Cornelius 000 PLUS User manual

AURORAR10,000 PLUS
COOLINGUNIT
Installation Manual
PRINTEDIN U.S.A
IMI CORNELIUS INC; 1989--93Ó
PartNo.300614000
November8,1989
Revised:April 12,1993
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i300614000
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 TOCOOLINGUNIT6........................
CONNECTINGELECTRICALPOWER CIRCUIT TOCOOLINGUNIT7....
CONNECTINGELECTRICALPOWER CIRCUIT TOREMOTE
CONDENSER COILAND FANASS’Y8................................
CONNECTINGPLAINWATERINLETSUPPLYLINETOCOOLINGUNIT8
CONNECTINGCO2INLETSUPPLYLINETOCOOLINGUNIT9.........
CONNECTINGSYRUP SOURCELINES TOCOOLINGUNITSYRUP
INLETLINES 9.....................................................
CONNECTINGCOOLINGUNITSYRUPOUTLETLINES TOINSULATED
PYTHONSYRUPLINES 9...........................................
CONNECTINGCOOLINGUNITPLAINWATEROUTLETLINES TO
INSULATEDPYTHONPLAINWATERLINES 9.........................
CONNECTINGCOOLINGUNITCARBONATEDWATEROUTLETLINES TO
INSULATEDPYTHON CARBONATEDWATERLINES 9.................
PLACINGCOOLINGUNITINOPERATINGPOSITION10.....................
PREPARINGCOOLINGUNIT FOROPERATION10..........................
OPERATION11..........................................................
LEAK CHECK AND INSULATINGCOOLINGUNITOUTLETLINES 12..........
DISPENSINGSTATIONADJUSTMENTS12.................................
ADJUSTINGWATERFLOWRATE12..................................
ADJUSTINGWATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT12
INSTALLINGLINEIDENTIFICATIONLABEL 12..............................
OPERATORSINSTRUCTIONS13..............................................
OPERATINGCONTROLS13..............................................
COOLINGUNITREFRIGERATIONPOWERSWITCH 13.................
COOLINGUNITCARBONATORMOTORSWITCH 13....................
COOLINGUNITCIRCULATINGMOTORSWITCH 13.....................
REFRIGERATIONSYSTEMTEMPERATURE SENSINGDEVICE AND
HIGH-PRESSURECUTOUTSWITCH 13...............................
DAILY PRE-OPERATION CHECK14........................................
ADJUSTMENTS14.......................................................

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TABLEOFCONTENTS(cont’d)
Page
ADJUSTINGCO2REGULATORS14...................................
ADJUSTINGDISPENSINGVALVES WATERFLOWRATE14.............
ADJUSTINGWATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT14.
ADJUSTINGSIZEOFDRINKDISPENSED14...........................
REPLENISHINGCO2SUPPLY14..........................................
REPLENISHINGSYRUP SUPPLY14...................................
CLEANINGAND SANITIZING14...........................................
DAILYCLEANING14.................................................
SANITIZINGSYRUP SYSTEMS15.....................................
COOLINGUNITMAINTENANCE15........................................
COOLINGUNITAIRINTAKE AND EXHAUST FILTERS15................
CHECKINGICEWATERBATH15......................................
COOLINGUNITCARBONATORMAINTENANCE15.....................
DOUBLELIQUID CHECK VALVE ASSEMBLIES YEARLYMAINTENANCE
(ORAFTERWATERSYSTEMDISRUPTIONS).15.......................
COOLINGUNITCARBONATEDWATER CIRCULATINGPUMPMOTOR
LUBRICATION15....................................................
REMOTECONDENSER COILAND FANASS’YMAINTENANCE16............
CLEANINGCO2GAS CHECK VALVES 16..................................
SERVICEAND MAINTENANCE17.............................................
COOLINGUNITMAINTENANCE17........................................
PERIODIC CLEANING17.............................................
CLEANINGCOOLINGUNITAIRINTAKE AND EXHAUST FILTERS.17.....
PREPARINGCOOLINGUNIT FORSHIPPING,STORING,OR RELOCATING17
PERIODICINSPECTION17...............................................
REMOTECONDENSER COILAND FANASSEMBLYMAINTENANCE18.......
CHECKINGICEWATERBATH18......................................
CHANGINGICEWATERBATH18.....................................
DOUBLELIQUID CHECK VALVE ASSEMBLIES YEARLYMAINTENANCE
(ORAFTERWATERSYSTEMDISRUPTIONS)19.......................
LUBRICATION21........................................................
ADJUSTMENTS21.......................................................
PRIMARYCO2REGULATOR21.......................................
SECONDARYCO2REGULATORS21..................................
WATERFLOWRATE22..............................................
WATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT22.............
CLEANINGAND SANITIZING22...........................................
DAILYCLEANING OFUNIT22........................................
SANITIZINGPOST-MIX SYRUP SYSTEMS23..........................
REPLENISHINGCO2SUPPLY26..........................................
REPLENISHINGSYRUP SUPPLY26.......................................
SYRUPFLAVOR CHANGE27.............................................
CLEANINGCO2SYSTEMGAS CHECK VALVES 27..........................
SECONDARYCO2REGULATORS AND CO2MANIFOLD CO2GAS
CHECK VALVES 27..................................................

iii 300614000
TABLEOFCONTENTS(cont’d)
Page
COOLINGUNITCO2INLETLINECO2GAS CHECK VALVE 27...........
TROUBLESHOOTING30......................................................
WATER-TO-SYRUP‘‘RATIO’’ OFDISPENSED DRINKTOO LOWORTOO
HIGH.30................................................................
ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES
NOTINCREASE TODESIREDWATER-TO-SYRUP‘‘RATIO”.30...............
ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES
NOTDECREASE TODESIREDWATER-TO-SYRUP‘‘RATIO’’.31.............
DISPENSEDPRODUCTCARBONATIONTOO LOW.31......................
DISPENSEDPRODUCTCOMES OUTOFDISPENSINGVALVE CLEARBUT
FOAMSIN CUP.31.......................................................
DISPENSEDPRODUCTPRODUCES FOAMAS ITLEAVES DISPENSING
VALVE.31...............................................................
ONLYCARBONATEDWATER DISPENSED.31..............................
ONLY SYRUPDISPENSED.32............................................
WARMPRODUCTBEINGDISPENSED.32..................................
WATERPUMPMOTORWILL NOTOPERATE.32............................
WATERPUMPMOTORWILL NOTSHUTOFF.32...........................
ERRATIC CYCLING OFCARBONATOR.32.................................
WATERPUMPMOTOROPERATES BUTWATERPUMPDOES NOTPUMP
WATER.33..............................................................
WATERPUMPCAPACITYTOO LOW.33...................................
COMPRESSOR DOES NOTOPERATE.33..................................
COMPRESSOROPERATES CONTINUOUSLY BUTDOES NOT FORM
SUFFICIENTICE BANK34................................................
CONDENSERFANMOTOR NOTOPERATING35...........................
AGITATORMOTOR NOTOPERATING.35..................................
WARRANTY36..............................................................
LISTOF FIGURES
FIGURE1.AURORAR10,000 PLUSCOOLINGUNIT1.......................
FIGURE2.FLOWDIAGRAM(TYPICALINSTALLATION)4...................
FIGURE3.240/24VACPOWERTRANSFORMER7.........................
FIGURE4.COOLINGUNITSPACEREQUIRED10...........................
FIGURE5.PARTSIDENTIFICATION20....................................
FIGURE6.LIQUID CHECK VALVE ASSEMBLY22...........................
FIGURE7.CO2GAS CHECK VALVE 26....................................
FIGURE8.REFRIGERATIONFLOWDIAGRAM(REQUIRES CONNECTIONTO
REMOTECONDENSER COILAND FANASS’Y)28..........................
FIGURE9.WIRINGDIAGRAM29..........................................
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
troubleshooting this equipment.
GENERALDESCRIPTION
This section givesthe description, theoryofoperation,and design dataforthe AuroraR10,000 PlusCooling
Unit, hereafter referred too asaCooling Unit.
COOLINGUNITDESCRIPTION
The Cooling Unitisdesigned to provide cooled syrup,carbonated water,and plainwatertothe dispensing
station through an insulated python (length asordered).The Cooling Unitrefrigeration systemis cooled bya
RemoteCondenserCoil and Fan Assemblywhichis connected tothe Cooling Unit.
The Cooling Unitconsistsofarefrigeration systemwithatwo horsepowercompressorand a HydroBoostR
(plainwaterpre-cooler) which pre-coolsplainwateron itswaytothe carbonated watertank.The Cooling Unit
alsoconsistsofa plainwaterpump.The plainwaterpump pumpsplainwaterthrough the HydroBoostR,
through the plainwatercooling coils,and intothe carbonated watertank.The carbonated watercirculating
pumpcirculates coldcarbonated waterfromthe Cooling Unit tothe dispensing station and back tothe Cooling
Unit.
The cabinetpanelsare easilyremoved tofacilitateinstallation and service and maintenance.
An optionalCooling UnitStand (P/N309309000)isavailableto elevateCooling Unitup off floor.Also available
isan AuroraServiceSystemAnalyzer (P/N30919700)thatmaybe used to analyze and troubleshoot the
Cooling Unitrefrigeration system.
CAUTION:Before shipping or relocating theCooling Unitsyrup cooling coilsmustbe
sanitizedand all sanitizing solution mustbepurgedfromthe coils.All watermustalso be
purgedfromtheplainand carbonatedwatersystems.Afreezing ambientenvironmentwill
cause residualsanitizing solution orwater remaining insidetheCooling Unit tofreezeresulting in
damagetointernalcomponents.
FIGURE1.AURORAR10,000 PLUSCOOLINGUNIT

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Table 1.Design Data
COOLINGUNITDATA
ModelNo.416654
Overall Dimensions:
Height25-inches
Width 36-1/2inches
Depth 24-1/2inches
NOTE:Overall dimensionsifCooling Unitisplaced on optionalCooling UnitStand (P/N309309069).
Height(approximate)72-5/16 inches
Width 37-1/2inches
Depth 25-3/8inches
Weights:
Shipping 385 pounds
DryWeightpounds
IceBankWeight40 ±pounds
Capacities:
WaterBath(no ice bank)18 gallons
CompressorHorsepower2HP
Refrigeration System:
RefrigerantType and Charge See Cooling UnitNameplate
AmbientOperating Temp.50° Fto 100° F
ElectricalRequirements:
Operating Voltage See Cooling
Unit
Nameplate
CurrentDraw
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

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SYSTEMTHEORYOFOPERATION
(see Figure 2)
ACO2cylinderdelivers carbon dioxide gas(CO2)to primaryCO2regulatorassemblywhich deliver regulated
CO2gasto adjustablesecondaryCO2regulators.SecondaryCO2regulatorsdeliversregulated CO2gastothe
carbonated watertankinside the Cooling Unitand alsotothe soft drinktanks.Plainwaterentersthe Cooling
Unitand ispumped through and ispre-cooled bythe refrigerated HydroBoostâcoil.Cooled watercontinues
through the plainwatercooling coilsand intothe carbonated watertank.Cold plainwaterentering the
carbonated watertankis carbonated byregulated CO2gaspressure also entering the tank.Carbonated water
leavesthe carbonated watertankand entersthe inletside of the carbonated watercirculating pump.
Carbonated waterpassesthrough the carbonated watercirculating pump, through the carbonated watercooling
coil,and exitsthe Cooling Unit through an insulated python toaturnaround inside the dispensing station.
Carbonated water returnstothe Cooling Unitbypassing through the insulated python, through the Cooling Unit
carbonated watercooling coils, through the carbonated watertankwhichmakesup the carbonated water
circulating system.As carbonated waterisbeing dispensed fromthe dispensing station,carbonated water
circulating systemis continuouslybeing replenished fromthe carbonated watertank.
Plainwaterentersthrough the Cooling Unit two plainwaterinletlines, through the plainwatercooling coils,and
existsthe Cooling Unitout through insulated python tothe dispensing station.Regulated CO2gaspressure
exerted upon the soft drinks contentsforces syrup fromtanks, through Cooling Unitsyrup inletlines, through
syrup cooling coils,and existsthe Cooling Unitout through an insulated python tothe dispensing station.
The Cooling Unitrefrigeration systemis cooled byaRemoteCondenserCoil and Fan Assembly(P/N
309602000)thatisauthorized byIMICorneliusInc.Use ofanyotherRemoteCondenserCoil and Fan
Assemblymustbe authorized byIMICorneliusInc.Use ofan unauthorized RemoteCondenserCoil and Fan
Assemblywill automatically voidthe Cooling Unit factorywarranty.

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PLAIN WATER
SOURCE
SHUTOFF
VALVE
WATER PRESSURE
REGULATOR
WATER FILTER
ASS’Y
DIET SYRUP
CO2REGULATOR
SUGAR SYRUP
CO2REGULATOR
CARBONATOR
CO2REGULATOR
CO2MANIFOLD
CO2GAS CHECK
VALVE(10)
PRIMARY
CO2REGULATOR
CO2CYLINDER SOFT DRINK TANKS(10)
CARBONATED WATER
TANK ASS’Y
TO
DISPENSING
STATION
HYDRO BOOSTR
BYPASS SHUTOFF
VALVE
HYDRO BOOSTR
COIL
LIQUID
CHECK
VALVE
CO2
CHECK
VALVE
PLAIN
WATER PUMP
*WATER TANK
WATER LEVEL
CONTROL
CARBONATED WATER
CIRCULATING PUMP
*SOME COOLING UNITS MAY BE EQUIPPED WITH THE WATER LEVEL FLOAT CONTROL.
COOLING UNIT MODEL:
416654
COOLING UNIT DOUBLE LIQUID
CHECK VALVE ASS’Y(2)
LINE LEGEND CO2 CARB WATER PLAIN WATER SYRUP
FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION)

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INSTALLATION
This section coversunpacking and inspection,selecting location,installing the Cooling Unitand the Remote
CondenserCoil and Fan Assemblypreparing foroperation,and operation.
UNPACKINGAND INSPECTION
NOTE:TheCooling Unitand theRemoteCondenserCoil and FanAssemblywerethoroughlyinspected
beforeleaving thefactory and the carrierhas acceptedand signedforthem.Anydamageor
irregularities should benotedat timeofdelivery(ornotlaterthan15 days fromdateofdelivery)and
immediatelyreportedtothedelivering carrier.Requestawritteninspection report fromClaims
Inspectortosubstantiate anynecessary claim.File claimwiththedelivering carrier,notwithIMI
CorneliusInc.
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 309852000 Tubing Clamp 24
2 770407 Barbed Connector,1/4 by3/8 12
3 770424 Barbed Connector,1/2 by1/2 2
4 311962000 Label,Line Identification 1
NOTE:Thefollowing RemoteCondenserCoil and FanAssembly and Refrigeration LineKits arerec-
ommendedforuse withCooling Unit (P/N416654000).Refrigeration Lines Kit (as ordered)isusedto
connectCondenserCoil and FanAssemblytotheCooling Unit.
5 309602000 RemoteCondenserCoil and Fan Ass’y1
6 300598025 Refrigeration Line Kit, 25-ft. long,90 1
300598050 Refrigeration Line Kit, 50-ft. long,90 1
IDENTIFICATIONOF LOOSE-SHIPPEDPARTS
1.BARBED CONNECTORS(item2)used toconnectCooling Unitoutletlinestoinsulated python lines.
Connectionsaresecured withTUBINGCLAMPS (item1).
2.BARBED CONNECTORS(item3)are used toconnectCooling Unitoutletcarbonated waterlinesto
insulated python lines.
3.LABEL,LINEIDENTIFICATION(item4)tobeinstalled on Cooling Unitand syrup flavorstoberecorded in
properspaceson label.
4.REFRIGERATIONLINE KIT(items6)isused toconnectREMOTECONDENSER COILAND FANASS’Y
(item5)toCooling 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

6300614000
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)Sufficientspace around
Cooling Unit(see Figure4)forproperaircirculation (18-incheson sidesand back, frontside open toroom,and
top open toceiling);(6)Becloseto permanent floordraintorouteCooling Unitwatertankdrain and overflow
hosestothe floordrain.
REMOTE CONDENSER COILAND FAN ASS’Y
CAUTION:RemoteCondenserCoil and FanAssemblies authorized byIMICorneliusInc.
(P/N309602000)
1.An extremewarmclimateinstallation mayrequire extracaution inRemoteCondenserCoil and Fan
Assemblylocation.Avoid hotsunnylocationsand seek shaded area ifpossible.The use ofastructureto
shade the Unit fromdirectsun exposure and/ora platformextending Unitan additional18-inchesabove
the rooftop ishighlyrecommended and will improve performance.Amplespacemustbe provided on all
sidesand aboveUnit forproperaircirculation through Unitand also access forservice and maintenance.
DONOTBLOCK AIR CIRCULATIONTHROUGH UNIT.
2.RemoteCondenserCoil and Fan Assemblymustbe installed inlevelposition and mustbe anchored with
adequatefastening devices.
INSTALLINGREMOTECONDENSER COILAND FAN ASS’Y
(see Figure 6)
1.RemoteCondenserCoil and Fan Assemblymustbe installed meeting requirementsofSELECTING
LOCATION.RemoteCondenserCoil and Fan Assemblymustbe installed inalevelposition and mustbe
anchored with adequatefastening devices.
2.Routerefrigeration linesofREFRIGERATIONLINE KIT(item6)fromRemoteCondenserCoil and Fan
AssemblydowntoCooling Unitlocation.
3.Connectendsofrefrigeration linestoCondenserCoil and Fan Assemblyrefrigeration connectors.
INSTALLINGCOOLINGUNIT
NOTE:Cooling Unitoutletlines,plainwater,CO2,and syrup inletlines,RemoteCondenserCoil and
FanAssemblyrefrigeration lines and powercircuitcable,and Cooling Unitpowercircuitcable each
mustbelong enough whenconnectedtoCooling Unit toallowpulling Unitoutapproximately
36-inches fromoperating position forservice and maintenance.WhenCooling Unitisin operating
position,excess powercircuitcable,RemoteCondenserCoil and FanAssemblyrefrigeration lines and
powercircuitcable and plainwatersource and CO2inletlines may be coiled up behind Unit.
PLACINGCOOLINGUNITINLOCATION
NOTE:An optionalCooling UnitStand (P/N309309069)is availabletoelevateCooling Unitup and off
thefloor.
1.PlaceCooling Unitin position approximately36-inchesout fromoperating position to allowaccess all
around the Unit.
2.Removetwoscrews securing Cooling Unit top cover, then removecover.
CONNECTINGREMOTE CONDENSER COILAND FAN ASS’Y REFRIGERATIONLINES
TOCOOLINGUNIT
(see Figure 5)
Connectrefrigeration lines, fromRemoteCondenserCoil and Fan Assembly, torefrigeration connectorson front
ofCooling Unit.

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CONNECTINGELECTRICALPOWER CIRCUIT TOCOOLINGUnit
(see Figures5 and 9)
IMPORTANT:Before 208/230VAC single-phase 60Hzelectricalpowercircuitis connectedtothe cooling
unit,service powervoltage entering thebuilding mustbeidentified.Service powervoltage entering the
building will eitherbe 208 or230VAC and may bepostedonthemainservice box. Ifnot,theinstaller
mustcontact thelocalelectricalpowercompanyforinformation. If these twovoltageidentification
attempts shouldfail, a voltagereading Mustbeperformed. Ifservice powervoltageisbelow218VAC,
theredelectricalwire connectedtothe 240VAC terminalon LINE(primary)sideof the 240/24VAC power
transformerinsidethe cooling unitswitches electricalcontrolbox(see Figure3and 9)mustbe
disconnectedfromthe 240VAC terminaland be connectedtothe 208VAC terminal. Ifvoltageis above
218VAC,powertransformer redelectricalwirewill remainconnectedtothe 240VAC terminal. Ifinstaller
isnotsureof the service powervoltage entering thebuilding, leave redelectricalwire connectedtothe
240VAC terminalon thepowertransformer. Ifservice powervoltageisbelow218VAC,proceedas
follows:
1.Remove fourscrews securing electricalcontrolbox cover,thenremove coverforaccess tothe
240/24VAC powertransformer.
2.Remove redelectricalwirefromthe 240VAC terminalon LINE(primary)sideofpowertransformer
and connectit tothe 208VAC terminal.
RESETBUTTON
C
208V
240V
FIGURE3.240/24VAC POWERTRANSFORMER
WARNING:Make sure 40-ampminimum-rated disconnectswitch(notprovided)isin‘‘OFF’’
position.
1.Removecoverfromelectricalhandyboxon back ofCooling Unit.
WARNING:TheCooling Unitmustbe electricallygroundedtoavoid possiblefatalelectrical
shock orseriousinjurytotheoperator.Agreen ground wireisprovidedinside electrical
boxtoconnectpowercircuitground wirewhichelectricallygroundstheCooling Unit.
Connect208/230VACSingle-Phase 60Hzpowercircuit from40-ampminimumrated disconnectswitch(not
provided)fused at40-amps(‘‘slow-blow’’)to electricalwiresinside electricalhandyboxon back ofCooling Unit.
COOLINGUNITMUSTBE PROPERLYGROUNDED.POWER CIRCUITMUSTBE MADEUPOFCOPPER
CONDUCTORS,AND ALL WIRINGMUSTCONFORMTONATIONALAND LOCALELECTRICALCODES.
DONOTCONNECTELECTRICALPOWERTOCOOLINGUNITAT THISTIME.

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CONNECTINGELECTRICALPOWER CIRCUIT TOREMOTE CONDENSER COILAND
FAN ASS’Y
(see Figure 5 and 9)
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.
NOTE:Electricalpowercircuitmay be connectedtotheRemoteCondenserCoil and FanAssembly
(P/N309602000)intwoways.Thepreferredway isto drawelectricalpowerfromthe cooling 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).
1.Connectand route electricalpowercircuitcablefromRemoteCondenserCoil and Fan Assemblythrough
fuse box(notprovided), fused at15-amps(maximum)downtoCooling Unitlocation.REMOTE
CONDENSER COILAND FANASSEMBLYMUSTBE PROPERLYGROUNDED,POWER CIRCUIT
MUSTBE MADEUPOFCOPPER CONDUCTORS,AND ALL WIRINGMUSTCONFORMTONATIONAL
AND LOCALELECTRICALCODES.
2.RouteRemoteCondenserCoil and Fan AssemblyPowercable electricalwiresthrough electricalhandy
boxon back ofCooling Unit toinside ofelectricalcontrolbox.
3.ConnectRemoteCondenserCoil and Fan Assemblypowercable electricalwirestoT1and T2terminalson
contactorinside Cooling Unitelectricalcontrolbox.
4. Install electricalcontrolbox coverand securewithfourscrews.
5. 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
300-GALLONS PER HOUR. If flowrateisless than300-gallonsperhour,‘‘starving’’ of
carbonatorwaterpumpwill occur.Starving will allow waterpumpto overheatcausing safety
thermostaton pump outlet to disruptelectricalpowertoand stop waterpumpmotor.Carbonated
watercirculating pump overheating could occurifwaterinletsupplylineflowratedropsbelow
300-gallonsperhour. INCOMINGPLAINWATERINLETSUPPLYLINEWATERPRESSUREMUST
REMAINAMINIMUMOF10-PSIBELOWTHECARBONATOR CO2OPERATINGPRESSURE.
(Example:Operating pressureis 90-psiand maximumwaterpressure can beno morethan80-psi,
etc.)
1.Beforeconnecting plainwaterinletsupplyline toCooling Unit, open waterline shutoff valvefora period of
timetoflush outanymetalshavingsand othercontaminatesthatmayhaveresulted fromplumbing
connections.

9300614000
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 Figure 2)
Connectsyrup sourcelines, fromNo.1through No.10 soft drinktanks location, toCooling Unitsyrup inletlines
labeled No.1through No.10.DONOTCONNECTSOFT DRINKTANKS INTOSYRUP SYSTEMS AT THIS
TIME.
CONNECTINGCOOLINGUNITSYRUP OUTLET LINES TOINSULATED PYTHON SYRUP
LINES
(see Figure 2)
ConnectCooling Unitsyrup outletlineslabeled No.1through No.10, toinsulated python lineslabeled No.1
though No.10 using BARBED CONNECTORS(item2).SecureconnectionswithTUBINGCLAMPS (item1).
CONNECTINGCOOLINGUNITPLAINWATER OUTLET LINES TOINSULATED PYTHON
PLAINWATER LINES
(see Figure 2)
ConnectCooling Unitplainwateroutletlinestoinsulated python plainwaterlinesusing BARBED
CONNECTORS(item2).SecureconnectionswithTUBINGCLAMPS (item1).
CONNECTINGCOOLINGUNITCARBONATED WATER OUTLET LINES TOINSULATED
PYTHON CARBONATED WATER LINES
(see Figure 2)
NOTE:TheCooling Unitcarbonatedwateroutletlines areusedtomake up the carbonatedwater
circulating systembetweentheCooling Unitand thedispensing station as explainedinSYSTEM
THEORYOFOPERATIONinGENERALINFORMATIONSECTION.
ConnectCooling Unitcarbonated wateroutletlinestoinsulated python carbonated waterlinesusing BARBED
CONNECTORS(item3).

10300614000
18--IN.18--IN.
18--IN.
COOLINGUNIT
AIRFLOW
(OPENTOROOM)
FIGURE4.COOLINGUNITSPACEREQUIRED
PLACINGCOOLINGUNITINOPERATINGPOSITION
1.Very carefully,moveCooling Unitback into operating position leaving space around Unit(see Figure 4)as
specified inSELECTINGLOCATION.MAKE SURETHERE ARENOKINKS IN COOLINGUNITINLET
LINES,AND (IFAPPLICABLE)REMOTECONDENSERAND FANASSEMBLYREFRIGERATIONLINES.
NOTE:To complywithNationalSanitation Foundation (NSF)requirements,Cooling Unitnotinstalled
on optionalCooling UnitStand (P/N309309-069)musthave itsbase sealedtofloorwithDow-Corning
RTV731 orequivalent.
2.TiltCooling Unitup to expose bottomofUnitbase.
3.Liberallyapply silastic sealantsuch asDow-Corning (RTV731)orequivalenton Unitbase bottomedges.
NOTE:Do notmove Cooling Unitafterpositioning orsealfromUnitbase tofloorwill bebroken.
4.LowerCooling Unitinto operating position tocompletesealfromUnitbasetofloor.Applyadditionalsealant
around bottomofbase.Sealmusthaveaminimumradiusof1/2-inchto preventcracks and crevicesand
to ensureacompleteseal.
5.RouteCooling Unitwatertankoverflowhoseto permanent floordrain.
6.Sealarea around drain and overflowhoseswheretheyexit fromUnitusing Dow Corning (RTV731)or
equivalent).
PREPARINGCOOLINGUNIT FOROPERATION
1.Makesure plug in end ofCooling Unitwatertankdrain hoseis secure.
Note:SomeCooling Units are equippedwithawatertankwaterlevelfloatcontrol. Openshutoff valve
in plainwaterinletsupplyline.Duetoslow waterfill rateof thewaterlevelfloatcontrol, watertankmay
behand filled until water runsoutof thewatertankoverflowhose.CLEAN LOW-MINERAL-CONTENT
WATERMUSTBEUSEDWHEREALOCALWATERPROBLEMEXIST.
2.Fill watertankwithclean wateruntil waterstartsflowing fromwatertankoverflowhose.USE LOW
MINERALCONTENTWATERWHEREALOCALWATERPROBLEMEXISTS.
3.Open shutoff valvein plainwaterinletsupplyline.
4.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.

11 300614000
5.AdjustcarbonatorsecondaryCO2regulator (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.
OPERATION
WARNING:DisconnectelectricalpowertoCooling Unitand RemoteCondenserCoil and
FanAssemblyto preventpersonal injurybefore attempting anyCooling UnitorRemote
CondenserCoil and FanAssemblyinternalmaintenance.Onlyqualified personnelshould
service internalcomponentsorelectricalwiring.
CAUTION: to preventHydro-Boostâcoil freezeup during initialCooling Unitstart-up,the
following start-up proceduremustbeperformedas follows:
1.MakesureHydroBoostâbypass shutoff valveinside Cooling Unit(see Figure 2)isin‘‘CLOSED’’ (handle
notinline withtubing)position.
2.MakesureCooling UnitREFRIGERATIONPOWER,CARBONATORMOTOR,and CIRCULATING
MOTORPowerswitchesarein‘‘OFF’’ positions.
3.ConnectelectricalpowertoCooling Unitatdisconnectswitch.ConnectelectricalpowertoRemote
CondenserCoil and Fan Assemblyatdisconnectswitch.
4.PlaceCARBONATORMOTORpowerswitchin‘‘ON’’ position.
5.PlaceREFRIGERATIONpowerswitchin‘‘ON’’ position.Agitatormotorand carbonatorpumpmotoronly
will startand fill Hydro-BoostRcoil with plainwater.APPROXIMATELY2-1/2MINUTES AFTER
CARBONATORPUMPMOTOR HAS STARTED,REFRIGERATION COMPRESSOR,AND
COMPRESSOR COOLINGFAN,WILL START.
NOTE:Asice bankformsinwatertank,waterexpansion will take place and excess waterwill escape
through watertankoverflowhose to permanent floordrain.
Cooling Unitwill beginforming an ice bankand refrigerated Hydro-Boostâcoil will alsobechilling water.When
full ice bankhasbeen formed,Cooling Unitcompressorand compressorcooling fan will stop butagitatormotor
will continue to operatecirculating icewaterbathinwatertank.
6.Dispensefromdispensing station until carbonated waterappearsatdispensing valvewhichindicates
Cooling Unitplain and carbonated watersystemshave been filled.
7.PlaceCIRCULATINGMOTORpowerswitchin‘‘ON’’ position.Circulating pumpwill startand begin
circulating carbonated waterincarbonated watercirculating systemasexplained inSYSTEMTHEORYOF
OPERATIONinGENERALINFORMATIONSECTION.
8.Dispensecarbonated waterfromdispensing valvetomakesure all airhasbeen purged fromsystem.
9. If Cooling Unitplainwateroutletline hasbeen connected toadispensing station dispensing valve,
dispensefromvalve until all airhasbeen purged fromplainwatersystem.
10.Adjustsoft drinktanks secondaryCO2regulators(see Figure 2)asfollows:Sugar
Syrup 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.

12300614000
Low-Calorie(diet)Syrup Soft DrinkTankCO2Regulator.
Adjustlow-calorie(diet)soft drinktank secondaryCO2regulatorforlow-calorie drinkat10-psigfor
syrup linesup to 30-feetinlength.Syrup lineslongerthan 30-feetinlengthmayrequireaslightlyhigher
CO2regulatorsetting to 12-psigmaximum.ExcessiveCO2pressuremay causelow-caloriesyrup
carbonation resulting infoam.
IMPORTANT:Syrup systemsmustbe sanitizedas instructed before syrup is connectedintosyrup
systems.
11.Connectsoft drinktanks intosyrup systems.
12.Dispensefromdispensing station dispensing valvesuntil productisdispensed.
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
ADJUSTINGWATER FLOWRATE
RefertoInstallation Instructionsprovided withDispensing Station fordispensing valvewaterflowrate
adjustmentinstructions.
ADJUSTINGWATER-TO-SYRUP ‘‘RATIO’’ OFDISPENSED PRODUCT
AdjustDispensing Station dispensing valvesforWater-to-Syrup ‘‘Ratio’’ ofdispensed productasinstructed in
dispensing station Installation Instructions.
INSTALLINGLINEIDENTIFICATIONLABEL
Install LABEL,LINEIDENTIFICATION(item4)on Cooling Unitand recordsyrup flavorsin properspaces.

13 300614000
OPERATORSINSTRUCTIONS
This section coversoperating controls,dailypre-operation check,adjustments,replenishing CO2and syrup
supplies,cleaning and sanitizing,Cooling Unitmaintenance,RemoteCondenserCoil and Fan Assembly
maintenance,lubrication,and servicing CO2gas check valves.
WARNING:DisconnectelectricalpowertoCooling Unitand RemoteCondenserCoil and
FanAssemblyto preventpersonal injurybefore attempting anyinternalmaintenance.Only
qualified personnelshouldservice internalcomponentsorelectricalwiring.
OPERATINGCONTROLS
COOLINGUNITREFRIGERATION POWER SWITCH
(see Figure 5)
REFRIGERATIONPOWERswitch,located on frontofCooling Unit, placed in‘‘OFF’’ position will interrupt
electricalpowertorefrigeration compressor,agitatormotor,compressorcooling fan,carbonated water
circulating pump,and the carbonatorpumpmotor.REFRIGERATIONPOWERswitch placed in‘‘ON’’ position
will start the carbonatorpumpmotor (ifcarbonated waterisbeing called for), the carbonated watercirculating
pumpmotor,and the agitatormotor.Undercertainconditionsapproximately2-1/2minutesafterthe
REFRIGERATIONPOWERSWITCH hasbeen placed in‘‘ON’’ position refrigeration compressorand
compressorcooling fan will start.
COOLINGUNITCARBONATORMOTOR SWITCH
(see Figure 5)
CARBONATORMOTORpowerswitch,located on frontofCooling Unit, placed in‘‘OFF’’ position will interrupt
electricalpowertocarbonatorpumpmotor.Switchmustbe placed in‘‘ON’’ position beforecarbonatorpump
motorwill operate.
COOLINGUNITCIRCULATINGMOTOR SWITCH
(see Figure 5)
CIRCULATINGMOTORpowerswitch,located on frontofCooling Unit, placed in‘‘OFF’’ position will interrupt
electricalpowertocarbonated watercirculating pump.Switchmustbe placed in‘‘ON’’ position beforecirculating
pumpwill operate.
REFRIGERATION SYSTEMTEMPERATURE SENSINGDEVICE AND HIGH-PRESSURE
CUTOUTSWITCH
(see Figure 5)
ThisCooling Unitisequipped witharefrigeration systemtemperaturesensing device and a high-pressure
sensing cutoutswitchthatwill shutrefrigeration systemdownshouldthe systemoverheatdue toaclogged
condensercoil inthe RemoteCondenserCoil and Fan Assembly.Ifrefrigeration systemdoesnotautomatically
restartitselfaftersystemhas cooled down,high-pressuresensing cutoutswitch(see Figure 5)will haveto be
pressed toresetswitch.MAKE SUREREFRIGERATIONSYSTEMPROBLEMISCORRECTED.OPERATING
REFRIGERATIONSYSTEMINTHISMANNERFORPROLONGEDPERIODOF TIMECOULD RESULTIN
COMPRESSORFAILURE.

14300614000
DAILY PRE-OPERATION CHECK
4.MakesureCO2cylinder regulatorassembly1800-psigage indicatorisnotinshaded (‘‘change CO2
cylinder’’)portion ofdial.Ifso,CO2cylinderisalmostemptyand mustbe replaced.
5.Sufficientsyrup supplyin all soft drinktanks.Ifnot, replenishsyrup supplyasinstructed.
ADJUSTMENTS
ADJUSTINGCO2REGULATORS
CO2regulators should be periodically checked forproperpressuresettingsand ifnecessary,adjusted as
instructed.
ADJUSTINGDISPENSINGVALVES WATER FLOWRATE
If adjustmentofdispensing valveswaterflowrateshould be necessary,adjustasinstructed inDispensing
Station Installation Instructions.
ADJUSTINGWATER-TO-SYRUP ‘‘RATIO’’ OFDISPENSED PRODUCT
Water-To-Syrup ‘‘Ratio’’ ofdispensed productshouldbechecked and ifnecessary,adjusted asinstructed in
Dispensing Station Installation Instructions.
ADJUSTINGSIZEOFDRINK DISPENSED
Adjustdrink size ofdispensed productasinstructed inDispensing Station Installation Instructions.
REPLENISHINGCO2SUPPLY
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.
NOTE:Whenindicatoron CO2cylinder regulatorassembly 1800-psigageisinshaded(’’changeCO2
cylinder’’)portion of thedial, CO2cylinderis almostempty and should be changed.CO2supply should
be checked daily and ifnecessary,replenishedas instructed.
REPLENISHINGSYRUP SUPPLY
Syrup supply shouldbechecked dailyand ifnecessary,replenished asinstructed.
CLEANINGAND SANITIZING
DAILY CLEANING
Performdaily cleaning ofdispensing station asinstructed in dispensing station installation instructions.Outside
ofCooling Unitmustbe cleaned periodically.

15 300614000
SANITIZINGSYRUP SYSTEMS
Syrup systems shouldbesanitized every90 days asinstructed following SanitizerManufacturer’s
recommendations.
COOLINGUNITMAINTENANCE
COOLINGUNITAIRINTAKE AND EXHAUST FILTERS
CAUTION:Airfilterson theCooling Unitmustberemovedand cleanedevery30days as
instructed.Excessive accumulation ofdust, lint,and grease on the airfilterswill restrict
airflowthrough theUnitwhichwill cause therefrigeration systemto overheat.
The Cooling Unitcabinetisequipped with areintake and exhaust filterswhich allowairtocirculatethrough the
cabinet tocoolthe compressor.Airfiltersmustbe cleaned every30 days asinstructed.Area around Cooling
Unitmustbe kept free ofobstructionsatall timesforproperaircirculation through the Unit.
CHECKINGICE WATER BATH
Note:SomeCooling Units are equippedwithawatertankwaterlevelfloatcontrol. Agurgleheardfrom
theCooling Unitindicates waterlevel inwatertankislow.Thisindicates thewaterlevelfloatcontrol is
notoperating properly and mustbereplaced.
Agurgle heardfromthe Cooling Unitindicateswaterlevel inwatertankislowand morewatershould be added
tothe tankformaximumproductcooling.Periodically check,and ifnecessary,add watertothe watertankas
instructed.
COOLINGUNITCARBONATORMAINTENANCE
Lubrication.
Carbonatorwaterpumpmotorbearingsmustbe oiled periodicallyasinstructed.
DOUBLELIQUID CHECK VALVE ASSEMBLIES YEARLYMAINTENANCE (OR AFTER
WATER SYSTEMDISRUPTIONS).
(see Figure 2)
The two doubleliquidcheck valve assembliesarelocated in plainwaterlines connected between the plain
watercooling coilsand the carbonated watertank.The doubleliquidcheck valve assembliesmustbe inspected
and cleaned atleastonceayearundernorwork,earthquake,etc.)Inspectand clean doubleliquidcheck valve
assembliesasinstructed.
COOLINGUNITCARBONATED WATER CIRCULATINGPUMPMOTORLUBRICATION
Carbonated watercirculating pumpmotorbearingsmustbe oiled periodicallyasinstructed.

16300614000
REMOTECONDENSER COILAND FAN ASS’YMAINTENANCE
(see Figure 5)
CAUTION:RemoteCondenserCoil and FanAssembly connectedtotheCooling Unitis
equippedwitha condensercoil thatmustbe cleanedevery 30-days.Allowing condenser
coil to become cloggedwill cause refrigeration systemto overheatwhichwill automatically
shutrefrigeration systemdown.Aftercondensercoil has beencleaned,high-pressure cutout
sensing switch(see Figure 5)will have to bepressedtorestartrefrigeration system.OPERATING
COOLINGUNITINTHISMANNERFORPROLONGEDPERIODOF TIMECOULD RESULT IN
COMPRESSORFAILURE.
Area on top ofand around RemoteCondenserCoil and Fan Assemblymustbe kept free ofobstruction atall
times.Condensercoil mustbe cleaned asinstructed tomaintain propercooling ofcoil.
CLEANINGCO2GASCHECK VALVES
(see Figure 2)
The CO2gas check valvesmustbe inspected and serviced atleastonceayearundernormalconditionsand
afteranyCO2systemservicing ordisruption asinstructed.