Cornelius Refrigerator 000 PLUS User Manual

AURORAR10,000 PLUS

COOLING UNIT

Ins tallation Manual

Part No. 300614000

November 8, 1989

Revised: April 12, 1993

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION

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

PRINTED IN U.S.A

ÓIMI CORNELIUS INC; 1989-93

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TABLE OF CONTENTS (cont’d)

Page

ADJUSTING CO2 REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING DISPENSING VALVES WATER FLOW RATE . . . . . . . . . . . . .

ADJUSTING WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED PRODUCT .

ADJUSTING SIZE OF DRINK DISPENSED . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING SYRUP SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING SYRUP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT AIR INTAKE AND EXHAUST FILTERS . . . . . . . . . . . . . . . .

CHECKING ICE WATER BATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT CARBONATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . .

DOUBLE LIQUID CHECK VALVE ASSEMBLIES YEARLY MAINTENANCE

(OR AFTER WATER SYSTEM DISRUPTIONS). . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT CARBONATED WATER CIRCULATING PUMP MOTOR

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE CONDENSER COIL AND FAN ASS’Y MAINTENANCE . . . . . . . . . . . .

CLEANING CO2 GAS CHECK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING COOLING UNIT AIR INTAKE AND EXHAUST FILTERS. . . . . .

PREPARING COOLING UNIT FOR SHIPPING, STORING, OR RELOCATING

PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE CONDENSER COIL AND FAN ASSEMBLY MAINTENANCE . . . . . . .

CHECKING ICE WATER BATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING ICE WATER BATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DOUBLE LIQUID CHECK VALVE ASSEMBLIES YEARLY MAINTENANCE

(OR AFTER WATER SYSTEM DISRUPTIONS) . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMARY CO2 REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY CO2 REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER FLOW RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED PRODUCT . . . . . . . . . . . . .

CLEANING AND SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING OF UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING POST-MIX SYRUP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING SYRUP SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP FLAVOR CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CO2 SYSTEM GAS CHECK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY CO2 REGULATORS AND CO2 MANIFOLD CO2 GAS

CHECK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS (cont’d)

Page

COOLING UNIT CO2 INLET LINE CO2 GAS CHECK VALVE . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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”. . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT PRODUCES FOAM AS IT LEAVES DISPENSING

VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ONLY CARBONATED WATER DISPENSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ONLY SYRUP DISPENSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARM PRODUCT BEING DISPENSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP MOTOR WILL NOT OPERATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP MOTOR WILL NOT SHUT OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ERRATIC CYCLING OF CARBONATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP

WATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP CAPACITY TOO LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR DOES NOT OPERATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM

SUFFICIENT ICE BANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSER FAN MOTOR NOT OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . .

AGITATOR MOTOR NOT OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF FIGURES

FIGURE 1. AURORAR10,000 PLUS COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION) . . . . . . . . . . . . . . . . . . .

FIGURE 3. 240/24VAC POWER TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 4. COOLING UNIT SPACE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 5. PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. LIQUID CHECK VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 7. CO2 GAS CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 8. REFRIGERATION FLOW DIAGRAM (REQUIRES CONNECTION TO

REMOTE CONDENSER COIL AND FAN ASS’Y) . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 9. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF TABLES

TABLE 1. DESIGN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 2. LOOSE-SHIPPED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

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GENERAL INFORMATION

IMPORTANT: To the us er of this manual - This manual is a guide for ins talling, operating, and

maintaining this equipment. Refer to Table of Contents for page location of detailed information

pertaining to ques tions that aris e during ins tallation, operation, s ervice and maintenance, or

troubles hooting this equipment.

GENERAL DESCRIPTION

This section gives the description, theory of operation, and design data for the AuroraR10,000 Plus Cooling

Unit, hereafter referred too as a Cooling Unit.

COOLING UNIT DESCRIPTION

The Cooling Unit is designed to provide cooled syrup, carbonated water, and plain water to the dispensing

station through an insulated python (length as ordered). The Cooling Unit refrigeration system is cooled by a

Remote Condenser Coil and Fan Assembly which is connected to the Cooling Unit.

The Cooling Unit consists of a refrigeration system with a two horsepower compressor and a Hydro BoostR

(plain water pre-cooler) which pre-cools plain water on its way to the carbonated water tank. The Cooling Unit

also consists of a plain water pump. The plain water pump pumps plain water through the Hydro BoostR ,

through the plain water cooling coils, and into the carbonated water tank. The carbonated water circulating

pump circulates cold carbonated water from the Cooling Unit to the dispensing station and back to the Cooling

Unit.

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. Also available

is an Aurora Service System Analyzer (P/N 30919700) that may be used to analyze and troubleshoot the

Cooling Unit refrigeration system.

CAUTION: Before s hipping or relocating the Cooling Unit s yrup cooling coils mus t be

s anitized and all s anitizing s olution mus t be purged from the coils . All water mus t als o be

purged from the plain and carbonated water s ys tems . A freezing ambient environment will

caus e res idual s anitizing s olution or water remaining ins ide the Cooling Unit to freeze res ulting in

damage to internal components .

FIGURE 1. AURORAR10,000 PLUS COOLING UNIT

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Table 1. Des ign Data

COOLING UNIT DATA

Model No.

416654

Overall Dimensions:

Height

25-inches

36-1/2 inches

24-1/2 inches

Width

Depth

NOTE: Overall dimens ions if Cooling Unit is placed on optional Cooling Unit Stand (P/N 309309069).

Height (approximate)

Width

Depth

72-5/16 inches

37-1/2 inches

25-3/8 inches

Weights:

Shipping

Dry Weight

Ice Bank Weight

385 pounds

pounds

40 ± pounds

Capacities:

Water Bath (no ice bank)

18 gallons

2 HP

Compressor Horsepower

Refrigeration System:

Refrigerant Type and Charge

See Cooling Unit Nameplate

Ambient Operating Temp.

50° F to 100° F

Electrical Requirements:

Operating Voltage

See Cooling

Unit

Nameplate

Current Draw

REMOTE CONDENSER COIL AND FAN ASS’Y DATA (P/N 309602000)

Overall Dimensions:

Height

27 inches

22-inches

38-inches

Width

Depth

Weight:

Shipping

85 pounds

Ambient Operating Temp.

Electrical Requirements:

Operating Voltage

-22° F to 158° F

208/230VAC, Single Phase,

60Hz

Current Draw

2.5 Amps

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SYSTEM THEORY OF OPERATION

(see Figure 2)

A CO₂cylinder delivers carbon dioxide gas (CO₂) to primary CO₂regulator assembly which deliver regulated

CO₂gas to adjustable secondary CO₂regulators. Secondary CO₂regulators delivers regulated CO₂gas to the

carbonated water tank inside the Cooling Unit and also to the soft drink tanks. Plain water enters the Cooling

Unit and is pumped through and is pre-cooled by the refrigerated Hydro Boostâ coil. Cooled water continues

through the plain water cooling coils and into the carbonated water tank. Cold plain water entering the

carbonated water tank is carbonated by regulated CO₂gas pressure also entering the tank. Carbonated water

leaves the carbonated water tank and enters the inlet side of the carbonated water circulating pump.

Carbonated water passes through the carbonated water circulating pump, through the carbonated water cooling

coil, and exits the Cooling Unit through an insulated python to a turnaround inside the dispensing station.

Carbonated water returns to the Cooling Unit by passing through the insulated python, through the Cooling Unit

carbonated water cooling coils, through the carbonated water tank which makes up the carbonated water

circulating system. As carbonated water is being dispensed from the dispensing station, carbonated water

circulating system is continuously being replenished from the carbonated water tank.

Plain water enters through the Cooling Unit two plain water inlet lines, through the plain water cooling coils, and

exists the Cooling Unit out through insulated python to the dispensing station. Regulated CO₂gas pressure

exerted upon the soft drinks contents forces syrup from tanks, through Cooling Unit syrup inlet lines, through

syrup cooling coils, and exists the Cooling Unit out through an insulated python to the dispensing station.

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.

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INSTALLATION

This section covers unpacking and inspection, selecting location, installing the Cooling Unit and the Remote

Condenser Coil and Fan Assembly preparing for operation, and operation.

UNPACKING AND INSPECTION

NOTE: The Cooling Unit and the Remote Condens er Coil and Fan As s embly were thoroughly ins pected

before leaving the factory and the carrier has accepted and s igned for them. Any damage or

irregularities s hould be noted at time of delivery (or not later than 15 days from date of delivery) and

immediately reported to the delivering carrier. Reques t a written ins pection report from Claims

Ins pector to s ubs tantiate any neces s ary 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. Loos e-Shipped Parts

Name

Item

No.

Part No.

309852000

770407

Qty.

Tubing Clamp

Barbed Connector, 1/4 by 3/8

Barbed Connector, 1/2 by 1/2

Label, Line Identification

770424

311962000

NOTE: The following Remote Condens er Coil and Fan As s embly and Refrigeration Line Kits are rec-

ommended for us e with Cooling Unit (P/N 416654000). Refrigeration Lines Kit (as ordered) is us ed to

connect Condens er Coil and Fan As s embly to the Cooling Unit.

309602000

300598025

300598050

Remote Condenser Coil and Fan Ass’y

Refrigeration Line Kit, 25-ft. long, 90

Refrigeration Line Kit, 50-ft. long, 90

IDENTIFICATION OF LOOSE-SHIPPED PARTS

1. BARBED CONNECTORS (item 2) used to connect Cooling Unit outlet lines to insulated python lines.

Connections are secured with TUBING CLAMPS (item 1).

2. BARBED CONNECTORS (item 3) are used to connect Cooling Unit outlet carbonated water lines to

insulated python lines.

3. LABEL, LINE IDENTIFICATION (item 4) to be installed on Cooling Unit and syrup flavors to be recorded in

proper spaces on label.

4. REFRIGERATION LINE KIT (items 6) is used to connect REMOTE CONDENSER COIL AND FAN ASS’Y

(item 5) to Cooling Unit.

SELECTING LOCATION

COOLING UNIT

Select location for Cooling Unit installation that will (1) Allow the shortest possible insulated python 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

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fused as indicated on the Unit nameplate. The power circuit may also be wired through an equivalent 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) Sufficient space around

Cooling Unit (see Figure4) 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

CAUTION: Remote Condens er Coil and Fan As s emblies authorized by IMI Cornelius Inc.

(P/N 309602000)

1. An extreme warm climate installation may require extra caution in Remote Condenser Coil and Fan

Assembly location. Avoid hot sunny locations and seek shaded area if possible. The use of a structure to

shade the Unit from direct sun exposure and/or a platform extending Unit an additional 18-inches above

the 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 with

adequate fastening devices.

INSTALLING REMOTE CONDENSER COIL AND FAN ASS’Y

(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 a level position and must be

anchored with adequate fastening devices.

2. Route refrigeration lines of REFRIGERATION LINE KIT (item 6) from Remote Condenser Coil and Fan

Assembly down to Cooling Unit location.

3. Connect ends of refrigeration lines to Condenser Coil and Fan Assembly refrigeration connectors.

INSTALLING COOLING UNIT

NOTE: Cooling Unit outlet lines , plain water, CO₂, and s yrup inlet lines , Remote Condens er Coil and

Fan As s embly refrigeration lines and power circuit cable, and Cooling Unit power circuit cable each

mus t be long enough when connected to Cooling Unit to allow pulling Unit out approximately

36-inches from operating pos ition for s ervice and maintenance. When Cooling Unit is in operating

pos ition, exces s power circuit cable, Remote Condens er Coil and Fan As s embly refrigeration lines and

power circuit cable and plain water s ource and CO₂inlet lines may be coiled up behind Unit.

PLACING COOLING UNIT IN LOCATION

NOTE: An optional Cooling Unit Stand (P/N 309309069) is available to elevate Cooling Unit up and off

the floor.

1. Place Cooling Unit in position approximately 36-inches out from operating position to allow access all

around the Unit.

2. Remove two screws securing Cooling Unit top cover, then remove cover.

CONNECTING REMOTE CONDENSER COIL AND FAN ASS’Y REFRIGERATION LINES

TO COOLING UNIT

(see Figure 5)

Connect refrigeration lines, from Remote Condenser Coil and Fan Assembly, to refrigeration connectors on front

of Cooling Unit.

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CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING Unit

(see Figures 5 and 9)

IMPORTANT: Before 208/230VAC s ingle-phas e 60Hz electrical power circuit is connected to the cooling

unit, s ervice power voltage entering the building mus t be identified. Service power voltage entering the

building will either be 208 or 230VAC and may be pos ted on the main s ervice box. If not, the ins taller

mus t contact the local electrical power company for information. If thes e two voltage identification

attempts s hould fail, a voltage reading Mus t be performed. If s ervice power voltage is below 218VAC,

the red electrical wire connected to the 240VAC terminal on LINE (primary) s ide of the 240/24VAC power

trans former ins ide the cooling unit s witches electrical control box (s ee Figure 3 and 9) mus t be

dis connected from the 240VAC terminal and be connected to the 208VAC terminal. If voltage is above

218VAC, power trans former red electrical wire will remain connected to the 240VAC terminal. If ins taller

is not s ure of the s ervice power voltage entering the building, leave red electrical wire connected to the

240VAC terminal on the power trans former. If s ervice power voltage is below 218VAC, proceed as

follows :

1. Remove four s crews s ecuring electrical control box cover, then remove cover for acces s to the

240/24VAC power trans former.

2. Remove red electrical wire from the 240VAC terminal on LINE (primary) s ide of power trans former

and connect it to the 208VAC terminal.

208V

240V

RESET BUTTON

FIGURE 3. 240/24VAC POWER TRANSFORMER

WARNING: Make s ure 40-amp minimum-rated dis connect s witch (not provided) is in ‘‘OFF’’

pos ition.

1. Remove cover from electrical handy box on back of Cooling Unit.

WARNING: The Cooling Unit mus t be electrically grounded to avoid pos s ible fatal electrical

s hock or s erious injury to the operator. A green ground wire is provided ins ide electrical

box to connect power circuit ground wire which electrically grounds the Cooling Unit.

Connect 208/230VAC Single-Phase 60Hz power circuit from 40-amp minimum rated disconnect switch (not

provided) fused at 40-amps (‘‘slow-blow’’) to electrical wires inside electrical handy box on back of Cooling Unit.

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.

DO NOT CONNECT ELECTRICAL POWER TO COOLING UNIT AT THIS TIME.

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CONNECTING ELECTRICAL POWER CIRCUIT TO REMOTE CONDENSER COIL AND

FAN ASS’Y

(see Figure 5 and 9)

CAUTION: The Cooling Unit refrigeration s ys tem is cooled by a Remote Condens er Coil

and Fan As s embly (P/N 309602000) that is authorized by IMI Cornelius Inc. Us e of an

unauthorized Remote Condens er Coil and Fan As s embly will automatically void the

Cooling Unit factory warranty.

NOTE: Electrical power circuit may be connected to the Remote Condens er Coil and Fan As s embly

(P/N 309602000) in two ways . The preferred way is to draw electrical power from the cooling unit

contactor which allows the Remote Condens er Coil and Fan As s embly to operate only when the

cooling unit refrigeration s ys tem is operating. The optional way is to connect a s eparate electrical

power circuit (independent of the cooling unit) through an appropriately rated and fus ed dis connect

s witch or an equivalent HACR circuit breaker which allows the Remote Condens er Coil and Fan

As s embly to operate at all times (independent of cooling unit operation).

1. 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.

2. Route Remote Condenser Coil and Fan Assembly Power cable electrical wires through electrical handy

box on back of Cooling Unit to inside of electrical control box.

3. Connect Remote Condenser Coil and Fan Assembly power cable electrical wires to T₁and T₂terminals on

contactor inside Cooling Unit electrical control box.

4. Install electrical control box cover and secure with four screws.

5. 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 s hutoff valve be ins talled in plain water inlet s upply

line connected to Cooling Unit and that water s upply 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.

CAUTION: Plain water inlet s upply line to Cooling Unit mus t be 1/2-inch I.D. minimum.

Check water flow rate of water inlet s upply line. MINIMUM FLOW RATE MUST BE AT LEAST

300-GALLONS PER HOUR. If flow rate is les s than 300-gallons per hour, ‘‘s tarving’’ of

carbonator water pump will occur. Starving will allow water pump to overheat caus ing s afety

thermos tat on pump outlet to dis rupt electrical power to and s top water pump motor. Carbonated

water circulating pump overheating could occur if water inlet s upply line flow rate drops below

300-gallons per hour. INCOMING PLAIN WATER INLET SUPPLY LINE WATER PRESSURE MUST

REMAIN A MINIMUM OF 10-PSI BELOW THE CARBONATOR CO₂OPERATING PRESSURE.

(Example: Operating pres s ure is 90-ps i and maximum water pres s ure can be no more than 80-ps i,

etc.)

1. 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.

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2. Connect flexible plain water inlet supply line (1/2-inch I.D. 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: CO₂dis places oxygen. Strict attention mus t be obs erved in the prevention of

CO₂(carbon dioxide) gas leaks in the entire CO₂and s oft drink s ys tem. If a CO₂gas leak is

s us pected, particularly in a s mall area, immediately ventilate the contaminated area before

attempting to repair the leak. Pers onnel expos ed to high concentration of CO₂gas will experience

tremors which are followed rapidly by los s of cons cious nes s and s uffocation.

Connect flexible CO₂inlet supply line to Cooling Unit 1/4-in. flare (7/16-20) bulkhead fitting of back of Unit

labeled “CO₂INLET’’. DO NOT TURN ON CO₂SUPPLY TO COOLING UNIT AT THIS TIME.

CONNECTING SYRUP SOURCE LINES TO COOLING UNIT SYRUP INLET LINES

(see Figure 2)

Connect syrup source lines, from No. 1 through No. 10 soft drink tanks location, to Cooling Unit syrup inlet lines

labeled No. 1 through No. 10. DO NOT CONNECT SOFT DRINK TANKS INTO SYRUP SYSTEMS AT THIS

TIME.

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. 10, to insulated python lines labeled No. 1

though No. 10 using BARBED CONNECTORS (item 2). Secure connections with TUBING CLAMPS (item 1).

CONNECTING COOLING UNIT PLAIN WATER OUTLET LINES TO INSULATED PYTHON

PLAIN WATER LINES

(see Figure 2)

Connect Cooling Unit plain water outlet lines to insulated python plain water lines using BARBED

CONNECTORS (item 2). Secure connections with TUBING CLAMPS (item 1).

CONNECTING COOLING UNIT CARBONATED WATER OUTLET LINES TO INSULATED

PYTHON CARBONATED WATER LINES

(see Figure 2)

NOTE: The Cooling Unit carbonated water outlet lines are us ed to make up the carbonated water

circulating s ys tem between the Cooling Unit and the dis pens ing s tation as explained in SYSTEM

THEORY OF OPERATION in GENERAL INFORMATION SECTION.

Connect Cooling Unit carbonated water outlet lines to insulated python carbonated water lines using BARBED

CONNECTORS (item 3).

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18 -IN.

COOLING UNIT

18 -IN.

AIR FLOW

(OPEN TO ROOM)

FIGURE 4. COOLING UNIT SPACE REQUIRED

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 COOLING UNIT INLET

LINES, AND (IF APPLICABLE) REMOTE CONDENSER AND FAN ASSEMBLY REFRIGERATION LINES.

NOTE: To comply with National Sanitation Foundation (NSF) requirements , Cooling Unit not ins talled

on optional Cooling Unit Stand (P/N 309309-069) mus t have its bas e s ealed to floor with Dow-Corning

RTV 731 or equivalent.

2. Tilt Cooling Unit up to expose bottom of Unit base.

3. Liberally apply silastic sealant such as Dow-Corning (RTV 731) or equivalent on Unit base bottom edges.

NOTE: Do not move Cooling Unit after pos itioning or s eal from Unit bas e to floor will be broken.

4. 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.

5. Route Cooling Unit water tank overflow hose to permanent floor drain.

6. Seal area around drain and overflow hoses where they exit from Unit using Dow Corning (RTV 731) or

equivalent).

PREPARING COOLING UNIT FOR OPERATION

1. Make sure plug in end of Cooling Unit water tank drain hose is secure.

Note: Some Cooling Units are equipped with a water tank water level float control. Open s hutoff valve

in plain water inlet s upply line. Due to s low water fill rate of the water level float control, water tank may

be hand filled until water runs out of the water tank overflow hos e. CLEAN LOW-MINERAL-CONTENT

WATER MUST BE USED WHERE A LOCAL WATER PROBLEM EXIST.

2. 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.

3. Open shutoff valve in plain water inlet supply line.

4. Adjust primary CO₂regulator (see Figure 2) on CO₂cylinder to a minimum nominal setting of 120-psi or

24-psi higher than highest setting required by the secondary CO₂regulators. Loosen CO₂regulator

adjusting screw locknut. Turn adjusting screw to the right (clockwise) until regulator gage registers nominal

120-psi, then tighten adjusting screw locknut.

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5. Adjust carbonator secondary CO₂regulator (see Figure 2) to a nominal 90-psi. Loosen CO₂regulator

adjusting screw locknut. Turn adjusting screw to the right (clockwise) until regulator gage registers nominal

90-psi, then tighten adjusting screw lock nut. CO₂PRESSURE TO CARBONATORS MUST NOT EXCEED

120-PSIG.

OPERATION

WARNING: Dis connect electrical power to Cooling Unit and Remote Condens er Coil and

Fan As s embly to prevent pers onal injury before attempting any Cooling Unit or Remote

Condens er Coil and Fan As s embly internal maintenance. Only qualified pers onnel s hould

s ervice internal components or electrical wiring.

CAUTION: to prevent Hydro-Boos tâ coil freeze up during initial Cooling Unit s tart-up, the

following s tart-up procedure mus t be performed as follows :

1. Make sure Hydro Boostâ bypass shutoff valve inside Cooling Unit (see Figure 2) is in ‘‘CLOSED’’ (handle

not in line with tubing) position.

2. Make sure Cooling Unit REFRIGERATION POWER, CARBONATOR MOTOR, and CIRCULATING

MOTOR Power switches are in ‘‘OFF’’ positions.

3. Connect electrical power to Cooling Unit at disconnect switch. Connect electrical power to Remote

Condenser Coil and Fan Assembly at disconnect switch.

4. Place CARBONATOR MOTOR power switch in ‘‘ON’’ position.

5. Place REFRIGERATION power switch in ‘‘ON’’ position. Agitator motor and carbonator pump motor only

will start and fill Hydro-BoostR coil with plain water. APPROXIMATELY 2-1/2 MINUTES AFTER

CARBONATOR PUMP MOTOR HAS STARTED, REFRIGERATION COMPRESSOR, AND

COMPRESSOR COOLING FAN, WILL START.

NOTE: As ice bank forms in water tank, water expans ion will take place and exces s water will es cape

through water tank overflow hos e to permanent floor drain.

Cooling Unit will begin forming an ice bank and refrigerated Hydro-Boostâ coil will also be chilling water. When

full ice bank has been formed, Cooling Unit compressor and compressor cooling fan will stop but agitator motor

will continue to operate circulating ice water bath in water tank.

6. Dispense from dispensing station until carbonated water appears at dispensing valve which indicates

Cooling Unit plain and carbonated water systems have been filled.

7. Place CIRCULATING MOTOR power switch in ‘‘ON’’ position. Circulating pump will start and begin

circulating carbonated water in carbonated water circulating system as explained in SYSTEM THEORY OF

OPERATION in GENERAL INFORMATION SECTION.

8. Dispense carbonated water from dispensing valve to make sure all air has been purged from system.

9. If Cooling Unit plain water outlet line has been connected to a dispensing station dispensing valve,

dispense from valve until all air has been purged from plain water system.

10. Adjust soft drink tanks secondary CO₂regulators (see Figure 2) as follows:Sugar

Syrup Soft Drink Tanks CO₂Regulator.

Adjust sugar syrup soft drink tanks secondary CO₂regulator 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 CO₂regulator setting.

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Low-Calorie (diet) Syrup Soft Drink Tank CO₂Regulator.

Adjust low-calorie (diet) soft drink tank

secondary CO₂regulator 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

CO₂regulator setting to 12-psig maximum. Excessive CO₂pressure may cause low-calorie syrup

carbonation resulting in foam.

IMPORTANT: Syrup s ys tems mus t be s anitized as ins tructed before s yrup is connected into s yrup

s ys tems .

11. Connect soft drink tanks into syrup systems.

12. Dispense from dispensing station dispensing valves until product is dispensed.

LEAK CHECK AND INSULATING COOLING UNIT OUTLET LINES

1. Check all CO₂, 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

ADJ USTING WATER FLOW RATE

Refer to Installation Instructions provided with Dispensing Station for dispensing valve water flow rate

adjustment instructions.

ADJ USTING WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED PRODUCT

Adjust Dispensing Station dispensing valves for Water-to-Syrup ‘‘Ratio’’ of dispensed product as instructed in

dispensing station Installation Instructions.

INSTALLING LINE IDENTIFICATION LABEL

Install LABEL, LINE IDENTIFICATION (item 4) on Cooling Unit and record syrup flavors in proper spaces.

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OPERATORS INSTRUCTIONS

This section covers operating controls, daily pre-operation check, adjustments, replenishing CO₂and syrup

supplies, cleaning and sanitizing, Cooling Unit maintenance, Remote Condenser Coil and Fan Assembly

maintenance, lubrication, and servicing CO₂gas check valves.

WARNING: Dis connect electrical power to Cooling Unit and Remote Condens er Coil and

Fan As s embly to prevent pers onal injury before attempting any internal maintenance. Only

qualified pers onnel s hould s ervice internal components or electrical wiring.

OPERATING CONTROLS

COOLING UNIT REFRIGERATION POWER SWITCH

(see Figure 5)

REFRIGERATION POWER switch, located on front of Cooling Unit, placed in ‘‘OFF’’ position will interrupt

electrical power to refrigeration compressor, agitator motor, compressor cooling fan, carbonated water

circulating pump, and the carbonator pump motor. REFRIGERATION POWER switch placed in ‘‘ON’’ position

will start the carbonator pump motor (if carbonated water is being called for), the carbonated water circulating

pump motor, and the agitator motor. Under certain conditions approximately 2-1/2 minutes after the

REFRIGERATION POWER SWITCH has been placed in ‘‘ON’’ position refrigeration compressor and

compressor cooling fan will start.

COOLING UNIT CARBONATOR MOTOR SWITCH

(see Figure 5)

CARBONATOR MOTOR power switch, located on front of Cooling Unit, placed in ‘‘OFF’’ position will interrupt

electrical power to carbonator pump motor. Switch must be placed in ‘‘ON’’ position before carbonator pump

motor will operate.

COOLING UNIT CIRCULATING MOTOR SWITCH

(see Figure 5)

CIRCULATING MOTOR power switch, located on front of Cooling Unit, placed in ‘‘OFF’’ position will interrupt

electrical power to carbonated water circulating pump. Switch must be placed in ‘‘ON’’ position before circulating

pump will operate.

REFRIGERATION SYSTEM TEMPERATURE SENSING DEVICE AND HIGH-PRESSURE

CUTOUT SWITCH

(see Figure 5)

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 system has cooled down, high-pressure sensing cutout switch (see Figure 5) 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.

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DAILY PRE-OPERATION CHECK

4. Make sure CO₂cylinder regulator assembly 1800-psi gage indicator is not in shaded (‘‘change CO₂

cylinder’’) portion of dial. If so, CO₂cylinder is almost empty and must be replaced.

5. Sufficient syrup supply in all soft drink tanks. If not, replenish syrup supply as instructed.

ADJ USTMENTS

ADJ USTING CO REGULATORS

CO₂regulators 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-Syrup ‘‘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.

REPLENISHING CO₂SUPPLY

WARNING: CO₂dis places oxygen. Strict attention mus t be obs erved in the prevention of

CO₂(carbon dioxide) gas leaks in the entire CO₂and s oft drink s ys tem. If a CO₂gas leak is

s us pected, particularly in a s mall area, immediately ventilate the contaminated area before

attempting to repair the leak. Pers onnel expos ed to high concentration of CO₂gas will experience

tremors which are followed rapidly by los s of cons cious nes s and s uffocation.

NOTE: When indicator on CO₂cylinder regulator as s embly 1800-ps i gage is in s haded (’’change CO₂

cylinder’’) portion of the dial, CO₂cylinder is almos t empty and s hould be changed. CO₂s upply s hould

be checked daily and if neces s ary, replenis hed as ins tructed.

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.

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SANITIZING SYRUP SYSTEMS

Syrup systems should be sanitized every 90 days as instructed following Sanitizer Manufacturer’s

recommendations.

COOLING UNIT MAINTENANCE

COOLING UNIT AIR INTAKE AND EXHAUST FILTERS

CAUTION: Air filters on the Cooling Unit mus t be removed and cleaned every 30 days as

ins tructed. Exces s ive accumulation of dus t, lint, and greas e on the air filters will res trict

airflow through the Unit which will caus e the refrigeration s ys tem to overheat.

The Cooling Unit cabinet is equipped with are intake and exhaust filters which allow air to circulate through the

cabinet to cool the compressor. Air filters must be cleaned every 30 days as instructed. Area around Cooling

Unit must be kept free of obstructions at all times for proper air circulation through the Unit.

CHECKING ICE WATER BATH

Note: Some Cooling Units are equipped with a water tank water level float control. A gurgle heard from

the Cooling Unit indicates water level in water tank is low. This indicates the water level float control is

not operating properly and mus t be replaced.

A gurgle heard from the Cooling Unit indicates water level in water tank is low and more water should be added

to the tank for maximum product cooling. Periodically check, and if necessary, add water to the water tank as

instructed.

COOLING UNIT CARBONATOR MAINTENANCE

Lubrication.

Carbonator water pump motor bearings must be oiled periodically as instructed.

DOUBLE LIQUID CHECK VALVE ASSEMBLIES YEARLY MAINTENANCE (OR AFTER

WATER SYSTEM DISRUPTIONS).

(see Figure 2)

The two double liquid check valve assemblies are located in plain water lines connected between the plain

water cooling coils and the carbonated water tank. The double liquid check valve assemblies must be inspected

and cleaned at least once a year under nor work, earthquake, etc.) Inspect and clean double liquid check valve

assemblies as instructed.

COOLING UNIT CARBONATED WATER CIRCULATING PUMP MOTOR LUBRICATION

Carbonated water circulating pump motor bearings must be oiled periodically as instructed.

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REMOTE CONDENSER COIL AND FAN ASS’Y MAINTENANCE

(see Figure 5)

CAUTION: Remote Condens er Coil and Fan As s embly connected to the Cooling Unit is

equipped with a condens er coil that mus t be cleaned every 30-days . Allowing condens er

coil to become clogged will caus e refrigeration s ys tem to overheat which will automatically

s hut refrigeration s ys tem down. After condens er coil has been cleaned, high-pres s ure cutout

s ens ing s witch (s ee Figure 5) will have to be pres s ed to res tart refrigeration s ys tem. 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 obstruction at all

times. Condenser coil must be cleaned as instructed to maintain proper cooling of coil.

CLEANING CO₂GAS CHECK VALVES

(see Figure 2)

The CO₂gas check valves must be inspected and serviced at least once a year under normal conditions and

after any CO₂system servicing or disruption as instructed.

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SERVICE AND MAINTENANCE

The Remote Rooftop 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. Clean

the condenser coil as follows:

1. Disconnect electrical power to Cooling Unit at disconnect switch, then disconnect electrical power from

Remote Condenser Coil and Fan Assembly 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 is 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, then connect electrical power to Remote

Condenser Coil and Fan Assembly at disconnect switch.

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 COOLING UNIT AIR INTAKE AND EXHAUST FILTERS.

(see Figure 5).

This section describes Service and Maintenance procedures to be performed on Cooling Unit and Remote

Condenser Coil and Fan Assembly.

WARNING: Dis connect electrical power to Cooling Unit and Remote Condens er Coil and

Fan As s embly to prevent pers onal injury before attempting any Cooling Unit or Remote

Condens er Coil and Fan As s embly internal maintenance. Only qualified pers onnel s hould

s ervice internal components or electrical wiring.

PREPARING COOLING UNIT FOR SHIPPING, STORING, OR RELOCATING

CAUTION: Before s hipping, s toring, or relocating this Unit, the s yrup s ys tems mus t be

s anitized and all s anitizing s olution mus t be purged from the s yrup s ys tems . All water mus t

als o be purged from the plain and carbonated water s ys tems . A freezing ambient

environment will caus e res idual water in the Unit to freeze res ulting in damage to internal

components .

PERIODIC INSPECTION

Check entire system for leaks or damaged components. Repair as necessary.

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REMOTE CONDENSER COIL AND FAN ASSEMBLY MAINTENANCE

CAUTION: Remote Condens er Coil and Fan As s embly connected to this Cooling Unit is

equipped with a condens er coil that mus t be cleaned every 30-days . Allowing condens er

coil to become clogged will caus e refrigeration s ys tem to overheat which will automatically

s hut refrigeration s ys tem down. After condens er coil has been cleaned, high-pres s ure s ens ing

cutout s witch (s ee Figure 5) mus t be pres s ed to res tart refrigeration s ys tem. OPERATING

COOLING UNIT IN THIS MANNER FOR PROLONGED PERIOD OF TIME COULD RESULT IN

COMPRESSOR FAILURE.

CAUTION: Air filters on the Cooling Unit mus t be removed and cleaned every 30 days as

ins tructed. Exces s ive accumulation of dus t, lint, and greas e on the air filters will res trict

airflow through the Unit which will caus e the refrigeration s ys tem to overheat.

The Cooling Unit cabinet is equipped with air intake and exhaust filters which allow air to circulate through the

cabinet to cool the compressor. The air filter must be cleaned every 30 days. Excessive accumulation of dust,

lint, and grease on filters will restrict air flow through the Unit. Air filter may be removed and washed out with

detergent solution or may be vacuumed. Area around Cooling Unit must be kept free of obstructions at all times

for proper air circulation throughout the Unit.

CHECKING ICE WATER BATH

(see Figure 5)

Note: Some Cooling Units are equipped with a water tank water level float control. A gurgle heard from

the Cooling Unit indicates water level in water tank is low. This indicates the water level float control is

not operating properly and mus t be replaced.

A gurgle heard from Cooling Unit indicates water level in water tank is low and more water should be added to

the tank for maximum product cooling. Ice water bath and ice bank should be checked for cleanliness and water

tank coils should be checked for excessive mineral deposit build-up as follows:

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 Figure 5)

1. Disconnect electrical power from Cooling Unit at disconnect switch.

2. Remove two screws securing Cooling Unit top cover, then remove cover.

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Note: If your Cooling Unit is equipped with a water tank water level float control, clos e s hutoff valve in

plain water inlet s upply line.

3. Make sure end of water tank drain hose is routed to floor drain, then remove plug from end of hose and

allow water to drain from tank.

CAUTION: Never us e an ice pick or other ins truments to remove ice from evaporator coils .

Such practice can res ult in punctured refrigeration circuit.

4. Allow ice bank to melt. Hot water may be used to speed melting.

5. Thoroughly rinse inside of water tank with clean water.

6. Install plug in end of water tank drain hose.

Note: If your Cooling Unit is equipped with a water tank water level float control, open s hutoff valve in

plain water inlet s upply line.

7. 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.

8. Install Cooling Unit top cover and secure with two screws.

9. Connect electrical power to Cooling Unit at disconnect switch.

DOUBLE LIQUID CHECK VALVE ASSEMBLIES YEARLY MAINTENANCE (OR AFTER

WATER SYSTEM DISRUPTIONS)

(see Figures 2 and 6)

WARNING: The two double liquid check valve as s emblies mus t be ins pected and s erviced

at leas t once a year under normal circums tances , and after any dis ruptions (plumbing

work, earthquake, etc.) to the water s upply s ys tem that might caus e turbulent (erratic) flow

of water through the s ys tem. Fouled liquid check valves could caus e CO₂gas to back flow from

the carbonated water tank into the water s ys tem and create a health hazard in the s ys tem.

The two double liquid check valve assemblies are located in plain water lines connected between the plain

water cooling coils and the carbonated water tank. Inspect and clean the double liquid check valve assemblies

as follows:

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 CO₂regulator, then turn regulator adjusting screw to the left

(counterclockwise) until regulator gage reads 0-psi.

4. Pull up on carbonator tank relief valve to release CO₂pressure from tank.

5. Remove two screws securing Cooling Unit top cover, then remove cover.

6. Remove double liquid check valve assembly from plain water line connected between plain water cooling

coil and carbonated water tank.

7. Remove one check valve from the other, then disassemble each check valve as shown in Figure 6.

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REMOTE CONDENSER

COIL AND FAN ASS’Y

FIGURE 5. PARTS IDENTIFICATION

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8. 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.

9. Reassemble check valves as shown in Figure 6. ALWAYS install new ball seat (QUAD RING) (P/N

312418-000.

NOTE: Make s ure when as s embling check valves together, check valve female end with white tapered

gas ket ins ide, is on inlet s ide of double liquid check valve as s embly.

10. Assemble check valves together. DO NOT OVERTIGHTEN.

11. Install double liquid check valve assembly in plain water line connected between plain water cooling coil

and carbonated water tank.

12. Repeat preceding steps 6 through 11 to service other double liquid check valve in other plain water line

connected between plain water cooling coil and carbonated water tank.

13. Turn carbonator CO₂regulator adjusting screw to the right (clockwise) until its gage indicates pressure

setting observed in step 3 preceding.

14. Open shutoff valve in plain water inlet supply line.

15. Restore electrical power to Cooling Unit at disconnect switch.

16. Dispense carbonated water at dispensing station and allow carbonator to cycle on and off. Check for water

leaks and repair if evident.

17. Disconnect electrical power from Cooling Unit at disconnect switch.

18. Install Unit top cover and secure with two screws.

19. Restore electrical power to Cooling Unit at disconnect switch.

LUBRICATION

The carbonator water pump and the carbonated water circulating pump motor bearings must be oiled

periodically, refer to oiling instructions on the motors. DO NOT OVER OIL.

ADJ USTMENTS

NOTE: To readjus t CO₂regulator to a lower s etting loos en adjus ting s crew lock nut, then turn s crew to

the left (counterclockwis e) until pres s ure gage reads 5-ps i lower than new s etting will be. Turn

adjus ting s crew to the right (clockwis e) until gage regis ters new s etting, then tighten lock nut.

PRIMARY CO REGULATOR

(see Figure 2).

Adjust primary CO₂regulator on CO₂cylinder to a minimum nominal setting of 120-psi or 24-psi higher than

highest setting required by the secondary CO₂regulators. Loosen CO₂regulator adjusting screw locknut. Turn

adjusting screw to the right (clockwise) until regulator gage registers nominal 120-psi, then tighten adjusting

screw locknut.

SECONDARY CO REGULATORS

(see Figure 2).

Carbonator Secondary CO₂Regulator.

Adjust carbonator secondary CO₂regulator to a nominal 90-psi. Loosen CO₂regulator adjusting screw locknut.

Turn adjusting screw to the right (clockwise) until regulator gage registers nominal 90-psi, then tighten adjusting

screw locknut. CO₂PRESSURE TO CARBONATORS MUST NOT EXCEED 125-PSIG.

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Sugar Syrup Soft Drink Tanks CO₂Regulators.

Adjust sugar syrup soft drink tanks secondary CO₂regulator 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 CO₂regulator settings.

ITEM

PART NO

NAME

317963000

312415000

*312418000

312419000

312196000

317965000

Housing

Flat Washer, Stainless Steel

Ball Seat (quad ring)

Ball

Spring

Retainer

FIGURE 6. LIQUID CHECK VALVE ASSEMBLY

Low-Calorie (diet) Syrup Soft Drink Tank CO₂Regulator.

Adjust low-calorie (diet) soft drink tank secondary CO₂regulator 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 CO₂regulator

setting to 12-psig maximum. Excessive CO₂pressure may cause low-calorie syrup carbonation resulting in

foam.

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-Syrup ‘‘Ratio’’ of dispensed product as instructed in

dispensing station Installation Instructions.

CLEANING AND SANITIZING

DAILY CLEANING OF UNIT

1. Remove cup rest from the drip tray.

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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 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.

SANITIZING POST-MIX SYRUP SYSTEMS

IMPORTANT: Only qualified Service Pers onnel s hould perform s anitizing procedure on the pos t-mix

s yrup s ys tems .

The post-mix syrup systems should be sanitized every 90-days using a non-scented household liquid bleach

containing a 5.25 % sodium hypochlorite concentration. Proceed as follows to sanitize the post-mix syrup

systems.

1. Disconnect syrup supplies from syrup systems.

2. Rinse quick disconnects (syrup tanks systems) or bag-in-box connectors (syrup bag-in-box systems) in

warm potable water.

STEP 1. WASH SYRUP SYSTEMS

3. 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.

4. Syrup Tank Systems.

A. Observe and note CO₂pressure setting on the syrup tanks CO₂regulator, then re-adjust CO₂

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.

5. 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.

6. Connect detergent solution to the remaining syrup systems and flush syrup out of the syrup systems as

instructed in step NO TAG preceding.

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7. Remove detergent solution source from the syrup system.

STEP 2. FLUSH SYRUP SYSTEMS

8. 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.

9. Flush detergent 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.

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.

10. 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.

11. Remove potable water source from the syrup system.

STEP 3. SANITIZE SYRUP SYSTEMS

12. 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.

13. 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.

14. Sanitize the syrup system and dispensing valve as follows:

A. Place waste container under applicable dispensing valve.

B. Activate the dispensing valve for one minute to purge all water from and install sanitizing solution in

the syrup system and dispensing valve.

C. Continue to activate the dispensing valve in cycles (“ON” for 15-seconds, “OFF”, then “ON” for

15-seconds). Repeat “ON” and “OFF” cycles for 15-cycles.

15. Repeat stepsNO TAG and NO TAG to flush water out of and install sanitizing solution in the remaining

syrup systems and dispensing valves.

16. Remove sanitizing solution source from the syrup system.

17. Allow sanitizing solution to remain in the syrup systems for not less than 10 or no more than 15-minutes

(max.) contact time.

STEP 4. WATER FLUSH SYRUP SYSTEMS

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WARNING: Flus h s anitizing s olution from the s yrup s ys tems as ins tructed. Res idual

s anitizing s olution left in the s yrup s ys tems could create a health hazard.

18. Fill syrup tank (syrup tank system) or a five-gallon container (bag-in-box system) with potable water.

19. 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.

20. Flush sanitizing solution from the syrup system and the dispensing valve as follows:

A. Place waste container under applicable dispensing valve.

B. Activate the dispensing valve for one minute to purge all sanitizing solution out of the syrup system

and the dispensing valve.

C. Continue to activate the dispensing valve in cycles (“ON” for 15-seconds, “OFF”, then “ON” for

15-seconds). Repeat “ON” and “OFF” cycles for 15-cycles.

21. Repeat steps 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 Systems.

A. Noting syrup tanks CO₂regulator pressure setting observed in step 4 preceding, readjust CO₂

regulator to the observed pressure setting,

B. Connect tanks 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.

WARNING: To avoid pos s ible pers onal injury or property damage, do not attempt to

remove the s yrup tank cover until CO₂pres s ure has been releas ed from the tank.

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 for sanitizing solution to remove all sanitizing solution

residue.

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REPLENISHING CO₂SUPPLY

WARNING: CO₂dis places oxygen. Strict attention mus t be obs erved in the prevention of

CO₂(carbon dioxide) gas leaks in the entire CO₂and s oft drink s ys tem. If a CO₂gas leak is

s us pected, particularly in a s mall area, immediately ventilate the contaminated area before

attempting to repair the leak. Pers onnel expos ed to high concentration of CO₂gas will experience

tremors which are followed rapidly by los s of cons cious nes s and s uffocation.

NOTE: When indicator on CO₂cylinder primary CO₂regulator as s embly 1800-ps i gage is in s haded

(‘‘change CO₂cylinder’’) portion of dial, CO₂cylinder is almos t empty and s hould be changed.

1. Fully close (clockwise) CO₂cylinder valve.

2. Slowly loosen primary CO₂regulator assembly coupling nut allowing CO₂pressure to escape, then remove

regulator assembly from empty CO₂cylinder.

3. Unfasten safety chain and remove empty CO₂cylinder.

FIGURE 7. CO₂GAS CHECK VALVE

WARNING: To avoid pers onal injury and/or property damage, always s ecure CO₂cylinder in

upright pos ition with s afety chain to prevent it from falling over. Should valve become

accidentally damaged or broken off, CO₂cylinder can caus e s erious pers onal injury.

4. Position CO₂cylinder and secure with safety chain.

5. Make sure gasket is in place inside primary CO₂regulator coupling nut, then install regulator on CO₂

cylinder.

6. Open (counterclockwise) CO₂cylinder 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 ins tructions are applicable only when replenis hing s ame flavor s yrup. Refer to

SYRUP FLAVOR CHANGE when changing s yrup 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.

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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.

CLEANING CO₂SYSTEM GAS CHECK VALVES

SECONDARY CO REGULATORS AND CO

MANIFOLD CO GAS CHECK VALVES

(see Figures 2 and 7)

The secondary CO₂regulators and CO₂manifold CO₂gas check valves must be inspected and serviced at

least once a year under normal conditions and after any servicing or disruption of the CO₂system. ALWAYS

REPLACE BALL SEAT (QUAD RING SEAL) EACH TIME GAS CHECK VALVES ARE SERVICED.

COOLING UNIT CO INLET LINE CO GAS CHECK VALVE

(see Figures 2 and 7)

CO₂inlet line CO₂gas check valve, located inside Cooling Unit, must be inspected and serviced at least once a

year under normal conditions and after any servicing or disruption of the CO₂system. ALWAYS INSTALL NEW

BALL SEAT (QUAD RING) SEAL EACH TIME GAS CHECK VALVE IS SERVICED.

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REFRIGERATION LINES CONNECTED

BETWEEN COOLING UNIT AND REMOTE

CONDENSER COIL AND FAN ASS’Y MUST

NOT EXCEED 50 -FEET IN LENGTH.

REMOTE CONDENSER

COIL AND FAN ASS’Y

REFRIGERATION LINES VERTICAL

RISE MUST NOT EXCEED 20 -FEET.

FIGURE 8. REFRIGERATION FLOW DIAGRAM (REQUIRES CONNECTION TO REMOTE CONDENSER

COIL AND FAN ASS’Y)

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TROUBLESHOOTING

IMPORTANT: Only qualified pers onnel s hould s ervice internal components or electrical wiring.

WARNING: If repairs are to be made to a product s ys tem, remove quick dis connects from

the applicable product tank, then relieve the s ys tem pres s ure before proceeding. If repairs

are to be made to the CO₂s ys tem, s top dis pens ing, s hut off the CO₂s upply, then relieve the

s ys tem pres s ure before proceeding. If repairs are to be made to the refrigeration s ys tem, make s ure

electrical power is dis connected from the unit.

TROUBLESHOOTING POSE-MIX SYSTEM

Trouble

Probable Cause

Remedy

WATER-TO-SYRUP ‘‘RATIO’’

OF DISPENSED DRINK TOO

LOW OR TOO HIGH.

A. Dispensing valve syrup flow

regulator not properly

adjusted.

A. Adjust Water-To-Syrup ‘’Ratio’’

(refer to dispensing station

installation Instructions).

B. CO₂gas pressure to soft drink B. Adjust soft drink tanks secondary

tanks insufficient to push

syrup out of tanks.

CO₂regulator as instructed.

ADJUSTMENT OF

A. No syrup supply.

A. Replenish syrup supply as

instructed.

DISPENSING VALVE SYRUP

FLOW REGULATOR DOES

NOT INCREASE TO DESIRED

WATER-TO-SYRUP ‘‘RATIO”.

B. Soft drink tank quick

disconnects not secure.

B. Secure quick disconnects.

C. Soft drink tanks secondary

CO₂regulator out of

adjustment.

C. Adjust soft drink tanks secondary

CO₂regulator as instructed.

D. Dispensing valve syrup flow

regulator, soft drink tank quick

disconnect, or syrup line

restricted.

D. Sanitize syrup system as

instructed.

E. Tapered nylon washer inside

tube swivel nut connector

distorted from being

E. Replace nylon washer. Make sure

washer seats properly in swivel

nut.

overtightened restricting syrup

flow.

F. Dirty or inoperative piston or

cylinder in dispensing valve

syrup flow regulator.

F. Disassemble and clean

dispensing valve syrup flow

regulator.

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Trouble

Probable Cause

Remedy

ADJUSTMENT OF

A. Dirty or inoperative piston or

cylinder in dispensing valve

syrup flow regulator.

A. Disassemble and clean

dispensing valve syrup flow

regulator.

DISPENSING VALVE SYRUP

FLOW REGULATOR DOES

NOT DECREASE TO

DESIRED WATER-TO- SYRUP

‘‘RATIO’’.

DISPENSED PRODUCT

CARBONATION TOO LOW.

A. Carbonator CO₂regulator out

of adjustment for existing

water conditions or

A. Adjust carbonator CO₂regulator

as instructed.

temperature.

B. Water, oil, or dirt in CO₂

supply.

B. Remove contaminated CO₂

supply. Clean CO₂system (lines,

regulators, etc.) using a mild

detergent. Replenish with a clean

CO₂supply.

DISPENSED PRODUCT

COMES OUT OF

A. Oil film or soap scum in cups.

A. Use clean cups.

DISPENSING VALVE CLEAR

BUT FOAMS IN CUP.

B. Ice used for finished drink is

sub-cooled.

B. Do not use ice directly from

freezer. Allow ice to become ‘‘wet’’

before using. (Refer to following

NOTE)

NOTE: Crus hed ice als o caus es dis pens ing problems . When finis hed drink hits s harp edges of ice,

carbonation is releas ed from finis hed drink.

DISPENSED PRODUCT

PRODUCES FOAM AS IT

LEAVES DISPENSING VALVE.

A. Carbonator CO₂regulator

pressure set too high for

existing water conditions or

temperature.

A. Reduce carbonator CO₂regulator

pressure setting as instructed.

B. Syrup over-carbonated with

CO₂.

B. Remove soft drink tank quick

disconnects. Relieve tank CO₂

pressure, shake tank vigorously,

then relieve tank CO₂pressure as

many times as necessary to

remove over-carbonation.

C. Tapered nylon washer inside

tube swivel nut connection

distorted from being

C. Replace nylon washer. Make sure

washer is properly seated in

swivel nut.

overtightened restricting syrup

flow.

ONLY CARBONATED WATER A. Quick disconnect not secure

DISPENSED. on soft drink tank.

A. Secure quick disconnect on soft

drink tank.

B. Out of syrup.

B. Replenish syrup supply as

instructed.

C. Inoperable Dispensing Station. C. Repair Dispensing Station.

D. Dispensing valve syrup flow

regulator not properly

adjusted.

D. Adjust dispensing valve syrup

flow regulator (refer to Installation

Instructions provided with

Dispensing Station).

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Trouble

Probable Cause

Remedy

ONLY CARBONATED WATER E. Dispensing valve syrup flow

E. Sanitize syrup system as

instructed.

DISPENSED (con’t).

regulator, soft drink tank quick

disconnect, or syrup lines

restricted.

ONLY SYRUP DISPENSED.

A. Plain water inlet supply line

shutoff valve closed.

A. Open plain water inlet supply line

shutoff valve.

B. CARBONATOR MOTOR

power switch in ‘‘OFF’’

position.

B. Place switch in ‘‘ON’’ position.

C. Water filter clogged.

C. Replace water filter.

WARM PRODUCT BEING

DISPENSED.

A. Carbonated water circulating

pump CIRCULATING MOTOR

power switch in ‘‘OFF’’

position.

A. Place circulating pump

CIRCULATING MOTOR power

switch in ‘‘ON’’ position.

Inoperable carbonated water

circulating pump or motor.

B. Replace pump or motor.

WATER PUMP MOTOR WILL

NOT OPERATE.

A. Inoperative water pump motor. A. Replace water pump motor.

B. Water safety thermostat

inoperative.

B. Replace safety thermostat.

C. Loose connections and/or

open electrical circuit.

C. Tighten connections and/or repair

open circuit.

D. Overheated motor cut off by

thermal overload protector.

D. Check for proper line voltage.

Check for restricted pump

discharge.

E. Water pump binding (new or

replacement pumps only.)

E. Remove water pump from motor,

rotate pump or motor shaft 180

degrees, then recouple pump to

motor.

F. Inoperative liquid level sensing F. Replace liquid level sensing

probe. probe.

G. Inoperative liquid level sensing G. Replace liquid level sensing PC

PC board.

board.

H. No 24 VAC to liquid level

sensing PC board.

H. Check electrical wiring and

transformer for 24 VAC output.

WATER PUMP MOTOR WILL

NOT SHUT OFF.

A. Inoperative liquid level sensing A. Replace liquid level sensing

probe. probe.

B. Inoperative liquid level sensing B. Replace liquid level sensing PC

PC board.

board.

C. Liquid level sensing probe

wired wrong.

C. Correct liquid sensing probe

wiring.

D. Leak in carbonated water

system.

D. Repair leak in carbonated water

system.

ERRATIC CYCLING OF

CARBONATOR.

A. Inoperative liquid level sensing A. Replace liquid level sensing

probe. probe.

B. Inoperative liquid level sensing B. Replace liquid level sensing PC

PC board. board.

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Trouble

Probable Cause

Remedy

ERRATIC CYCLING OF

CARBONATOR (con’t).

C. Liquid level sensing probe

wired wrong.

C. Correct liquid level sensing probe

wiring.

D. Dirty or oily liquid level sensing D. Clean liquid level sensing probe.

probe.

WATER PUMP MOTOR

OPERATES BUT WATER

PUMP DOES NOT PUMP

WATER.

A. Water inlet supply line shutoff

valve closed.

A. Open water inlet supply line

shutoff valve.

B. Kinked water inlet supply line.

B. Straighten water inlet supply line.

C. Remove restriction.

C. Restriction between water

pump outlet and carbonator

tank inlet.

D. Foreign object in water pump

bypass.

D. Clean bypass. (Note: Count

number of turns bypass screw

makes when removing and install

same number of turns).

E. Water pump worn out.

E. Replace water pump.

WATER PUMP CAPACITY

TOO LOW.

A. Water supply capacity too low. A. Water inlet supply must be at a

minimum of 300-gallons per hour

with a maximum water pressure

of 80-psi.

B. Water filter clogged.

B. Replace water filter cartridge as

instructed.

C. Inoperative water pump.

C. Replace water pump.

TROUBLESHOOTING REFRIGERATION SYSTEM

COMPRESSOR DOES NOT

OPERATE.

A. Ice bank sufficient.

A. Refrigeration not called for.

B. REFRIGERATION POWER

switch in ‘‘OFF’’ position.

B. Place REFRIGERATION POWER

switch in ‘‘ON’’ position.

C. Electrical power to Cooling

Unit turned off.

C. Turn on electrical power to

Cooling Unit.

D. No Cooling Unit power source. D. Replace fuse or reset circuit

Blown fuse or tripped circuit

breaker.

E. Loose, disconnected, or

broken wiring.

E. Tighten connections or replace

broken wiring.

F. Hi-pressure cutout switch

tripped.

F. Reset pressure switch (see

REFRIGERATION SYSTEM

TEMPERATURE SENSING

DEVICE AND HIGH-PRESSURE

CUTOUT SWITCH in

OPERATORS INSTRUCTIONS

SECTION.

G. Low Voltage.

G. Voltage must be at least 208 volts

at compressor terminals when

compressor is trying to start.

H. Inoperable run capacitor, start H. Replace inoperable part.

capacitor, or relay.

Inoperable compressor.

Replace compressor.

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Trouble

Probable Cause

Remedy

COMPRESSOR DOES NOT

OPERATE (con’t).

J. Inoperable control board

J. Replace control board.

K. Inoperable contactor

K. Replace contactor.

L. No voltage to control board.

Check for loose or broken wiring.

Check 240/24 VAC power

transformer for 24 VAC output.

(see NOTE below).

M. Inoperable control board or

water/ice sensor PC board.

M. Replace control board.

N. Inoperable ICE SENSOR.

N. Replace ICE SENSOR.

O. EVAP IN, COND OUT, or

EVAP OUT sensor is open,

shorted, or out of temperature

range.

O. Replace inoperable sensor.

P. Hydro Boostâ WATER

SENSOR is shorted or open

circuit.

P. Check for loose, broken, or

disconnected wire or plug at

pre-cool coil. Repair or replace

wire or secure plug. If Hydro

Boostâ WATER SENSOR is

inoperable, replace sensor.

NOTE: Confirm which s ens or has failed by us ing the Aurora Series Sys tem Analyzer (P/N 309197-000).

NOTE: The 240/24 VAC power trans former has an overload res et button located on its 24 VAC output

s ide (s ee Figure 3). An overload on the trans former will caus e its res et button to pop out dis rupting

the 24 VAC output to the main control board. Overload button mus t be pres s ed in to res tore 24 VAC

output.

COMPRESSOR OPERATES

CONTINUOUSLY BUT DOES

NOT FORM SUFFICIENT ICE

BANK

A. Cooling capacity is exceeded

by overdrawing.

A. Reduce amount of drinks drawn

per given time.

B. Air circulation through Remote B. Check and if necessary, clean

Condenser Coil and Fan

Assembly Condenser Coil is

restricted.

condenser coil as instructed.

C. Insufficient refrigerant charge.

C. Check Cooling Unit sight glass for

bubbles or liquid break. Find and

repair refrigeration leak, the

replenish refrigerant charge.

D. Inoperative or disconnected

pulse-modulating expansion

valve (see REFRIGERATION

FLOW DIAGRAM).

D. 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.

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Trouble

Probable Cause

Remedy

COMPRESSOR OPERATES

CONTINUOUSLY BUT DOES

NOT FORM SUFFICIENT ICE

BANK (con’t).

Inoperative control board. No

output from board to

solenoids.

E. 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.

CONDENSER FAN MOTOR

NOT OPERATING

A. Blown power circuit fuse.

B. Fan blade obstructed.

A. Replace power circuit fuse.

B. Remove obstruction.

C. Inoperative condenser fan

motor.

C. Replace condenser fan motor.

D. Compressor contactor

inoperable.

D. Replace compressor contactor.

A. Remove obstruction.

AGITATOR MOTOR NOT

OPERATING.

A. Agitator motor propeller

obstructed.

B. Low voltage.

B. Voltage must be at least 208 volts

at compressor terminals when

compressor is trying to start.

C. Loose, disconnected, or

broken wiring.

C. Tighten connections or replace

broken wiring.

D. Inoperative agitator motor.

D. Replace agitator motor.

300614000

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WARRANTY

IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship un-

der normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire prod-

uct, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the

equipment model number, serial number and the date of purchase.

IMI Cornelius Offices

AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166

AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930

BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552

FAX (32) 3 665 2307

BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829

ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644

FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201

GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438

GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491

HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222

ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814

NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361

SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604

SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379

USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (612) 421-6120 D FAX (612) 422-3255

LD004

4/21/98

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IMI CORNELIUS INC.

CORPORATE HEADQUARTERS:

One Cornelius Place

Anoka, Minnesota 55303-6234

(612) 421-6120

(800) 238-3600

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