Cornelius 000 PLUS Unit installation

AURORAR10,000 PLUS
COOLING UNIT
Installation/Service
Manual
(R-404A REFRIGERANT)
IMPORTANT:
TO THE INSTALLER.
It is the responsibility of the Installer to
ensure that the water supply to the
dispensing equipment is provided with
protection against backflow by an air gap
as defined in ANSI/ASME A112. 1.2-1979; or
an approved vacuum breaker or other such
method as proved effective by test.
Water pipe connections and fixtures
directly connected to a potable water
supply shall be sized, installed, and
maintained according to Federal, State,
and Local codes.
Part No. 312022000
January 24, 1996
Revised January 13, 1998
Control Code A--B
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
Ó IMI CORNELIUS INC; 1996 - 98
PRINTED IN U.S.A
TABLE OF CONTENTS
Page
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
RECOGNIZE SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDERSTAND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
FOLLOW SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO2 (CARBON DIOXIDE) WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIPPING, STORING, OR RELOCATING UNIT . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
REFRIGERATION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD (AIR-COOLED) COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . .
“WATER-COOLED”COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING UNIT REQUIRING CONNECTION TO A REMOTE CONDENSER
COIL AND FAN ASS’Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION OF LOOSE-SHIPPED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELECTING LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE ROOFTOP CONDENSER COIL AND FAN ASS’Y . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLACING COOLING UNIT IN LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLACING REMOTE CONDENSER COIL AND FAN ASS’Y (IF APPLICABLE)
IN LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING REMOTE CONDENSER COIL AND FAN ASS’Y (IF
APPLICABLE) REFRIGERATION LINES TO COOLING UNIT . . . . . . . . . . .
CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING UNIT . . . .
CONNECTING ELECTRICAL POWER CIRCUIT TO REMOTE
CONDENSER COIL AND FAN ASS’Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING CITY PLAIN WATER SOURCE LINE TO COOLING UNIT
CONNECTING CO2 INLET SUPPLY LINE TO COOLING UNIT . . . . . . . . .
CONNECTING SYRUP SOURCE LINES TO COOLING UNIT SYRUP
INLET LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING COOLING UNIT SYRUP OUTLET LINES TO INSULATED
PYTHON SYRUP LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING COOLING UNIT PLAIN WATER OUTLET LINES TO
INSULATED PYTHON PLAIN WATER LINES . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING COOLING UNIT CARBONATED WATER OUTLET LINES TO
INSULATED PYTHON CARBONATED WATER LINES . . . . . . . . . . . . . . . . .
PLACING COOLING UNIT IN OPERATING POSITION . . . . . . . . . . . . . . . . . . . . .
PREPARING COOLING UNIT FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAK CHECK AND INSULATING COOLING UNIT OUTLET LINES . . . . . . . . . .
i
5
5
5
6
6
9
9
9
9
9
10
10
10
11
11
11
12
12
13
13
13
14
14
14
15
17
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TABLE OF CONTENTS (cont’d)
Page
DISPENSING STATION ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING WATER FLOW RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
17
ADJUSTING WATER-TO-SYRUP ‘‘RATIO’’OF DISPENSED PRODUCT .
INSTALLING LINE IDENTIFICATION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATORS INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
17
19
OPERATING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING UNIT REFRIGERATION POWER SWITCH . . . . . . . . . . . . . . . . .
COOLING UNIT CARBONATOR MOTOR SWITCH . . . . . . . . . . . . . . . . . . . .
COOLING UNIT CIRCULATING MOTOR SWITCH . . . . . . . . . . . . . . . . . . . . .
REFRIGERATION SYSTEM TEMPERATURE SENSING DEVICE AND
HIGH-PRESSURE CUTOUT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY PRE-OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING CO2 REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING DISPENSING VALVES WATER FLOW RATE . . . . . . . . . . . . .
ADJUSTING WATER-TO-SYRUP ‘‘RATIO’’OF DISPENSED PRODUCT .
19
19
19
19
ADJUSTING SIZE OF DRINK DISPENSED . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLENISHING CO2 SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING AND SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZING SYRUP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING UNIT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING UNIT WITH INTERNAL CONDENSER COIL AND FAN ASS’Y .
20
20
20
20
20
21
21
CHECKING ICE WATER BATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING UNIT CARBONATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . .
COOLING UNIT CARBONATED WATER CIRCULATING PUMP MOTOR
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE CONDENSER COIL AND FAN ASS’Y MAINTENANCE . . . . . . . . . . . .
CLEANING CO2 GAS CHECK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
PREPARING COOLING UNIT FOR SHIPPING, STORING, OR RELOCATING
PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING UNIT EQUIPPED WITH INTERNAL CONDENSER COIL AND
FAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING UNIT UTILIZING A REMOTE CONDENSER COIL AND FAN
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
23
19
20
20
20
20
20
21
21
22
23
23
COOLING UNIT EQUIPPED WITH WATER-COOLED REFRIGERATION
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
COOLING UNIT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
CLEANING CONDENSER COIL (COOLING UNIT EQUIPPED WITH
INTERNAL CONDENSER COIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING ICE WATER BATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
CHANGING ICE WATER BATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
312022000
ii
TABLE OF CONTENTS (cont’d)
Page
DOUBLE LIQUID CHECK VALVE ASSEMBLIES YEARLY MAINTENANCE
(OR AFTER WATER SYSTEM DISRUPTIONS) . . . . . . . . . . . . . . . . . . . . . . .
27
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE CONDENSER COIL AND FAN ASSEMBLY MAINTENANCE . . . . . . .
PERIODIC CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIMARY CO2 REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECONDARY CO2 REGULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
28
29
29
29
29
WATER FLOW RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER-TO-SYRUP ‘‘RATIO’’OF DISPENSED PRODUCT . . . . . . . . . . . . .
ADJUSTING WATER-COOLED REFRIGERATION SYSTEM VARIABLE
WATER REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING AND SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY CLEANING OF UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
30
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
33
34
34
35
COOLING UNIT CO2 INLET LINE CO2 GAS CHECK VALVE . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
41
30
30
30
35
WATER-TO-SYRUP ‘‘RATIO’’OF DISPENSED DRINK TOO LOW OR TOO
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES NOT
INCREASE TO DESIRED WATER-TO-SYRUP ‘‘RATIO’-’ . . . . . . . . . . . . . . . . . . .
41
ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES
NOT DECREASE TO DESIRED WATER-TO- SYRUP ‘‘RATIO’’. . . . . . . . . . . . . .
41
DISPENSED PRODUCT CARBONATION TOO LOW. . . . . . . . . . . . . . . . . . . . . . .
41
DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT
FOAMS IN CUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
DISPENSED PRODUCT PRODUCES FOAM AS IT LEAVES DISPENSING
VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
ONLY CARBONATED WATER DISPENSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
ONLY SYRUP DISPENSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
WARM PRODUCT BEING DISPENSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP MOTOR WILL NOT OPERATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
43
WATER PUMP MOTOR WILL NOT SHUT OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ERRATIC CYCLING OF CARBONATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
43
WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP
WATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP CAPACITY TOO LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR DOES NOT OPERATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
44
44
iii
312022000
TABLE OF CONTENTS (cont’d)
Page
COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM
SUFFICIENT ICE BANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
CONDENSER FAN MOTOR NOT OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . .
AGITATOR MOTOR NOT OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
46
47
LIST OF FIGURES
FIGURE 1. AURORA 10,000 PLUS COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION FOR PRODUCT
CONNECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
7
FIGURE 3. COOLING UNIT SPACE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
FIGURE 4. PARTS IDENTIFICATION (COOLING UNIT W/INTERNAL
CONDENSER COIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
FIGURE 5. PARTS IDENTIFICATION (COOLING UNIT REQUIRING CONNECTION
TO REMOTE CONDENSER COIL AND FAN ASSEMBLY) . . . . . . . . . . . . . . . . . .
26
FIGURE 6. LIQUID CHECK VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
FIGURE 7. CO2 GAS CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 8. REFRIGERATION FLOW DIAGRAM (REQIURES CONNECTION TO
REMOTE CONDENSER COIL AND FAN ASS’Y) . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 9. REFRIGERATION FLOW DIAGRAM (UNIT WITH WATER-COOLED
OR AIR-COOLED REFRIGERATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 10. WIRING DIAGRAM (MODELS 4002 AND 4003) . . . . . . . . . . . . . . . .
FIGURE 11. WIRING DIAGRAM (MODELS 4004, 4005, 561400006 AND
561400007) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
36
37
38
39
LIST OF TABLES
TABLE 1. DESIGN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 2. LOOSE-SHIPPED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
312022000
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9
SAFETY INFORMATION
Recognize Safety Information
This is the safety-alert symbol. When you see this
symbol on our machine or in this manual, be alert to
the potentially of personal injury.
Follow recommended precautions and safe operating
practices.
Understand Signal Words
A signal word - DANGER, WARNING, OR CAUTION
is used with the safety-alert symbol. DANGER identifies the most serious hazards.
Safety signs with signal word DANGER or WARNING
are typically near specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety messages in this manual.
DANGER
WARNING
CAUTION
Follow Safety Instructions
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in
good condition. Replace missing or damaged safety signs. Learn how to operate the machine and how to
use the controls properly. Do not let anyone operate the machine without instructions. Keep your machine in
proper working condition. Unauthorized modifications to the machine may impair function and/or safety and
affect the machine life.
CO2 (Carbon Dioxide) Warning
CO2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO2 (carbon dioxide)
gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is suspected, particularly in a
small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO2 gas will experience tremors which are followed rapidly by
loss of consciousness and suffocation.
Shipping, Storing, Or Relocating Unit
CAUTION: Before shipping, storing, or relocating this Unit, the syrup systems must be sanitized and
all sanitizing solution must be purged from the syrup systems. All water must also be purged from
the plain and carbonated water systems. A freezing ambient temperature will cause residual water
remaining inside the Unit to freeze resulting in damage to internal components of the Unit.
1
312022000
THIS PAGE LEFT BLANK INTENTIONALLY
312022000
2
GENERAL INFORMATION
IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, and
maintaining this equipment. Refer to Table of Contents for page location of detailed information
pertaining to questions that arise during installation, operation, service and maintenance, or
troubleshooting this equipment.
GENERAL DESCRIPTION
This section gives the description, theory of operation, and design data for the AuroraR 10,000 Plus Cooling
Unit, hereafter referred to as a Cooling Unit.
This Unit must be installed and serviced by a qualified Service Person. This Unit contains no user serviceable
parts.
COOLING UNIT DESCRIPTION
The Cooling Unit is designed to provide cooled soft drink syrup, carbonated water, and plain water to a
dispensing station through an insulated python (length as ordered). On the standard Cooling Unit, the
refrigeration system is cooled by a condenser coil and a fan assembly located inside the Cooling Unit. The other
Cooling Units not provided with an internal condenser coil and fan assembly to cool their refrigeration systems
are cooled by either a Remote Condenser Coil and Fan Assembly which is connected to the Cooling Unit or the
Cooling Unit refrigeration system is cooled by a Refrigeration Cooling Coil Assembly with city plain water
circulating through the coil.
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 the Cooling Unit up off the floor. Also available is a
Service System Analyzer (P/N 309197000) that may be used to analyze and troubleshoot the AuroraR10,000
Plus Cooling Unit refrigeration system.
CAUTION: Before shipping, storing, or relocating this Unit, the syrup systems must be
sanitized and all sanitizing solution must be purged from the syrup systems. All water must
also be purged from the plain and carbonated water systems. A freezing ambient
environment will cause residual water in the Unit to freeze resulting in damage to internal
components.
WARRANTY REFERENCE INFORMATION
Warranty Registration Date
(to be filled out by customer)
Unit Part Number:
Serial Number:
Install Date:
Local Authorized
Service Center:
3
312022000
FIGURE 1. AURORAR 10,000 PLUS COOLING UNIT
Table 1. Design Data
COOLING UNIT DATA
Cooling Unit Part Numbers;
60 HZ UNIT:
Standard (air-cooled) Cooling Unit Equipped with Internal Condenser
Coil and Fan Assembly.
Cooling Unit (water-cooled) Equipped With Water-Cooled Condenser
Cooling Unit Requiring Connection to a Remote Condenser Coil and
Fan Assembly.
50 HZ UNIT:
Standard (air-cooled) Cooling Unit with Internal Condenser Coil and Fan
Assembly.
Cooling Unit (water-cooled) Equipped With Water-Cooled Condenser
Cooling Unit Requiring Connection to a Remote Condenser Coil and
Fan Assembly.
Overall Dimensions:
Height
Width
Depth
4002
561400006
4004
4003
561400007
4005
25-inches
36-1/2 inches
24-1/2 inches
NOTE:Overall dimensions 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
360 pounds
40 pounds
Capacities:
Water Bath (no ice bank)
312022000
18 gallons
4
Table 1. Design Data (cont’d)
Compressor Capacity
(ARI Rating)
15,000 BTUH
Refrigeration System:
Refrigerant Type and Charge
See Cooling
Unit
Nameplate
50°F to 100°F
Ambient Operating Temperature
Electrical Requirements:
60 HZ Cooling Units:
Operating Voltage and Current Draw
See Cooling
Unit
Nameplate
50 HZ Cooling Units:
Operating Voltage and Current Draw
See Cooling
Unit
Nameplate
REMOTE CONDENSER COIL AND FAN ASS’Y DATA (P/N 4000)
Overall Dimensions:
Height
Width
Depth
Weight:
Shipping
32 inches
22 inches
38 inches
85 pounds
Ambient Operating Temp.
-22°F to
158°F
Electrical Requirements:
Operating Voltage
208/230VAC, Single Phase,
50/60Hz
2.5 Amps
Current Draw
REFRIGERATION SYSTEMS
STANDARD (AIR-COOLED) COOLING UNIT
(see Figure 8)
The standard (air-cooled) Cooling Unit refrigeration system is cooled by a condenser coil and fan assembly
located inside the Cooling Unit.
“WATER-COOLED” COOLING UNIT
(see Figure 9)
The “water-cooled”Cooling Unit refrigeration system is equipped with a Refrigeration Cooling Coil Assembly
that contains both refrigerant and plain water cooling coils. Circulating cool plain water through the cooling coils
cools the refrigerant inside the coil. During installation, City cold plain water is connected to the cooling coil
water inlet labeled “CONDENSER WATER IN”. The water drain line labeled “CONDENSER WATER OUT”must
be routed to and be connected to a permanent drain.
5
312022000
COOLING UNIT REQUIRING CONNECTION TO A REMOTE CONDENSER COIL AND
FAN ASS’Y
(see Figure 9)
NOTE: The Remote Condenser Coil and Fan Assembly (P/N 4000) is a 208/230 VAC, 50/60 HZ Unit that
may be used with either Cooling Units (P/N 4004, a 60 HZ Unit) or (P/N 4005, a 50 HZ Unit) which require
connection to a Remote Condenser Coil and Fan Assembly.
The Cooling Unit refrigeration system is cooled by a Remote Condenser Coil and Fan Assembly
(P/N 4000) 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.
SYSTEM THEORY OF OPERATION
(see Figure 2)
A CO2 cylinder delivers carbon dioxide gas (CO2) to a primary CO2 regulator assembly which delivers regulated
CO2 gas to adjustable secondary CO2 regulators. The secondary CO2 regulators delivers regulated CO2 gas 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 BoostR coil. Cooled water
continues on through the plain water cooling coils and on into the carbonated water tank. Cold plain water
entering the carbonated water tank is carbonated by regulated CO2 gas 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, the carbonated
water circulating system is continuously being replenished from the carbonated water tank. The regulated CO2
gas pressure, exerted upon soft drink tanks contents, forces syrup from the tanks, through the Cooling Unit
cooling coils, and on to the dispensing station through the insulated python lines.
312022000
6
7
312022000
FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION FOR PRODUCT CONNECTION)
0905 REV: D
THIS PAGE LEFT BLANK INTENTIONALLY
312022000
8
INSTALLATION
This section covers unpacking and inspection, selecting location, installing the 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. 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. Request 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
Item
No.
Part No.
Name
Qty.
1
309852000
Tubing Clamp
24
2
770407
Barbed Connector, 1/4 by 3/8
12
3
770424
Barbed Connector, 1/2 by 1/2
2
4
311962000
Label, Line Identification
1
NOTE: The following Remote Condenser Coil and Fan Assembly and Refrigeration Lines Kits are
recommended for use with Cooling Units (Part numbers 4004 and 4005). Refrigeration Lines Kit (as
ordered) is used to connect the Remote Condenser Coil and Fan Assembly to the Cooling Unit.
5
4000
Remote Condenser Coil and Fan Ass’y
1
6
301115025
Refrigeration Line Kit, 25-ft. long, 90°
1
301115050
Refrigeration Line Kit, 50-ft. long, 90°
1
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
CAUTION: This Unit is intended for indoor installation only. Do not install this Unit in an
outdoor environment which would expose it to the outside elements.
9
312022000
Locate the Cooling Unit so the following requirements are satisfied.
1. Allow the shortest possible insulated python route from the Cooling Unit to the Dispensing Station location.
2. Cooling Unit Requiring Connection to a Remote Rooftop Condenser Coil and Fan Assembly.
Allow the shortest possible refrigeration lines (not to exceed 50-feet in length) route from the Remote
Condenser Coil and Fan Assembly to the Cooling Unit.
3. REFER TO COOLING UNIT NAMEPLATE FOR THE REQUIRED POWER CIRCUIT OPERATING
VOLTAGE, HERTZ, 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 fused as indicated on the Unit nameplate. The power circuit
may also be wired through an equivalent HACR type circuit breaker rather then through a disconnect
switch. THE POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING
MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES.
4. The Cooling Unit must be located close to a plain water source supply line with requirements as specified
under CONNECTING CITY PLAIN WATER SOURCE LINE TO THE COOLING UNIT in this section of the
manual.
5. Water-Cooled Cooling Unit.
The water-cooled Cooling Unit refrigeration system requires that a 1/2-inch I.D. (minimum) City plain water
source line with a minimum pressure of 12-psi be available to connect to the Cooling Unit Refrigeration
Cooling Coil Assembly.
6. The Cooling Unit must be close to a permanent drain to route the Cooling Unit water tank drain and
overflow hoses, and the Refrigeration Cooling Coil Assembly water dump line if a Water-Cooled Cooling
Unit.
7. Allow sufficient space around the Cooling Unit for proper air circulation (18-inches on sides and back, front
side open to the room, and top open to the ceiling.
REMOTE ROOFTOP CONDENSER COIL AND FAN ASS’Y
NOTE: The Remote Condenser Coil and Fan Assembly (P/N 4000) is a 208/230 VAC, 50/60 HZ Unit that
may be used with either Cooling Unit (P/N 4004, a 60 HZ Unit) or (P/N 4005, a 50 HZ Unit) which requires
connection to a Remote Condenser Coil and Fan Assembly.
The Cooling Unit refrigeration systems of Cooling Units (P/N 4004) and (P/N 4005) must be connected to a
Remote Condenser Coil and Fan Assembly (P/N 4000) 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 Units factory warranty.
An extreme warm climate installation may require extra caution in the Remote Condenser Coil and Fan
Assembly location. Avoid hot sunny locations and seek a shaded area if possible. The use of a structure to
shade the Unit from direct sun exposure and/or a platform extending the 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 the Unit for proper air circulation through the Unit and also access for service and maintenance. DO NOT
BLOCK AIR CIRCULATION THROUGH THE UNIT.
INSTALLATION
PLACING COOLING UNIT IN LOCATION
The Cooling Unit must be installed meeting requirements of SELECTING LOCATION as follows:
NOTE: The Cooling Unit inlet and outlet lines, power cables, and the Remote Condenser Coil and Fan
Assembly refrigeration lines (if applicable) must be long enough when connected to the Cooling Unit
to allow pulling the Unit out approximately 36-inches from the operating location for service and
maintenance. When Cooling Unit is in the operating location, the excess inlet and outlet lines, power
cables, and the refrigeration lines may be coiled up behind the Cooling Unit.
312022000
10
NOTE: An optional Cooling Unit Stand (P/N 309309069) is available to elevate the Cooling Unit up and
off the floor.
1. Place Cooling Unit in location approximately 36-inches out from operating location to allow access all
around the Unit.
2. Remove four screws securing the Cooling Unit top cover, then remove the cover.
PLACING REMOTE CONDENSER COIL AND FAN ASS’Y (IF APPLICABLE) IN
LOCATION
(see Figure 5)
The Remote Condenser Coil and Fan Assembly must be installed meeting requirements of SELECTING
LOCATION. The Remote Condenser Coil and Fan Assembly must be installed in a level position and must be
anchored to the rooftop with adequate fastening devices.
1. The Remote Condenser Coil and Fan Assembly must be installed meeting requirements of SELECTING
LOCATION. Install the Remote Condenser Coil and Fan Assembly in a level position. Make sure the
Remote Condenser Coil and Fan Assembly is anchored to the rooftop with adequate fastening devices.
2. Route refrigeration lines of REFRIGERATION LINE KIT (item 6) from Remote Condenser Coil and Fan
Assembly down to the Cooling Unit location.
3. Connect ends of the refrigeration lines to the Remote Condenser Coil and Fan Assembly refrigeration
connectors.
CONNECTING REMOTE CONDENSER COIL AND FAN ASS’Y (IF APPLICABLE)
REFRIGERATION LINES TO COOLING UNIT
(see Figure 5)
Connect refrigeration lines, from the Remote Condenser Coil and Fan Assembly, to the refrigeration connectors
on back of the Cooling Unit.
CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING UNIT
(see applicable Figure 4 or 5 and applicable10 or 11)
WARNING: Make sure 40-amp minimum-rated disconnect switch (not provided) is in ‘‘OFF’’
position.
1. Remove cover from electrical handy box on back of Cooling Unit.
WARNING: The Cooling Unit must be electrically grounded to avoid possible fatal electrical
shock or serious injury to the operator. A green ground wire is provided inside electrical
box to connect power circuit ground wire which electrically grounds the Cooling Unit.
2. 60 HZ Cooling Unit.
Connect (Refer to Cooling Unit nameplate for power circuit requirements) power circuit from 40-amp
minimum rated disconnect switch (not provided) fused at 40-amps (maximum) with GFCI or circuit
connected through an equivalent HACR circuit breaker with GFCI to electrical wires inside the electrical
handy box on back of the Cooling Unit. THE COOLING UNIT MUST BE PROPERLY GROUNDED. THE
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 THE COOLING UNIT AT THIS TIME.
11
312022000
3. 50 HZ Cooling Unit.
Connect (Refer to Cooling Unit nameplate for power circuit requirements) power circuit from a 40-amp
minimum rated disconnect switch (not provided) fused at 40-amps (maximum) with ELCB to terminals
wires inside of the Cooling Unit. COOLING UNIT MUST BE PROPERLY GROUNDED AND POWER
CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS.
DO NOT CONNECT ELECTRICAL POWER TO COOLING UNIT AT THIS TIME.
CONNECTING ELECTRICAL POWER CIRCUIT TO REMOTE CONDENSER COIL AND
FAN ASS’Y
(see Figures 5 and 11)
NOTE: Electrical power circuit may be connected to the Remote Condenser Coil and Fan Assembly
(P/N 4000) 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).
A.
Connect and route electrical power circuit cable from Remote Condenser Coil and Fan Assembly
through fuse box (not provided), fused at 15-amps (‘‘slow-blow’’) down to Cooling Unit location. THE
REMOTE CONDENSER COIL AND FAN ASSEMBLY MUST BE PROPERLY GROUNDED, THE
POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS, AND ALL WIRING MUST
CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES
B.
Route Remote Condenser Coil and Fan Assembly Power cable electrical wires through electrical
handy box on back of the Cooling Unit to inside of the electrical control box.
C.
Connect Remote Condenser Coil and Fan Assembly power cable electrical wires to T1 and T2
terminals on contactor inside Cooling Unit electrical control box.
D.
Install electrical control box cover and secure with four screws.
E.
Install cover on electrical handy box on back of Cooling Unit.
CONNECTING CITY PLAIN WATER SOURCE LINE TO COOLING UNIT
(see Figure 2)
Connecting City Plain Water Source Line to Unit Post-Mix System.
NOTE: IMI Cornelius Inc. recommends that a water shutoff valve be installed in the City plain water
source line to be connected to the Cooling Unit and that the water supply be filtered. THE 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: The plain water inlet supply line to Cooling Unit must be 1/2-inch I.D. minimum.
Check water flow rate of water inlet supply line. MINIMUM FLOW RATE MUST BE AT LEAST
300-GALLONS PER HOUR. If flow rate is less than 300-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
water circulating pump overheating could occur if water inlet supply line flow rate drops below
300-gallons per hour. INCOMING PLAIN WATER INLET SUPPLY LINE WATER PRESSURE MUST
NOT EXCEED 45 PSIG.
312022000
12
1. Before connecting City plain water source line to the Cooling Unit, open the 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 I.D. min.), meeting water inlet supply line
requirements of preceding CAUTION note, to the Cooling Unit 3/8-in. flare (5/8-18) bulkhead fitting on back
of the Unit labeled ‘‘WATER INLET’’Seal connection with a tapered gasket. DO NOT OPEN WATER
INLET SUPPLY LINE SHUTOFF VALVE AT THIS TIME.
Connecting City Plain Water Source Line to Cooling Unit with Water-Cooled Refrigeration System.
NOTE: IMI Cornelius Inc. recommends that a water shutoff valve be installed in the City plain water
source line to be connected to the Cooling Unit refrigeration cooling coil. THE WATER PIPE
CONNECTIONS AND FIXTURES DIRECTLY CONNECTED TO THE WATER SUPPLY SHALL BE SIZED,
INSTALLED AND MAINTAINED ACCORDING TO FEDERAL, STATE, AND LOCAL LAWS.
1. Connect flexible plain water inlet supply line (1/2-inch I.D. min.), meeting water inlet supply line
requirements of preceding NOTE, to Cooling Unit refrigeration cooling coil 3/8-in. male flare (5/8-18)
bulkhead fitting on back of the Cooling Unit labeled ‘‘CONDENSER WATER IN’’Seal connection with a
tapered gasket. DO NOT OPEN WATER INLET SUPPLY LINE SHUTOFF VALVE AT THIS TIME.
2. Connect a water drain line (1/2-inch I.D. min.) to the Cooling Unit refrigeration cooling coil 3/8-in. male
flare (5/8-18) bulkhead fitting on back of the Unit labeled ‘‘CONDENSER WATER OUT’’. Seal connection
with a tapered gasket.
CONNECTING CO2 INLET SUPPLY LINE TO COOLING UNIT
(see Figure 2)
WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of
CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is
suspected, particularly in a small area, immediately ventilate the contaminated area before
attempting to repair the leak. Personnel exposed to high concentration of CO2 gas will experience
tremors which are followed rapidly by loss of consciousness and suffocation.
Connect a flexible CO2 inlet supply line to the Cooling Unit 1/4-in. flare (7/16-20) bulkhead fitting of back of the
Unit labeled ‘‘CO2 INLET’’. Seal connection with a tapered gasket. DO NOT TURN ON CO2 SUPPLY 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).
13
312022000
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 used to make up the carbonated water
circulating system between the Cooling Unit and the Dispensing Station as explained in SYSTEM
THEORY OF OPERATION in the GENERAL INFORMATION section of this manual.
Connect Cooling Unit carbonated water outlet lines to insulated python carbonated water lines using BARBED
CONNECTORS (item 3).
18-- IN.
18-- IN.
COOLING UNIT
18-- IN.
AIR FLOW
(OPEN TO ROOM)
FIGURE 3. COOLING UNIT SPACE REQUIRED
PLACING COOLING UNIT IN OPERATING POSITION
1. Very carefully, move Cooling Unit back into operating location leaving space around Unit (see Figure 3) as
specified in SELECTING LOCATION. MAKE SURE THERE ARE NO KINKS IN COOLING UNIT INLET
LINES, AND (IF APPLICABLE) REMOTE ROOFTOP CONDENSER AND FAN ASSEMBLY
REFRIGERATION LINES.
NOTE: To comply with National Sanitation Foundation (NSF) requirements, the Cooling Unit not
installed on an optional Cooling Unit Stand (P/N 309309069) must have its base sealed to the floor with
Dow-Corning RTV 731 or equivalent.
2. Tilt Cooling Unit up to expose bottom of the Unit base.
3. Liberally apply silastic sealant such as Dow-Corning (RTV 731) or equivalent on the Unit base bottom
edges.
NOTE: Do not move Cooling Unit after positioning or seal from the Unit base to the floor will be
broken.
4. Lower Cooling Unit into operating location to complete seal from Unit base to the floor. Apply additional
sealant around bottom of the base. The seal must have a minimum radius of 1/2-inch to prevent cracks
and crevices and to ensure a complete seal.
312022000
14
5. Route Cooling Unit water tank overflow hose to a permanent floor drain.
6. Cooling Unit with Water-Cooled Refrigeration System.
Route end of the Cooling Unit refrigeration cooling coil drain line to and connect to a permanent drain.
7. Seal area around drain and overflow hoses where they exit from the Unit using Dow Corning (RTV 731) or
equivalent.
PREPARING COOLING UNIT FOR OPERATION
1. Make sure plug in end of the Cooling Unit water tank drain hose is secure.
2. Fill water tank with clean water until water starts flowing from the water tank overflow hose. USE LOW
MINERAL CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS.
3. Open shutoff valve in the plain water inlet supply line. Check for water leaks and repair if evident.
4. Adjust primary CO2 regulator (see Figure 2) on CO2 cylinder to a minimum nominal setting of 120-psi or
24-psi higher than highest setting required by the secondary CO2 regulators. Loosen the CO2 regulator
adjusting screw locknut. Turn the adjusting screw to the right (clockwise) until the regulator gage registers
nominal 120-psi, then tighten the adjusting screw locknut.
5. Adjust the carbonator secondary CO2 regulator (see Figure 2) to a nominal 90-psi. Loosen the CO2
regulator adjusting screw locknut. Turn the adjusting screw to the right (clockwise) until the regulator gage
registers nominal 90-psi, then tighten the adjusting screw lock nut. CO2 PRESSURE TO THE
CARBONATORS MUST NOT EXCEED 120-PSIG.
OPERATION
WARNING: Disconnect electrical power to Cooling Unit and Remote Condenser Coil and
Fan Assembly 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.
CAUTION: To prevent Hydro-BoostR coil freeze-up during initial Cooling Unit start-up, the
following start-up procedure must be performed as follows:
1. Make sure the Hydro BoostR bypass shutoff valve inside the Cooling Unit (see Figure 2) is in the
‘‘CLOSED’’(handle not in line with tubing) position.
2. Open shutoff valve in the city plain water source line connected to the Cooling Unit post-mix system.
3. Make sure the Cooling Unit REFRIGERATION POWER, CARBONATOR MOTOR, and CIRCULATING
MOTOR Power switches are in the ‘‘OFF’’positions.
4. Cooling Unit with Water-Cooled Refrigeration System.
Open shutoff valve in the City water line connected to the Refrigeration Cooling Coil Assembly. Check for
water leaks and repair if evident.
5. Connect electrical power to the Cooling Unit at the disconnect switch.
6. Cooling Unit Connected to a Remote Condenser Coil and Fan Assembly.
Connect electrical power to Remote Condenser Coil and Fan Assembly at disconnect switch.
15
312022000
7. Cooling Unit with Water-Cooled Refrigeration System.
IMPORTANT NOTICE
Water flow rate through the refrigeration cooling coil varies due to pressure change on the high side
of the refrigeration compressor which influences opening and closing of the variable water regulator (see Figure 9). The variable water regulator must be adjusted to maintain 240-psi refrigeration
high-side pressure.
Adjust the variable water regulator (see Figure 9) to maintain 240-psi refrigeration high-side pressure as
instructed in the SERVICE AND MAINTENANCE section of this manual.
8. Place the CARBONATOR MOTOR power switch in the ‘‘ON’’position.
9. Place the REFRIGERATION power switch in the ‘‘ON’’position. The agitator motor and the carbonator
pump motor only will start and fill the Hydro BoostR coil with plain water. APPROXIMATELY 2-1/2
MINUTES AFTER THE CARBONATOR PUMP MOTOR HAS STARTED, THE REFRIGERATION
COMPRESSOR AND THE COMPRESSOR COOLING FAN WILL START.
NOTE: As the ice bank forms in the water tank, water expansion will take place and excess water will
escape through the water tank overflow hose to the permanent floor drain.
The Cooling Unit will begin forming an ice bank and the refrigerated Hydro BoostR coil will also be chilling the
water. When full ice bank has been formed, the Cooling Unit compressor and the compressor cooling fan will
stop but the agitator motor will continue to operate circulating ice water bath in the water tank.
10. Dispense from the dispensing station until carbonated water appears at the dispensing valve which
indicates the Cooling Unit plain and carbonated water systems have been filled.
11. Place the CIRCULATING MOTOR power switch in the ‘‘ON’’position.The Circulating pump will start and
begin circulating carbonated water in the carbonated water circulating system as explained in SYSTEM
THEORY OF OPERATION in GENERAL INFORMATION SECTION.
12. Dispense carbonated water from the dispensing valve to make sure all air has been purged from the
system.
13. If the Cooling Unit plain water outlet line has been connected to a dispensing station dispensing valve,
dispense from the valve until all air has been purged from the plain water system.
14. Adjust the soft drink tanks secondary CO2 regulators (see Figure 2) as follows:
Sugar Syrup Soft Drink Tanks CO2 Regulator.
Adjust sugar syrup soft drink tanks secondary CO2 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 CO2 regulator setting.
Low-Calorie (diet) Syrup Soft Drink Tank CO2 Regulator.
Adjust low-calorie (diet) soft drink tank secondary CO2 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 CO2 regulator
setting to 12-psig maximum. Excessive CO2 pressure may cause low-calorie syrup carbonation resulting in
foam.
IMPORTANT: The syrup systems must be sanitized as instructed before syrup is connected into the
syrup systems.
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16
15. Connect soft drink tanks into the syrup systems.
16. Dispense from the 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 the Cooling Unit outlet lines connections to the insulated python lines are well insulated.
3. Install the Cooling Unit top cover and secure with two screws.
DISPENSING STATION ADJUSTMENTS
ADJUSTING WATER FLOW RATE
Refer to Installation Instructions provided with the Dispensing Station for dispensing valve water flow rate
adjustment instructions.
ADJUSTING WATER-TO-SYRUP ‘‘RATIO’’OF DISPENSED PRODUCT
Adjust the Dispensing Station dispensing valves for Water-to-Syrup ‘‘Ratio’’of the dispensed product as
instructed in Dispensing Station Installation Instructions.
INSTALLING LINE IDENTIFICATION LABEL
Install LABEL, LINE IDENTIFICATION (item 4) on the Cooling Unit, then record syrup flavors in the proper
spaces.
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THIS PAGE LEFT BLANK INTENTIONALLY
312022000
18
OPERATORS INSTRUCTIONS
This section covers operating controls, daily pre-operation check, adjustments, replenishing CO2 and syrup
supplies, cleaning and sanitizing, Cooling Unit maintenance, Remote Condenser Coil and Fan Assembly
maintenance, lubrication, and servicing CO2 gas check valves.
wiring.
WARNING: Disconnect electrical power to the Cooling Unit and the Remote Condenser
Coil and Fan Assembly to prevent personal injury before attempting any internal
maintenance. Only qualified personnel should service the internal components or electrical
OPERATING CONTROLS
COOLING UNIT REFRIGERATION POWER SWITCH
(see applicable Figure 4 or 5)
The REFRIGERATION POWER switch, located on the front of the Cooling Unit, placed in the ‘‘OFF’’position
will interrupt electrical power to the refrigeration compressor, agitator motor, compressor cooling fan, carbonated
water circulating pump, and the carbonator pump motor. The REFRIGERATION POWER switch placed in the
‘‘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 the ‘‘ON’’position, the refrigeration
compressor and compressor cooling fan will start.
COOLING UNIT CARBONATOR MOTOR SWITCH
(see applicable Figure 4 or 5)
The CARBONATOR MOTOR power switch, located on the front of the Cooling Unit, placed in the ‘‘OFF’’
position, will interrupt electrical power to the carbonator pump motor. The switch must be placed in the ‘‘ON’’
position before the carbonator pump motor will operate.
COOLING UNIT CIRCULATING MOTOR SWITCH
(see applicable Figure 4 or 5)
The CIRCULATING MOTOR power switch, located on the front of the Cooling Unit, placed in the ‘‘OFF’’
position, will interrupt electrical power to the carbonated water circulating pump. The switch must be placed in
the ‘‘ON’’position before the circulating pump will operate.
REFRIGERATION SYSTEM TEMPERATURE SENSING DEVICE AND HIGH-PRESSURE
CUTOUT SWITCH
(see Figure 5)
The Cooling Unit is equipped with a refrigeration system temperature sensing device and a high-pressure
sensing cutout switch that will shut the refrigeration system down should the system overheat due to a low
water supply (Unit with water-colled refrigeration system) or a clogged condenser coil (Unit with a Remote
Condenser Coil and Fan Assembly). If the refrigeration system does not automatically restart itself after the
system has cooled down, the high-pressure sensing cutout switch (located inside electrical control box) will
have to be pressed to reset the switch. MAKE SURE THE REFRIGERATION SYSTEM PROBLEM IS
CORRECTED. OPERATING THE REFRIGERATION SYSTEM IN THIS MANNER FOR A PROLONGED
PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE.
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312022000
DAILY PRE-OPERATION CHECK
1. Make sure the CO2 cylinder regulator assembly 1800-psi gage indicator is not in the shaded (‘‘change CO2
cylinder’’) portion of the dial. If so, the CO2 cylinder is almost empty and must be replaced.
2. Sufficient syrup supply in all the soft drink tanks. If not, replenish the syrup supply as instructed.
ADJUSTMENTS
ADJUSTING CO2 REGULATORS
The CO2 regulators should be periodically checked for proper pressure settings and if necessary, adjusted as
instructed in the SERVICE AND MAINTENANCE section of this manual.
ADJUSTING DISPENSING VALVES WATER FLOW RATE
If adjustment of the dispensing valves water flow rate should be necessary, adjust as instructed in the
Dispensing Station Installation Instructions.
ADJUSTING WATER-TO-SYRUP ‘‘RATIO’’OF DISPENSED PRODUCT
The Water-To-Syrup ‘‘Ratio’’of the dispensed product should be checked and if necessary, adjusted as
instructed in the Dispensing Station Installation Instructions.
ADJUSTING SIZE OF DRINK DISPENSED
Adjust the drink size of the dispensed product as instructed in the Dispensing Station Installation Instructions.
REPLENISHING CO2 SUPPLY
WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of
CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is
suspected, particularly in a small area, immediately ventilate the contaminated area before
attempting to repair the leak. Personnel exposed to high concentration of CO2 gas will experience
tremors which are followed rapidly by loss of consciousness and suffocation.
NOTE: When indicator on the CO2 cylinder regulator assembly 1800-psi gage is in the shaded (‘‘change
CO2 cylinder’’) portion of the dial, CO2 cylinder is almost empty and should be changed.
The CO2 supply should be checked daily and if necessary, be replenished as instructed.
CLEANING AND SANITIZING
DAILY CLEANING
Perform daily cleaning of the dispensing station as instructed in the dispensing station installation instructions.
The outside of the Cooling Unit must be cleaned periodically.
SANITIZING SYRUP SYSTEMS
The syrup systems should be sanitized every 90--days as instructed in the SERVICE AND MAINTENANCE
section of this manual.
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20
COOLING UNIT MAINTENANCE
COOLING UNIT WITH INTERNAL CONDENSER COIL AND FAN ASS’Y
Air to cool the Cooling Unit internal condenser coil is drawn in through the end access panel on end of the Unit
and is exhausted out through the front and rear access panels on the Unit. The Cooling Unit condenser coil
surface area must be cleaned every 30-days as instructed in the SERVICE AND MAINTENANCE section of this
manual. The area around the Cooling Unit must be kept free of obstructions at all times for proper air circulation
through the Unit.
CHECKING ICE WATER BATH
A gurgle heard from the Cooling Unit indicates the water level in the 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 in the SERVICE AND MAINTENANCE section of this manual.
COOLING UNIT CARBONATOR MAINTENANCE
NOTE: Periodically operate carbonator tank relief valve.
Lubrication.
The carbonator water pump motor bearings must be oiled periodically as instructed in the SERVICE AND
MAINTENANCE section of this manual.
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 the 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 normal circumstances and after any water system disruption (plumbing
work, earthquake, etc.) Inspect and clean the double liquid check valve assemblies as instructed in the
SERVICE AND MAINTENANCE section of this manual.
COOLING UNIT CARBONATED WATER CIRCULATING PUMP MOTOR LUBRICATION
The carbonated water circulating pump motor bearings must be oiled periodically as instructed in the SERVICE
AND MAINTENANCE section of this manual.
REMOTE CONDENSER COIL AND FAN ASS’Y MAINTENANCE
(see Figure 5)
CAUTION: The Remote Condenser Coil and Fan Assembly connected to the Cooling Unit is
equipped with a condenser coil that must be cleaned every 30-days. Allowing the
condenser coil to become clogged will cause the refrigeration system to overheat which
will automatically shut the refrigeration system down. After the condenser coil has been cleaned,
the high-pressure cutout sensing switch (located inside the Cooling Unit electrical control box)
will have to be pressed to restart the refrigeration system. OPERATING THE COOLING UNIT IN
THIS MANNER FOR A PROLONGED PERIOD OF TIME, COULD RESULT IN COMPRESSOR
FAILURE.
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Area on top of and around the Remote Condenser Coil and Fan Assembly must be kept free of obstructions at
all times. The Condenser coil must be cleaned as instructed in the SERVICE AND MAINTENANCE section of
this manual to maintain proper cooling of the coil.
CLEANING CO2 GAS CHECK VALVES
(see Figure 2)
The CO2 gas check valves must be inspected and serviced at least once a year under normal conditions and
after any CO2 system servicing or disruption as instructed in the SERVICE AND MAINTENANCE section of this
manual.
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22
SERVICE AND MAINTENANCE
This section describes the Service and Maintenance procedures to be performed on the Cooling Unit and the
Remote Condenser Coil and Fan Assembly.
WARNING: Disconnect electrical power to the Cooling Unit and the Remote Condenser
Coil and Fan Assembly to prevent personal injury before attempting any Cooling Unit or
Remote Condenser Coil and Fan Assembly internal maintenance. Only qualified personnel
should service the internal components or electrical wiring.
PREPARING COOLING UNIT FOR SHIPPING, STORING, OR RELOCATING
CAUTION: Before shipping, storing, or relocating the Cooling Unit, the syrup system must
be sanitized and all sanitizing solution must be purged from the syrup systems. All water
must be purged from the plain and the carbonated water systems and the ice bank must be
melted and all water drained from the water tank. A freezing ambient environment will cause
residual water remaining inside the Unit to freeze resulting in damage to the internal components.
PERIODIC INSPECTION
COOLING UNIT EQUIPPED WITH INTERNAL CONDENSER COIL AND FAN ASSEMBLY
(see Figure 4)
CAUTION: The internal condenser coil must be cleaned every 30-days as instructed.
Circulating air required to cool the condenser coil is drawn in through the end access
panel and is exhausted out through the front access panel on front of the Unit. Failure to
clean, and allowing the condenser coil to become clogged, will cause the refrigeration system to
overheat which will automatically shut the refrigeration system down. After the refrigeration
system has cooled down, the system will automatically restart and operate until overheated and
then will shut down again. OPERATING THE COOLING UNIT IN THIS MANNER FOR A
PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE.
Clean condenser coil every 30-days as instructed in this section of the manual. Area around the Cooling Unit
must be kept free of obstructions at all times for proper air circulation through the unit.
COOLING UNIT UTILIZING A REMOTE CONDENSER COIL AND FAN ASSEMBLY
(see Figure 5)
CAUTION: The Remote Condenser Coil and Fan Assembly connected to the Cooling Unit is
equipped with a condenser coil that must be cleaned every 30-days. Allowing the
condenser coil to become clogged will cause the refrigeration system to overheat which
will automatically shut the refrigeration system down. After the condenser coil has been cleaned,
the high-pressure sensing cutout switch (located inside the Cooling Unit electrical control box)
will have to be pressed to restart the refrigeration system. OPERATING THE COOLING UNIT IN
THIS MANNER FOR A PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR
FAILURE.
Clean the Remote Condenser Coil and Fan Assembly condenser coil every 30-days, as instructed in this
section of the manual. Make sure area on top and around the Unit are kept free of obstructions at all times. Air
must be allowed to enter and leave the Unit to remove heat from the condenser coil. Restricting air through the
condenser coil will cause the Cooling Unit refrigeration system to overheat.
23
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COOLING UNIT EQUIPPED WITH WATER-COOLED REFRIGERATION SYSTEM
The Cooling Unit equipped with a water-cooled refrigeration system requires no cleanning of it’s condenser coil.
COOLING UNIT MAINTENANCE
PERIODIC CLEANING
Periodically operate the carbonator tank relief valve.
Periodically wash all external surfaces of the 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 INTERNAL
CONDENSER COIL)
(see Figure 4)
CAUTION: The Cooling Unit condenser coil must be cleaned every 30 days. Excessive
accumulation of dust, lint, and grease on the condenser coil will restrict air flow through
the coil which will cause the refrigeration system to overheat.
Note: The Cooling Unit end access panel must be removed for access to the condenser coil.
Excessive accumulation of dust, lint, and grease on the condenser coil will restrict air flow through the coil and
cause a loss of cooling efficiency. Vacuum or use a soft brush to clean the condenser coil. If available, use
low-pressure compressed air to clean the coil.
CHECKING ICE WATER BATH
(see applicable Figure 4 or 5)
A gurgle heard from the Cooling Unit indicates water level in the water tank is low and more water should be
added to the tank for maximum product cooling. The ice water bath and the ice bank should be checked for
cleanliness and the water tank coils should be checked for excessive mineral deposit build-up as follows:
1. Disconnect electrical power from the Cooling Unit at the disconnect switch.
2. Remove two screws securing the Cooling Unit top cover, then remove the cover.
3. Using a flashlight, inspect the ice water bath and the ice bank for cleanliness.The ice water bath should be
clear and the ice bank should be free of foreign particles.
4. If cleaning of the water tank is necessary, refer to CHANGING ICE WATER BATH in this section.
5. Fill the water tank with clean water until water starts flowing from the water tank overflow hose. USE LOW
MINERAL CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS.
6. Install Cooling Unit top cover and secure with four screws.
7. Restore electrical power to the Cooling Unit at the disconnect switch.
CHANGING ICE WATER BATH
(see applicable Figure 4 or 5)
1. Disconnect electrical power from the Cooling Unit at the disconnect switch.
2. Remove four screws securing the Cooling Unit top cover, then remove the cover.
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24
SYSTEM ANALYZER
TEST PLUG
*HIGH-PRESSURE
SENSING CUTOUT
SWITCH LOCATED INSIDE CONTROL BOX
(WATER-COOLED)
ELECTRICALCONTROL BOX
CIRCULATING AIR OUT
CIRCULATION
MOTOR SWITCH
CARBONATOR
MOTOR
SWITCH
REFRIGERATION
POWER SWITCH
FRONT ACCESS
PANEL
CIRCULATING AIR IN
CIRCULATING AIR OUT
END ACCESS PANEL
MODELS:
4002
4003
*561400006
*561400007
*Water-Cooled Refrigeration System.
FIGURE 4. PARTS IDENTIFICATION (COOLING UNIT W/INTERNAL CONDENSER COIL)
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312022000
AIR FLOW
ROMOTE ROOFTOP CONDENSER
COIL AND FAN ASSEMBLY
REFRIGERATION
LINES (ITEM 4)
SYSTEM ANALYZER
TEST PLUG
ELECTRICALCONTROL BOX
HIGH-PRESSURE
SENSING CUTOUT
SWITCH (LOCATED
INSIDE CONTROL
BOX)
REFRIGERATION LINE
CONNECTIONS (ON BACK
SIDE OF COOLING UNIT)
CIRCULATION
MOTOR SWITCH
CARBONATOR
MOTOR
SWITCH
REFRIGERATION
POWER SWITCH
FRONT ACCESS
PANEL
CIRCULATING AIR IN
CIRCULATING AIR OUT
END ACCESS PANEL
MODELS:
4004
4005
FIGURE 5. PARTS IDENTIFICATION (COOLING UNIT REQUIRING CONNECTION TO REMOTE
CONDENSER COIL AND FAN ASSEMBLY)
312022000
26
3. Make sure end of the water tank drain hose is routed to the floor drain, then remove plug from end of the
hose and allow water to drain from tank.
CAUTION: Never use an ice pick or other instruments to remove ice from the evaporator
coils. Such practice can result in punctured refrigeration circuit.
4. Allow ice bank to melt. Hot water may be used to speed melting.
5. Thoroughly rinse inside of the water tank with clean water.
6. Install plug in end of the water tank drain hose.
7. Fill water tank with clean water until water starts flowing from the water tank overflow hose. USE LOW
MINERAL CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS.
8. Install Cooling Unit top cover and secure with four screws.
9. Connect electrical power to the Cooling Unit at the 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 assemblies 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) flow
of water through the system. Fouled liquid check valves could cause CO2 gas to back flow from
the carbonated water tank into the water system and create a health hazard in the system.
The two double liquid check valve assemblies are located in the 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 the Cooling Unit at the disconnect switch.
2. Close shutoff valve in the plain water inlet supply line.
3. Note pressure setting on the carbonator CO2 regulator, then turn the regulator adjusting screw to the left
(counterclockwise) until the regulator gage reads 0-psi.
4. Remove four screws securing the Cooling Unit top cover, then remove the cover.
5. Pull up on the carbonator tank relief valve to release CO2 pressure from the tank.
6. Remove the double liquid check valve assembly from the plain water line connected between the plain
water cooling coil and the carbonated water tank.
7. Remove one check valve from the other, then disassemble each check valve as shown in Figure 6.
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 a new ball seat (QUAD RING) (P/N
312418000.
NOTE: Make sure when assembling the check valves together, the check valve female end with white
tapered gasket inside, is on the inlet side of the double liquid check valve assembly.
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312022000
1
3
2
6
4
5
Index Part
Name
No. No.
1
317963
Housing
2
312415
Flat Washer, Stainless Steel
3
*312418
Ball Seat (quad ring)
4
312419
Ball
5
312196
Spring
6
317965
Retainer
* Install new ball seat at each servicing.
FIGURE 6. LIQUID CHECK VALVE ASSEMBLY
10. Assemble the check valves together. DO NOT OVERTIGHTEN.
11. Install the double liquid check valve assembly in the plain water line connected between the plain water
cooling coil and the carbonated water tank.
12. Repeat preceding steps 6) through 11) to service the other double liquid check valve in the other plain
water line connected between the plain water cooling coil and the carbonated water tank.
13. Turn the carbonator CO2 regulator adjusting screw to the right (clockwise) until its gage indicates the
pressure setting observed in step 3) preceding.
14. Open shutoff valve in the plain water inlet supply line.
15. Restore electrical power to the Cooling Unit at the disconnect switch.
16. Dispense carbonated water at the dispensing station and allow the carbonator to cycle on and off. Check
for water leaks and repair if evident.
17. Disconnect electrical power from the Cooling Unit at the disconnect switch.
18. Install Unit top cover and secure with two screws.
19. Restore electrical power to the Cooling Unit at the 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.
REMOTE CONDENSER COIL AND FAN ASSEMBLY MAINTENANCE
(see Figure 5)
PERIODIC CLEANING
Periodically wash all external surfaces of the Remote Condenser Coil and Fan Assembly, rinse with clean water,
then wipe dry with a clean soft cloth. DO NOT USE ABRASIVE TYPE CLEANERS.
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28
CLEANING CONDENSER COIL
CAUTION: Circulating air, required to pass through and cool the condenser coil, is drawn
in at the bottom and is exhausted out through the top of the Unit. Failure to clean the
condenser coil will cause the refrigeration system to overheat.
1. Disconnect electrical power to the Cooling Unit at the disconnect switch.
2. Clean bottom side of the condenser coil using a vacuum cleaner, whisk broom, or soft-bristle brush to
remove any debris from the coil.
3. Check and make sure the fan blade moves freely and is not touching any surfaces, are not bent, or out of
balance. Check and make sure the wire guard is properly installed and is securely fastened.
4. Check and make sure the roof area immediately surrounding the Unit is free and clear of any debris that
may have collected such as leaves, paper,trash, etc.
5. Restore electrical power to the Cooling Unit at the disconnect switch.
ADJUSTMENTS
NOTE: To readjust the CO2 regulator to a lower setting loosen the adjusting screw lock nut, then turn
the screw to the left (counterclockwise) until the pressure gage reads 5-psi lower than the new setting
will be. Turn the adjusting screw to the right (clockwise) until the gage registers new setting, then
tighten the lock nut.
PRIMARY CO2 REGULATOR
(see Figure 2).
Adjust the primary CO2 regulator on the CO2 cylinder to a minimum nominal setting of 120-psi or 24-psi higher
than the highest setting required by the secondary CO2 regulators. Loosen the CO2 regulator adjusting screw
locknut. Turn the adjusting screw to the right (clockwise) until the regulator gage registers nominal 120-psi, then
tighten the adjusting screw locknut.
SECONDARY CO2 REGULATORS
(see Figure 2).
Carbonator Secondary CO2 Regulator.
Adjust the carbonator secondary CO2 regulator to a nominal 90-psi. Loosen the CO2 regulator adjusting screw
locknut. Turn the adjusting screw to the right (clockwise) until the regulator gage registers nominal 90-psi, then
tighten the adjusting screw locknut. CO2 PRESSURE TO THE CARBONATORS MUST NOT EXCEED
125-PSIG.
Sugar Syrup Soft Drink Tanks CO2 Regulators.
Adjust sugar syrup soft drink tanks secondary CO2 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 CO2 regulator settings.
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312022000
Low-Calorie (diet) Syrup Soft Drink Tank CO2 Regulator.
Adjust low-calorie (diet) soft drink tank secondary CO2 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 CO2 regulator
setting to 12-psig maximum. Excessive pressure may cause low-calorie syrup carbonation resulting in foam.
WATER FLOW RATE
Refer to Installation Instructions provided with the dispensing station for dispensing valve water flow rate
adjustment instructions.
WATER-TO-SYRUP ‘‘RATIO’’OF DISPENSED PRODUCT
Adjust the dispensing station dispensing valves for Water-to-Syrup ‘‘Ratio’’of the dispensed product as
instructed in dispensing station Installation Instructions.
ADJUSTING WATER-COOLED REFRIGERATION SYSTEM VARIABLE WATER
REGULATOR
IMPORTANT: Water flow rate through the refrigeration cooling coil varies due to pressure change on
the high side of the refrigeration compressor, which influences opening and closing of the variable
water regulator (see Figure 9). The variable water regulator must be adjusted to maintain a 240-psi
refrigeration system high-side pressure. Adjust the variable water regulator as follows:
1. Disconnect electrical power from the Cooling Unit at the disconnect switch.
2. Remove the Cooling Unit left side panel and front grille.
3. Connect gauges to the high-pressure side of the refrigeration system.
4. Restore electrical power to the Unit at the disconnect switch.
5. Operate the refrigeration system with the gauges installed. After approximately 5 minutes of operation,
adjust the refrigeration cooling coil variable water regulator (see Figure 9) to maintain a 240-psi
refrigeration system high-side pressure. The adjustment screw is located on the end of the coil assembly
and must be turned to the right (clockwise) to decrease the pressure or to the left (counterclockwise) to
increase the pressure.
6. After the pressure adjustment has been completed, disconnect electrical power to the Cooling Unit at the
disconnect switch.
7. Install left side panel and front grille on the Cooling Unit.
8. Restore electrical power to the Cooling Unit at the disconnect switch.
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.
312022000
30
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 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 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 CO2 pressure setting on the syrup tanks CO2 regulator, 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 5 preceding.
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.
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312022000
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 9 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 steps13 and 14 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
WARNING: Flush sanitizing solution from the syrup systems as instructed. Residual
sanitizing solution left in the syrup systems 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.
32
312022000
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 19 and 20 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 CO2 regulator 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 possible personal injury or property damage, do not attempt to
remove the syrup tank cover until CO2 pressure has been released 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.
REPLENISHING CO2 SUPPLY
WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of
CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is
suspected, particularly in a small area, immediately ventilate the contaminated area before
attempting to repair the leak. Personnel exposed to high concentration of CO2 gas will experience
tremors which are followed rapidly by loss of consciousness and suffocation.
NOTE: When indicator on the CO2 cylinder primary CO2 regulator assembly 1800-psi gage is in the
shaded (‘‘change CO2 cylinder’’) portion of dial, the CO2 cylinder is almost empty and should be
changed.
1. Fully close (clockwise) the CO2 cylinder valve.
2. Slowly loosen the primary CO2 regulator assembly coupling nut allowing the CO2 pressure to escape, then
remove the regulator assembly from the empty CO2 cylinder.
33
312022000
3. Unfasten safety chain and remove the empty CO2 cylinder
WARNING: To avoid personal injury and/or property damage, always secure the CO2
cylinder in an upright position with a safety chain to prevent it from falling over. Should the
valve become accidentally damaged or broken off, the CO2 cylinder can cause serious
personal injury.
4. Position CO2 cylinder and secure with a safety chain.
5. Make sure gasket is in place inside the primary CO2 regulator coupling nut, then install the regulator on the
CO2 cylinder.
6. Open (counterclockwise) the CO2 cylinder valve slightly to allow the lines to slowly fill with gas, then open
the valve fully to back-seat the valve. (Back-seating the valve prevents leakage around the valve shaft).
FIGURE 7. CO2 GAS CHECK VALVE
REPLENISHING SYRUP SUPPLY
NOTE: The following instructions are applicable only when replenishing the same flavor syrup. Refer
to SYRUP FLAVOR CHANGE when changing the syrup flavor.
1. Disconnect empty soft drink tank from the syrup system.
2. Check the soft drink tank quick disconnects for sticky or restricted operation. Wash the disconnects in
warm water.
3. Connect full tank of syrup into the syrup system.
SYRUP FLAVOR CHANGE
1. Perform sanitizing procedure on the syrup system syrup flavor change will be made on.
2. Check the soft drink tank quick disconnects for sticky or restricted operation. Wash the disconnects in
warm water.
3. Connect full tank of new flavor syrup into the syrup system.
312022000
34
CLEANING CO2 SYSTEM GAS CHECK VALVES
SECONDARY CO2 REGULATORS AND CO2 MANIFOLD CO2 GAS CHECK VALVES
(see Figures 2 and 7)
The secondary CO2 regulators and the CO2 manifold CO2 gas check valves must be inspected and serviced at
least once a year under normal conditions and after any servicing or disruption of the CO2 system. ALWAYS
REPLACE BALL SEAT (QUAD RING SEAL) EACH TIME THE GAS CHECK VALVES ARE SERVICED.
COOLING UNIT CO2 INLET LINE CO2 GAS CHECK VALVE
(see Figures 2 and 7)
The CO2 inlet line CO2 gas check valve, located inside the Cooling Unit, must be inspected and serviced at
least once a year under normal conditions and after any servicing or disruption of the CO2 system. ALWAYS
INSTALL NEW BALL SEAT (QUAD RING) SEAL EACH TIME THE GAS CHECK VALVE IS SERVICED.
35
312022000
REMOTE CONDENSER
COIL AND FAN ASS’Y
REFRIGERATION LINES CONNECTED
BETWEEN COOLING UNIT AND REMOTE
CONDENSER COIL AND FAN ASS’Y MUST
NOT EXCEED 50-- FEET IN LENGTH.
REFRIGERATION LINES VERTICAL
RISE MUST NOT EXCEED 20-- FEET.
FIGURE 8. REFRIGERATION FLOW DIAGRAM (REQIURES CONNECTION TO REMOTE CONDENSER
COIL AND FAN ASS’Y)
312022000
36
COOLING WATER OUT
(TO DRAIN)
ADJUSTMENT
SCREW
COOLING WATER IN
(CITY PLAIN WATER)
*VARIABLE WATER
REGULATOR
*WATER FLOW RATE THROUGH COIL
WATER-COOLED
REFRIGERATION
COOLING COIL ASS’Y
VARIES DUE TO PRESURE CHANGE
ON HIGH SIDE OF COMPRESSOR
WHICH INFLUENCES OPENING AND
CLOSING OF VARIABLE WATER REGULATOR. ADJUST VARIABLE WATER
REGULATOR TO MAINTAIN 240-PSI
REFRIERATION HIGH-SIDE PRESSURE.
AIR-COOLED
REFRIGERATION
CONDENSER COIL
FIGURE 9. REFRIGERATION FLOW DIAGRAM (UNIT WITH WATER-COOLED OR
AIR-COOLED REFRIGERATION)
37
312022000
312022000
38
FIGURE 10. WIRING DIAGRAM (MODELS 4002 AND 4003)
39
312022000
FIGURE 11. WIRING DIAGRAM (MODELS 4004, 4005, 561400006 AND 561400007)
THIS PAGE LEFT BLANK INTENTIONALLY
312022000
40
TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
WARNING: If repairs are to be made to a product system, remove quick disconnects from
the applicable product tank, then relieve the system pressure before proceeding. If repairs
are to be made to the CO2 system, stop dispensing, shut off the CO2 supply, then relieve the
system pressure before proceeding. If repairs are to be made to the refrigeration system, make sure
electrical power is disconnected from the unit.
TROUBLESHOOTING POST-MIX SYSTEM
Trouble
WATER-TO-SYRUP ‘‘RATIO’’
OF DISPENSED DRINK TOO
LOW OR TOO HIGH
Probable Cause
Remedy
A.
Dispensing valve syrup flow
regulator not properly
adjusted.
A.
Adjust Water-To-Syrup ‘’Ratio’’
(refer to dispensing station
installation Instructions).
B.
CO2 gas pressure to soft drink
tanks insufficient to push syrup
out of tanks.
B.
Adjust soft drink tanks secondary
CO2 regulator as instructed.
A.
No syrup supply.
A.
Replenish syrup supply as
instructed.
B.
Soft drink tank quick
disconnects
B.
Secure quick disconnects.
C.
Soft drink tanks secondary
CO2 regulator out of
adjustment.
C.
Adjust soft drink tanks secondary
CO2 regulator 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
overtightened restricting syrup
flow.
E.
Replace nylon washer. Make sure
washer seats properly in swivel
nut.
F.
Dirty or inoperative piston or
cylinder in dispensing valve
syrup flow regulator.
F.
Disassemble and clean
dispensing valve syrup flow
regulator.
ADJUSTMENT OF
DISPENSING VALVE SYRUP
FLOW REGULATOR DOES
NOT DECREASE TO
DESIRED WATER-TO- SYRUP
‘‘RATIO’’.
A.
Dirty or inoperative piston or
cylinder in dispensing valve
syrup flow regulator.
A.
Disassemble and clean
dispensing valve syrup flow
regulator.
DISPENSED PRODUCT
CARBONATION TOO LOW.
A.
Carbonator CO2 regulator out
of adjustment for existing
water conditions or
temperature.
41
A.
Adjust carbonator CO2 regulator
as instructed.
ADJUSTMENT OF
DISPENSING VALVE SYRUP
FLOW REGULATOR DOES
NOT INCREASE TO DESIRED
WATER-TO-SYRUP ‘‘RATIO’-’
312022000
Trouble
Probable Cause
Remedy
DISPENSED PRODUCT
CARBONATION TOO LOW
(CONT’D).
B.
Water, oil, or dirt in CO2
supply.
B.
Remove contaminated CO2
supply. Clean CO2 system (lines,
regulators, etc.) using a mild
detergent. Replenish with a clean
CO2 supply
DISPENSED PRODUCT
COMES OUT OF
DISPENSING VALVE CLEAR
BUT FOAMS IN CUP.
A.
Oil film or soap scum in cups.
A.
Use clean cups.
B.
Ice used for finished drink is
sub-cooled.
B.
Do not use ice directly from
freezer. Allow ice to become ‘‘wet’’
before using. (Refer to following
NOTE)
NOTE: Crushed ice 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.
ONLY SYRUP DISPENSED.
312022000
A.
Carbonator CO2 regulator
pressure set too high for
existing water conditions or
temperature.
A.
Reduce carbonator CO2 regulator
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 CO2 pressure as
many times as necessary to
remove over-carbonation.
C.
Tapered nylon washer inside
tube swivel nut connection
distorted from being
overtightened restricting syrup
flow.
C.
Replace nylon washer. Make sure
washer is properly seated in
swivel nut.
A.
Quick disconnect not secure
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).
E.
Dispensing valve syrup flow
regulator, soft drink tank quick
disconnect, or syrup lines
restricted.
E.
Sanitize syrup system as
instructed.
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.
42
Trouble
WARM PRODUCT BEING
DISPENSED.
Probable Cause
Remedy
A.
Carbonated water circulating
pump CIRCULATING MOTOR
power switch in ‘‘OFF’’
position. position.
A.
Place circulating pump
CIRCULATING MOTOR power
switch in ‘‘ON’’
B.
Inoperable carbonated water
circulating pump or motor.
B.
Replace pump or motor.
TROUBLESHOOTING CARBONATOR
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.
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
probe.
F.
Replace liquid level sensing
probe.
G.
Inoperative liquid level sensing
PC board.
G.
Replace liquid level sensing PC
board.
H.
No 24 VAC to liquid level
sensing PC board.
H.
Check electrical wiring and
transformer for 24 VAC output.
A.
Inoperative liquid level sensing
probe.
A.
Replace liquid level sensing
probe.
B.
Inoperative liquid level sensing
PC board.
B.
Replace liquid level sensing PC
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.
A.
Inoperative liquid level sensing
probe.
A.
Replace liquid level sensing
probe.
B.
Inoperative liquid level sensing
PC board.
B.
Replace liquid level sensing PC
board.
C.
Liquid level sensing probe
wired wrong.
C.
Correct liquid level sensing probe
wiring.
D.
Dirty or oily liquid level sensing
probe.
D.
Clean liquid level sensing probe.
A.
Water inlet supply line shutoff
valve closed.
A.
Open water inlet supply line
shutoff valve.
B.
Kinked water inlet supply line.
43
B.
Straighten water inlet supply line.
312022000
Trouble
WATER PUMP MOTOR
OPERATES BUT WATER
PUMP DOES NOT PUMP
WATER (CONT’D).
WATER PUMP CAPACITY
TOO LOW.
Probable Cause
Remedy
C.
Restriction between water
pump outlet and carbonator
tank inlet.
C.
Remove restriction.
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.
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.
312022000
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.
Blown fuse or tripped circuit
breaker.
D.
Replace fuse or reset 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 SECTION.
G.
Unit with Water-Cooled
Refrigeration--Water supply to
the refrigeration cooling coil
insufficient.
G.
Restore water supply to the
refrigeration cooling coil.
H.
Low Voltage.
H.
Voltage must be at least 187 volts
(domestic) or 198 volts (export) at
compressor terminals when
Compressor is trying to start.
I.
Inoperable run capacitor, start
capacitor, or relay.
I.
Replace inoperable part.
J.
Inoperable compressor.
J.
Replace compressor.
K.
Inoperable control board
K.
Replace control board.
L.
Inoperable contactor
44
L.
Replace contactor.
Trouble
COMPRESSOR DOES NOT
OPERATE (CONT’D).
Probable Cause
Remedy
M.
No voltage to control board.
M.
Check for loose or broken wiring.
Check 208/240 VAC power
transformer for 24 VAC output.
(see NOTE below).
N.
Inoperable control board or
water/ice sensor PC board.
N.
Replace control board.
O.
Inoperable ICE SENSOR.
O.
Replace ICE SENSOR.
P.
EVAP IN, COND OUT, or
EVAP OUT sensor is open,
shorted, or out of temperature
range.
P.
Replace inoperable sensor.
Q.
Hydro Boost WATER
SENSOR is shorted or open
circuit.
Q.
Check for loose, broken, or
disconnected wire or plug at
pre-cool coil. Repairor replace
wire or secure plug. If Hydro
Boost WATER SENSOR is
inoperable, replace sensor.
NOTE: Confirm which sensor has failed by using the AuroraR Series System Analyzer
(P/N 309197000).
NOTE: The 208/240 VAC power transformer has an overload reset button located on its 24 VAC output
side. An overload on the transformer will cause its reset button to pop out disrupting the 24 VAC
output to the main control board. Overload button must be pressed in to restore 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.
Standard Cooling Unit with
condenser coil and fan
assembly-- Cooling Unit
located in excessively hot area
or air circulation through
condenser coil is restricted.
B.
Relocate unit or check and if
necessary, condenser coil as
instructed.
C.
Remote Rooftop Condenser
Coil and Fan Assembly-- Air
circulation through condenser
coil is restricted.
C.
Check and if necessary, clean
condenser coil as instructed.
D.
Unit with Water-Cooled
Refrigeration--Water supply to
the refrigeration cooling coil
insufficient.
D.
Restore water supply to the
refrigeration cooling coil.
E.
Insufficient refrigerant charge.
E.
Find and repair refrigeration leak,
then replenish refrigerant charge.
F.
Inoperative or disconnected
pulse-modulating expansion
valve (see REFRIGERATION
FLOW DIAGRAM).
F.
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 close to
or in a vacuum.
45
312022000
Trouble
COMPRESSOR OPERATES
CONTINUOUSLY BUT DOES
NOT FORM SUFFICIENT ICE
BANK (CONT’D)
Probable Cause
G.
Inoperative control board. No
output from board to
solenoids.
Remedy
G.
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
AGITATOR MOTOR NOT
OPERATING.
312022000
A.
Blown power circuit fuse.
A.
Replace power circuit fuse.
B.
Fan blade obstructed.
B.
Remove obstruction.
C.
Inoperative condenser fan
motor.
C.
Replace condenser fan motor.
D.
Compressor contactor
inoperable.
D.
Replace compressor contactor.
A.
Agitator motor propeller
obstructed.
A.
Remove obstruction.
B.
Low voltage.
B.
Voltage must be at least 187 volts
(domestic) or 198 volts (export) 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.
46
WARRANTY
IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire product, 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 D 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
47
312022000
IMI CORNELIUS INC.
CORPORATE HEADQUARTERS:
One Cornelius Place
Anoka, Minnesota 55303-6234
(612) 421-6120
(800) 238-3600