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Cornelius 10 User's Manual

1. Ex t YLM NIW1d l ULM auvo ULM S3NIT dfYHAS moam moai moai egent HT oy IT rug f N Lei e DTA re oh Ei A TI es REY AP EE NE e d S HATVA n J 4 23H2 sv5 702 zx i OD 200 HY G g Z 3AIVA 23HD SVD YOLV1NDAY OD O dnuAs Lana SYOLV1NDAY ZOD SHOLVNOSNV FATWA 440LNHS YOLV1NDAY COD NIV Td ASSV NM 5 YVONS dNYAS ULUM auvo YALVM 02 XON35311 3NI 72 ULUM UALYM 32unos C s 2nn2291nnn INSTALLATION This section covers unpacking and inspection selecting location installing Cooling Unit preparing for operation and operation UNPACKING AND INSPECTION NOTE The Cooling Unit was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it
2. 42 COMPRESSOR DOES NOT 42 COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM SUFFICIENT ICE BANK z bie rho et 43 CONDENSER FAN MOTOR NOT OPERATING 44 AGITATOR MOTOR NOT OPERATING 44 WARRANTY o ceeded pace n a aa wi OR CR a an 45 LIST OF FIGURES FIGURE 1 AURORAR10 000 COOLING UNIT FIGURE 2 FLOW DIAGRAM TYPICAL INSTALLATION FIGURE 3 240 24VAC POWER TRANSFORMER 7 FIGURE 4 COOLING UNIT SPACE REQUIRED 10 FIGURE 5 PARTS IDENTIFICATION STANDARD COOLING UNIT W INTERNAL CONDENSER AND FAN 55 22 FIGURE 6 PARTS IDENTIFICATION COOLING UNIT REQUIRING CONNECTION TO REMOTE CONDENSER COIL AND FAN ASSEMBLY 23 FIGURE 7 CARBONATOR LIQUID LEVEL CONTROL SWITCHES 25 FIGURE 8 WATER STRAINER SCREEN AND LIQUID DOUBLE CHECK VALME Scr eter eder cac ue rene td 26 FIGURE 9 LIQUID CHECK VALVE ASSEMBLY 27 FIGURE 10 CO2 GAS CHECK VALVE 32 FIGURE 11 REFRIGERATION FLOW DIAGRAM STANDARD COOLING UNIT W INTERNAL CONDENSER COIL AND FANASSYY 33 FIGURE 12 REFRIGERATION FLOW D
3. LINES CONNECTORS 2 REFRIGERATION POWER SWITCH TI il RESET BUTTON Ua 11 system ANALYZER MOTOR 2 TEST PLUG 1 a S N CARBONATOR TANKS 2 55 GRILLE REFRIGERATION COMPRESSOR SYSTEM SIGHT GLASS COMPRESSOR COOLING FAN FIGURE 6 PARTS IDENTIFICATION COOLING UNIT REOUIRING CONNECTION TO REMOTE CONDENSER COIL AND FAN ASSEMBLY 23 300381000 Servicing Carbonator Water Pump Water Strainer Screen see applicable Figure 5 or 6 and 8 1 Disconnect electrical power from Cooling Unit at disconnect switch 2 Close shutoff valve in plain water inlet supply line 3 Note pressure setting on carbonator regulator then turn regulator adjusting screw to the left counterclockwise until regulator gage reads 0 psi 4 Remove two screws securing Cooling Unit top cover then remove cover for access to carbonators water pumps CAUTION Condenser Coil and Fan Assembly condenser coil must be cleaned every 30 days Excessive accumulation of debris on condenser coil will restrict cooling air flow through coil and cause coil and refrigeration system overheat Operating refrigeration system in overheated condition will eventually result in Cooling Unit compressor failure 5 If left side facing front switch side of Cooling Unit is obstructed unit will have to be pulled out for removal of left side panel for access to carbonator tanks and
4. C Remote Rooftop Condenser C Check and if necessary clean Coil and Fan Assembly Air condenser coil as instructed circulation through condenser coil is restricted D Insufficient refrigerant charge D Check refrigeration system with gage set and Aurora Series System Analyzer P N 309197000 Find and repair refrigeration leak then replenish refrigerant charge 43 300381000 Trouble COMMPRESSOR OPERATES CONTINUOUSLS BUT DOES NOT FORM SUFFICIENT ICE BANK CONT D Probable Cause E Inoperative or disconnected pulse modulating expansion valve see applicable REFRIGERATION FLOW DIAGRAM F Inoperative control board No output from board to solenoids Remedy Check that expansion valve is operating by touch should be able to feel valve pulse Check for loose or disconnected wire to solenoid coil If necessary troubleshoot expansion valve with a gage set to see if it is opening If expansion valve is not opening suction pressure will be in a vacuum Check LED s on control board to see if they are modulating Check for 24V output to pulse modulating expansion valve see WIRING DIAGRAM If control board green LED is on and yellow LED Is flashing but no 24V output replace board NOTE If overload protector cuts out compressor condenser fan motor will continue to operate otherwise troubleshooting condenser fan motor problem is same as for COMPRESSOR DOES NOT OPERATE paragraph plus the following
5. IMI Cornelius Offices AUSTRALIA e P O 210 e RIVERWOOD e NSW 2210 AUSTRAL AUSTRIA e AM LANGEN FELDE 32 e A 1222 e VIENNA A BELGIUM e BOSKAPELLEI 122 e B 2930 BRAASCHAAT B BRAZIL e RUA ITAOCARA 97 e TOMAS COELHO e RIO D ENGLAND e TYTHING ROAD ALCESTER e WARWICKSHI FRANCE e 71 ROUTE DE ST DENIS e F 95 ERMANY eCARL LEVERKUS STRASSE 15 eD 4018 LANGENFELD GERMANY e REECE e 488 MESSOGION AVENUE e AGIA PARASKEVI e 153 42 e ATHENS GREE ONG KONG e 1104 TAIKOTSUI CENTRE e 11 15 KOK CHEUNG ST e TAIKOKTSUE ALY VIA PELLIZZARI 11 e 1 20059 e VIM ARCATE ITALY e 39 39 608 0817 e FA EW ZEALAND e 20 LANSFORD CRES e P O BOX 19 044 AVONDALE NGAPORE e 16 TUAS STREET e SINGAPORE 2263 e 65 862 5542 e PAIN e POLIGONO INDUSTRAIL e RIERA DEL FONOLLAR e E 08830 SANT BOI DE SA eONE CORNELIUS PLACE eANOKA MINNESOTA e 612 421 6120 e FAX 612 A 6 ELGIUM 32 3 664 0552 E JANEIRO RE B49 6 EU 2 533 31226 USTRIA 43 1 233 520 BRAZIL e 55 ENGLAND e 70 DEUIL LA BARRE e PARIS FRANCE e e AUCKLAND FAX 65 862 56 FAX 61 2 534 2166 FAX 43 1 2335 2930 e FAX 32 3 665 2307 21 591 7150 e FAX 55 21 593 1829 44 789 763 101 e FAX 44 789 763 644 33 1 34 28 6200 e FAX 33 1 34 28 6201 49 2173 7930 e FAX 49 2173 77 438 CE 30 1 600 1073 e FAX 30 1 601 2491 HONG KONG e 852 789 9882 e FAX 852 391 6222 X 39 39 608 0814 7 NEW ZEALAND e 64 9 8200 357 e FAX
6. 25 300381000 CARBONATED WATER CIRCULATING PUMP MOTOR LUBRICATION see applicable Figure 5 or 6 Carbonated water circulating pump motor bearings must be oiled periodically Refer to oiling instructions on motor DO NOT OVER OIL ADJ USTMENTS NOTE To readjust CO regulator to a lower setting loosen adjusting screw lock nut then turn screw to the left counterclockwise until pressure gage reads 5 psi lower than new setting will be Turn adjusting screw to the right clockwise until gage registers new setting then tighten lock nut PRIMARY REGULATOR see Figure 2 Adjust primary regulator on cylinder to a minimum nominal setting of 120 psi or 24 psi higher than highest setting required by the secondary regulators Loosen CO regulator adjusting screw locknut Turn adjusting screw to the right clockwise until regulator gage registers nominal 120 psi then tighten adjusting screw locknut LINE TO TANK THERMOSTAT e n 318040000 M FIGURE 8 WATER STRAINER SCREEN AND LIQUID DOUBLE CHECK VALVE 300381000 26 Ball Seat guad ring sr TT 317965000 Reiner FIGURE 9 LIQUID CHECK VALVE ASSEMBLY SECONDARY CO REGULATORS see Figure 2 Carbonator Secondary CO gt Regulator Adjust carbonators secondary CO regulator to a nominal 90 psi Loosen CO regulator adjusting screw locknut Turn adjus
7. 64 9 8200 361 04 LLOBREGAT e BARCELONA SPAIN e 34 3 640 2839 e FAX 34 3 654 3379 422 3255 LD004 4 21 98 45 300381000 IMI CORNELIUS INC CORPORATE HEADQUARTERS One Cornelius Place Anoka M innesota 55303 6234 612 421 6120 800 238 3600
8. CAUTION Air filter on back of Cooling Unit must be removed and cleaned every 30 days Excessive accumulation of dust lint and grease on air filter will restrict air flow through the Unit and cause refrigeration system to overheat Condenser coil air intake filter on back of Cooling Unit may either be removed and washed out with detergent solution or may be vacuumed in place on Unit Remote Condenser Coil and Fan Assembly If applicable see Figure 6 CAUTION The Remote Condenser Coil and Fan Assembly condenser coil must be cleaned every 30 days Circulating air required to cool the coil is drawn in at bottom and is exhausted out through top of unit Failure to clean condenser coil will cause refrigeration system to overheat 1 Disconnect electrical power to Cooling Unit at disconnect switch 2 Clean bottom side of condenser coil using vacuum cleaner whisk broom or soft bristle brush to remove any debris from coil 3 Check and make sure fan blade moves freely and are not touching any surfaces are not bent or out of balance Check and make sure wire guard is properly installed and securely fastened 4 Check and make sure roof area immediately surrounding unit is free and clear of any debris that may have collected such as leaves paper trash etc 5 Restore electrical power to Cooling Unit at disconnect switch CHECKING ICE WATER BATH see applicable Figure 5 or 6 A gurgle heard from Cooling Unit indicates
9. the red electrical wire connected to the 240VAC terminal on LINE primary side of the 240 24VAC power transformer inside the Cooling Unit switches electrical control box see Figure 3 and 15 must be disconnected from the 240VAC terminal and be connected to the 208VAC terminal If voltage is above 218VAC power transformer red electrical wire will remain connected to the 240VAC terminal If installer is not sure of the service power voltage entering the building leave the red electrical wire connected to the 240VAC terminal on the power transformer If service power voltage is below 218VAC proceed as follows 1 Remove four screws securing switches electrical control box see Figure 5 or 6 to Cooling Unit cabinet 2 Pull switches electrical control box out for access to the 240 24VAC power transformer 3 Remove red electrical wire from the 240VAC terminal on LINE primary side of power transformer and connect it to the 208 VAC terminal 4 Install Cooling Unit switches electrical control box and secure with four screws RESET BUTTON FIGURE 3 240 24VAC POWER TRANSFORMER applicable is in OFF position WARNING Make sure 40 amp minimum rated disconnect switch or HACR circuit breaker if 1 Remove cover from electrical box on back of Cooling Unit 7 300381000 WARNING The Cooling Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the op
10. BE USED WHERE A LOCAL WATER PROBLEM EXIST 3 Adjust primary regulator see Figure 2 on CO cylinder to a minimum nominal setting of 120 psi or 24 psi higher than highest setting required by the secondary regulators Loosen regulator adjusting screw locknut Turn adjusting screw to the right clockwise until regulator gage registers nominal 120 psi then tighten adjusting screw locknut 4 Adjustcarbonators secondary CO regulator see Figure 2 to a nominal 90 psi Loosen CO regulator adjusting screw locknut Turn adjusting screw to the right clockwise until regulator gage registers nominal 90 psi then tighten adjusting screw lock nut CO PRESSURE TO CARBONATORS MUST NOT EXCEED 120 PSIG CAUTION Before starting refrigeration system Hydro Boost coil must be completely flooded with carbonated water to prevent coil freeze up Proceed as follows to fill carbonated water system 5 Make sure both carbonated water shutoff valves inside Cooling Unit see Figure 2 are in OPEN handles in line with tubing positions 6 Make sure Hydro Boost bypass valve inside Cooling Unit see Figure 2 is in CLOSED handle not in line with tubing position 7 Make sure Cooling Unit REFRIGERATION POWER CARBONATOR MOTORS and CIRCULATING MOTOR Power switches are in OFF down positions 8 Connect electrical power to Cooling Unit at disconnect switch 9 Place CARBONATOR MOTORS power switch in ON up position to sta
11. CARBONATORS CO2 INLET LINES CO2 GAS CHECK VALVE 32 CONNECTING EXTERNAL CARBONATOR TO COOLING UNIT 32 300381000 i TABLE OF CONTENTS contd Page TROUBLESHOOTING 39 WATER TO SYRUP RATIO OF DISPENSED DRINK TOO LOW OR FOO GHGs TEE 39 ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES NOT INCREASE TO DESIRED WATER TO SYRUP RATIO 39 ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES NOT DECREASE TO DESIRED WATER TO SYRUP RATIO 40 DISPENSED PRODUCT CARBONATION TOO LOW 40 DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT FOAMS ING CUR rr tule edic tt me e k aa fox Robe e ca 40 DISPENSED PRODUCT PRODUCES FOAM AS IT LEAVES DISPENSING MAIN E kG itd a kasta ua etr C da t se E 40 ONLY CARBONATED WATER DISPENSED 40 ONLY SYRUP DISPENSED 41 WARM PRODUCT BEING 15 41 WATER PUMP MOTOR WILL NOT OPERATE 41 WATER PUMP MOTOR WILL NOT SHUT OFF 41 ERRATIC CYCLING OF CARBONATOR 42 WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP WATER Lau cum tunu is a eur rtt re ccu E 42 WATER PUMP CAPACITY TOO LOW
12. CONDENSER FAN MOTOR NOT OPERATING AGITATOR MOTOR NOT OPERATING 300381000 Standard Cooling Unit with Condenser Coil and Fan Assembly A Jumper cord loose or disconnected from condenser fan motor or terminals inside control box Broken wire in cord B Fan blade obstructed C Inoperative condenser fan motor Remote Condenser Coil and Fan assembly A Blown power circuit fuse Fan blade obstructed C Inoperative condenser fan motor D Cooling unit contactor inoperable A Agitator motor propeller obstructed B Low voltage C Loose disconnected or broken wiring D Inoperative agitator motor 44 Tighten connections or replace cord Remove obstruction Replace condenser fan motor Replace power circuit fuse Remove obstruction Replace condenser fan motor Replace Cooling Unit contactor Remove obstruction Voltage must be at least 208 volts at compressor terminals when compressor is trying to start Tighten connections or replace broken wiring Replace agitator motor 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 IM Cornelius office nearest you Please provide the equipment model number serial number and the date of purchase
13. COOLING UNIT 9 CONNECTING SYRUP SOURCE LINES TO COOLING UNIT SYRUP INEET EINES saaa ss si aate e rte en 6 asta a NG 9 CONNECTING COOLING UNIT SYRUP OUTLET LINES TO INSULATED PYTHONS Y RUPSLINES vas enc it ER vanes IOS Rn 10 CONNECTING COOLING UNIT PLAIN WATER OUTLET LINE TO INSULATED PYTHON PLAIN WATER LINE 10 CONNECTING COOLING UNIT CARBONATED WATER OUTLET LINES TO INSULATED PYTHON CARBONATED WATER LINES 10 PLACING COOLING UNIT IN OPERATING POSITION 10 PREPARING COOLING UNIT FOR OPERATION 11 OPERATION ic bern erem e rm e ear ine Seas ea geen hs 11 STARTING COOLING UNIT REFRIGERATION SYSTEM 12 STARTING CARBONATED WATER CIRCULATING PUMP 12 ACTIVATING SYRUP SYSTEMS 12 LEAK CHECK AND INSULATING COOLING UNIT OUTLET LINES 13 DISPENSING STATION ADJUSTMENTS 13 INSTALLING LINE IDENTIFICATION LABEL 13 OPERATORS INSTRUCTIONS 15 OPERATING CONTROLS 15 COOLING UNIT REFRIGERATION POWER SWITCH 15 COOLING UNIT CARBONATOR MOTOR SWITCH 15 COOLING UNIT CIRCULATING MOTOR SWITCH 15 REFRIGERATION SYSTEM TEMPERATURE SENSING DEVICE AND HIGH PRESSURE CUTOUT
14. SWITCH 15 DAILY PRE OPERATION CHECK 16 ADJ USTMENTS go a irn RES tto en RD Ee ho PRU Pe Se 16 ADJUSTING CO2 REGULATORS 16 i 300381000 TABLE OF CONTENTS cont d Page ADJUSTING DISPENSING VALVES WATER FLOW RATE 16 ADJUSTING WATER TO SYRUP RATIO OF DISPENSED PRODUCT 16 ADJUSTING SIZE OF DRINK DISPENSED 16 ADJUSTING CARBONATOR TANK LIQUID LEVEL 16 REPLEENISHING CO2 SUPPLY ise e denen td ete a Ren Ro a 16 REPLENISHING SYRUP 17 CLEANING AND SANITIZING ssss Hn 17 DAILYSCLEANING etre tee cR t ne vete ee a 17 SANITIZING SYRUP 65 5 5 17 COOLING UNIT MAINTENANCE 17 COOLING UNIT EQUIPPED WITH CONDENSER COIL AND AIR INTAKE FILTER u u nh reed db ata dau ba een ar Sasha RA doe 17 COOLING UNIT CARBONATOR MAINTENANCE 17 COOLING UNIT CARBONATED WATER CIRCULATING PUMP MOTOR LUBRICATION z a atti eq Ba aa a RR ala 18 REMOTE CONDENSER COIL AND FAN 55 Y MAINTENANCE 18 CLEANING CO2 GAS CHECK VALVES 18 SERVICE AND MAINTENANCE 19 PREPARING COOLING UNIT FOR SHIPPING STORING OR RELOCATING 19 PERIODIC INSPE
15. and record syrup flavors in proper spaces 13 300381000 THIS PAGE LEFT BLANK INTENTIONALLY 300381000 14 OPERATORS INSTRUCTIONS This section covers operating controls daily pre operation check adjustments replenishing and syrup supplies cleaning and sanitizing Cooling Unit maintenance Remote Condenser Coil and Fan Assembly if applicable maintenance lubrication and servicing gt gas check valves attempting any Cooling Unit or Rooftop Condenser Coil and Fan Assembly if applicable internal maintenance Only qualified personnel should service internal components or electrical wiring WARNING Disconnect electrical power to Cooling Unit to prevent personal injury before OPERATING CONTROLS COOLING UNIT REFRIGERATION POWER SWITCH see Figure 5 or 6 REFRIGERATION POWER switch located on front of Cooling Unit placed in OFF position will interrupt electrical power to refrigeration compressor agitator motor condenser fan motor if applicable and carbonated water circulating pump S witch must be in ON up position for operation REFRIGERATION POWER SWITCH DOES NOT DISRUPT ELECTRICAL POWER TO CARBONATORS PUMPS MOTORS COOLING UNIT CARBONATOR MOTOR SWITCH see Figure 5 or 6 CARBONATOR MOTORS power switch located on front of Cooling Unit placed in OFF down position will interrupt electrical power to both carbonators pumps motors Switch must be placed in ON up position before carbonators
16. gas could then back flow into water system and create a health hazard in water system 21 300381000 ELECTRICAL CONTROL BOK RETAINING SCREW 2 AIR FILTER HYDRO BOOST RETAINING SCREW 4 Wi FILTER 4 BRACKET E AIR FILTER CARBONATED WATER CIRCULATING PUMP CIRCULATING PUMP MOTOR CO INLET CO INLET CHECK VALVE LIQUID DOUBLE CHECK VALVE 2 CONTROL BOX CIRCULATING MOTOR CARBONATOR POWER SWITCH WATER PUMP 2 CARBONATORS MOTOR POWER SWITCH WATER PUMP MOTOR 2 LEFT SIDE PANEL REFRIGERATION 2 POWER SWITCH CARBONATOR e SYSTEM ANALYZER TANK 2 TEST PLUG 4 COMPRESSOR CONDENSER COIL FIGURE 5 PARTS IDENTIFICATION STANDARD COOLING UNIT W INTERNAL CONDENSER COIL AND FAN ASSEMBLY 300381000 22 REMOTE ROOFTOP CONDENSER COIL AND FAN ASS Y REFRIGERATION LINES ITEM 4 AND 5 TOP COVER TOP COVER RETAINING SCREW 2 HYDRO BOOST C PLAIN WATER INLET CARBONATED WATER CIRCULATING PUMP gt CIRCULATING SRM PUMP MOTOR gt AGITATOR MOTOR A AL A SWITCHES ELECTRICAL 522 CONTROL BOX e CIRCULATING MOTOR POWER SWITCH CARBONATORS MOTOR POWER SWITCH ELECTRICAL CONTROL BOX CO INLET CHECK VALVE CO INLET LIQUID DOUBLE CHECK VALVE 2 CARBONATOR WATER PUMP 2 REFRIGERATION
17. note pressure setting on the syrup tanks regulator then re adjust CO regulator to 60 to 80 psi Pressurize syrup tank containing detergent solution to 60 to 80 psi B Connect detergent solution tank pressurized at 60 to 80 psi into one of the syrup systems Bag in Box Syrup Systems C Install bag valves cut from empty bag in box syrup containers on ends of syrup containers syrup outlet tubes connectors D Place all syrup outlet tubes with bag valves on their ends in container containing detergent solution Flush 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 syrup and flush out the syrup system 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 Connect detergent solution to the remaining syrup systems and flush syrup out of the syrup systems as instructed in step NO TAG preceding Remove detergent solution source from the syrup system STEP 2 FLUSH SYRUP SYSTEMS 8 9 Syrup Tank Systems Connect syrup tank containing potable water pressurized at 60 to 80 psi into one of the syrup systems Bag in Box Syrup System Fill five gallon container with potable water then place all bag in box syrup containers syrup outlet tubes in container containing potable water Flush deterg
18. only REFRIGERATION SYSTEM TEMPERATURE SENSING DEVICE AND HIGH PRESSURE CUTOUT SWITCH in OPERATORS INSTRUCTIONS SECTION J No voltage to control board J Check for loose or broken wiring Check 240 24 VAC power transformer for 24 VAC output see NOTE below Inoperative compressor K Replace compressor m L Temperature sensor is shorted Check for loose broken or or open circuit disconnected wire or plug at pre cool coil Repair or replace wire Confirm which temperature sensor has failed by using the Aurora Series System Analyzer P N 309197 000 M Loose or broken wire to M Repair or replace wire satellite board from ice sensor probe on main control board see low voltage system wiring diagram NOTE The 240 24 VAC power transformer has an overload reset button located on its 24 VAC output side see Figure 3 An overload on the transformer will cause its reset button to pop out disrupting the 24 VAC output to the main control board Overload reset button must be pressed in to restore 24 VAC output COMPRESSOR OPERATES A Cooling capacity is exceeded A Reduce amount of drinks drawn CONTINUOUSLY BUT DOES by overdrawing per given time NOT FORM SUFFICIENT ICE BANK B Standard Cooling Unit with Relocate unit or check and if condenser coil and fan necessary clean air filter as assembly Cooling Unit instructed located in excessively hot area or air circulation through condenser coil is restricted
19. tanks carbonated water outlet lines liquid single check valves 6 Remove Cooling Unit left side panel 7 Loosen carbonator water pump screen retainer then pull screen retainer and strainer screen from water pump 8 Pullstrainer screen from screen retainer Clean any sediment from screen retainer and pump screen retainer port 9 Inspect strainer screen for holes restrictions corrosion and other damage Discard damaged strainer screen 10 Check O Ring on screen retainer Replace worn or damaged O Ring P N 315349000 NOTE A strainer screen should always be used otherwise particles could foul liquid double check valve 1l Install good or new strainer screen P N 315348000 in screen retainer then screw retainer into water pump and tighten securely 12 Service other carbonator water pump water strainer screen by repeating preceding steps 7 through 11 13 Service carbonator water inlet liquid double check valve and carbonated water tank water outlet line single check valve Refer to next paragraph Servicing Carbonator Plain Water Inlet Liquid Double Check Valve and Carbonated Water Tank Carbonated Water Outlet Line Liquid Single Check Valve Servicing Carbonator P lain Water Inlet Liquid Double Check Valve and Carbonated Water Tank Carbonated Water Outlet Line Single Liquid Check Valve see Figures 2 8 and 9 l Service water strainer screen as instructed in previous paragraph before servicing liquid double and single che
20. the Cooling Unit factory warranty CAUTION The Cooling Unit refrigeration system is cooled by a Remote Condenser Coil Remote Condenser Coil and Fan Assembly P N 309602000 NOTE Electrical power circuit may be connected to the Remote Condenser Coil and Fan Assembly P N 309602000 in two ways The preferred way is to draw electrical power from the Cooling Unit contactor which allows the Remote Condenser Coil and Fan assembly to operate only when the Cooling Unit refrigeration system is operating The optional way is to connect a separate electrical power circuit independent of the cooling unit through an appropriately rated and fused disconnect switch or an equivalent HACR circuit breaker which allows the Remote Condenser Coil and Fan Assembly to operate at all times independent of Cooling Unit operation Connect and route electrical power circuit cable from Remote Condenser Coil and Fan Assembly through fuse box not provided fused at 15 amps maximum down to Cooling Unit location REMOTE CONDENSER COIL AND FAN ASSEMBLY MUST BE PROPERLY GROUNDED POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES A Remove four screws securing electrical control box to Cooling Unit back panel see Figure 6 then pull control box out for access to contactor inside box B Route Remote Condenser Coil and Fan Assembly power cable electrical wires through electrical handy box on bac
21. water level in water tank is low This indicates the water tank water level float control is not operating properly and must be repaired or replaced If a continuous trickle of water is coming out of the water tank overflow tube this indicates the water level float control is not shutting off properly and must be repaired or replaced Ice water bath and ice bank should be checked for cleanliness and water tank coils and the water level float control should be checked for excessive mineral deposit build up as follows 300381000 20 1 Disconnect electrical power from Cooling Unit at disconnect switch 2 Remove two screws securing Cooling Unit top cover then remove cover 3 Using flashlight inspect ice water bath and ice bank for cleanliness ice water bath should be clear and ice bank free of foreign particles 4 If cleaning of water tank is necessary refer to CHANGING ICE WATER BATH in this section 5 Fill water tank with clean water until water starts flowing from water tank overflow hose USE LOW MINERAL CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS 6 Install Cooling Unit top cover and secure with two screws 7 Restore electrical power to Cooling Unit at disconnect switch CHANGING ICE WATER BATH see Figures 5 or 6 l Disconnect electrical power from Cooling Unit at disconnect switch 2 Close shutoff valve in plain water inlet supply line 3 Remove two screws securing the Cooling Unit top cover then remove the cov
22. 6 lt 96 6 lt 9 S HH8INFIN 1300lN NOISIA3u TOO Obt6 Ot Se MOSN3S 100 NO3US dYA3 8 355 dYA3 84 MOSNIS 100 ts FP ra pata Ni NO3UA dYA3 QYA3 3ATTYA NYdX3 MOSN3S NOSN1S 13 x M 0WNIMHAL E Lure Em Th LH 69 Go 224 WAYI Ms AY138 OO 300381000 35 IN31SAS 39V L1OA MO T INVUDVIA FT 390914 vesoTr 9 V NOISIA3H VSOT OLD3NNOD Nid 2b e MOSN3S 1 at 2 100 NO3Mj MS 9 YOSNIS 100 ONOS ATBMSSSY dYA3 te 805 25 NI NO3Hi dYA3 dYA3 JAWA NYdX3 NOSNAS 805835 321 H lt a G ES SE n W T ET TER JAWA 4015 3ATYA NYdX3 e DM In Ak EE V W 39018 IYNINYIL E ae E T Fd E 1 D cc A awa Oral TG x Me og z 2 300381000 IN31SAS 3SV LIOA H IH DNIMUIM ST 3805914 ANNO ONISN3QNOO 310023 WOSH30NOD 031005 NW CI AINO 9NISN3ONO2 310834 X08 3503 01314 ANO 9NISN3ONOO 310838 Ez u31Y3H 214 I 112 4 2
23. ATING PRESSURE Example operating pressure is 90 psi and maximum water pressure can be no more than 80 psi etc l Before connecting plain water inlet supply line to Cooling Unit open water line shutoff valve for a period of time to flush out any metal shavings and other contaminates that may have resulted from plumbing connections 2 Connect flexible plain water inlet supply line 1 2 inch 1 0 min meeting water inlet supply line requirements of preceding CAUTION note to Cooling Unit 3 8 in flare 5 8 18 bulkhead fitting on back of unit labeled WATER INLET DO NOT OPEN WATER INLET SUPPLY LINE SHUTOFF VALVE AT THIS TIME CONNECTING CO INLET SUPPLY LINE TO COOLING UNIT see Figure 2 WARNING CO displaces oxygen Strict attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire CO and soft drink system If a CO gas 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 CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation Connect flexible CO inlet supply line to Cooling Unit 1 4 in flare 7 16 20 bulkhead fitting of back of unit labeled gt INLET DO NOT TURN ON CO SUPPLY TO COOLING UNIT AT THIS TIME CONNECTING SYRUP SOURCE LINES TO COOLING UNIT SYRUP INLET LINES see Figure 2 Connect syrup sour
24. Any damage or irregularities should be noted at time of delivery or not later than 15 days from date of delivery and immediately reported to the delivering carrier Reguest a written inspection report from Claims Inspector to substantiate any necessary claim File claim with the delivering carrier not with IMI Cornelius Inc 1 After Cooling Unit has been unpacked remove shipping tape and other packing material 2 Unpack LOOSE SHIPPED PARTS Make sure all items are present and in good condition Table 2 Loose Shipped Parts 1 110085000 Tubing Clamp 2 111353000 Tubing 3 311962000 Label Line Identification NOTE The following Remote Condenser Coil and Fan Assembly and Refrigeration Lines Kits are rec ommended for use with the Cooling Units 309602000 Remote Condenser Coil and Fan Ass y 300598025 Refrigeration Line Kit 25 ft long 90 300598050 Refrigeration Line Kit 50 ft long 90 Straight IDENTIFICATION OF LOOSE SHIPPED PARTS 1 TUBING CLAMPS item 1 used to secure insulated python lines to Cooling Unit carbonated water outlet lines 2 TUBING CLAMPS item 2 used to secure insulated python lines to Cooling Unit syrup and plain water lines 3 REFRIGERATION LINE KITS item 5 is used to connectthe REMOTE CONDENSER COIL AND FAN ASS Y item 4 to the Cooling Unit SELECTING LOCATION COOLING UNIT Select location for Cooling Unit installation that will 1 Allow the shortest possible insulated py
25. C Cinel D AURORA 10 000 COOLING UNIT Installation Manual MJ 4 300381000 July 13 1988 Revised April 12 1993 THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this eguipment IMI CORNELIUS INC 1988 93 PRINTED IN U S A TABLE OF CONTENTS Page GENERAL 1 GENERAL DESCRIPTION 1 COOLING UNIT DESCRIPTION 1 SYSTEM THEORY OF OPERATION 3 INSTALLATION ee n ew eee as IRR RR S 5 UNPACKING AND INSPECTION 5 IDENTIFICATION OF LOOSE SHIPPED PARTS 5 SELECTING uin r Ie estt reri teh tab dha bas ies 5 COGQ LINGUNER 5 REMOTE CONDENSER COIL AND FAN ASSY 6 INSTALLING REMOTE CONDENSER COIL AND FAN ASSY 6 INSTALLING COOLINGZUNIT elei e Recte TRO Rn Ort eee cen 6 PLACING COOLING UNIT IN LOCATION 6 CONNECTING REMOTE CONDENSER COIL AND FAN ASS Y REFRIGERATION LINES TO COOLING UNIT 7 CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING UNIT 7 CONNECTING PLAIN WATER INLET SUPPLY LINE TO COOLING UNIT 9 CONNECTING CO2 INLET SUPPLY LINE TO
26. GTION 5 rex MA ES Ies 19 COOLING UNIT MAINTENANCE 20 PERIODIC CEEANING 2 2 ries I a a rs 20 CLEANING CONDENSER 20 CHECKING ICE WATER 20 CHANGING ICE WATER BATH 21 WATER PUMP YEARLY MAINTENANCE OR AFTER WATER SYSTEM DISRUPTIONS 21 CARBONATED WATER CIRCULATING PUMP MOTOR LUBRICATION 26 ADpUSTMENTS dorem n ate ete ante cn e Pedo m xd 26 PRIMARY CO2 REGULATOR 26 SECONDARY CO2 REGULATORS 27 WATERFLOW RATE 7 eia Rer RR s a a a 28 WATER TO SYRUP RATIO OF DISPENSED PRODUCT 28 ADJ USTING CARBONATORS TANKS LIQUID LEVELS 28 CLEANING AND SANITIZING 2 22 28 DAILY CLEANING OF UNIT upaya put c eer eg 28 SANITIZING POST MIX SYRUP SYSTEMS 29 REPLENISHING CO2 5 31 REPLENISHING SYRUP 32 SYRUP ELAVOR CHANGE iu EE paykin REEL RES 32 CLEANING CO2 SYSTEM GAS CHECK VALVES 32 SECONDARY CO2 REGULATORS AND CO2 MANIFOLD CO2 GAS CHECK VALVES 2i as eat yc tt es D s Pei 32
27. IAGRAM COOLING UNIT REQUIRING CONNECTION TO REMOTE CONDENSER COIL AND FAN ASS Y 34 FIGURE 13 WIRING DIAGRAM LOW VOLTAGE 5 5 35 iii 300381000 TABLE OF CONTENTS cont d Page LIST OF FIGURES CONT D FIGURE 14 WIRING DIAGRAM LOW VOLTAGE 5 5 36 FIGURE 15 WIRING DIAGRAM HIGH VOLTAGE SYSTEM 37 LIST OF TABLES TABLE T DESIGN DATA Lr PESE rex ee seein pas 2 5 TABLE 2 LOOSE SHIPPED PARIS 300381000 iv GENERAL INFORMATION IMPORTANT To the user of this manual This manual is a guide for installing operating and maintaining this eguipment Refer to Table of Contents for page location of detailed information pertaining to guestions that arise during installation operation service and maintenance or trouble shooting this eguipment GENERAL DESCRIPTION This section gives the description theory of operation and design data for the Aurora 10 000 Cooling Unit hereafter referred to as a Cooling Unit COOLING UNIT DESCRIPTION The Cooling Unit is designed to provide cooled soft drink syrup carbonated water and plain water to dispensing station through an insulated python length as ordered On the standard Cooling Unit refrigeration system is cooled by condenser coil and fan assembly located inside the Cooling Unit Cooling Unit not provided with internal condenser coil and fan assembly is coo
28. IL AND FAN ASS Y IF APPLICABLE MAINTENANCE see Figure 6 equipped with a condenser coil that must be cleaned every 30 days Allowing condenser coil to become clogged will cause refrigeration system to overheat which will automatically shut refrigeration system down After condenser coil has been cleaned high pressure cutout CAUTION Remote Condenser Coil and Fan Assembly connected to this Cooling Unit is switch reset button on top of switches electrical control box under Cooling Unittop cover will have to be pressed to restart refrigeration system OPERATING COOLING UNIT IN THIS MANNER FOR PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE Area on top of and around Remote Condenser Coil and Fan Assembly must be kept free of obstructions at all times Condenser coil must be cleaned as instructed to maintain proper cooling of coil CLEANING CO GAS CHECK VALVES see Figure 2 The gas check valves must be inspected and serviced at least once a year under normal conditions and after any system servicing or disruption as instructed 300381000 18 SERVICE AND MAINTENANCE This section describes Service and Maintenance procedures to be performed on the Cooling Unitand the Remote Condenser Coiland Fan Assembly WARNING Disconnect electrical power to Cooling Unit to prevent personal injury before attempting any Cooling Unit or Remote Rooftop Condenser Coil and Fan Assembly if applicable internal maint
29. INES CO AND PLAIN WATER INLET LINES AND REMOTE CONDENSER AND FAN ASSEMBLY REFRIGERATION LINES IF APPLICABLE NOTE To comply with National Sanitation Foundation NSF requirements Cooling Unit not installed on optional Cooling Unit Stand P N 309309069 must have its base sealed to floor with Dow Corning RTV 731 or equivalent 1 Tilt Cooling Unit up to expose bottom of unit base 2 Liberally apply silastic sealant such as Dow Corning RTV 731 or equivalent on unit base bottom edges NOTE Do not move Cooling Unit after positioning or seal from unit base to floor will be broken 18 IN 1 AIR FLOW OPEN TO ROOM FIGURE 4 COOLING UNIT SPACE REQUIRED 300381000 10 3 Lower Cooling Unit into operating position to complete seal from unit base to floor Apply additional sealant around bottom of base Seal must have a minimum radius of 1 2 inch to prevent cracks and crevices and to ensure a complete seal 4 Route Cooling Unit water tank overflow hose to permanent floor drain 5 Sealarea around overflow hose where they exit from unit using permagum sealant or equivalent PREPARING COOLING UNIT FOR OPERATION 1 Make sure plug in end of Cooling Unit water tank drain hose is secure 2 Open shutoff valve in plain water inlet supply line Due to slow water fill rate of water level float control water tank may be hand filled until water runs out of water tank overflow hose CLEAN LOW MINERAL CONTENT WATER MUST
30. LUVLS HOLI YAYI NOW 7 NOISIAJH a ae 000 95 6 0 E Suga ung LJ 33A we 3O19V1N05 t ma MO12Y1NOO 1OMINOI pen il _ X08 AGNYH 6 lt 967 t6S9T1tr 6 lt 9 S HH8INFTN 1300lN 231134 NIVULS SNIHS 8 dYNS AINO 9NISN30NOO 310438 NOLOM NOSS3NdNOO 300381000 37 THIS PAGE LEFT BLANK INTENTIONALLY 300381000 38 TROUBLESHOOTING IMPORTANT Only qualified personnel should service intemal components or electrical wiring the applicable product tank then relieve the system pressure before proceeding If repairs 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 TROUBLESHOOTING POST MIX SYSTEM Trouble WATER TO SYRUP RATIO OF DISPENSED DRINK TOO LOW OR TOO HIGH ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES NOT INCREASE TO DESIRED WATER TO SYRUP RATIO A Probable Cause Dispensing valve syrup flow regulator not properly adjusted CO gas pressure to soft drink tanks insufficient to push syrup out of tanks No syrup supply S oft drink tank quick disconnects not secure Soft drink tanks secondary CO regulator out o
31. VALVES ARE SERVICED CARBONATORS CO INLET LINES GAS CHECK VALVE see Figures 2 and 10 Carbonators inlet lines gas check valve located inside Cooling Unit must be inspected and serviced atleast once a year under normal conditions and after any servicing or disruption of the CO system ALWAYS INSTALL NEW BALL SEAT QUAD RING P N 312418000 EACH TIME CHECK VALVE IS SERVICED CONNECTING EXTERNAL CARBONATOR TO COOLING UNIT An external carbonator may be connected to the Cooling Unit see Figure 2 fora larger supply of carbonated water 300381000 32 PULSE MODULATING EXPANSION VALVE mi MiS ZA SHUTOFF SOLENOID P VALVE WE HYDRO BOOST RECEIVER COMPRESSOR FIGURE 11 REFRIGERATION FLOW DIAGRAM STANDARD COOLING UNIT W INTERNAL CONDENSER COIL AND FAN ASS Y 33 300381000 50000800000 ROOFTOP CONDENSER PULSE MODULATING EXPANSION VALVE ICE BANK EVAPORATOR SHUTOFF SOLENOID VALVE L q TR EK i PULSE MODULATING EXPANSION VALVE D qmi SITE Al GLASS SCHRADER EEE VALVE HYDRO BOOST RECEIVER COMPRESSOR FIGURE 12 REFRIGERATION FLOW DIAGRAM COOLING UNIT REQUIRING CONNECTION TO REMOTE CONDENSER COIL AND FAN ASS Y 300381000 34 IN31SAS 39V L1OA MOY INVu5VIG 9NIHIM 38n5l3
32. ce lines from No 1 through No 6 soft drink tanks location to Cooling Unit syrup inlet lines labeled No 1 through No 6 DO NOT CONNECT SOFT DRINK TANKS INTO SYRUP SYSTEMS AT THIS TIME 9 300381000 CONNECTING COOLING UNIT SYRUP OUTLET LINES TO INSULATED PYTHON SYRUP LINES see Figure 2 Connect Cooling Unit syrup outlet lines labeled No 1 through No 6 with barbed fittings on their ends to insulated python lines labeled No 1 through No 6 Secure connections with TUBING CLAMPS item 2 CONNECTING COOLING UNIT PLAIN WATER OUTLET LINE TO INSULATED PYTHON PLAIN WATER LINE see Figure 2 NOTE Shutoff valve in plain water line inside Cooling Unit must remain closed if plain water is not desired at dispensing valve Connect Cooling Unit plain water outlet line with barbed fitting on its end to insulated python plain water line Secure connection with TUBING CLAMP item 2 CONNECTING COOLING UNIT CARBONATED WATER OUTLET LINES TO INSULATED PYTHON CARBONATED WATER LINES see Figure 2 Connect Cooling Unit carbonated water outlet lines with barbed connectors on their ends to insulated python carbonated water lines secure Connections with TUBING CLAMPS item 1 PLACING COOLING UNIT IN OPERATING POSITION 1 Very carefully move Cooling Unit back into operating position leaving space around unit see Figure 4 as specified in SELECTING LOCATION MAKE SURE THERE ARE NO KINKS IN SYRUP INLET LINES INSULATED PYTHON INTERNAL L
33. ck valves 2 Pull up on carbonator tanks relief valves to release pressure from tanks 3 Disconnect carbonator tank water inlet line from liquid double check valve outlet then remove double check valve from elbow in water pump outlet 4 Remove one check valve from the other then disassemble each check valve as shown in Figure 9 5 Wipe each part with clean lint free cloth Inspect each part especially the ball for burrs nicks corrosion deterioration and other damage Discard ball seat and any damaged or suspicious parts and replace with new parts during reassemble 300381000 24 6 Reassemble check valves as shown in Figure 9 ALWAYS INSTALL NEW BALL SEAT QUAD RING P N 312418000 NOTE Make sure when assembling check valves together check valve female end with white tapered gasket inside is on inlet side of liquid double check valve assembly 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 Assemble check valves together as shown in Figure 8 DO NOT OVERTIGHTEN Make sure white tapered gasket is in place inside female end of liquid double check valve then install double check valve on elbow in water pump outlet port Connect carbonator tank water inlet line to liquid double check valve outlet Remove liquid single check valve from carbonated water tank carbonated water outlet line Disassemble check valve as shown in Figure 9 Wipe each part with clean lint free cl
34. cool the coil is drawn in through air filter on back and is exhausted out through coil on front of Unit Failure to clean and allowing air filter to become clogged will cause refrigeration system to CAUTION Cooling Unit equipped with condenser coil is equipped with an air filter that overheat which will automatically shut refrigeration system down After refrigeration system has cooled down system will automatically restart and operate until overheated and shut down again OPERATING COOLING UNIT IN THIS MANNER FOR PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE Area around Cooling Unit must be kept free of obstructions at all times for proper air circulation through the Unit Air filter must be cleaned every 30 days as instructed COOLING UNIT CARBONATOR MAINTENANCE Lubrication Carbonator water pump motor bearings must be oiled periodically as instructed Water Pump Yearly Maintenance or After Water System Disruptions Carbonator water pump water strainer screen and liquid double check valve must be inspected and cleaned at least once a year under normal circumstances and after any water system disruption plumbing work earthquake etc Inspect and clean water strainer screen and liquid double check valve as instructed 17 300381000 COOLING UNIT CARBONATED WATER CIRCULATING PUMP MOTOR LUBRICATION Carbonated water circulating pump motor bearings must be oiled periodically as instructed REMOTE CONDENSER CO
35. d 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 300381000 30 21 Repeatsteps NO TAG and NO TAG preceding to purge sanitizing solution out of the remaining syrup systems and dispensing valves 22 Remove potable water source from the syrup system STEP 5 PURGE WATER OUT OF SYRUP SYSTEMS RESTORE OPERATION 23 Syrup Tank S ystems A Noting syrup tanks gt regulator pressure setting observed in step 4 preceding readjust CO regulator to the observed pressure setting B Connecttanks containing syrup into syrup systems Bag in Box Syrup System C Remove all bag valves from bag in box syrup containers outlet tubes connectors D Connect bag in box syrup containers into the syrup systems 24 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 remove the syrup tank cover until CO pressure has been released from the tank N WARNING To avoid possible personal injury or property damage do not attempt to 25 Dispose of waste sanitizing solution in a sanitary sewer not in a storm drain then thoroughly rinse the inside and the outside of the container that was used f
36. dispensing station through insulated lines Standard Cooling Unit The standard Cooling Unit refrigeration system is cooled by a condenser coil and fan assembly located inside Cooling Unit Cooling Unit Requiring Connection to Remote Condenser Coil and Fan Assembly The Cooling Unit refrigeration system is cooled by a Remote Condenser Coil and Fan Assembly P N 309602000 that is authorized by IMI Cornelius Inc Use of any other Remote Condenser Coil and Fan Assembly must be authorized by IMI Cornelius Inc Use of an unauthorized Remote Condenser Coil and Fan Assembly will automatically void the Cooling Unit factory warranty 300381000 Z ANTIWA MIIHI ainon ATONIS Z ANTIWA A44OLNHS ULUM aalvNOSuvo HOLIVNOSHVvD TVNY31X4 N AATWA MIIHI SVD 02 NOLLV TIVLSNI TVOIdA LD INVUDVIA Z JUNDII 3ATVA 323HD AATWA SSVdAgH LSOOd aalvNOSuvo5 SE Z dINNd YOLVNOSYVD LI Z ANTWA MIIHI ainon S gt INV L ANIYA 1405 YAGNIMAD COD 4 gt gt 915009 lt aX o
37. e Figure 2 A CO cylinder delivers carbon dioxide gas CO2 to primary gt regulator assembly which delivers regulated CO gas to adjustable secondary regulators Secondary CO regulators deliver regulated CO gas to both carbonated water tanks inside Cooling Unit and also to soft drink tanks Plain water is pumped into carbonated water tanks by water pumps and is carbonated by regulated gas pressure also entering tanks Carbonated water leaves carbonated water tanks and passes through the Hydro Boost E carbonated water pre cooler which pre cools carbonated water on its way to carbonated water circulating pump P re cooled carbonated water enters carbonated water circulating system through inlet side of carbonated water circulating pump Carbonated water passes from outlet side of carbonated water circulating pump through cooling coils inside water tank and out through insulated line to turnaround inside dispensing station Carbonated water returns to Cooling Unit by passing through insulated line through cooling coils and on to carbonated water circulating pump inlet which makes up the carbonated water circulating system As carbonated water is being dispensed from dispensing station carbonated water circulating system is continuously being replenished from both carbonated water tanks Regulated gas pressure exerted upon soft drink tanks contents forces syrup from tanks through Cooling Unit cooling coils and on to
38. enance Only qualified personnel should service internal components or electrical wiring PREPARING COOLING UNIT FOR SHIPPING STORING OR RELOCATING CAUTION Before shipping storing or relocating Cooling Unit syrup systems must be sanitized and all sanitizing solution must be purged from syrup systems All water must be purged from plain and carbonated water systems and ice bank must be melted and all water drained from water tank A freezing ambient environment will cause residual water remaining inside unit to freeze resulting in damage to internal components PERIODIC INSPECTION Cooling Unit Equipped With Condenser Coil and Air Intake F ilter see Figure 5 CAUTION Cooling Unit equipped with condenser coil is equipped with an air filter that must be cleaned every 30 days as instructed Circulating air required to cool the coil is drawn in through air filter on back and is exhausted out through coil on front of Unit Failure to clean and allowing the air filter to become clogged will cause refrigeration system to overheat which will automatically shut refrigeration system down After refrigeration system has cooled down system will automatically restart and operate until overheated and shut down again OPERATING COOLING UNIT IN THIS MANNER FOR PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE Clean air filter every 30 days as instructed Area around Cooling Unit must be kept free of obstructions at all times f
39. ensing 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 Repeat stepsNO TAG and NO TAG to flush water out of and install sanitizing solution in the remaining syrup systems and dispensing valves Remove sanitizing solution source from the syrup system Allow sanitizing solution to remain in the syrup systems for notless than 10 or no more than 15 minutes max contact time STEP 4 WATER FLUSH SYRUP SYSTEMS WARNING Flush sanitizing solution from the syrup systems as instructed Residual 18 19 20 sanitizing solution left in the syrup systems could create a health hazard Fill syrup tank syrup tank system or a five gallon container bag in box system with potable water Syrup Tank Systems Connect syrup tank containing potable water pressurized at 60 to 80 psi into one of the syrup systems Bag in Box Syrup System Place all bag in box syrup containers syrup outlet tubes in container containing potable water 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 an
40. ent solution out of 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 detergent solution and flush out the syrup System 29 300381000 10 11 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 Connect potable water source to the remaining syrup systems and flush detergent solution out of the syrup systems as instructed in step NO TAG preceding Remove potable water source from the syrup system STEP 3 SANITIZE SYRUP SYSTEMS 12 13 14 15 16 17 Using a clean syrup tank syrup tanks system or a five gallon container bag in box system prepare sanitizing solution using 70 F 21 C to100 F 38 C potable water and 0 5 oz 15 ml of non scented household liquid bleach that contains a 5 25 sodium hypochlorite concentration to one gallon of potable water This mixture must not exceed 200 PPM of chlorine Stir sanitizing solution to thoroughly mix Syrup Tank Systems Connect sanitizing solution tank pressurized at 60 to 80 psi into one of the syrup systems Bag in Box Syrup System Place all bag in box syrup containers syrup outlet tubes in container containing sanitizing solution Sanitize the syrup system and dispensing valve as follows A Place waste container under applicable disp
41. er 4 Make sure end of water tank drain hose is routed to the floor drain then remove plug from end of hose and allow water to drain from water tank CAUTION Never use an ice pick or other instrument to remove ice from evaporator coils Such practice can result in punctured refrigeration circuit 5 Allow ice bank to melt Hot water may be used to speed melting 6 Thoroughly rinse inside of water tank with clean water 7 Install plug in end of water tank drain hose 8 Open shutoff valve in plain water inlet supply line Due to slow water fill rate of the water level float control the water tank may be hand filled until water runs out of the overflow tube USE LOW MINERAL CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS 9 Install Cooling Unit top cover and secure with two screws 10 Connect electrical power to Cooling Unit at disconnect switch WATER PUMP YEARLY MAINTENANCE OR AFTER WATER SYSTEM DISRUPTIONS carbonated water tanks water outlet lines single check valves 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 WARNING The carbonators water inlet strainer screens double liquid check valves and flow of water through system Water pump with no screen or defective screen in the strainer would allow foreign particles to foul the liquid double check valve
42. er Allow Hydro Boost Coil to thaw then check for refrigeration problem Place circulating pump CIRCULATING MOTOR power switch in ON position Replace pump or motor Remedy Replace water pump motor Clean balance mechanism Tighten connections and or repair open circuit Check for proper line voltage Check for restricted pump discharge Replace level control switches Repair or replace balance mechanism Remove water pump from motor rotate pump or motor shaft 180 degrees then recouple pump to motor Replace water pump as instructed Replace safety thermostat Remove foreign object Clean balance mechanism Tighten or replace line Replace level control switches 300381000 Trouble ERRATIC CYCLING OF CARBONATOR WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP WATER WATER PUMP CAPACITY TOO LOW D Probable Cause Binding or damaged balance mechanism Balance mechanism spring obstructed or cocked Dirty balance mechanism Water pump inlet water strain screen dirty Kinked water supply line Restriction between water pump outlet and carbonator tank inlet Foreign object in water pump bypass Water pump worn out Water pump inlet water strainer screen dirty Water supply capacity too low Water filter clogged Inoperative water pump TROUBLESHOOTING REFRIGERATION SYSTEM COMPRESSOR DOES NOT OPERATE 300381000 A Ice bank suf
43. erator A green ground wire is provided inside electrical box to connect power circuit ground wire which electrically grounds the Cooling Unit 2 60HZ Cooling Unit Connect 208 230VAC Single Phase 60Hz electrical power circuit with a 40 amp minimum rated disconnect switch not provided fused at 40 amps maximum or circuit connected through an equivalent HACR circuit breaker to electrical wires inside electrical handy box on back of cooling unit DO NOT CONNECT ELECTRICAL POWER TO COOLING UNIT AT THIS TIME COOLING UNIT MUST BE PROPERLY GROUNDED POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES 50HZ Cooling Unit Connect 208 230VAC Single Phase 50Hz electrical power circuit with a 40 amp minimum rated disconnect switch not provided fused at 40 amps maximum or circuit connected through an equivalent HACR circuit breaker to electrical wires inside electrical handy box on back of cooling unit DO NOT CONNECT ELECTRICAL POWER TO COOLING UNIT AT THIS TIME COOLING UNIT MUST BE PROPERLY GROUNDED POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS AND WIRING MUST CONFORM TO APPLICABLE ELECTRICAL CODES CONNECTING ELECTRICAL POWER CIRCUIT TO REMOTE CONDENSER COIL AND FAN ASS Y IF APPLICABLE see Figures 6 and 15 and Fan Assembly P N 309602000 that is authorized by IMI Cornelius Inc Use of an unauthorized Remote Condenser Coil and Fan Assembly will automatically void
44. f adjustment Dispensing valve syrup flow regulator soft drink tank quick disconnect or syrup line restricted Tapered nylon washer inside tube swivel nut connection distorted from being overtightened restricting syrup flow Dirty or inoperative piston or cylinder in dispensing valve syrup flow regulator 39 A Remedy Adjust Water To S yrup Ratio refer to dispensing station installation Instructions Adjust soft drink tanks secondary CO regulator as instructed Replenish syrup supply as instructed Secure quick disconnects Adjust soft drink tanks secondary CO regulator as instructed Sanitize syrup system as instructed Replace nylon washer Make sure washer seats properly in swivel nut Disassemble and clean dispensing valve syrup flow regulator 300381000 Trouble ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES NOT DECREASE TO DESIRED WATER TO SYRUP RATIO DISPENSED PRODUCT CARBONATION TOO LOW DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT FOAMS IN CUP Probable Cause Dirty or inoperative piston or cylinder in dispensing valve syrup flow regulator Carbonator regulator out of adjustment for existing water conditions or temperature Water oil or dirt in CO2 supply Oil film or soap scum in cups Ice used for finished drink is sub cooled Remedy Disassemble and clean dispensing valve syrup flow regulator Adju
45. ficient REFRIGERATION POWER switch in OFF position Electrical power to Cooling Unitturned off No Cooling Unit power source Blown fuse or tripped circuit breaker Low voltage Loose disconnected or broken wiring Inoperable contactor Inoperable control board 42 Remedy Repair or replace balance mechanism Remove obstruction Make sure spring is perpendicular to spring release and is not twisted Clean balance mechanism Clean or replace water strainer screen as instructed Straighten water supply line Remove restriction Clean bypass Note Count number of turns bypass screw makes when removing and install same number of turns Replace water pump Clean or replace water strainer screen as instructed Inlet water supply must be at a minimum of 250 gallons per hour with a maximum water pressure of 80 psi Replace water filter cartridge as instructed Replace water pump Refrigeration not called for Place REFRIGERATION POWER switch in ON position Turn on electrical power to Cooling Unit Replace fuse or reset circuit breaker Voltage must be atleast 208 volts at compressor terminals when compressor is trying to start Tighten connections or replace broken wiring Replace contactor Replace control board Trouble Probable Cause Remedy COMPRESSOR DOES NOT l Hi pressure cutout tripped Reset pressure switch see OPERATE CONT D remote Cooling Unit
46. further adjustment If incorrect adjustment is suspected adjust as instructed REPLENISHING SUPPLY WARNING displaces oxygen Strict attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire CO and soft drink system If a CO gas 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 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation 300381000 16 NOTE When indicator on CO cylinder regulator assembly 1800 psi gage is in shaded change CO cylinder portion of the dial CO cylinder is almost empty and should be changed CO supply should be checked daily and if necessary replenished as instructed REPLENISHING SYRUP SUPPLY Syrup supply should be checked daily and if necessary replenished as instructed CLEANING AND SANITIZING DAILY CLEANING Perform daily cleaning of dispensing station as instructed in dispensing station Installation Instructions Outside of Cooling Unit must be cleaned periodically SANITIZING SYRUP SYSTEMS S yrup systems should be sanitized every 90 days as instructed following Sanitizer Manufacturer s recommendations COOLING UNIT MAINTENANCE COOLING UNIT EQUIPPED WITH CONDENSER COIL AND AIR INTAKE FILTER must be cleaned every 30 days as instructed Circulating air required to
47. in ON up position Refrigeration compressor condenser fan motor and agitator motor will start and begin forming an ice bank When full ice bank has been formed compressor and condenser fan motor will stop but agitator motor will continue to operate circulating ice water bath in water tank STARTING CARBONATED WATER CIRCULATING PUMP 1 Place CIRCULATING MOTOR power switch in ON up position Circulating pump will start and begin circulating carbonated water in system 2 Dispense carbonated water from dispensing valve to make sure all air has been purged from system 3 If Cooling Unit plain water outlet line is connected to dispensing system open plain water shutoff valve inside unit Dispense from valve until all air is purged from plain water system ACTIVATING SYRUP SYSTEMS 1 Adjust soft drink tanks secondary regulators see Figure 2 as follows Sugar Syrup Soft Drink Tanks Regulator Adjust sugar syrup soft drink tanks secondary regulator at 40 psig for syrup lines up to 10 feet in length plus one pound for each additional length of 10 feet plus one pound for each 2 feet of vertical lift For example if syrup line total length is 30 feet and total vertical lift is 6 feet then 40 psig 2 psig 1 pound for every 10 feet of length over 10 feet which is 20 feet 3 psig 1 pound for every 2 feet of vertical lift which is 6 feet total equals 40 2 3 45 psig CO regulator setting Low Calorie die
48. just dispensing valve syrup flow regulator refer to Installation Instructions provided with dispensing station Trouble ONLY CARBONATED WATER DISPENSED CONT D ONLY SYRUP DISPENSED WARM PRODUCT BEING DISPENSED Trouble Probable Cause Dispensing valve syrup flow regulator soft drink tank guick disconnect or syrup lines restricted Plain water inlet supply line shutoff valve closed CARBONATOR MOTORS power switch in OFF position Water filter clogged Frozen Hydro Boost Coil Carbonated water circulating pump CIRCULATING MOTOR power switch in OFF position Inoperable carbonated water circulating pump or motor Probable Cause TROUBLESHOOTING CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE WATER PUMP MOTOR WILL NOT SHUT OFF Inoperative water pump motor Dirty balance mechanism Loose connections and or open electrical circuit Overheated motor cut off by thermal overload protector Inoperative level control switches Binding or damaged balance mechanism Water pump binding new or replacement pumps only Water pump damaged Safety thermostat inoperative Foreign object restricting tank movement Dirty balance mechanism Leak in carbonated water line Inoperative level control switches 41 Remedy Sanitize syrup system as instructed Open plain water inlet supply line shutoff valve Place switch in ON position Replace water filt
49. k of Cooling Unit to inside of electrical control box Connect Remote Condenser Coil and Fan Assembly power cable electrical wires to and terminals on contactor inside Cooling Unit electrical control box 300381000 8 D Reinstall Cooling Unit electrical control box and secure with four screws E Install cover on electrical handy box on back of Cooling Unit CONNECTING PLAIN WATER INLET SUPPLY LINE TO COOLING UNIT see Figure 2 NOTE IMI Cornelius Inc recommends that a water shutoff valve be installed in plain water inlet supply line connected to Cooling Unit and that water supply be filtered 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 Check water flow rate of water inlet supply line MINIMUM FLOW RATE MUST BE AT LEAST 250 GALLONS PER HOUR If flow rate is less than 250 gallons per hour starving of carbonator water pump will occur Starving will allow water pump to overheat causing safety thermostat on pump outlet to disrupt electrical power to and stop water pump motor Carbonated CAUTION Plain water inlet supply line to Cooling Unit must be 1 2 inch I D minimum water circulating pump overheating could occur if water inlet supply line flow rate drops below 250 gallons per hour INCOMING PLAIN WATER INLET SUPPLY LINE WATER PRESSURE MUST REMAIN A MINIMUM OF 10 PSI BELOW THE CARBONATOR CO OPER
50. led by Remote Condenser Coil and Fan Assembly which is connected to Cooling Unit The Cooling Unit consists basically of two carbonator tanks each having its own water pump to pump plain water into tanks one carbonated water circulating pump a Hydro Boost carbonated water pre cooler which pre cools carbonated water on its way to carbonated water circulating pump and a two horsepower refrigeration compressor The cabinet panels are easily removed to facilitate installation and service and maintenance An optional Cooling Unit Stand P N 309309000 is available to elevate Cooling Unit up off floor A System Status Display Kit P N 0913 is available and when installed on the Cooling Unit allows operator or technician to monitor operation of Cooling Unit and to be aware when service is required Also available is an Aurora Service S ystem Analyzer P N 309197000 that may be used to analyze and troubleshoot the Aurora 10 000 Cooling Unit refrigeration system sanitized and all sanitizing solution must be purged from coils All water must also be purged from plain and carbonated water systems A freezing ambient environment will cause residual sanitizing solution or water remaining inside Cooling Unit to freeze resulting in damage to internal components CAUTION Before shipping or relocating Cooling Unit syrup cooling coils must be FIGURE 1 AURORA 10 000 COOLING UNIT 1 300381000 11659 I S a SEU Cooling U
51. m has cooled down high pressure sensing cutout switch reset button see Figure 6 will have to be pressed to reset switch MAKE SURE REFRIGERATION SYSTEM PROBLEM IS CORRECTED OPERATING REFRIGERATION SYSTEM IN THIS MANNER FOR PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE DAILY PRE OPERATION CHECK 1 Make sure CO cylinder regulator assembly 1800 psi gage indicator is not in shaded change cylinder portion of dial If so CO cylinder is almost empty and must be replaced 2 Sufficient syrup supply in all soft drink tanks If not replenish syrup supply as instructed ADJ USTMENTS ADJ USTING CO REGULATORS CO regulators should be periodically checked for proper pressure settings and if necessary adjusted as instructed ADJ USTING DISPENSING VALVES WATER FLOW RATE If adjustment of dispensing valves water flow rate should be necessary adjust as instructed in dispensing station Installation Instructions ADJ USTING WATER TO SYRUP RATIO OF DISPENSED PRODUCT Water To S yrup Ratio of dispensed product should be checked and if necessary adjusted as instructed in dispensing station Installation Instructions ADJ USTING SIZE OF DRINK DISPENSED Adjust drink size of dispensed product as instructed in dispensing station Installation Instructions ADJ USTING CARBONATOR TANK LIQUID LEVEL The carbonator tank liquid level 40 to 60 ounces pump cut in and cut out were adjusted at the factory and should require no
52. nd Fan Assembly refrigeration lines and power circuit cable if applicable and plain water source and CO inlet lines may be coiled up behind unit NOTE An external carbonator may be connected to Cooling Unit as shown in Figure 2 for larger supply of carbonated water PLACING COOLING UNIT IN LOCATION NOTE An optional Cooling Unit Stand P N 309309069 is available to elevate Cooling Unit up off floor 1 Place Cooling Unit in position approximately 36 inches out from operating position to allow access all around unit 2 Remove two screws securing Cooling Unit top cover then remove cover 300381000 6 CONNECTING REMOTE CONDENSER COIL AND ASS Y IF APPLICABLE REFRIGERATION LINES TO COOLING UNIT see Figure 6 Connect refrigeration lines from Remote Condenser Coil and Fan Assembly to refrigeration connectors on back of Cooling Unit CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING UNIT see Figures 5 or 6 and 15 IMPORTANT Before applicable single phase 60HZ or 50HZ electrical power circuit is connected to the Cooling Unit service power voltage entering the building must be identified Service power voltage entering the building will either be 208 or 230VAC and may be posted on the main service box If not the installer must contact the local electrical power company for information If these two voltage identification attempts should fail a voltage reading must be performed If service power voltage is below 218VAC
53. nit Requiring Connection to Remote Condenser Coil and Fan 416594 Assembly a E TIN 50 HZ Unit Standard Cooling Unit with Internal Condenser Coil and Fan Assembly 49659 epo 5 2 s ue aw ool COOLING UNIT DATA 28 inche 36 1 2 inche 24 1 2 ehe a Css C TII NOTE Overall dimensions if Cooling Unit is placed on optional Cooling Unit Stand P N 309309069 Height approximate 75 5 16 Inche 37 1 2 inche 25 3 8 inche ja O odels 416593 and 496593 Shipping 378 pound Dry Weight 358 pound Is 52222 2 2 odel 416594 Shipping 381 pound Dry Weight 361 pound Ice Bank Weight 40 to 45 pound Water Bath no Ice ban 18 gallon Compressor Horsepower 2H jai EC KEEN efrigeration S ystem Refrigerant Type and Charge See Cooling Unit Nameplate I ITA ESA Ambient O perating Temp 5 to 1000 X i I ectrical Requirements 60 HZ Cooling Unit Operating voltage See Cooling Unit Current Draw Nameplate 3 OHZ Cooling Unit Operating Voltage See Cooling Current Draw Unit 300381000 Table 1 Design Data cont d EMOTE CONDENSER COIL AND FAN ASS Y DATA P N 309602000 verall Dimensions Height 27 inche Wiat 22 Inche Dept 38 Inche Weight Shipping 85 pound Ambient Operating Temp 22 F to 158 ectrical Requirements Operating Voltage 208 230VAC Single Phase 60Hz Current Draw 2 5 Amp SYSTEM THEORY OF OPERATION se
54. on Installation Instructions ADJ USTING CARBONATORS TANKS LIQUID LEVELS see Figure 7 NOTE The carbonator tanks liquid levels 40 to 60 ounces pump cut in and cut out were adjusted at the factory and should require no further adjustment If incorrect adjustment is suspected check and make necessary adjustment as follows Under 40 ounces of carbonated water dispensed If total amount of carbonated water dispensed is under 40 ounces loosen screw securing switch adjustment bracket and move bracket up slightly Moving bracket up allows weight of more water in tank to push tank further down before activating liquid level control switches which shuts off water pump Tighten screw after adjustment Over 60 ounces of carbonated water dispensed If total measurement of carbonated water dispensed is over 60 ounces loosen screw securing switch adjustment bracket and move bracket down slightly Moving bracket down allows weight of less water in tank o activate liquid level control switches which shuts off water pump motor Tighten screw after adjustment CLEANING AND SANITIZING DAILY CLEANING OF UNIT 1 Remove cup rest from the drip tray 2 Wash drip tray in place on the Unit then rinse drip tray with hot water allowing water to drain out through the drain hose 3 Wash cup rest then rinse the cup rest with clean water Install cup rest in the drip tray 4 Clean all external surfaces of the Unit with a sponge Rinse out the sponge
55. or a platform extending unit an additional 18 inches above rooftop is highly recommended and will improve performance Ample space must be provided on all sides and above unit for proper air circulation through unit and also access for service and maintenance DO NOT BLOCK AIR CIRCULATION THROUGH UNIT 2 Remote Condenser Coil and Fan Assembly must be installed in level position and must be anchored to rooftop with adequate fastening devices INSTALLING REMOTE CONDENSER COIL AND FAN ASS Y IF APPLICABLE see Figure 6 1 Remote Condenser Coil and Fan Assembly must be installed meeting requirements of SELECTING LOCATION Remote Condenser Coil and Fan Assembly must be installed in level position and must be anchored to with adequate fastening devices 2 Route REFRIGERATION LINES item 5 from Remote Condenser Coil and Fan Assembly down to Cooling Unit location 3 Connect ends of refrigeration lines to Remote Condenser Coil and Fan Assembly refrigeration connectors INSTALLING COOLING UNIT NOTE Cooling Unit outlet lines plain water CO5 and syrup inlet lines Remote Condenser Coil and Fan Assembly refrigeration lines and power circuit cable if applicable and Cooling Unit power circuit cable each must be long enough when connected to Cooling Unit to allow pulling unit out approximately 36 inches from operating position for service and maintenance When Cooling Unit is in operating position excess power circuit cable Remote Condenser Coil a
56. or proper air circulation through the unit Cooling Unit Utilizing a Remote Condenser Coil and Fan Assembly CAUTION Remote Condenser Coil and Fan assembly connected to this Cooling Unit is equipped with a condenser coil that must be cleaned every 30 days Allowing condenser coil to become clogged will cause refrigeration system to overheat which will automatically shut refrigeration system down After condenser coil has been cleaned high pressure cutout switch reset button on top of switches electrical control box under Cooling Unit top cover will have to be pressed to restart refrigeration system OPERATING COOLING UNIT IN THIS MANNER FOR PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE Clean Remote Condenser Coil and Fan Assembly condenser coil every 30 days as instructed Make sure area on top and around unit are kept free of obstructions at all times Air must be allowed to enter and leave unit to remove heat from condenser coil Restricting air through condenser coil will cause Cooling Unit refrigeration system to overheat 3 Check entire system for leaks or damaged components Repair as necessary 19 300381000 COOLING UNIT MAINTENANCE PERIODIC CLEANING Periodically wash all external surfaces of Cooling Unit rinse with clean water then wipe dry with a clean soft cloth DO NOT USE ABRASIVE TYPE CLEANERS CLEANING CONDENSER COIL Cooling Unit Equipped With Condenser Coil and Air Filter see Figure 5
57. or sanitizing solution to remove all sanitizing solution residue REPLENISHING SUPPLY CO carbon dioxide gas leaks in the entire CO and soft drink system If a CO gas 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 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation WARNING CO displaces oxygen Strict attention must be observed in the prevention of NOTE When indicator on CO cylinder primary CO regulator assembly 1800 psi gage is in shaded change CO cylinder portion of dial CO cylinder is almost empty and should be changed 1 Fully close clockwise cylinder valve 2 Slowly loosen primary CO regulator assembly coupling nut allowing pressure to escape then remove regulator assembly from empty CO cylinder 3 Unfasten safety chain and remove empty cylinder WARNING To avoid personal injury and or property damage always secure CO cylinder in upright position with safety chain to prevent it from falling over Should valve become accidentally damaged or broken off cylinder can cause serious personal injury 4 Position CO cylinder and secure with safety chain 5 Make sure gasket is in place inside primary regulator coupling nut then install regulator on CO cylinder 31 300381000 6 O
58. oth Inspect each part especially the ball for burrs nicks corrosion deterioration and other damage Discard ball seat and any damaged or suspicious parts and replace with new parts during reassemble Reassemble liquid check valve as shown in Figure 9 ALWAYS INSTALL NEW BALL SEAT QUAD RING P N 312418 000 Install check valve in carbonated water tank carbonated water outlet line Repeat procedures in Servicing Carbonator Water Pump Water Strainer Screen and this paragraph for servicing water strainer screen and liquid check valves on other carbonator Turn carbonator gt regulator adjusting screw to the right clockwise until its gage indicates pressure setting observed in step 3 of Servicing Carbonator Water Pump Water Strainer Screen Open shutoff valve in plain water inlet supply line Restore electrical power to Cooling Unit at disconnect switch Dispense carbonated water at dispensing station and allow carbonators to cycle on and off Check for water leaks and repair if evident Disconnect electrical power from Cooling Unit at disconnect switch Install Cooling Unit left side panel and top cover Place unit back in operating position if moved out for panel removal Restore electrical power to Cooling Unit at disconnect switch O TANK BRACKET SWITCH ADJ USTMENT BRACKET 0 O LEVEL CONTROL lo SWITCH ACTUATOR 2 FIGURE 7 CARBONATOR LIQUID LEVEL CONTROL SWITCHES
59. pen counterclockwise CO 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 valve shaft REPLENISHING SYRUP SUPPLY NOTE The following instructions are applicable only when replenishing same flavor syrup Refer to SYRUP FLAVOR CHANGE when changing syrup flavor 1 Disconnect empty soft drink tank from syrup system 2 Check soft drink tank quick disconnects for sticky or restricted operation Wash disconnects in warm water 3 Connect full tank of syrup into syrup system SYRUP FLAVOR CHANGE 1 Perform sanitizing procedure on syrup system syrup flavor change will be made on 2 Check soft drink tank quick disconnects for sticky or restricted operation Wash disconnects in warm water 3 Connect full tank of new flavor syrup into syrup system QUAD RING 183294 000 A BALL 183296 000 1 d SPRING 83297 000 RETAINER 183298 000 BODY 183295 100 Quad ring seal must be replaced each time check valve is serviced FIGURE 10 CO GAS CHECK VALVE CLEANING CO SYSTEM GAS CHECK VALVES SECONDARY CO REGULATORS AND CO MANIFOLD CO GAS CHECK VALVES see Figures 2 and 10 The secondary gt regulators and CO manifold CO gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO system ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK
60. rt carbonators 10 Dispense from dispensing station until carbonated water appears at valve indicating Hydro Boost and carbonated water system have been completely filled with carbonated water OPERATION WARNING Disconnect electrical power to Cooling Unit and Remote Condenser Coil and Fan Assembly if applicable to prevent personal injury before attempting any Cooling Unit or Remote Condenser Coil and Fan Assembly internal maintenance Only qualified personnel should service internal components or electrical wiring 11 300381000 STARTING COOLING UNIT REFRIGERATION SYSTEM NOTE As ice bank forms in water tank water expansion will take place and excess water will escape through water tank overflow hose to permanent floor drain Cooling Unit Connected To Remote Condenser Coil and Fan Assembly P N 309602000 Place Cooling Unit REFRIGERATION POWER switch in ON up position Refrigeration compressor compressor cooling fan agitator motor and Remote Condenser Coil and Fan Assembly will start Cooling Unit will begin forming an ice bank and refrigerated Hydro Boost coil will also be chilling water When full ice bank has been formed Remote Condenser oil and Fan Assembly Cooling Unit compressor and compressor cooling fan will stop but agitator motor will continue to operate circulating ice water bath in water tank Standard Cooling Unit Utilizing Condenser Coil and Fan Assembly Place Cooling Unit REFRIGERATION POWER switch
61. st carbonator CO regulator as instructed Remove contaminated supply Clean CO system lines regulators etc using a mild detergent Replenish with a clean CO supply Use clean cups Do not use ice directly from freezer Allow ice to become wet before using Refer to following NOTE NOTE Crushed ice also causes dispensing problems When finished drink hits sharp edges of ice carbonation is released from finished drink DISPENSED PRODUCT PRODUCES FOAM AS IT LEAVES DISPENSING VALVE ONLY CARBONATED WATER DISPENSED 300381000 A Carbonator regulator pressure set too high for existing water conditions or temperature S yrup over carbonated with CO Tapered nylon washer inside tube swivel nut connection distorted from being overtightened restricting syrup flow Quick disconnect not secure on soft drink tank Out of syrup Inoperable dispensing station Dispensing valve syrup flow regulator not properly adjusted 40 A Reduce carbonator gt regulator pressure setting as instructed Remove soft drink tank quick disconnects Relieve tank pressure shake tank vigorously then relieve tank pressure as many times as necessary to remove over carbonation Replace nylon washer Make sure washer is properly seated in Swivel nut Secure quick disconnect on soft drink tank Replenish syrup supply as instructed Repair dispensing station Ad
62. t Syrup Soft Drink Tank Regulator Adjust low calorie diet soft drink tank secondary regulator for low calorie drink at 10 psig for syrup lines up to 30 feet in length Syrup lines longer than 30 feet in length may require a slightly higher CO regulator setting to 12 psig maximum Excessive CO pressure may cause low calorie syrup carbonation resulting in foam IMPORTANT Syrup systems must be sanitized as instructed before syrup is connected into syrup systems 2 Connect soft drink tanks into syrup systems 3 Dispense from all dispensing stations dispensing valves until product is dispensed 300381000 12 LEAK CHECK AND INSULATING COOLING UNIT OUTLET LINES 1 plain and carbonated water and syrup connections for leaks and repair if evident 2 Make sure Cooling Unit outlet lines connections to insulated python lines are well insulated 3 Install Cooling Unit top cover and secure with two screws DISPENSING STATION ADJ USTMENTS ADJUSTING WATER FLOW RATE Refer to Installation Instructions provided with dispensing station for dispensing valve water flow rate adjustment instructions ADJUSTING WATER TO SYRUP RATIO OF DISPENSED PRODUCT Adjust dispensing station dispensing valves for Water to S yrup Ratio of dispensed product as instructed in dispensing station Installation Instructions INSTALLING LINE IDENTIFICATION LABEL Install LABEL LINE IDENTIFICATION item 3 on Cooling Unit
63. thon route from the Cooling Unit to the Dispensing Station location 2 Allow the shortest possible refrigeration lines not to exceed 50 ft in length route from Remote Condenser Coil and Fan Assembly to the Cooling Unit 3 REFER TO THE COOLING UNIT NAMEPLATE FOR THE REQUIRED POWER CIRCUIT OPERATING VOLTAGE HZ AND THE MINIMUM CIRCUIT AMPACITY OF THE COOLING UNIT The power circuit for the Cooling Unit must be wired through a 40 amp minimum rated disconnect switch not provided and the power circuit must be 5 300381000 fused as indicated on the Unit nameplate The power circuit may also be wired through an eguivalent HACR type circuit breaker rather then the disconnect switch THE POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES 4 Close to a plain water source supply line with proper requirements 5 Allow sufficient space around Cooling Unit see Figure 4 for proper air circulation 18 inches on sides and back front side open to room and top open to ceiling 6 Be close to permanent floor drain to route Cooling Unit water tank drain and overflow hoses to the floor drain REMOTE CONDENSER COIL AND FAN ASS Y IF APPLICABLE 1 An extreme warm climate installation may require extra caution in Remote Rooftop Condenser Coil and Fan Assembly location Avoid hot sunny locations and seek shaded area if possible The use of structure to shade unit from direct sun exposure and
64. ting screw to the right clockwise until regulator gage registers nominal 90 psi then tighten adjusting screw locknut CO PRESSURE TO CARBONATORS MUST NOT EXCEED 125 PSIG Sugar Syrup Soft Drink Tanks Regulator Adjust sugar syrup soft drink tanks secondary CO regulator at 40 psig for syrup lines up to10 feet in length plus one pound for each additional length of 10 feet plus one pound for each 2 feet of vertical lift For example if syrup line total length is 30 feet and total vertical lift is 6 feet then 40 psig 2 psig 1 pound for every10 feet of length over10 feet which is 20 feet 3 psig 1 pound for every 2 feet of vertical lift which is 6 feet total equals 40 2 3 45 psig regulator setting Low Calorie diet Syrup Soft Drink Tank Regulator Adjust low calorie diet soft drink tank secondary regulator for low calorie drink at 10 psig for syrup lines up to 30 feet in length Syrup lines longer than 30 feet in length may require a slightly higher regulator setting to 12 psig maximum Excessive pressure may cause low calorie syrup carbonation resulting in foam 21 300381000 WATER FLOW RATE Refer to Installation Instructions provided with dispensing station for dispensing valve water flow rate adjustment instructions WATER TO SYRUP RATIO OF dISPENSED PRODUCT Adjust dispensing station dispensing valves for Water to S yrup Ratio of dispensed product as instructed in dispensing stati
65. will operate COOLING UNIT CIRCULATING MOTOR SWITCH see Figure 5 or 6 CIRCULATING MOTOR power switch located on front of Cooling Unit placed in OFF down position will interrupt electrical power to carbonated water circulating pump S witch must be placed in ON up position before circulating pump will operate REFRIGERATION SYSTEM TEMPERATURE SENSING DEVICE AND HIGH PRESSURE CUTOUT SWITCH Cooling Unit with Internal Condenser Coil and Fan Assembly see Figure 5 The Cooling Unit is equipped with a refrigeration system temperature sensor which will automatically initiate shutdown if the temperature of the liquid return line from the condenser exceeds 155xF Temperature rise may be caused by a clogged condenser coil air intake filter or refrigeration components problem After cool down the refrigeration system will restart as required immediate attention is required to avoid compressor failure CAUTION If the refrigeration system continues to short cycle following restart 15 300381000 Cooling Unit Connected to Remote Condenser Coil and Fan Assembly see Figure 6 This Cooling Unit is equipped with a refrigeration system temperature sensing device and a high pressure sensing cutout switch that will shut refrigeration system down should the system overheat due to a clogged condenser coil in the Remote Condenser Coil and Fan Assembly If refrigeration system does not automatically restart itself after syste
66. with clean water then wring excess water out of the sponge and wipe off all external surfaces on the Unit Wipe Unit dry with a clean soft cloth DO NOT USE ABRASIVE CLEANERS 5 Remove nozzle and syrup diffusers from the dispensing valves Place nozzles and syrup diffusers in sanitizing solution 6 Wash the nozzles and syrup diffusers in sanitizing solution then rinse them with potable water 7 Re install nozzles and syrup diffusers back on the dispensing valves 300381000 28 SANITIZING POST MIX SYRUP SYSTEMS IMPORTANT Only gualified Service Personnel should perform sanitizing procedure on the post mix syrup systems The post mix syrup systems should be sanitized every 90 days using a non scented household liguid bleach containing a 5 25 96 sodium hypochlorite concentration P roceed as follows to sanitize the post mix syrup Systems 1 2 Disconnect syrup supplies from syrup systems Rinse guick disconnects syrup tanks systems or bag in box connectors syrup bag in box systems in warm potable water STEP 1 WASH SYRUP SYSTEMS 3 7 Using a clean syrup tank syrup tank system or a five gallon container bag in box system prepare a full tank or container of liquid dishwasher detergent by using 70 F 21 C to 100 F 38 C potable water and 0 5 oz 15 ml of liquid dishwasher detergent to one gallon of potable water Stir detergent solution to thoroughly mix the solution Syrup Tank Systems A Observe and

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