Cornelius 0 User manual

AURORAR10,000
COOLINGUNIT
Installation Manual
PRINTEDIN U.S.A
IMI CORNELIUS INC; 1988--93Ó
PartNo.300381000
July13,1988
Revised:April 12,1993
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i300381000
TABLEOFCONTENTS
Page
GENERALINFORMATION1..................................................
GENERALDESCRIPTION1..............................................
COOLINGUNITDESCRIPTION1.........................................
SYSTEMTHEORYOFOPERATION3.....................................
INSTALLATION5............................................................
UNPACKINGAND INSPECTION5........................................
IDENTIFICATIONOFLOOSE-SHIPPEDPARTS5...........................
SELECTINGLOCATION5................................................
COOLINGUNIT5...................................................
REMOTECONDENSER COILAND FANASS’Y6......................
INSTALLINGREMOTECONDENSER COILAND FANASS’Y6...............
INSTALLINGCOOLINGUNIT6...........................................
PLACINGCOOLINGUNITINLOCATION6............................
CONNECTINGREMOTECONDENSER COILAND FANASS’Y
REFRIGERATIONLINES TOCOOLINGUNIT7........................
CONNECTINGELECTRICALPOWER CIRCUIT TOCOOLINGUNIT7....
CONNECTINGPLAINWATERINLETSUPPLYLINETOCOOLINGUNIT9
CONNECTINGCO2INLETSUPPLYLINETOCOOLINGUNIT9.........
CONNECTINGSYRUP SOURCELINES TOCOOLINGUNITSYRUP
INLETLINES 9.....................................................
CONNECTINGCOOLINGUNITSYRUPOUTLETLINES TOINSULATED
PYTHONSYRUPLINES 10...........................................
CONNECTINGCOOLINGUNITPLAINWATEROUTLETLINETO
INSULATEDPYTHONPLAINWATERLINE10...........................
CONNECTINGCOOLINGUNITCARBONATEDWATEROUTLETLINES TO
INSULATEDPYTHON CARBONATEDWATERLINES 10.................
PLACINGCOOLINGUNITINOPERATINGPOSITION10.....................
PREPARINGCOOLINGUNIT FOROPERATION11......................
OPERATION11......................................................
STARTINGCOOLINGUNITREFRIGERATIONSYSTEM12...............
STARTINGCARBONATEDWATER CIRCULATINGPUMP12.............
ACTIVATINGSYRUP SYSTEMS12....................................
LEAK CHECK AND INSULATINGCOOLINGUNITOUTLETLINES 13......
DISPENSINGSTATIONADJUSTMENTS13.............................
INSTALLINGLINEIDENTIFICATIONLABEL 13..........................
OPERATORSINSTRUCTIONS15..............................................
OPERATINGCONTROLS15..............................................
COOLINGUNITREFRIGERATIONPOWERSWITCH 15.................
COOLINGUNITCARBONATORMOTORSWITCH 15....................
COOLINGUNITCIRCULATINGMOTORSWITCH 15.....................
REFRIGERATIONSYSTEMTEMPERATURE SENSINGDEVICE AND
HIGH-PRESSURECUTOUTSWITCH 15...............................
DAILY PRE-OPERATION CHECK16...................................
ADJUSTMENTS16.......................................................
ADJUSTINGCO2REGULATORS16...................................

ii
300381000
TABLEOFCONTENTS(cont’d)
Page
ADJUSTINGDISPENSINGVALVES WATERFLOWRATE16.............
ADJUSTINGWATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT16.
ADJUSTINGSIZEOFDRINKDISPENSED16...........................
ADJUSTINGCARBONATORTANKLIQUIDLEVEL 16....................
REPLENISHINGCO2SUPPLY16......................................
REPLENISHINGSYRUP SUPPLY17...................................
CLEANINGAND SANITIZING17...........................................
DAILYCLEANING17.................................................
SANITIZINGSYRUP SYSTEMS17.....................................
COOLINGUNITMAINTENANCE17........................................
COOLINGUNITEQUIPPEDWITH CONDENSER COILAND AIR
INTAKE FILTER17...................................................
COOLINGUNITCARBONATORMAINTENANCE17.....................
COOLINGUNITCARBONATEDWATER CIRCULATINGPUMPMOTOR
LUBRICATION18....................................................
REMOTECONDENSER COILAND FANASS’YMAINTENANCE18............
CLEANINGCO2GAS CHECK VALVES 18..................................
SERVICEAND MAINTENANCE19.............................................
PREPARINGCOOLINGUNIT FORSHIPPING,STORING,OR RELOCATING19
PERIODICINSPECTION19...............................................
COOLINGUNITMAINTENANCE20........................................
PERIODIC CLEANING20.............................................
CLEANINGCONDENSER COIL 20.....................................
CHECKINGICEWATERBATH20......................................
CHANGINGICEWATERBATH21.....................................
WATERPUMP YEARLYMAINTENANCE(ORAFTERWATER
SYSTEMDISRUPTIONS)21..........................................
CARBONATEDWATER CIRCULATINGPUMPMOTORLUBRICATION26......
ADJUSTMENTS26.......................................................
PRIMARYCO2REGULATOR26.......................................
SECONDARYCO2REGULATORS27..................................
WATERFLOWRATE28..............................................
WATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT28.............
ADJUSTINGCARBONATORSTANKS LIQUIDLEVELS28................
CLEANINGAND SANITIZING28...........................................
DAILYCLEANING OFUNIT28........................................
SANITIZINGPOST-MIX SYRUP SYSTEMS29..........................
REPLENISHINGCO2SUPPLY31......................................
REPLENISHINGSYRUP SUPPLY32...................................
SYRUPFLAVOR CHANGE32.........................................
CLEANINGCO2SYSTEMGAS CHECK VALVES 32..........................
SECONDARYCO2REGULATORS AND CO2MANIFOLD CO2GAS
CHECK VALVES 32..................................................
CARBONATORSCO2INLETLINES CO2GAS CHECK VALVE 32.........
CONNECTINGEXTERNALCARBONATORTOCOOLINGUNIT32........

iii 300381000
TABLEOFCONTENTS(cont’d)
Page
TROUBLESHOOTING39......................................................
WATER-TO-SYRUP‘‘RATIO’’ OFDISPENSED DRINKTOO LOWOR
TOO HIGH.39...........................................................
ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES
NOTINCREASE TODESIREDWATER-TO-SYRUP‘‘RATIO”39...............
ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES
NOTDECREASE TODESIREDWATER-TO-SYRUP‘‘RATIO’’.40.............
DISPENSEDPRODUCTCARBONATIONTOO LOW.40......................
DISPENSEDPRODUCTCOMES OUTOFDISPENSINGVALVE CLEARBUT
FOAMSIN CUP.40.......................................................
DISPENSEDPRODUCTPRODUCES FOAMAS ITLEAVES DISPENSING
VALVE.40...............................................................
ONLYCARBONATEDWATER DISPENSED.40..............................
ONLY SYRUPDISPENSED.41............................................
WARMPRODUCTBEINGDISPENSED.41..................................
WATERPUMPMOTORWILL NOTOPERATE.41............................
WATERPUMPMOTORWILL NOTSHUTOFF.41...........................
ERRATIC CYCLING OFCARBONATOR.42.................................
WATERPUMPMOTOROPERATES BUTWATERPUMPDOES NOTPUMP
WATER42...............................................................
WATERPUMPCAPACITYTOO LOW.42...................................
COMPRESSOR DOES NOTOPERATE.42..................................
COMPRESSOROPERATES CONTINUOUSLY BUTDOES NOT FORM
SUFFICIENTICE BANK.43...............................................
CONDENSERFANMOTOR NOTOPERATING.44...........................
AGITATORMOTOR NOTOPERATING.44..................................
WARRANTY45..............................................................
LISTOF FIGURES
FIGURE1.AURORAR10,000 COOLINGUNIT1............................
FIGURE2.FLOWDIAGRAM(TYPICALINSTALLATION)4...................
FIGURE3.240/24VACPOWERTRANSFORMER7.........................
FIGURE4.COOLINGUNITSPACEREQUIRED10...........................
FIGURE5.PARTSIDENTIFICATION(STANDARD COOLINGUNITW/INTERNAL
CONDENSER COILAND FANASSEMBLY)22...............................
FIGURE6.PARTSIDENTIFICATION(COOLINGUNITREQUIRINGCONNECTION
TOREMOTECONDENSER COILAND FANASSEMBLY)23..................
FIGURE7.CARBONATORLIQUIDLEVELCONTROLSWITCHES 25..........
FIGURE8.WATERSTRAINERSCREENAND LIQUID DOUBLECHECK
VALVE 26................................................................
FIGURE9.LIQUID CHECK VALVE ASSEMBLY27...........................
FIGURE10.CO2GAS CHECK VALVE 32...................................
FIGURE11.REFRIGERATIONFLOWDIAGRAM(STANDARD COOLINGUNIT
W/INTERNALCONDENSER COILAND FANASS’Y)33.......................
FIGURE12.REFRIGERATIONFLOWDIAGRAM(COOLINGUNITREQUIRING
CONNECTIONTOREMOTECONDENSER COILAND FANASS’Y)34.........
FIGURE13.WIRINGDIAGRAM(LOW-VOLTAGE SYSTEM)35................

iv
300381000
TABLEOFCONTENTS(cont’d)
Page
LISTOF FIGURES CONT’D)
FIGURE14.WIRINGDIAGRAM(LOW-VOLTAGE SYSTEM)36................
FIGURE15.WIRINGDIAGRAM(HIGH-VOLTAGE SYSTEM)37...............
LISTOF TABLES
TABLE1.DESIGN DATA2...............................................
TABLE2.LOOSE-SHIPPEDPARTS5.....................................

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GENERALINFORMATION
IMPORTANT:To theuserof thismanual-Thismanual isaguideforinstalling,operating,and
maintaining this equipment.Referto TableofContentsforpagelocation ofdetailedinformation
pertaining to questionsthatarise during installation,operation,service and maintenance,or
trouble-shooting this equipment.
GENERALDESCRIPTION
This section givesthe description, theoryofoperation,and design dataforthe AuroraR10,000 Cooling Unit,
(hereafter referred to asa‘‘Cooling Unit’’).
COOLINGUNITDESCRIPTION
The Cooling Unitisdesigned to provide cooled soft drink syrup,carbonated water,and plainwaterto dispensing
station through an insulated python (length asordered).Onthe standardCooling Unit, refrigeration systemis
cooled by condensercoil and fan assemblylocated inside the Cooling Unit. Cooling Unitnotprovided with
internalcondensercoil and fan assemblyis cooled byRemoteCondenserCoil and Fan Assemblywhichis
connected toCooling Unit. The Cooling Unitconsistsbasicallyof twocarbonatortanks each having itsown
waterpumpto pump plainwaterintotanks,one carbonated watercirculating pump,aHydroBoostâ
(carbonated waterpre-cooler) which pre-cools carbonated wateron itswaytocarbonated watercirculating
pumpandatwo horsepower refrigeration compressor.The cabinetpanelsare easilyremoved tofacilitate
installation and service and maintenance.
An optionalCooling UnitStand (P/N309309000)isavailableto elevateCooling Unitup off floor.A System
StatusDisplayKit(P/N0913)isavailable and when installed on the Cooling Unit, allowsoperatorortechnician
tomonitoroperation ofCooling Unitand to be awarewhen serviceisrequired.Also availableisan Aurora
ServiceSystemAnalyzer (P/N309197000)thatmaybe used to analyze and troubleshoot the Aurora 10,000
Cooling Unitrefrigeration system.
CAUTION:Before shipping or relocating Cooling Unit,syrup cooling coilsmustbe
sanitizedand all sanitizing solution mustbepurgedfromcoils.All watermustalso be
purgedfromplainand carbonatedwatersystems.Afreezing ambientenvironmentwill
cause residualsanitizing solution orwater remaining insideCooling Unit tofreezeresulting in
damagetointernalcomponents.
FIGURE1.AURORAR10,000 COOLINGUNIT

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Table 1.Design Data
COOLINGUNITMODELNUMBERS:
60 HZUnit:
StandardCooling UnitwithInternalCondenserCoil and Fan Assembly416593
Cooling UnitRequiring Connection toRemoteCondenserCoil and Fan
Assembly416594
50 HZUnit:
StandardCooling UnitwithInternalCondenserCoil and Fan Assembly496593
COOLINGUNITDATA
Overall Dimensions:
Height28-inches
Width 36-1/2inches
Depth 24-1/2inches
NOTE:Overall dimensionsifCooling Unitisplaced on optionalCooling UnitStand (P/N309309069).
Height(approximate)75-5/16 inches
Width 37-1/2inches
Depth 25-3/8inches
Weights:
Models416593 and 496593:
Shipping 378 pounds
DryWeight358 pounds
Model416594:
Shipping 381 pounds
DryWeight361 pounds
IceBankWeight40 to 45 pounds
Capacities:
WaterBath(no ice bank)18 gallons
CompressorHorsepower2HP
Refrigeration System:
RefrigerantType and Charge See Cooling UnitNameplate
AmbientOperating Temp.50° Fto 100° F
ElectricalRequirements:
60 HZCooling Unit:
Operating voltage
CurrentDrawSee Cooling Unit Nameplate
50HZCooling Unit:
Operating Voltage
CurrentDrawSee Cooling Unit
Nameplate

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Table 1.Design Data(cont’d)
REMOTECONDENSER COILAND FAN ASS’YDATA(P/N309602000)
Overall Dimensions:
Height27 inches
Width 22-inches
Depth 38-inches
Weight:
Shipping 85 pounds
AmbientOperating Temp.-22° Fto 158° F
ElectricalRequirements:
Operating Voltage 208/230VAC,SinglePhase,
60Hz
CurrentDraw2.5Amps
SYSTEMTHEORYOFOPERATION
(see Figure 2)
ACO2cylinderdelivers carbon dioxide gas(CO2)to primaryCO2regulatorassemblywhich deliversregulated
CO2gasto adjustablesecondaryCO2regulators.SecondaryCO2regulatorsdeliver regulated CO2gasto both
carbonated watertanks inside Cooling Unitand alsotosoft drinktanks.Plainwaterispumped intocarbonated
watertanks bywaterpumpsand is carbonated byregulated CO2gaspressure also entering tanks.Carbonated
waterleaves carbonated watertanks and passesthrough the HydroBoostR(carbonated waterpre-cooler)
which pre-cools carbonated wateron itswaytocarbonated watercirculating pump.Pre-cooled carbonated
waterenters carbonated watercirculating systemthrough inletside ofcarbonated watercirculating pump.
Carbonated waterpassesfromoutletside ofcarbonated watercirculating pump, through cooling coilsinside
watertank,and out through insulated line toturnaround inside dispensing station.Carbonated water returnsto
Cooling Unitbypassing through insulated line, through cooling coils,and on tocarbonated watercirculating
pumpinletwhichmakesup the carbonated watercirculating system.As carbonated waterisbeing dispensed
fromdispensing station,carbonated watercirculating systemis continuouslybeing replenished fromboth
carbonated watertanks.Regulated CO2gaspressure,exerted upon soft drinktanks contents, forces syrup
fromtanks, through Cooling Unitcooling coils,and on to dispensing station through insulated lines.
StandardCooling Unit.
The standardCooling Unitrefrigeration systemis cooled byacondensercoil and fan assemblylocated inside
Cooling Unit.
Cooling UnitRequiring Connection toRemoteCondenserCoil and Fan Assembly.
The Cooling Unitrefrigeration systemis cooled byaRemoteCondenserCoil and Fan Assembly
(P/N309602000)thatisauthorized byIMICorneliusInc.Use ofanyotherRemoteCondenserCoil and Fan
Assemblymustbe authorized byIMICorneliusInc.Use ofan unauthorized RemoteCondenserCoil and Fan
Assemblywill automatically voidthe Cooling Unit factorywarranty.

4
3
0
0
3
8
1
0
0
0
LINE LEGEND CO2 PLAIN WATER CARB WATER SYRUP
SHUTOFF
VALVE
WATER PRESSURE
REGULATOR
WATER FILTER
ASS’Y
PLAIN WATER
SOURCE
PLAIN WATER
SHUTOFF VALVE
SUGAR SYRUP
CO2REGULATOR
DIET SYRUP
CO2REGULATOR
CO2GAS CHECK
VALVE(5)
CARBONATORS CO2
REGULATORS
GAS CHECK
VALVE(2) CO2MANIFOLD
PRIMARY CO2
REGULATOR
CO2CYLINDER SOFT DRINK TANKS
SYRUP
LINES
PLAINWTR
CARB WTR
CARB WTR
HYDRO BOOSTR
BYPASS VALVE
CHECK
VALVE
TEE FITTING
HYDDRO
BOOSTR
CARBONATED
WATER
CIRCULATING
PUMP
CARBONATOR
WATER PUMP(2)
DOUBLE
LIQUID
CHECK
VALVE(2)
EXTERNAL
CARBONATOR
CARBONATED
WATER
SHUTOFF
VALVE(2)
SINGLE
LIQUID
CHECK
VALVE(2)
CO2GAS CHECK VALVE
CARBONATED
WATER TANK(2)
FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION)

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INSTALLATION
This section coversunpacking and inspection,selecting location,installing Cooling Unit, preparing foroperation,
and operation.
UNPACKINGAND INSPECTION
NOTE:TheCooling Unitwas thoroughlyinspected beforeleaving thefactory and the carrierhas
acceptedand signedforit.Anydamageorirregularities should benotedat timeofdelivery(ornotlater
than15 days fromdateofdelivery)and immediatelyreportedtothedelivering carrier.Requestawritten
inspection report fromClaimsInspectortosubstantiate anynecessary claim.File claimwiththe
delivering carrier,notwithIMICorneliusInc.
1.AfterCooling Unithasbeen unpacked,removeshipping tape and otherpacking material.
2.Unpack LOOSE-SHIPPEDPARTS.Makesure all itemsare presentand in good condition.
Table 2.Loose-ShippedParts
Item
No.PartNo.NameQty.
1 110085000 Tubing Clamp 2
2 111353000 Tubing Clamp 7
3 311962000 Label,Line Identification 1
NOTE:Thefollowing RemoteCondenserCoil and FanAssembly and Refrigeration Lines Kits arerec-
ommendedforuse withtheCooling
Units.
4 309602000 RemoteCondenserCoil and Fan Ass’y1
5 300598025 Refrigeration Line Kit, 25-ft. long,90°1
300598050 Refrigeration Line Kit, 50-ft. long,90°Straight1
IDENTIFICATIONOF LOOSE-SHIPPEDPARTS
1.TUBINGCLAMPS (item1)used tosecureinsulated python linestoCooling Unitcarbonated wateroutlet
lines.
2.TUBINGCLAMPS (item2)used tosecureinsulated python linestoCooling Unitsyrup and plainwater
lines.
3.REFRIGERATIONLINE KITS(item5)isused toconnect the REMOTECONDENSER COILAND FAN
ASS’Y(item4)tothe Cooling Unit.
SELECTINGLOCATION
COOLINGUNIT
Selectlocation forCooling Unitinstallation thatwill (1)Allowthe shortestpossibleinsulated python routefrom
the Cooling Unit tothe Dispensing Station location;(2)Allowthe shortestpossiblerefrigeration lines(not to
exceed 50-ft inlength) routefromRemoteCondenserCoil and Fan Assemblytothe Cooling Unit; (3)REFER
TOTHECOOLINGUNITNAMEPLATEFORTHEREQUIREDPOWER CIRCUITOPERATINGVOLTAGE,HZ,
AND THEMINIMUMCIRCUITAMPACITYOF THECOOLINGUNIT.The powercircuit forthe Cooling Unit
mustbe wired through a 40-ampminimumrated disconnectswitch(notprovided)and the powercircuitmustbe

300381000 6
fused asindicated on the Unitnameplate.The powercircuitmayalsobewired through an equivalentHACR
type circuitbreaker ratherthen the disconnectswitch.THE POWER CIRCUITMUSTBE MADEUPOF
COPPER CONDUCTORS AND ALL WIRINGMUSTCONFORMTONATIONALAND LOCALELECTRICAL
CODES;(4)Closetoaplainwatersourcesupplyline with proper requirements;(5)Allowsufficientspace
around Cooling Unit(see Figure 4)forproperaircirculation (18-incheson sidesand back, frontside open to
room,and top open toceiling);(6)Becloseto permanent floordraintorouteCooling Unitwatertankdrain and
overflowhosestothe floordrain.
REMOTE CONDENSER COILAND FAN ASS’Y(IFAPPLICABLE)
1.An extremewarmclimateinstallation mayrequire extracaution inRemoteRooftop CondenserCoil and
Fan Assemblylocation.Avoid hotsunnylocationsand seek shaded area ifpossible.The use ofstructure
toshade unit fromdirectsun exposure and/ora platformextending unitan additional18-inchesabove
rooftop ishighlyrecommended and will improve performance.Amplespacemustbe provided on all sides
and above unit forproperaircirculation through unitand also access forservice and maintenance.DO
NOTBLOCK AIR CIRCULATIONTHROUGH UNIT.
2.RemoteCondenserCoil and Fan Assemblymustbe installed inlevelposition and mustbe anchored to
rooftop with adequatefastening devices.
INSTALLINGREMOTECONDENSER COILAND FAN ASS’Y(IF
APPLICABLE)
see Figure 6
1.RemoteCondenserCoil and Fan Assemblymustbe installed meeting requirementsofSELECTING
LOCATION.RemoteCondenserCoil and Fan Assemblymustbe installed inlevelposition and mustbe
anchored towith adequatefastening devices.
2.RouteREFRIGERATIONLINES (item5)fromRemoteCondenserCoil and Fan AssemblydowntoCooling
Unitlocation.
3.Connectendsofrefrigeration linestoRemoteCondenserCoil and Fan Assemblyrefrigeration connectors.
INSTALLINGCOOLINGUNIT
NOTE:Cooling Unitoutletlines,plainwater,CO2,and syrup inletlines,RemoteCondenserCoil and
FanAssemblyrefrigeration lines and powercircuitcable(ifapplicable),and Cooling Unitpowercircuit
cable eachmustbelong enough whenconnectedtoCooling Unit toallowpulling unitout
approximately 36-inches fromoperating position forservice and maintenance.WhenCooling Unitisin
operating position,excess powercircuitcable,RemoteCondenserCoil and FanAssemblyrefrigeration
lines and powercircuitcable(ifapplicable)and plainwatersource and CO2inletlines may be coiled up
behind unit.
NOTE:Anexternalcarbonatormay be connectedtoCooling Unitas shownin Figure2forlargersupply
ofcarbonatedwater.
PLACINGCOOLINGUNITINLOCATION
NOTE:An optionalCooling UnitStand (P/N309309069)is availabletoelevateCooling Unitup off floor.
1.PlaceCooling Unitin position approximately36-inchesout fromoperating position to allowaccess all
around unit.
2.Removetwoscrews securing Cooling Unit top cover, then removecover.

7300381000
CONNECTINGREMOTE CONDENSER COILAND FAN ASS’Y(IFAPPLICABLE)
REFRIGERATIONLINES TOCOOLINGUNIT
(see Figure6)
Connectrefrigeration lines, fromRemoteCondenserCoil and Fan Assembly, torefrigeration connectorson
back ofCooling Unit.
CONNECTINGELECTRICALPOWER CIRCUIT TOCOOLINGUNIT
(see Figures5 or6 and 15)
IMPORTANT:Before applicable single-phase 60HZ or50HZelectricalpowercircuitis connectedtothe
Cooling Unit,service powervoltage entering thebuilding mustbeidentified.Service powervoltage
entering thebuilding will eitherbe 208 or230VAC and may bepostedonthemainservice box. Ifnot,
theinstallermustcontact thelocalelectricalpowercompanyforinformation. If these twovoltage
identification attempts shouldfail, a voltagereading mustbeperformed. Ifservice powervoltageis
below218VAC,theredelectricalwire connectedtothe 240VAC terminalon LINE(primary)sideof the
240/24VAC powertransformerinsidetheCooling Unitswitches electricalcontrolbox(see Figure3and
15)mustbedisconnectedfromthe 240VAC terminaland be connectedtothe 208VAC terminal. If
voltageis above 218VAC,powertransformer redelectricalwirewill remainconnectedtothe 240VAC
terminal. Ifinstallerisnotsureof the service powervoltage entering thebuilding, leave thered
electricalwire connectedtothe 240VAC terminalon thepowertransformer. Ifservice powervoltageis
below218VAC,proceedas follows:
1.Removefourscrews securing switcheselectricalcontrolbox(see Figure5or6)toCooling Unitcabinet.
2.Pull switcheselectricalcontrolboxout foraccess tothe 240/24VACpowertransformer.
3.Removered electricalwirefromthe 240VACterminalon LINE(primary)side ofpowertransformerand
connectit tothe 208 VACterminal.
4. Install Cooling Unitswitcheselectricalcontrolboxand securewithfourscrews.
RESETBUTTON
C
208V
240V
FIGURE3.240/24VAC POWERTRANSFORMER
WARNING:Make sure 40-ampminimum-rated disconnectswitch orHACR circuitbreaker(if
applicable)isin‘‘OFF’’ position.
1.Removecoverfromelectricalboxon back ofCooling Unit.

300381000 8
WARNING:TheCooling Unitmustbe electricallygroundedtoavoid possiblefatalelectrical
shock orseriousinjurytotheoperator.Agreen ground wireisprovidedinside electrical
boxtoconnectpowercircuitground wirewhichelectricallygroundstheCooling Unit.
2.60HZCooling Unit
Connect208/230VACSinglePhase 60Hzelectricalpowercircuitwith a 40-ampminimumrated disconnect
switch(notprovided)fused at40-amps(maximum)orcircuitconnected through an equivalentHACR circuit
breakerto electricalwiresinside electricalhandyboxon back ofcooling unit. DONOTCONNECT
ELECTRICALPOWERTOCOOLINGUNITAT THISTIME.
COOLINGUNITMUSTBE PROPERLYGROUNDED,POWER CIRCUITMUSTBE MADEUPOF
COPPER CONDUCTORS,AND ALL WIRINGMUSTCONFORMTONATIONALAND LOCAL
ELECTRICALCODES.
50HZCooling Unit
Connect208/230VACSinglePhase 50Hzelectricalpowercircuitwith a 40-ampminimumrated disconnect
switch(notprovided)fused at40-amps(maximum)orcircuitconnected through an equivalentHACR circuit
breakerto electricalwiresinside electricalhandyboxon back ofcooling unit. DONOTCONNECT
ELECTRICALPOWERTOCOOLINGUNITAT THISTIME.
COOLINGUNITMUSTBE PROPERLYGROUNDED,POWER CIRCUITMUSTBE MADEUPOFCOPPER
CONDUCTORS,AND WIRINGMUSTCONFORMTOAPPLICABLE ELECTRICALCODES.
CONNECTINGELECTRICALPOWER CIRCUIT TOREMOTECONDENSER COILAND FANASS’Y(IF
APPLICABLE)see Figures6 and 15)
CAUTION:TheCooling Unitrefrigeration systemis cooled by a RemoteCondenserCoil
and FanAssembly(P/N309602000) thatis authorized byIMICorneliusInc.Use ofan
unauthorizedRemoteCondenserCoil and FanAssemblywill automatically voidthe
Cooling Unit factorywarranty.
RemoteCondenserCoil and Fan Assembly(P/N309602000)
NOTE:Electricalpowercircuitmay be connectedtotheRemoteCondenserCoil and FanAssembly
(P/N309602000)intwoways.Thepreferredway isto drawelectricalpowerfromtheCooling Unit
contactorwhichallowstheRemoteCondenserCoil and Fanassemblyto operateonlywhenthe
Cooling Unitrefrigeration systemisoperating.Theoptionalway istoconnecta separate electrical
powercircuit (independentof the cooling unit) through anappropriatelyratedand fused disconnect
switch oranequivalentHACR circuitbreakerwhichallowstheRemoteCondenserCoil and Fan
Assemblyto operate atall times (independentofCooling Unitoperation).
Connectand route electricalpowercircuitcablefromRemoteCondenserCoil and Fan Assemblythrough fuse
box(notprovided), fused at15-amps(maximum)downtoCooling Unitlocation.REMOTECONDENSER COIL
AND FANASSEMBLYMUSTBE PROPERLYGROUNDED,POWER CIRCUITMUSTBE MADEUPOF
COPPER CONDUCTORS,AND ALL WIRINGMUSTCONFORMTONATIONALAND LOCALELECTRICAL
CODES.
A.Removefourscrews securing electricalcontrolboxtoCooling Unitback panel,(see Figure 6)then
pull controlboxout foraccess tocontactorinside box.
B.RouteRemoteCondenserCoil and Fan Assemblypowercable electricalwiresthrough electrical
handyboxon back ofCooling Unit toinside ofelectricalcontrolbox.
C.ConnectRemoteCondenserCoil and Fan Assemblypowercable electricalwirestoT1and T2
terminalson contactorinside Cooling Unitelectricalcontrolbox.

9300381000
D.Reinstall Cooling Unitelectricalcontrolboxand securewithfourscrews.
E. Install coveron electricalhandyboxon back ofCooling Unit.
CONNECTINGPLAINWATER INLETSUPPLYLINE TOCOOLINGUNIT
(see Figure 2)
NOTE:IMICorneliusInc.recommendsthatawatershutoff valve beinstalledin plainwaterinletsupply
line connectedtoCooling Unitand thatwatersupplybefiltered.WATERPIPE CONNECTIONSAND
FIXTURES DIRECTLYCONNECTEDTOAPOTABLEWATERSUPPLY SHALL BE SIZED, INSTALLED
AND MAINTAINED ACCORDINGTOFEDERAL,STATE,AND LOCAL LAWS.
CAUTION:PlainwaterinletsupplylinetoCooling Unitmustbe 1/2-inchI.D.minimum.
Check waterflowrateofwaterinletsupplyline.MINIMUMFLOWRATEMUSTBEAT LEAST
250-GALLONS PER HOUR. If flowrateisless than250-gallonsperhour,‘‘starving’’ of
carbonatorwaterpumpwill occur.Starving will allow waterpumpto overheatcausing safety
thermostaton pump outlet to disruptelectricalpowertoand stop waterpumpmotor.Carbonated
watercirculating pump overheating could occurifwaterinletsupplylineflowratedropsbelow
250-gallonsperhour. INCOMINGPLAINWATERINLETSUPPLYLINEWATERPRESSUREMUST
REMAINAMINIMUMOF10-PSIBELOWTHECARBONATOR CO2OPERATINGPRESSURE
(Example:operating CO2pressureis 90-psiand maximumwaterpressure can beno morethan
80-psi, etc.)
1.Beforeconnecting plainwaterinletsupplyline toCooling Unit, open waterline shutoff valvefora period of
timetoflush outanymetalshavingsand othercontaminatesthatmayhaveresulted fromplumbing
connections.
2.Connect flexible plainwaterinletsupplyline (1/2-inchI.D.min.),meeting waterinletsupplyline
requirementsofpreceding CAUTIONnote, toCooling Unit3/8-in. flare(5/8-18)bulkhead fitting on back of
unitlabeled ‘‘WATERINLET’’.DONOTOPENWATERINLETSUPPLYLINE SHUTOFF VALVE AT THIS
TIME.
CONNECTINGCO2INLETSUPPLYLINE TOCOOLINGUNIT
(see Figure 2)
WARNING:CO2displaces oxygen.Strictattention mustbeobservedintheprevention of
CO2(carbon dioxide)gas leaks inthe entireCO2and soft drink system. IfaCO2gas leak is
suspected,particularlyina small area,immediatelyventilatethe contaminatedarea before
attempting torepairtheleak.Personnelexposedto high concentration ofCO2gas will experience
tremorswhicharefollowedrapidlybyloss ofconsciousness and suffocation.
Connect flexibleCO2inletsupplyline toCooling Unit1/4-in. flare(7/16-20)bulkhead fitting ofback ofunit
labeled ‘‘CO2INLET’’.DONOT TURN ON CO2SUPPLYTOCOOLINGUNITAT THISTIME.
CONNECTINGSYRUP SOURCE LINES TOCOOLINGUNITSYRUP INLET LINES
(see Figure2)
Connectsyrup sourcelines, fromNo.1through No.6soft drinktanks location, toCooling Unitsyrup inletlines
labeled No.1through No.6.DONOTCONNECTSOFT DRINKTANKS INTOSYRUP SYSTEMS AT THIS
TIME.

300381000 10
CONNECTINGCOOLINGUNITSYRUP OUTLET LINES TOINSULATED PYTHON SYRUP
LINES
(see Figure 2)
ConnectCooling Unitsyrup outletlineslabeled No.1through No.6,with barbed fittingson theirends, to
insulated python lineslabeled No.1through No.6.SecureconnectionswithTUBINGCLAMPS (item2).
CONNECTINGCOOLINGUNITPLAINWATER OUTLET LINE TOINSULATED PYTHON
PLAINWATER LINE
(see Figure 2)
NOTE:Shutoff valve in plainwaterlineinsideCooling Unitmustremainclosedifplainwaterisnot
desiredatdispensing valve.
ConnectCooling Unitplainwateroutletline,with barbed fitting on itsend, toinsulated python plainwaterline.
Secureconnection withTUBINGCLAMP(item2).
CONNECTINGCOOLINGUNITCARBONATED WATER OUTLET LINES TOINSULATED
PYTHON CARBONATED WATER LINES
(see Figure 2)
ConnectCooling Unitcarbonated wateroutletlines,with barbed connectorson theirends, toinsulated python
carbonated waterlines.secureConnectionswithTUBINGCLAMPS (item1).
PLACINGCOOLINGUNITINOPERATINGPOSITION
1.Very carefully,moveCooling Unitback into operating position leaving space around unit(see Figure 4)as
specified inSELECTINGLOCATION.MAKE SURETHERE ARENOKINKS INSYRUPINLETLINES,
INSULATEDPYTHONINTERNAL LINES,CO2AND PLAINWATERINLETLINES,AND REMOTE
CONDENSERAND FANASSEMBLYREFRIGERATIONLINES (IFAPPLICABLE).
NOTE:To complywithNationalSanitation Foundation (NSF)requirements,Cooling Unitnotinstalled
on optionalCooling UnitStand (P/N309309069)musthave itsbase sealedtofloorwithDow-Corning
RTV731 orequivalent.
1.TiltCooling Unitup to expose bottomofunitbase.
2.Liberallyapply silastic sealantsuch asDow Corning (RTV731)orequivalenton unitbase bottomedges.
NOTE:Do notmove Cooling Unitafterpositioning orsealfromunitbase tofloorwill bebroken.
18--IN.18--IN.
18--IN.
COOLINGUNIT
AIRFLOW
(OPENTOROOM)
FIGURE4.COOLINGUNITSPACEREQUIRED

11 300381000
3.LowerCooling Unitinto operating position tocompletesealfromunitbasetofloor.Applyadditionalsealant
around bottomofbase.Sealmusthaveaminimumradiusof1/2-inchto preventcracks and crevicesand
to ensureacompleteseal.
4.RouteCooling Unitwatertankoverflowhoseto permanent floordrain.
5.Sealarea around overflowhosewheretheyexit fromunitusing permagumsealantorequivalent.
PREPARINGCOOLINGUNIT FOROPERATION
1.Makesure plug in end ofCooling Unitwatertankdrain hoseis secure.
2.Open shutoff valvein plainwaterinletsupplyline.Due toslow waterfill rate ofwaterlevelfloatcontrol,
watertankmaybe hand filled until water runsoutofwatertankoverflowhose.CLEAN
LOW-MINERAL-CONTENTWATERMUSTBE USEDWHEREALOCALWATERPROBLEMEXIST.
3.AdjustprimaryCO2regulator (see Figure 2)on CO2cylindertoaminimumnominalsetting of120-psior
24-psihigherthan highestsetting required bythe secondaryCO2regulators.Loosen CO2regulator
adjusting screwlocknut. Turn adjusting screwtothe right(clockwise)until regulatorgage registersnominal
120-psi, then tighten adjusting screwlocknut.
4.Adjustcarbonators secondaryCO2regulator (see Figure 2)to a nominal90-psi.Loosen CO2regulator
adjusting screwlocknut. Turn adjusting screwtothe right(clockwise)until regulatorgage registersnominal
90-psi, then tighten adjusting screwlock nut. CO2PRESSURETOCARBONATORSMUSTNOTEXCEED
120-PSIG.
CAUTION:Before starting refrigeration system,HydroBoostâcoil mustbe completely
floodedwithcarbonatedwaterto preventcoil freeze-up.Proceedas followstofill
carbonatedwatersystem.
5.Makesure bothcarbonated watershutoff valvesinside Cooling Unit(see Figure 2)arein‘‘OPEN’’ (handles
inline withtubing)positions.
6.MakesureHydroBoostâbypass valveinside Cooling Unit(see Figure 2)isin‘‘CLOSED’’ (handle notin
line withtubing)position.
7.MakesureCooling UnitREFRIGERATIONPOWER,CARBONATORMOTORS,and CIRCULATING
MOTORPowerswitchesarein‘‘OFF’’ (down)positions.
8.ConnectelectricalpowertoCooling Unitatdisconnectswitch.
9.PlaceCARBONATORMOTORSpowerswitchin‘‘ON’’ (up)position tostartcarbonators.
10.Dispensefromdispensing station until carbonated waterappearsatvalveindicating HydroBoostâand
carbonated watersystemhave been completelyfilled withcarbonated water.
OPERATION
WARNING:DisconnectelectricalpowertoCooling Unitand RemoteCondenserCoil and
FanAssembly(ifapplicable) to preventpersonal injurybefore attempting anyCooling Unit
orRemoteCondenserCoil and FanAssemblyinternalmaintenance.Onlyqualified
personnelshouldservice internalcomponentsorelectricalwiring.

300381000 12
STARTINGCOOLINGUNITREFRIGERATION SYSTEM
NOTE:Asice bankformsinwatertank,waterexpansion will take place and excess waterwill escape
through watertankoverflowhose to permanent floordrain.
Cooling UnitConnected ToRemoteCondenserCoil and Fan Assembly.(P/N309602000).
PlaceCooling UnitREFRIGERATIONPOWERswitchin‘‘ON’’ (up)position.Refrigeration compressor,
compressorcooling fan,agitatormotor,and RemoteCondenserCoil and Fan Assemblywill start. Cooling Unit
will beginforming an ice bankand refrigerated HydroBoostâcoil will alsobechilling water.When full ice bank
hasbeen formed,RemoteCondenseroil and Fan Assembly,Cooling Unitcompressor,and compressorcooling
fan will stop butagitatormotorwill continue to operatecirculating icewaterbathinwatertank.
StandardCooling UnitUtilizing CondenserCoil and Fan Assembly.
PlaceCooling UnitREFRIGERATIONPOWERswitchin‘‘ON’’ (up)position.Refrigeration compressor,
condenserfan motor,and agitatormotorwill startand beginforming an ice bank.When full ice bankhasbeen
formed,compressorand condenserfan motorwill stop but, agitatormotorwill continue to operatecirculating ice
waterbathinwatertank.
STARTINGCARBONATED WATER CIRCULATINGPUMP
1.PlaceCIRCULATINGMOTORpowerswitchin‘‘ON’’ (up)position.Circulating pumpwill startand begin
circulating carbonated waterinsystem.
2.Dispensecarbonated waterfromdispensing valvetomakesure all airhasbeen purged fromsystem.
3. If Cooling Unitplainwateroutletline is connected to dispensing system,open plainwatershutoff valve
inside unit. Dispensefromvalve until all airispurged fromplainwatersystem.
ACTIVATINGSYRUP SYSTEMS
1.Adjustsoft drinktanks secondaryCO2regulators(see Figure 2)asfollows:
SugarSyrup Soft DrinkTanks CO2Regulator.
Adjustsugarsyrup soft drinktanks secondaryCO2regulatorat40-psigforsyrup linesup to 10-feetin
length plusone pound foreach additional length of10-feet, plusone pound foreach 2-feetofvertical lift.
Forexample:ifsyrup line total lengthis30-feetand totalvertical lift is6-feet, then 40-psig+2-psig
(1-pound forevery10-feetoflength over10-feetwhichis20-feet)+3-psig(1-pound forevery2-feetof
vertical lift whichis6-feet); totalequals40 +2+3=45-psigCO2regulatorsetting.
Low-Calorie(diet)Syrup Soft DrinkTankCO2Regulator.
Adjustlow-calorie(diet)soft drinktank secondaryCO2regulatorforlow-calorie drinkat10-psigforsyrup
linesup to 30-feetinlength.Syrup lineslongerthan 30-feetinlengthmayrequireaslightlyhigherCO2
regulatorsetting to 12-psigmaximum.ExcessiveCO2pressuremay causelow-caloriesyrup carbonation
resulting infoam.
IMPORTANT:Syrup systemsmustbe sanitizedas instructed before syrup is connectedintosyrup
systems.
2.Connectsoft drinktanks intosyrup systems.
3.Dispensefromall dispensing stationsdispensing valvesuntil productisdispensed.

13 300381000
LEAK CHECK AND INSULATINGCOOLINGUNITOUTLET LINES
1.Check all CO2,plain and carbonated water,and syrup connectionsforleaks and repairifevident.
2.MakesureCooling Unitoutletlines connectionstoinsulated python linesarewell insulated.
3. Install Cooling Unit top coverand securewithtwoscrews.
DISPENSINGSTATION ADJUSTMENTS
ADJUSTINGWATERFLOWRATE
RefertoInstallation Instructionsprovided with dispensing station fordispensing valvewaterflowrate adjustment
instructions.
ADJUSTINGWATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT
Adjustdispensing station dispensing valvesforWater- to-Syrup ‘‘Ratio’’ ofdispensed productasinstructed in
dispensing station Installation Instructions.
INSTALLINGLINE IDENTIFICATIONLABEL
Install LABEL,LINEIDENTIFICATION(item3)on Cooling Unitand recordsyrup flavorsin properspaces.

300381000 14
THIS PAGELEFT BLANKINTENTIONALLY

300381000
15
OPERATORSINSTRUCTIONS
This section coversoperating controls,dailypre-operation check,adjustments,replenishing CO2and syrup
supplies,cleaning and sanitizing,Cooling Unitmaintenance,RemoteCondenserCoil and Fan Assembly(if
applicable)maintenance,lubrication,and servicing CO2gas check valves.
WARNING:DisconnectelectricalpowertoCooling Unit to preventpersonal injurybefore
attempting anyCooling UnitorRooftop CondenserCoil and FanAssembly(ifapplicable)
internalmaintenance.Onlyqualified personnelshouldservice internalcomponentsor
electricalwiring.
OPERATINGCONTROLS
COOLINGUNITREFRIGERATION POWER SWITCH
(see Figure5or6)
REFRIGERATIONPOWERswitch,located on frontofCooling Unit, placed in‘‘OFF’’ position will interrupt
electricalpowertorefrigeration compressor,agitatormotor,condenserfan motor (ifapplicable),and carbonated
watercirculating pump.Switchmustbe in‘‘ON’’ (up)position foroperation.REFRIGERATIONPOWER
SWITCH DOES NOTDISRUPTELECTRICALPOWERTOCARBONATORS PUMPS MOTORS.
COOLINGUNITCARBONATORMOTOR SWITCH
(see Figure5or6)
CARBONATORMOTORSpowerswitch,located on frontofCooling Unit, placed in‘‘OFF’’ (down)position will
interruptelectricalpowerto bothcarbonatorspumpsmotors.Switchmustbe placed in‘‘ON’’ (up)position before
carbonatorswill operate.
COOLINGUNITCIRCULATINGMOTOR SWITCH
(see Figure5or6)
CIRCULATINGMOTORpowerswitch,located on frontofCooling Unit, placed in‘‘OFF’’ (down)position will
interruptelectricalpowertocarbonated watercirculating pump.Switchmustbe placed in‘‘ON’’ (up)position
beforecirculating pumpwill operate.
REFRIGERATION SYSTEMTEMPERATURE SENSINGDEVICE AND HIGH-PRESSURE
CUTOUTSWITCH
Cooling UnitwithInternalCondenserCoil and Fan Assembly.
(see Figure 5)
The Cooling Unitisequipped witharefrigeration systemtemperaturesensorwhichwill automaticallyinitiate
shutdownif the temperature of the liquidreturnline fromthe condenserexceeds155° F.Temperaturerisemay
be caused byaclogged condensercoil airintakefilter,or refrigeration componentsproblem.Aftercooldown,
the refrigeration systemwill restartasrequired.
CAUTION:If therefrigeration systemcontinues to‘‘shortcycle’’ following restart,
immediate attention isrequiredtoavoidcompressorfailure.