COUNTER INTELLIGENCE

BEVERAGE SYSTEM

CI6160 and CI9010

Service Manual

Release Date: June 23, 2004

Publication Number: 84169

Revision Date: NA

Revision: O

Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

SERVICE MANUAL

The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met, in addition to the information contained in this manual.

To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact:

www.cornelius.com

800-238-3600

Trademarks and copyrights:

Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olympus, and Vista are registered trademarks of IMI Cornelius Inc.

Optifill trademark is pending.

This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius.

Printed in U.S.A.

Copyright © 2004, All Rights Reserved, IMI Cornelius, Inc.

Counter Intelligence CI6160 & CI9010 Installation & Service Manual

TABLE OF CONTENTS

CI6160 and CI9010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Dispenser Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CI6160 CI9010 Counter Intelligence Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CI6160 CI9010 Counter Intelligence Assembly Parts List . . . . . . . . . . . . . . . . . . . . 6

Gasket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Flow Diagram, Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

MER52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Changing Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Changing the Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

MER52 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

MER52 Exploded View Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

© 2004, IMI Cornelius Inc.

- i Publication Number: 84169

Counter Intelligence CI6160 & CI9010 Installation & Service Manual

Publication Number: 84169 - ii © 2004, IMI Cornelius Inc.

Counter Intelligence CI6160 & CI9010 Installation & Service Manual

CI6160 AND CI9010

IMPORTANT: To the user - This manual is a guide for installing, operating and maintaining this

equipment. Please read and maintain this document for service and trouble shooting.

G

ENERAL

D

ESCRIPTION

The COUNTER INTELLIGENCE CI6160 and CI9010 BEVERAGE SYSTEMS consists of five submodules in an integrated package:

The CI6160 consists of:

Model CF682 Wilshire Beverage

Dispenser

Model CF682 Wilshire Beverage

Dispenser

Model M15

Model MER52

Installation Kit

SerVend Ice Dispenser

Merchandiser

Side Panels, Drain Pan

Skirt, etc.

The CI9010 consists of:

Model CF682 Wilshire Beverage

Dispenser

Model CF484 Wilshire Beverage

Dispenser

Model M15

Model MER52

Installation Kit

SerVend Ice Dispenser

Merchandiser

Side Panels, Drain Pan,

Skirt, etc.

S

PECIFICATIONS

See individual manuals for specifications.

U

NPACKING AND

I

NSPECTION

The units, packed individually, were thoroughly inspected before leaving the factory. Any damage should be noted at the time of delivery (no later than 15 days from date of delivery) and immediately reported to the carrier. File the claim with the delivering carrier.

I

NSTALLATION

R

EQUIREMENTS

Counter

A flat surface able to support approximately 700 pounds. Counter cut outs for product lines, drainage lines, and electrical cords. See template provided with installation kit for dimensions and locations.

Seal

Electrical

Drain

Water

Clearance above the CI6160 or CI9010 must be a minimum of 15" to allow removal of the upper cabinet for servicing the power deck, filling the ice bin, as well as providing adequate ventilation. There should be a minimum of 4 inches clearance on each side and rear of the unit. FAILURE TO COMPLY MAY RESTRICT AIR

MOVEMENT SUFFICIENTLY TO IMPAIR REFRIGERATION PERFORMANCE.

A silastic caulk approved for use in a food zone (Dow Corning 732 or equivalent) is required to seal equipment to the counter top.

Use separate 120VAC 20 amp 60HZ grounded duplex outlets to accommodate each module and/or accessories. The outlets should be located below the counter and within three (3) feet of the unit and installed according to national and local electrical codes.

An approved three (3) inch or larger drain must be located within three (3) feet of the dispenser. The preferred drain is an open floor sink with a center cone. Do not use copper for soft drink drains.

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. A minimum of 3/8"ID tubing is required to dispenser.

An optional carbonator is required.

© 2004, IMI Cornelius Inc.

- 1 Publication Number: 84169

Counter Intelligence CI6160 & CI9010 Installation & Service Manual

CO

2

System

Syrup System

Noncarbonated drinks require a minimum incoming water pressure of 40 psi and a maximum of 75 psi. An optional booster pump is required if pressure is not maintained at or above 40 psi. If over 75 psi, install water regulator.

Use water filters to eliminate undesirable elements in the water, such as chlorine in excess of 1.5 ppm. Use a type that does not remove all chlorine.

The CO

2 tank must be located next to a solid wall and chained.

The CO

2 storage area must be open and vented.

On bulk CO

2 tanks ensure vaporizing and regulator capacity is sufficient (i.e., 8-9 scfm average per dispenser and carbonator).

Set CO

2 regulators as appropriate:

Room temp. carbonators - 105 psi for all valves with minimum flow rate of 1.5oz/sec

Cold carbonator - 90 psi

If CO

2 is to be located under the counter, 30 inches under counter clearance is required.

Allow no more than two (2) Fast Flow Valves per Bag-In-Box (BIB) pump or Figal.

Up to 4 BIB's can be connected together, whether a selector (automatic switch-over device) is used or not, as long as all bags are at the same level, not above or below each other.

Because of pressure drop within figal fittings, no more than two (2) Figals should be connected in series.

I

NSTALLATION

I

NSTRUCTIONS

The installation process described below should be performed in the sequence as presented:

Dispenser Module Assembly

1.

Remove packing and crating material from each module. Save the packing material in case items need to be returned. Remove protective covering as each part is assembled.

2.

Prior to locating the three individual units side by side, remove the shipping screws from both sides of each beverage dispenser as marked on the equipment.

3.

Using the template provided with the installation kit, mark the counter to indicate the location of the modules.

4.

Cut the access holes and slots as indicated.

5.

Apply a generous bead of silastic to the counter top where each module will contact the counter and around the cutout for the ice dispenser drain. NOTE: All openings cut into the counter top must be sealed with an acceptable material in accordance with local and state health and building codes.

6.

Set the CF682 beverage dispenser on the counter in the left most position, making sure the cabinet is set on the silastic seal.

7.

Set the CF682 or CF484 beverage dispenser on the counter in the right most position, making sure the cabinet is set on the silastic seal.

8.

Set the M15 ice dispenser on the counter top in the center position, making sure that the cabinet is placed on the silastic seal. Gently slide it to the rear engaging the dowel pins on the back panels of the beverage units (two pins on each beverage unit as shown in Figure 1). The 3" (76 mm) wide slot in the bottom of the ice dispenser should align with the corresponding hole in the counter top.

9.

Pull the three modules together at the front by using the merchandiser support bracket assemblies, lower bracket, and trim strip, shipped in the Installation Kit. Fasten the merchandiser support brackets and lower bracket to the beverage dispensers at the adjoining parting line of the ice dispenser with #10-32 screws found in the kit. Compress the formed merchandiser support rods and place them into the pivot holes found on the merchandiser brackets. Pulling the units together, drop the trim strip onto the protruding merchandiser support tips at the top, engaging the holes in

Publication Number: 84169 - 2 © 2004, IMI Cornelius Inc.

Counter Intelligence CI6160 & CI9010 Installation & Service Manual the trim strip. Lock the trim strip into place by forcing the stud receiver clips onto the merchandiser support tips, pushing them down to the trim strip.

10.

Connect all product lines carbonated water lines, potable water lines, and drain lines as marked.

11.

Remove the lower cover plate and the upper plastic cover on the face of the ice dispenser to gain access to the drain connections.

12.

Temporarily set the drain pan support frame and drain pan in position at the front of the counter.

13.

Install the drain tube assembly in position beneath the ice dispenser. The 3/4" plastic tee fitting, supplied with the Installation Kit, is to be connected to the ice dispenser drain and drip pan drain, utilizing proper length drain hose cut from the 3/4" ID black rubber hose included in the Installation

Kit. Cut the remaining hose to connect the tee end to the field drain. Check all connections for leaks.

14.

Apply silastic to the counter top to seal the drain pan support frame and install it on the front of the beverage dispensers using 10-32 screws through the back of the frame into the angle framework of the dispensers.

15.

Complete sealing all the modules to the counter top by wiping the excess silastic off the counter and leave a smooth joint between the counter and modules.

16.

Install the drain pan. Connect the drain fitting with the rubber hoses, using hose clamps provided on the non-barbed drains.

17.

Bend each of the beverage units overflow lines out so that they drain into the drain pan.

18.

The MER52 is a lighted sign and is shipped partially assembled:

A. Place gasket strips on both the right- and left-hand beverage dispensers (see Figure 2);

B. Remove two screws from MER52;

C. Remove top cover and plastic lens;

D. Remove fluorescent lamps packed inside MER52;

E. Install the MER52 merchandiser by mating the slip hinges at the top of the merchandiser and dispensers;

F. Rotate the MER52 upward and rest it on the two shelf supports mounted on the front channel assembly;

G. Plug the MER52 cord into the outlet located on the top front panel of the CF484 or CF682; then close supports to allow the MER52 to hang in its vertical position; tuck cord into outlet slot before lowering the MER52 into position to ensure it rests flush against beverage system;

H. Attach two (2) rubber bumpers, supplied in installation kit, to the lower corners of the MER52;

I. Install fluorescent lamps into lamp holders;

J. Clean the lens and diffuser panels, being careful not to scratch. Insert the graphics panels between the diffuser and lens panels; then carefully slide lens and graphic panel into slots along front edge of the merchandiser body;

K. Replace MER52 top cover and secure with two screws.

Merchandiser is illuminated when dispenser is plugged in and power switch is on.

19.

Seal all counter cutouts in accordance with state and local requirements.

20.

Activate the ice lever to assure proper placement of the ice dispenser front cover.

21.

Mount the splash plate and cup rests.

The installation is now complete. The system should be sanitized in accordance with the cleaning and sanitizing procedures found in the Installation and Service Manuals for the modules. See individual manuals for start-up and operation.

© 2004, IMI Cornelius Inc.

- 3 Publication Number: 84169

Counter Intelligence CI6160 & CI9010 Installation & Service Manual

Publication Number: 84169 - 4 © 2004, IMI Cornelius Inc.

ILLUSTRATED PARTS LIST

CI6160 CI9010 C

OUNTER

I

NTELLIGENCE

A

SSEMBLY

IMI CORNELIUS INC.

www.cornelius.com

1-800-238-3600

FIGURE 1

CI6160 and CI9010 Counter Intelligence Illustrated Parts List 5 of 8

© IMI Cornelius Inc., 2004

Part Number: 84169

June 23, 2004

Revision: O

IMI CORNELIUS INC.

www.cornelius.com

Telephone 1-800-238-3600

CI6160 CI9010 C

OUNTER

I

NTELLIGENCE

A

SSEMBLY

P

ARTS

L

IST

Item No.

Part No.

1 84106-002

84106-102

2

3

4

5

6

84106-001

84106-101

84104-001

84104-003

84104-201

84108-005

84108-004

84120-002

84120-001

84120-101

84120-102

84112

84110-001

Name

Top Plate Assembly,

Right, Grey

Top Plate Assembly,

Right, White

Top Plate Assembly,

Left, Grey

Top Plate Assembly,

Left, White

Side Panel, Left, Grey

Side Panel, Left, Stainless Steel

Side Panel, Left, White

Front Plate Assembly,

CF682

Front Plate Assembly,

CF484

Back Panel, Grey, Left

Back Panel, Grey, Right

Back Panel, White,

Right

Back Panel, White, Left

Drip Pan

Drip Pan Skirt

Item No.

7

8

12

Part No.

84111

84113

84116

84116-001

13

14

15

16

17

84135-001

84104-002

84104-004

84104-202

Consult

Factory

84000-200

84000-204

84000-553

18

19

84000-562

84000-560

84132-004

84161

Name

Cup Rest, Beverage

Cup Rest, Ice

Splash Panel

Splash Panel with Push

Button Ice Dispenser

Front Bracket

Side Panel, Right, Grey

Side Panel, Right, Stainless Steel

Side Panel, Right, White

Dispensing Valve

M15 Ice Dispenser

M15B Ice Dispenser

MER52 Merchandiser,

Grey

MER52 Merchandiser,

Stainless Steel

MER52 Merchandiser,

White

Trim Strip

Template

Part Number: 84169

June 23, 2004

Revision: O

6 of 8 CI6160 and CI9010 Counter Intelligence Illustrated Parts List

© IMI Cornelius Inc., 2004

G

ASKET

I

NSTALLATION

IMI CORNELIUS INC.

www.cornelius.com

1-800-238-3600

FIGURE 2

CI6160 and CI9010 Counter Intelligence Illustrated Parts List 7 of 8

© IMI Cornelius Inc., 2004

Part Number: 84169

June 23, 2004

Revision: O

IMI CORNELIUS INC.

www.cornelius.com

Telephone 1-800-238-3600

F

LOW

D

IAGRAM

, T

YPICAL

I

NSTALLATION

Part Number: 84169

June 23, 2004

Revision: O

8 of 8

FIGURE 3

CI6160 and CI9010 Counter Intelligence Illustrated Parts List

© IMI Cornelius Inc., 2004

Counter Intelligence CI6160 & CI9010 Installation & Service Manual

MER52

IMPORTANT: To the user - This manual is a guide for installing, operating and maintaining this

equipment. Please read and maintain this document for service and trouble shooting.

G

ENERAL

D

ESCRIPTION

The MER52 merchandiser is an internally lit graphics display illuminated by two 40 watt (F40CW) fluorescent lamps.

I

NSTALLATION

R

EQUIREMENTS

Location

The MER52 is designed to be mounted on a vertical surface. The supporting structure must be able to support 40 pounds. The MER52 is approximately 52 inches long by 14 inches high by 5 inches deep.

Electrical

Use a 120VAC 20 amp 60HZ grounded outlet.

I

NSTALLATION

I

NSTRUCTIONS

The top back corners of the MER52 contain two slip pin hinges half brackets which are used to hang the sign. The sign may be attached to a rigid surface and mounted so that the sign may be rotated about the hinge brackets.

1.

Fasten the two hinge halves to the wall according to the preparation drawing. The half which has the spring-loaded pin must be mounted on the right side. The fasteners used must be able to support a minimum of 40 pounds.

2.

Pull the spring-loaded pin to the right and insert the left side of the merchandiser onto the left hinge half attached to a rigid surface.

3.

Align the right hinge half on the merchandise with the spring hinge half.

4.

Release the spring pin to engage the hinge.

5.

Move the merchandiser form side to side to make sure the pins are engaged.

6.

Fluorescent tubes have been carefully packed inside the MER52 and have to be installed. Refer to

Changing Lamps.

O

PERATION

Plug power cord into a 120VAC 60HZ grounded outlet.

C

HANGING

L

AMPS

1.

Unplug the MER52 from power source.

2.

Remove two screws at the top of the MER52 and remove the cover.

3.

Carefully slide the plastic lens and graphics panels up and out.

4.

Remove the old lamp by rotating it 90 degrees and lift it out of its socket.

5.

Install the new lamp by inserting and rotating 90 degrees to the locked position.

6.

Carefully replace the lens and graphics panels, making sure that the clear plastic panel is on the outside.

7.

Replace the cover and two screws.

C

HANGING THE

G

RAPHICS

1.

Unplug the MER52 from power source.

2.

Remove two screws at the top of the MER52 and remove the cover.

3.

Spread the lens panels slightly and lift the graphics panel out the top.

4.

Insert the new graphics panel.

5.

Replace the cover and two screws.

© 2004, IMI Cornelius Inc.

- 9 Publication Number: 84169

Counter Intelligence CI6160 & CI9010 Installation & Service Manual

Publication Number: 84169 - 10 © 2004, IMI Cornelius Inc.

ILLUSTRATED PARTS LIST

MER52 E

XPLODED

V

IEW

Consult factory for service requirements.

IMI CORNELIUS INC.

www.cornelius.com

1-800-238-3600

FIGURE 4

MER52 Counter Intelligence Illustrated Parts List

© IMI Cornelius Inc., 2004

11 of 12 Part Number: 84169

June 23, 2004

Revision: O

IMI CORNELIUS INC.

www.cornelius.com

Telephone 1-800-238-3600

MER52 E

XPLODED

V

IEW

P

ARTS

L

IST

4

5

6

2

3

Item No.

Part No.

1

7

84141-100

84141-201

84141-008

84141-006

60098-001

84141-003

60097-001

84142

84142-001

Consult

Factory

Name

Body, Grey

Body, White

Body, Stainless Steel

Lamp Holder Assembly

Lamp Socket

Cover, Wireway

Ballast

Clear Panel Lens

Clear Panel Lens

Graphic Panel

Item No.

8

Part No.

84143

84143-001

9

10

10a

Not

Shown

Not

Shown

84140

84140-200

84141-004

84148-002

84148-004

82051-004

60040-077

Name

Diffuser Panel Lens,

White

Diffuser Panel Lens,

White

Top Assembly, Grey

Top Assembly, White

Top Assembly, Stainless steel

Hinge, Right

Hinge, Left

Cord Set

Strain Relief

Part Number: 84169

June 23, 2004

Revision: O

12 of 12 MER52 Counter Intelligence Illustrated Parts List

© IMI Cornelius Inc., 2004