIRED BT LOCAL CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PREPARATION FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ADJUST CARBONATOR CO2 REGULATOR AND TURN WATER INLET
SUPPLY LINE ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WATER PUMP MOTOR WILL NOT OPERATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WATER PUMP MOTOR WILL NOT SHUT OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ERRATIC CYCLING OF CARBONATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP
WATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WATER PUMP CAPACITY TOO LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
NO PLAIN WATER DISPENSED WHEN DISPENSING VALVE IS OPENED. . . 15

LIST OF FIGURES
FIGURE 1. CARBONATOR WITH PLAIN-WATER BOOSTER . . . . . . . . . . . . . . . 4
 TABLE OF CONTENTS (cont’d)
Page
FIGURE 2. WIRING DIAGRAM (MODEL NO. 416417000 AND 496417000) . . . 11
FIGURE 3. WIRING DIAGRAM (MODEL NO. 496417020) . . . . . . . . . . . . . . . . . . 12
FIGURE 4. WIRING DIAGRAM (MODEL NO. 496417040) . . . . . . . . . . . . . . . . . . 13

LIST OF TABLES
TABLE 1. DESIGN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TABLE 2. LOOSE-SHIPPED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
 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.

Understand Signal Words

A signal word - DANGER, WARNING, OR CAUTION
is used with the safety-alert symbol. DANGER identi-
DANGER
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.
CAUTION
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

CO2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO2 (carbon dioxide)
gas leaks in the entire CO2 and soft drink system. If a CO2 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 CO2 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.

Publication Number: 319642005 1 © 1984-2014 Cornelius Inc.

 THIS PAGE LEFT BLANK INTENTIONALLY

© 1984-2014 Cornelius Inc. 2 Publication Number: 319642005

 GENERAL INFORMATION

TO THE USER OF THIS MANUAL

This Manual is a guide for installing and operating this equipment. Refer to Table of Contents for page location
of detailed information pertaining to questions that may arise during installation or operation of this equipment.
A Service Manual (P/N 319642004) 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 Cornelius immediately. In the event of dam-age,
notify the carrier. Cornelius is not responsible for damage occurring in transit, but will gladly render
assistance necessary to pursue 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:
Local Authorized
Service Center:

DESIGN DATA

Table 1. Design Data

Model Numbers
115 VAC Unit 416417000
230 VAC Unit 496417000
230 VAC Unit 496417020
230 VAC Unit 496417040

Overall Dimensions:
Width 6-3/8 inches
Height 18-1/4 inches
Depth 14 inches

Publication Number: 319642005 3 © 1984-2014 Cornelius Inc.

 Table 1. Design Data (cont’d)
Weight:
Dry 35 pounds
Shipping 38 pounds

Ambient Operating Temperature 40° F to 100° F

Maximum CO2 Operating Pressure 125 psi

Electrical Requirements:
Model No. 416417000:
Operating Voltage 115 VAC, 60 Hz
Current Draw 6.5 Amps
Model No. 496417000, 496417020, and 496417040:
Operating Voltage 220/230 VAC, 50/60 Hz
Current Draw 3.3 Amps

COVER

PLAIN WATER INLET

CO2 INLET

CARBONATED WATER OUTLET

POWER CORD

PLAIN WATER OUTLET

24 VAC TWO-CONDUCTOR CORD

(TO BE CONNECTED TO DISPENSING
VALVE THAT WILL DISPENSE A STILL
(NON-CARBONATED) DRINK)

FIGURE 1. CARBONATOR WITH PLAIN-WATER BOOSTER

© 1984-2014 Cornelius Inc. 4 Publication Number: 319642005

 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 a system. The purpose of the Unit is to mix plain water and
carbon dioxide (CO2) gas which results in and provides carbonated water for a post-mix dispenser or a system.
The Unit consists basically of a water pump, motor and a carbonated water tank. The water pump has a double-
liquid check valve on its outlet to prevent carbonated water from back flowing into the city water system. The
Unit CO2 inlet has a single check valve to prevent carbonated water back flow into CO2 regulator.

THEORY OF OPERATION

A CO2 cylinder delivers carbon dioxide (CO2) gas through a CO2 regulator to the carbonator tank. When carbo-
nator tank calls for water, an electrical circuit is completed through the level control switches, which opens the
water solenoid valve and also starts the water pump motor. Plain water is pumped through the water solenoid
valve into the carbonator tank which is carbonated by CO2 which is also entering the tank. When carbonator
tank is full, the weight of the water in the tank forces the tank and the balance control mechanism down activat-
ing the level control switches which stops the water pump motor and also closes the water solenoid valve.

When still (non–carbonated) drink dispensing valve is activated, it sends an electrical signal to start the carbo-
nator water pump motor. The carbonator water pump provides pressurized plain-water to the dispensing valve
which dispenses a still (non-carbonated) drink. When the dispensing valve lever is released, the electrical signal
to the carbonator water pump motor is cut off which stops the water pump motor.

Publication Number: 319642005 5 © 1984-2014 Cornelius Inc.

 THIS PAGE LEFT BLANK INTENTIONALLY

© 1984-2014 Cornelius Inc. 6 Publication Number: 319642005

 INSTALLATION

UNPACKING AND INSPECTION

NOTE: This Unit was thoroughly inspected before leaving the factory and the carrier has accepted
andsigned for it. Any damage or irregularities should be noted at the time of delivery and
immediately re-ported to the delivering carrier. Request a written inspection report from the Claims
Inspector to sub-stantiate any necessary claim. File the claim with the delivering carrier, not
Cornelius Inc.
1. After unit has been uncrated, remove shipping tape and other packing material. Check for obvious damage
and follow procedure in preceding NOTE if damage is evident.

2. Unpack LOOSE–SHIPPED PARTS. Make sure items are present and in good condition.

Table 2. Loose-Shipped Parts

Item
No. Part No. Name Qty.
1 178025100 Tapered Gasket, White 2
2 311304000 Tapered Gasket, Black 2

IDENTIFICATION OF LOOSE–SHIPPED PARTS

1. TAPERED GASKETS, WHITE (item 1) are used to seal connections when connecting lines to fittings la-
beled CO2 INLET and CARB WATER OUTLET on the Unit.

2. TAPERED GASKETS, BLACK (item 2) are used to seal connections when connecting water inlet supply
line to the Unit and when connecting plain-water line from the post–mix dispenser or system to the Unit
plain-water outlet.

SELECTING LOCATION

CAUTION: This Unit must not be installed in an unsheltered outdoor location where it will
be exposed to the elements.

Locate unit so following requirements are satisfied.

1. Locate the Unit in a cool area close to a properly grounded and fused electrical outlet with proper electrical
requirements (see TABLE 1). For accessibility, the electrical outlet must not be located behind the Unit.

2. Close to a food grade flexible plastic potable water inlet supply line with proper water inlet supply line re-
quirements.

3. Unit must be installed in up-right level position for proper operation.

INSTALLING UNIT
IMPORTANT: Before putting the carbonator into operation, the front cover must be removed and the
packing block must be removed from below the water pump motor.

Publication Number: 319642005 7 © 1984-2014 Cornelius Inc.

CONNECTING PLAIN WATER INLET SUPPLY LINE

(see Figure 1)

NOTE: Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the po-
table water inlet supply line. A Cornelius Water Filter (P/N 313860000) and Quick Disconnect Set
(P/N 313867000) are recommended.

CAUTION: Check minimum flow rate and pressure of potable water inlet supply line.
MINIMUM FLOW RATE MUST BE AT LEAST 100-GALLONS PER HOUR AND WATER
PRESSURE MUST NOT EXCEED 30-PSI. If flow rate is less than 100-gallons per hour,
starving of carbonator water pump will occur. Starving will allow carbonator water pump to
overheat causing safety thermostat on pump outlet to disrupt electrical power to and stop water
pump motor. Overheating could occur if plain water inlet supply line flow rate drops below
100-gallons per hour.

If fitting connector is not available, tap into plain water supply line with a 3/8-flare saddle valve
(P/N 315664000) or equivalent.

1. Make sure food grade flexible plastic potable water inlet supply line provides adequate water flow rate and
pressure as outlined in CAUTION note.

Before connecting the potable water inlet supply line to the Unit, open the water line for a period of time to
flush out any metal shavings resulting from connecting the water line to the fitting connector or the saddle
valve.

2. Remove shipping cap from 3/8-inch flare (5/8-18) male fitting on the Unit stamped WATER INLET.

3. Install TAPERED GASKET, BLACK (item 2) in water inlet supply line swivel nut, then connect water inlet
supply line to 3/8-flare male fitting labeled WATER INLET on the Unit.

CONNECTING CO2 INLET SUPPLY LINE

(see Figure 1)

1. Remove shipping cap from 1/4–inch flare (7/16-20) male fitting on the Unit stamped CO2 INLET.

2. Connect CO2 inlet supply line from CO2 regulator to 1/4-inch flare (7/16-20) male fitting on the Unit labeled
CO2 INLET. Seal connection with TAPERED GASKET, WHITE (item 1).

CONNECTING CARBONATED WATER OUTLET LINE

(see Figure 1)

WARNING: Under no circumstances should copper tubing, copper fittings, or brass fittings be used
to connect the Unit carb (carbonated) water outlet to the post–mix dispenser or system. CO2 gas
contact with copper tubing, copper fittings, or brass fittings will cause a health hazard.

1. Remove shipping cap from 1/4–inch flare (7/16-20) male fitting stamped CARB WATER on the Unit.

2. Extend length of food grade flexible plastic tubing from the Unit carbonated water outlet to the carbonated
water inlet of the post-mix dispenser or system, then connect to dispenser or system.

3. Connect food grade flexible plastic tubing to 1/4-inch flare (7/16-20) male fitting labeled CARB WATER on
the Unit. Seal connection with TAPERED GASKET, WHITE (item 1).

© 1984-2014 Cornelius Inc. 8 Publication Number: 319642005

 CONNECTING PLAIN WATER OUTLET LINE

(see Figure 1)

1. Remove shipping cap from 3/8-inch flare (5/8-18) plain-water outlet male bulkhead fitting on the Unit.

2. Install TAPERED GASKET, BLACK (item 2) in water line swivel nut from post-mix dispenser or system,
then connect line to the Unit 3/8-inch flare (5/8-18) plain-water outlet bulkhead connector.

CONNECTING UNIT 24 VAC TWO–CONDUCTOR CORD TO ELECTRIC DISPENSING

VALVE

(see Figure 1 and applicable Figure 3, 4, 5)

1. Route unit 24 VAC two–conductor cord (24-ft. long) following plain-water line) to the dispensing station.

2. Route two-conductor cord to inside of the dispensing station, then connect cord to the dispensing valve
solenoid coil as shown in applicable Figure 3, 4, 5.

PERMANENT ELECTRICAL POWER CONNECTION TO DOMESTIC UNIT IF

REQUIRED BY LOCAL CODES
(see applicable Figure 2, 3, or 4)

1. Loosen two screws securing the motor wiring compartment cover, then remove the cover.

2. Disconnect ground electrical wire from under the ground terminal connection screw located inside the mo-
tor wiring compartment.

3. Disconnect the black and white power cord wires inside the motor wiring compartment.

4. Remove power cord and strain relief from the Unit.

COVER
WATER PUMP MOTOR
(ELECTRICAL CONNECTIONS)
RETAINING SCREWS (2)
CARBONATED
WATER TANK
RELIEF
VALVE

LIQUID DUAL CHECK VALVE

OR
VENTED DUAL–CHECK VALVE

WATER PUMP

SAFETY THERMOSTAT

FIGURE 2. CARBONATOR ASSEMBLY COMPONENTS

Publication Number: 319642005 9 © 1984-2014 Cornelius Inc.
 WARNING: The Unit must be electrically grounded to avoid possible fatal electrical shock
or serious injury to the operator. The Unit power cord is equipped with a three-prong plug.
If a three-hole (grounded) electrical outlet is not available, use an approved method to
ground the Unit.

5. Connect 115 VAC, 60 Hz or 220–240 VAC, 50 Hz electrical power from the disconnect switch (not fur-
nished) fused at 15-amps (slow-blow) to the Unit with No. 16 AWG wire in suitable conduit or BX sheath.
Install power source green or green/yellow wire under the ground terminal lug located inside control box as
shown. Connect black or brown power cord wire with wire nut and white or blue wire under nut on motor
terminal. All WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES.

6. Install motor wiring compartment cover and secure the two cover screws.

7. Install cabinet cover and secure with two screws.

PREPARATION FOR OPERATION

ADJUST CARBONATOR CO2 REGULATOR AND TURN WATER INLET SUPPLY LINE ON

CAUTION: Before connecting CO2 regulator assembly to the CO2 cylinder, turn the
regulator adjusting screw to the left (counterclockwise) until all tension is relieved from
adjusting screw spring.

1. Open (counterclockwise) CO2 cylinder valve slightly to allow lines to slowly fill with gas, then open valve
fully to back-seat valve. (Back-seating valve prevents leakage around the valve shaft).

2. Adjust carbonator CO2 regulator as instructed.

3. Open post-mix system dispensing valve to exhaust trapped air inside the carbonator tank.

CAUTION: Never operate the carbonator with the water inlet supply line shutoff valve
closed. ‘‘Dry running’’ the water pump will burn out the pump. A pump damaged in this
manner is not covered by warranty.

4. Open water inlet supply line shutoff valve.

UNIT OPERATION

WARNING: Unit must be electrically grounded to avoid possible fatal electrical shock or
serious injury to operator. Unit power cord is equipped with a three-prong plug. If a
three-hole (grounded) electrical outlet is not available, use an approved method to ground
unit.

CAUTION: To prevent a fire hazard, no object should be placed or stored on top of the Unit.

1. Connect electrical power to the Unit. The water pump will start and fill the carbonator tank. The water pump
will stop when the carbonator tank is full.

2. Open the dispensing valve that will dispense a noncarbonated (still) drink. Dispense from the valve until all
air is purged from the system and a solid stream of plain water is dispensed.

3. Check for water leaks and tighten any loose connections.

© 1984-2014 Cornelius Inc. 10 Publication Number: 319642005
 24 VOLT
CONNECTOR CORD
WATER SOLENOID SAFETY THERMOSTAT WATER PUMP MOTOR

STRAIN RELIEF

CARBONATOR

BRN
YEL

RELAY
WHT

YEL POWER CORD

BLACK BROWN
LEVEL SWITCH
BLUE
GREEN OR YELLOW/GREEN

MICRO SWITCH
TRANSFORMER
(115V/24V)
OR
(230/24V) NO. 3 DISPENSING VALVE
SOLENOID COIL

MICRO SWITCH
24 VAC TWO-CONDUCTOR CORD
(CONNECTED TO NO. 3 DISPENSING VALVE
SOLENOID COIL) NO. 4 DISPENSING VALVE
SOLENOID COIL

DISPENSING STATION

496417000
REV: R

FIGURE 3. WIRING DIAGRAM (MODEL NO. 416417000 AND 496417000)

Publication Number: 319642005 11 © 1984-2014 Cornelius Inc.

 MICRO SWITCH
TRANSFORMER
(230V/24V)
NO. 3 DISPENSING VALVE
SOLENOID COIL

MICRO SWITCH
24 VAC TWO-CONDUCTOR CORD
(CONNECTED TO NO. 3 DISPENSING VALVE
SOLENOID COIL) NO. 4 DISPENSING VALVE
SOLENOID COIL

DISPENSING STATION

496417020
REV: J

FIGURE 4. WIRING DIAGRAM (MODEL NO. 496417020)

© 1984-2014 Cornelius Inc. 12 Publication Number: 319642005

 MICRO SWITCH
TRANSFORMER
(230V/24V)
NO. 3 DISPENSING VALVE
SOLENOID COIL

MICRO SWITCH
24 VAC TWO-CONDUCTOR CORD
(CONNECTED TO NO. 3 DISPENSING VALVE
SOLENOID COIL) NO. 4 DISPENSING VALVE
SOLENOID COIL

DISPENSING STATION

FIGURE 5. WIRING DIAGRAM (MODEL NO. 496417040)

Publication Number: 319642005 13 © 1984-2014 Cornelius Inc.

 TROUBLESHOOTING

IMPORTANT: Only qualified personnel should service internal components or electrical wiring.

WARNING: If repairs are to be made to a product system, remove quick disconnects from
the applicable product tank, then relieve the system pressure before proceeding. If repairs
are to be made to the CO2 system, stop dispensing, shut off the CO2 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 Probable Cause Remedy

WATER PUMP MOTOR WILL A. Power cord unplugged or A. Plug in power cord or reset circuit
NOT OPERATE. circuit breaker open in panel breaker.
box.
B. Inoperative water pump motor. B. Replace water pump motor as
instructed.
C. Dirty balance mechanism. C. Clean balance mechanism.
D. Loose connections and/or D. Tighten connections and/or repair
open electrical circuit. open circuit. Check line voltage.
E. Overheated motor cut off by E. Check for proper line voltage.
thermal overload protector. Check for restricted pump
discharge or water solenoid not
opening.
F. Inoperative level control F. Replace level control switches as
switches. instructed.
G. Binding or damaged balance G. Repair or replace balance
mechanism. mechanism.
H. Water pump binding (new or H. Remove water pump from motor,
replacement pumps only). rotate pump or motor shaft 180
degrees, then recouple pump to
motor.
I. Water pump damaged. I. Replace water pump as
instructed.
J. Safety thermostat inoperative. J. Replace safety thermostat as
instructed.
WATER PUMP MOTOR WILL A. Foreign object restricting tank A. Remove foreign object.
NOT SHUT OFF. movement.
B. Dirty balance mechanism. B. Clean balance mechanism.
C. Leak in carbonated water line. C. Tighten or replace line.
D. Inoperative level control D. Replace level control switches as
switches. instructed.
E. Binding or damaged balance E. Repair or replace balance
mechanism. mechanism.

Publication Number: 319642005 15 © 1984-2014 Cornelius Inc.

 Trouble Probable Cause Remedy
ERRATIC CYCLING OF A. Balance mechanism spring A. Remove obstructions. Make sure
CARBONATOR. obstructed or ‘‘cocked’’. spring is perpendicular to spring
release and is not twisted.
B. Dirty balance mechanism. B. Clean balance mechanism
C. Erratic safety thermostat. C. Replace thermostat.
D. Erratic water inlet supply to D. Correct water supply (refer to
carbonator causing safety manual for water supply
thermostat to interrupt requirements).
electrical supply to pump
motor.
WATER PUMP MOTOR A. Water pump inlet water A. Clean or replace water strainer
OPERATES BUT WATER strainer screen dirty. screen as instructed.
PUMP DOES NOT PUMP
WATER.
B. Kinked water supply line. B. Straighten water supply line.
C. Restriction between water C. Remove restriction or replace
pump outlet and carbonator water solenoid.
tank inlet or water solenoid not
operating.
D. Foreign object in water pump D. Clean. (Note: Count number of
bypass. turns bypass screw makes when
removing and install same
number of turns.)
E. Water pump worn out. E. Replace water pump as
instructed.
WATER PUMP CAPACITY A. Water pump inlet water A. Clean or replace water strainer
TOO LOW. strainer screen dirty. screen as instructed.
B. Water supply capacity too low. B. Inlet water supply must be at a
minimum of 100-gallons per hour
not to exceed water pressure of
30-psi.
C. Water filter clogged. C. Replace water filter.
D. Water pump worn out. D. Replace water pump as
instructed.
NO PLAIN WATER A. Inoperative dispensing valve A. Replace micro switch or coil.
DISPENSED WHEN micro switch or solenoid coil.
DISPENSING VALVE IS
OPENED.
B. Poor electrical connection or B. Repair connection or repair or
broken 24 VAC service cord replace service cord.
from dispensing valve to
carbonator.
C. Inoperative carbonator 24 VAC C. Replace relay as instructed.
relay.

© 1984-2014 Cornelius Inc. 16 Publication Number: 319642005

Publication Number: 319642005 17 © 1984-2014 Cornelius Inc.
 CORNELIUS INC.

CORPORATE HEADQUARTERS:

One Cornelius Place

Anoka, Minnesota 55303-6234
(763) 421-6120
(800) 238-3600