Cornelius AURORA 10 User manual

Installation Manual
AURORA 10,000 PLUS
COOLINGUNIT(V2.5)
IMPORTANT:
TOTHEINSTALLER.
Itistheresponsibilityof
theInstallertoensurethat
thewatersupplytothe
dispensing equipmentis
providedwith protection
againstbackflowby anair
gapas definedin
ANSI/ASMEA112.1.2-1979;
oranapprovedvacuum
breakerorothersuch
method as provedeffective
bytest.
Waterpipe connections
and fixtures directly
connectedtoapotable
watersupply shall be
sized, installed,and
maintainedaccording to
Federal, State,and Local
Codes.CAUTION:Priortostarting theCooling Unit,thetwoser-
vice valves on therefrigeration systemreceivertank(see
applicableFIGURES 10 or11)mustbefullyopenedto
release refrigerantchargeintothe system.Operating
Cooling Unitwiththe service valves closedwill damage
the compressorwhichwill voidthefactorywarranty.
PRINTEDIN U.S.A
IMI CORNELIUS INC; 1992--93Ó
IMICORNELIUSINC gOne CorneliusPlacegAnoka,MN55303-6234
Telephone [phone] Facsimile(612)422-3246
PartNo.1593
December21,1992
Revised:April 12,1993
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i1593
TABLEOFCONTENTS
Page
GENERALDESCRIPTION1..................................................
COOLINGUNITDESCRIPTION1.........................................
UNITDESCRIPTION2...................................................
SYSTEMTHEORYOFOPERATION3.....................................
STANDARD COOLINGUNIT3........................................
COOLINGUNITREQUIRINGCONNECTIONTOREMOTECONDENSER
COILAND FANASSEMBLY3........................................
INSTALLATION5............................................................
UNPACKINGAND INSPECTION5........................................
IDENTIFICATIONOFLOOSE--SHIPPEDPARTS5..........................
SELECTINGLOCATION6................................................
COOLINGUNIT6...................................................
REMOTECONDENSER COILAND FANASS’Y6.......................
INSTALLINGREMOTECONDENSER COILAND FANASS’Y6...............
INSTALLINGCOOLINGUNIT6...........................................
PLACINGCOOLINGUNITINLOCATION7............................
CONNECTINGREMOTECONDENSER COILAND FANASS’Y
REFRIGERATIONLINES TOCOOLINGUNIT7........................
CONNECTINGELECTRICALPOWER CIRCUIT TOCOOLINGUNIT7....
CONNECTINGELECTRICALPOWER CIRCUIT TOREMOTECONDENSER
COILAND FANASS’Y(IFAPPLICABLE)8.............................
CONNECTINGPOTABLEWATERSOURCE SUPPLYLINES TO
COOLINGUNIT8...................................................
CONNECTINGCO2SOURCE SUPPLYLINETOCOOLINGUNIT9.......
CONNECTINGSYRUP SOURCELINES TOCOOLINGUNITSYRUP
INLETLINES 9.....................................................
CONNECTINGCOOLINGUNITSYRUPOUTLETLINES TOINSULATED
PYTHONSYRUPLINES 9...........................................
CONNECTINGCOOLINGUNITPOTABLEWATEROUTLETLINES TO
INSULATEDPYTHONPOTABLEWATERLINES 9......................
CONNECTINGCOOLINGUNITCARBONATEDWATEROUTLETLINES TO
INSULATEDPYTHON CARBONATEDWATERLINES 10.................
PLACINGCOOLINGUNITINOPERATINGPOSITION10.................
PREPARINGCOOLINGUNIT FOROPERATION10..........................
OPERATION11..........................................................
STARTINGCOOLINGUNITREFRIGERATIONSYSTEM11...............
STARTINGCARBONATEDWATER CIRCULATINGPUMP12.............
ACTIVATINGSYRUP SYSTEMS12....................................
LEAK CHECK AND INSULATINGCOOLINGUNITOUTLETLINES 12..........
DISPENSINGSTATIONADJUSTMENTS12.................................
ADJUSTINGWATERFLOWRATE12..................................
ADJUSTINGWATER--TO--SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT13.
INSTALLINGLINEIDENTIFICATIONLABEL 13..............................
OPERATORSINSTRUCTIONS15..............................................
OPERATINGCONTROLS15..............................................

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TABLEOFCONTENTS(cont’d)
Page
COOLINGUNITREFRIGERATIONPOWERSWITCH 15.................
COOLINGUNITCARBONATORMOTORS SWITCH 15...................
COOLINGUNITCIRCULATINGMOTORSWITCH 15.....................
REFRIGERATIONSYSTEMTEMPERATURE SENSINGDEVICE AND
HIGH--PRESSURECUTOUTSWITCH 15...................................
COOLINGUNITWITHINTERNALCONDENSER COILAND FAN
ASSEMBLY15.......................................................
COOLINGUNITCONNECTEDTOREMOTECONDENSER COILAND
FANASSEMBLY16..................................................
DAILY PRE--OPERATION CHECK16.......................................
ADJUSTMENTS16.......................................................
ADJUSTINGCO2REGULATORS16...................................
ADJUSTINGDISPENSINGVALVES WATERFLOWRATE16.............
ADJUSTINGWATER--TO--SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT16.
ADJUSTINGSIZEOFDRINKDISPENSED16...........................
REPLENISHINGCO2SUPPLY16..........................................
REPLENISHINGSYRUP SUPPLY16.......................................
CLEANINGAND SANITIZING17...........................................
DAILYCLEANING17.................................................
SANITIZINGSYRUP SYSTEMS17.....................................
COOLINGUNITMAINTENANCE17........................................
COOLINGUNITEQUIPPEDWITH CONDENSER COILAND AIR
INTAKE FILTERS17..................................................
COOLINGUNITCARBONATORMAINTENANCE17.....................
COOLINGUNITCARBONATEDWATER CIRCULATINGPUMPMOTOR
LUBRICATION17....................................................
REMOTECONDENSER COILAND FANASS’Y(IFAPPLICABLE)
MAINTENANCE18.......................................................
CLEANINGCO2GAS CHECK VALVES 18..................................
SERVICEAND MAINTENANCE19.............................................
PREPARINGCOOLINGUNIT FORSHIPPING,STORING,OR RELOCATING19
PERIODICINSPECTION19...............................................
REMOTECONDENSER COILAND FANASSEMBLYMAINTENANCE19.......
COOLINGUNITMAINTENANCE20........................................
CLEANINGCOOLINGUNITAIRINTAKE FILTERS20....................
CHECKINGICEWATERBATH20......................................
CHANGINGICEWATERBATH20.....................................
WATERPUMP YEARLYMAINTENANCE(ORAFTERWATERSYSTEM
DISRUPTIONS)23...................................................
ADJUSTMENTS24.......................................................
PRIMARYCO2REGULATOR26.......................................
SECONDARYCO2REGULATORS26..................................
WATERFLOWRATE26..............................................
WATER--TO--SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT26.............
CLEANINGAND SANITIZING26...........................................
DAILYCLEANING OFUNIT26........................................

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TABLEOFCONTENTS(cont’d)
Page
SANITIZINGPOST-MIX SYRUP SYSTEMS27..........................
REPLENISHINGCO2SUPPLY29..........................................
REPLENISHINGSYRUP SUPPLY30.......................................
SYRUPFLAVOR CHANGE30.............................................
CLEANINGCO2SYSTEMGAS CHECK VALVES 30..........................
SECONDARYCO2REGULATORS AND CO2MANIFOLD CO2GAS
CHECK VALVES 30..................................................
CARBONATOR CO2INLETLINECO GAS CHECK VALVE 31.............
NON--CRITICALTEMPERATURE SENSORFAILURES 37....................
ICE BANKINLET TEMPERATURE SENSOR.37.........................
HYDROBOOST)WATERTEMPERATURE SENSOR37..................
CRITICALTEMPERATURE SENSORFAILURES 37..........................
ICE BANKOUTLET TEMPERATURE SENSOR.37.......................
CONDENSEROUTLET TEMPERATURE SENSOR.37...................
AURORA BUILT--IN ANALYZER37.............................................
SCANMODE37..........................................................
“HOLD”MODE”38........................................................
“WATERTEMP”MODE38.................................................
TEMPERATURE SENSORSTATUS38......................................
SHORTEDTEMPERATURE SENSOR38...................................
OPENTEMPERATURE SENSOR38........................................
TEMPERATURE SENSORISOUTOFRANGE38...........................
TROUBLESHOOTING41......................................................
WATER--TO--SYRUP‘‘RATIO’’ OFDISPENSED DRINKTOO LOWOR
TOO HIGH41............................................................
ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES
NOTINCREASE TODESIREDWATER--TO--SYRUP‘‘RATIO’’ 41..............
ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES
DECREASE TODESIREDWATER--TO--SYRUP“RATIO”41...................
DISPENSEDPRODUCTCARBONATIONTOO LOW.42......................
DISPENSEDPRODUCTCOMES OUTOFDISPENSINGVALVE CLEARBUT
FOAMSIN CUP.42.......................................................
DISPENSEDPRODUCTPRODUCES FOAMAS ITLEAVES DISPENSING
VALVE.42...............................................................
ONLYCARBONATEDWATER DISPENSED.42..............................
ONLY SYRUPDISPENSED.43............................................
WARMPRODUCTBEINGDISPENSED.43..................................
WATERPUMPMOTORWILL NOTOPERATE.43............................
WATERPUMPMOTORWILL NOTSHUTOFF.43...........................
ERRATIC CYCLING OFCARBONATOR.43.................................
WATERPUMPMOTOROPERATES BUTWATERPUMPDOES NOT
PUMPWATER44........................................................
WATERPUMPCAPACITYTOO LOW44....................................
COMPRESSOR DOES NOTOPERATE.44.................................

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TABLEOFCONTENTS(cont’d)
Page
COMPRESSOROPERATES CONTINUOUSLY BUTDOES NOT FORM
SUFFICIENTICE BANK45................................................
CONDENSERFANMOTOR NOTOPERATING46...........................
AGITATORMOTOR NOTOPERATING46...................................
WARRANTY47..............................................................
LISTOF FIGURES
FIGURE1.AURORA10,000R COOLINGUNIT(V2.5)1.....................
FIGURE2.FLOWDIAGRAM4............................................
FIGURE3.208 AND 240/24 VACPOWERTRANSFORMER7................
FIGURE4.COOLINGUNITSPACEREQUIRED10...........................
FIGURE5.PARTSIDENTIFICATION(STANDARD COOLINGUNITW/INTERNAL
CONDENSER COILAND FANASSEMBLY)21...............................
FIGURE6.PARTSIDENTIFICATION(COOLINGUNITREQUIRINGCONNECTION
TOREMOTE
ROOFTOPCONDENSER COILAND FANASSEMBLY)22....................
FIGURE7.WATERSTRAINERSCREENAND LIQUID DOUBLECHECK
VALVE 25................................................................
FIGURE8.LIQUID CHECK VALVE ASSEMBLY25...........................
FIGURE9.CO2GAS CHECK VALVE 30....................................
FIGURE10.REFRIGERATIONFLOWDIAGRAM(STANDARD COOLINGUNIT
WITHINTERNALCONDENSER COILAND FANASSEMBLY)32...............
FIGURE11.REFRIGERATIONFLOWDIAGRAM(COOLINGUNITREQUIRING
CONNECTIONTOREMOTEROOFTOPCONDENSER COILAND FAN
ASSEMBLY33...........................................................
FIGURE12.WIRINGDIAGRAM(MODELS1602 AND 1603)34...............
FIGURE13.WIRINGDIAGRAM(MODELS1604 AND 1605)35...............
FIGURE14.AURORA BUILT--INANALYZER39..............................
LISTOF TABLES
TABLE1.DESIGN DATA2...............................................
TABLE2.LOOSE-SHIPPEDPARTS5.....................................

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GENERALDESCRIPTION
This section givesthe Unitdescription, theoryofoperation,and design dataforthe AuroraR10,000 PlusCool-
ing Unit(V2.5)hereinafter referred to asa“Cooling Unit”.
IMPORTANT:To theuserof thismanual-Thismanual isaguideforinstalling,operating,and main-
taining this equipment.RefertotheTableofContentsforpagelocation fordetailedinformation per-
taining to questionsthatarise during installation,operation,service,ormaintenance of this
equipment.
COOLINGUNITDESCRIPTION
The Cooling Unitisdesigned to provide cooled soft drink syrup,carbonated water,and potablewatertothe dis-
pensing station through an insulated python (length asordered).Onthe standardCooling Unit, refrigeration sys-
temis cooled byacondensercoil and fan assemblylocated inside the Cooling Unit. Cooling Unitnotprovided
withaninternalcondensercoil and fan assemblyis cooled byaRemoteCondenserCoil and Fan Assembly
whichis connected tothe Cooling Unit.
The Cooling Unitconsistsbasicallyofone carbonated watertankwithtwowaterpumpsto pump potablewater
intothe tank,one carbonated watercirculating pump,aHydroBoostâ(waterpre-cooler) which pre-coolswater
on itswaytothe carbonated watertank,and a two horsepower refrigeration compressor.The Cooling Unitback,
top,and side panelsare easilyremoved tofacilitateinstallation,service,and maintenance.
An optionalcooling unitstand (P/N309309069)isavailableto elevatethe Cooling Unitup off the floor.
FIGURE1.AURORA 10,000RCOOLINGUNIT(V2.5)
CAUTION:Before shipping,storing,or relocating thisUnit,the syrup systemsmustbe
sanitizedand all sanitizing solution mustbepurgedfromthe syrup systems.All watermust
also bepurgedfromtheplainand carbonatedwatersystems.Afreezing ambient
environmentwill cause residualwaterintheUnit tofreezeresulting in damagetointernal
components.

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UNITDESCRIPTION
Table 1.Design Data
COOLINGUNITDATA
Cooling UnitPartNumbers:
60 HZModel:
StandardCooling UnitwithInternalCondenserCoil and Fan Assembly1602
Cooling UnitRequiring 1604
Connection toRemoteCondenserCoil and Fan Assembly
50 HZModel:
StandardCooling UnitwithInternalCondenserCoil and Fan Assembly1603
Cooling UnitRequiring
Connection toRemoteCondenserCoil and Fan Assembly1605
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:(Approximate)
Models1602 and 1603:
Shipping 425 pounds
Models1604 and 1605:
Shipping 415 pounds
IceBank:40 to 45 pounds
Capacities:
WaterBath(no ice bank)18 gallons
CompressorHorsepower:2HP
Refrigeration System:
RefrigerantType and Charge See Cooling UnitNameplate
AmbientOperating Temp.50° Fto 100° F
ElectricalRequirements:
60 HZCooling Unit: See Cooling
Operating Voltage
CurrentDrawUnitNameplate
50 HZCooling Unit:
Operating Voltage
CurrentDraw
See Cooling Unit
Nameplate

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REMOTECONDENSER COILAND FAN ASS’YDATA
ModelNumber
(50/60 HZ)309602000
Overall Dimensions:
Height27 inches
Width 22 inches
Depth 38 inches
Weight:
Shipping 85 pounds
Refrigeration System:
AmbientOperating Temp.--22° Fto 120° F
ElectricalRequirements:
(50/60 HZ)
Operating Voltage See cooling unitnameplate
CurrentDrawSee cooling unitnameplate
SYSTEMTHEORYOFOPERATION
ACO2cylinderdelivers carbon dioxide gas(CO2)to primaryCO2regulatorassemblywhich deliversregulated
CO2gasto adjustablesecondaryCO2regulators(see FIGURE2).The secondaryCO2regulatorsdeliverspres-
sureregulated CO2gastothe carbonated watertankinside the cooling unitand alsotothe soft drinktanks.Po-
tablewaterispumped intothe carbonated watertankbytwowaterpumpsand is carbonated byregulated CO2
gaspressure also entering the tank.
Carbonated waterleavesthe carbonated watertankand entersinletside of the carbonated watercirculating
pump.Carbonated waterpassesfromoutletside of the carbonated watercirculating pump,out through the
cooling unitoutletlines,and through the insulated python line toaturnaround inside the Dispensing Station.
Carbonated water returnstothe cooling unitback through the insulated python line, through the carbonated wa-
tercooling coil inside the cooling unit, and back tothe carbonated watertankwhichmakesup the carbonated
watercirculating system.As carbonated waterisbeing dispensed fromthe Dispensing Station,carbonated wa-
tercirculating systemis continuouslybeing replenished fromthe carbonated watertank.Regulated CO2gas
pressure,exerted upon soft drinktanks contents,pushes syrup fromthe syrup tanks, through the cooling unit
syrup cooling coils,and on tothe Dispensing Station through the insulated python
STANDARD COOLINGUNIT
The standardCooling Unitrefrigeration systemis cooled byacondensercoil and fan assemblylocated inside
Cooling Unit
COOLINGUNITREQUIRINGCONNECTIONTOREMOTE CONDENSER COILAND FAN
ASSEMBLY
The Cooling Unitrefrigeration systemis cooled byaRemoteCondenserCoil and Fan Assembly
(P/N309602000)thatisauthorized byIMICorneliusInc.Use ofanyotherRemoteCondenserCoil and Fan As-
semblymustbe authorized byIMICorneliusInc.Use ofan unauthorized RemoteCondenserCoil and Fan
Assemblywill automatically voidthe Cooling Unit factorywarranty.

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c
FIGURE 2. FLOW DIAGRAM
WATER PRESSURE
REGULATOR
SHUTOFF
VALVE WATER FILTER
ASS’Y
SUGAR SYRUP
CO2REGULATOR
DIET SYRUP
CO2REGULATOR
HYDRO BOOSTâ
BYPASS VALVE
CARBONATOR
CO2REGULATOR
CO2MANIFOLD
CO2GAS
CHECK VALVE
PRIMARY CO2
REGULATOR
CO2CYLINDER SOFT DRINK TANKS
CO2CHECK
VALVE
CARBONATED
WATER TANK
WATER TANK WATER
LEVEL FLOAT CONTROL
CARBONATOR
WATER
CIRCULATING
PUMP
OUTLET
LINES
CARBONATOR
WATER PUMP (2)
DOUBLE LIQUID
CHECK VALVE (2) COOLING UNIT
LINE LEGEND CO2
PLAIN WATER CARB WATER SYRUP
HYDRO BOOSTâ
COIL
SYRUP
COIL (10)
PW
COIL
RECIRC
CO2
WTR
COIL
PW
COIL
1
2
3
4
5 6
7 8
9
10
1 2 34 5 6 7 8 9 10
P0TABLE WATER
SOURCE

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INSTALLATION
This section coversunpacking and inspection,selecting location,installing Unit, preparing foroperation,and
operation.
UNPACKINGAND INSPECTION
NOTE:TheUnitwas thoroughlyinspected beforeleaving thefactory and the carrierhas acceptedand
signedforit.Anydamageorirregularities should benotedat thetimeofdelivery(ornotlaterthan15
days fromdateofdelivery)and immediatelyreportedtothedelivering carrier.Requestawritteninspec-
tion report fromClaimsInspectortosubstantiate anynecessary claim.File claimwiththedelivering
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 770407 Barbed Connector,1/4x3/8 12
2 770424 Barbed Connector,1/2x1/2 2
3 300200000 Tubing Clamps12
4 309852000 Tubing Clamps36
5 111085000 Tubing Clamps8
6 311962000 Label, Identification 1
NOTE:Refrigeration LineKit (notprovidedand as ordered)isusedtoconnectRemoteCondenser
Coil and FanAssemblytoCooling Unit.
7 309602000 RemoteRooftop CondenserCoil and Fan Ass’y(50/60 HZ)1
8 300598025 Refrigeration Line Kit, 25--ft. long,90_1
300598050 Refrigeration Line Kit, 50--ft. long,90_1
IDENTIFICATIONOF LOOSE--SHIPPEDPARTS
1.BARBED CONNECTORS(item1)are used toconnectCooling Unitsyrup and potablewateroutletlinesto
insulated python syrup and potablewaterlines.SecureconnectionswithTUBINGCLAMPS (items3 and
4).
2.BARBED CONNECTORS(item2)are used toconnectinsulated python 1/2--inchI.D.carbonated water
linestoCooling Unit1/2--inchI.D.carbonated waterlines.SealconnectionswithTUBINGCLAMPS (item
5)
3.LABEL,LINEIDENTIFICATION(item6)tobeinstalled on Cooling Unitand syrup flavorstoberecorded in
properspaceson label.
4.REFRIGERATIONLINE KIT(items8)tobeconnected between REMOTEROOFTOPCONDENSER COIL
AND FANASS’Y(item7)and the Cooling Unit.

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SELECTINGLOCATION
COOLINGUNIT
Selectlocation forCooling Unitinstallation thatwill (1)allowshortestpossibleinsulated python run to dispensing
station location;(2)allowshortestpossiblerefrigeration lines(not to exceed 50-feet)) routefromRemoteRoof-
top CondenserCoil and Fan AssemblytoCooling Unit; (3)The 60 HzCooling Unitisaccessibleto an electrical
powercircuit(voltage requirementis specified on the Unitnameplate).The powercircuitmustbe wired through
a 40-ampminimumrated disconnectswitch(notprovided)and the circuitmustbe fused at40-amps(maxi-
mum).The powercircuitmayalsobewired through an equivalentHACR circuitbreaker.The 50HZCooling Unit
isaccessibleto an electricalpowercircuit(voltage requirementis specified on the Unitnameplate)and the pow-
ercircuitmustbe wired through a 40-ampminimumrated disconnectswitch(notprovided).The powercircuit
must fused at40-amps(maximum).POWER CIRCUITMUSTBE MADEUPOFCOPPER CONDUCTORS
AND ALL WIRINGMUSTCONFORMTONATIONALAND LOCALELECTRICALCODES;(4)closetoaplain
watersourcesupplyline with proper requirements;(5)sufficientspace around Cooling Unit(see Figure 4)for
properaircirculation (18-incheson sidesand back, frontside open toroom,and top open toceiling);(6)be
closeto permanent floordraintowhichtoroutewatertankdrain and overflowhoses.
REMOTE CONDENSER COILAND FAN ASS’Y(IFAPPLICABLE)
1.An extremewarmclimateinstallation mayrequire extracaution inRemoteCondenserCoil and Fan As-
semblylocation.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(IF
APPLICABLE)
1.RemoteCondenserCoil and Fan Assembly(see FIGURE6)mustbe installed meeting requirementsof
SELECTINGLOCATION.RemoteCondenserCoil and Fan Assemblymustbe installed inalevelposition
and mustbe anchored with adequatefastening devices.
2.Routerefrigeration linesofREFRIGERATIONLINE KIT(item8)fromRemoteCondenserCoil and Fan
AssemblydowntoCooling Unitlocation.
NOTE:REFRIGERATIONLINES INSTALLATION REQUIREMENTS SHOWNINFIGURE11.
3.Connectendsofrefrigeration linestoRemoteCondenserCoil and Fan Assemblyrefrigeration connectors.
INSTALLINGCOOLINGUNIT
NOTE:Cooling Unitoutletlines,potablewater,CO2,and syrup inletlines,RemoteCondenserCoil and
FanAssemblyrefrigeration lines and powercircuitcable,and Cooling Unitpowercircuitcable each
mustbelong enough whenconnectedtoCooling Unit toallowpulling Unitoutapproximately 36--in-
ches fromoperating position forservice and maintenance.WhenCooling Unitisin operating position,
excess powercircuitcable,RemoteCondenserCoil and FanAssemblyrefrigeration lines and power
circuitcable and potablewatersource and CO2inletlines may be coiled up behind Unit.

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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.Remove bothtop coversfromCooling Unit.
CONNECTINGREMOTE CONDENSER COILAND FAN ASS’Y(IFAPPLICABLE)
REFRIGERATIONLINES TOCOOLINGUNIT
Connectrefrigeration lines(see FIGURE6), fromRemoteCondenserCoil and Fan Assembly, torefrigeration
connectorson back ofCooling Unit.
RESETBUTTON
C
208V
240V
FIGURE3.208 AND 240/24 VAC POWERTRANSFORMER
CONNECTINGELECTRICALPOWER CIRCUIT TOCOOLINGUnit
Note:Inaddition totheCooling Unitswiring diagrams(FIGURES 12 or13) found intheback of this
manual, wiring diagrams are alsolocated on undersideof theCooling Unitstop covers.
WARNING:Make sure 40--ampminimumrated disconnectswitch orHACR circuitbreaker(if
applicable)isin‘‘OFF’’ position
1.Removecoverfromelectricalhandyboxon back ofCooling Unit.
WARNING:TheCooling Unitmustbe electricallygroundedtoavoid possiblefatal
electricalshock orseriousinjurytotheoperator.Agrounding lug isprovidedinside
electricalboxtoconnectpowercircuitground wirewhichelectricallygroundstheCooling
Unit.

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2.60 HZCooling Unit(see applicableFigure 12 or13).
Connect208VACSingle--Phase 60Hzelectricalpowercircuit from40--ampminimumrated disconnect
switch(notprovided)fused at30--amps(‘‘slow--blow’’)orcircuitconnected through an an equivalentHACR
circuitbreakerto electricalwiresinside electricalhandyboxon back ofCooling Unit. DONOTCONNECT
ELECTRICALPOWERTOCOOLINGUNITAT THISTIME.
COOLINGUNITMUSTBE PROPERLYGROUNDED.POWER CIRCUITMUSTBE MADEUPOFCOP-
PER CONDUCTORS,AND ALL WIRINGMUSTCONFORMTONATIONALAND LOCALELECTRICAL
CODES.
50 HZCooling Unit(see applicableFIGURE12 or13).
Connect230VACsingle--phase 50HZelectricalpowercircuitwith a 40--ampminimumrated disconnect
switch(notprovided)fused at30--amps(‘‘slow--blow’’)to electricalwiresinside electricalhandyboxon
back ofcooling unit. DONOTCONNECTELECTRICALPOWERTOCOOLINGUNITAT THISTIME.
COOLINGUNITMUSTBE PROPERLYGROUNDED,POWER CIRCUITMUSTBE MADEUPOFCOP-
PER CONDUCTORS,AND WIRINGMUSTCONFORMTOAPPLICABLE ELECTRICALCODES.
CONNECTINGELECTRICALPOWER CIRCUIT TOREMOTE CONDENSER COILAND
FAN ASS’Y(IFAPPLICABLE)
CAUTION:TheCooling Unitrefrigeration systemis cooled byaRemoteCondenserCoil
and FanAssembly(P/N309602000) thatis authorized byIMICorneliusInc.Use ofan
unauthorizedRemoteCondenserCoil and FanAssemblywill automatically voidthe
Cooling Unit factorywarranty.
NOTE:Electricalpowercircuitmay be connectedtotheRemoteCondenserCoil and FanAssemblyin
twoways.Thepreferredway isto drawelectricalpowerfromtheCooling Unitcompressorcontactor
whichallowstheRemoteCondenserCoil and FanAssemblyto operateonlywhentheCooling Unitre-
frigeration systemisoperating.Theoptionalway istoconnecta separate electricalpowercircuit (inde-
pendentof theCooling Unit) through anappropriatelyratedand fused disconnectswitch oran
equivalentHACR circuitbreakerwhichallowstheRemoteCondenserCoil and FanAssemblyto oper-
ate atall times (independentofCooling Unitoperation).
1.Connectand route electricalpowercircuitcablefromRemoteCondenserCoil and Fan Assemblythrough
fuse box(notprovided), fused at15--amps(‘‘slow--blow’’)downtoCooling Unitlocation (see FIGURE6).
REMOTECONDENSER COILAND FANASSEMBLYMUSTBE PROPERLYGROUNDED,POWER
CIRCUITMUSTBE MADEUPOFCOPPER CONDUCTORS,AND ALL WIRINGMUSTCONFORMTO
NATIONALAND LOCALELECTRICALCODES.
2.RouteRemoteCondenserCoil and Fan AssemblyPowercable electricalwiresintothe electricalhandybox
on back of the Cooling Unit.
3.ConnectRemoteCondenserCoil and Fan Assemblypowercable electricalwirestotwored wireslocated
inside the Cooling Unitelectricalhandybox(see FIGURE13).MAKE SUREREMOTECONDENSER
COILAND FANASSEMBLYIS PROPERLYGROUNDEDACCORDINGTONATIONALAND LOCAL
ELECTRICALCODES.
4. Install coveron electricalhandyboxon back ofCooling Unit.
CONNECTINGPOTABLEWATER SOURCE SUPPLYLINES TOCOOLINGUNIT
NOTE:IMICorneliusInc.recommendsthatawatershutoff valve beinstalledinthepotablewater
source supplyline connectedtoCooling Unit (see FIGURE2)and thatwatersupplybefiltered.WATER
PIPE CONNECTIONSAND FIXTURES DIRECTLYCONNECTEDTOAPOTABLEWATERSUPPLY SHALL
BE SIZED, INSTALLED AND MAINTAINED ACCORDINGTOFEDERAL,STATE,AND LOCAL LAWS.

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CAUTION:Potablewatersource supplylineto be connectedtotheCooling Unitwaterinlet
lines mustbe 1/2--inchI.D.minimum.Check waterflowrateofwaterinletsupplyline.
MINIMUMFLOWRATEMUSTBEAT LEAST300--GALLONS PER HOUR. If flowrateisless
than300--gallonsperhour,‘‘starving’’ ofcarbonatorwaterpumpswill occur.Starving will allow
waterpumpsto overheatcausing safetythermostaton pumpsoutletsto disruptelectricalpowerto
and stop waterpumpsmotors.Carbonatedwatercirculating pump overheating could occurif
waterinletsupplylineflowratedropsbelow300--gallonsperhour. INCOMINGWATERINLET
SUPPLYLINEWATERPRESSUREMUSTREMAINAMINIMUMOF10--PSIBELOWTHE
CARBONATOR CO2OPERATINGPRESSURE.(Example:Operating pressureis 90--psiand
maximumwaterpressure can beno morethan80--psi,etc.)
1.Beforeconnecting potablewatersourcesupplylinestoCooling Unit, open waterline shutoff valvefora
period of timetoflush outanymetalshavingsand othercontaminatesthatmayhaveresulted fromplumb-
ing connections.
2.Connect flexible potablewatersourcesupplyline (1/2--inchI.D.min.),meeting waterinletsupplyline re-
quirementsofpreceding CAUTIONnote, toCooling Unitpotablewaterinletline labeled “POTABLEWA-
TER”.DONOTOPENWATERINLETSUPPLYLINE SHUTOFF VALVE AT THISTIME.
3.Connect two potablewatersourcesupplylinestotwoCooling Unitpotablewaterinletlineslabeled “W1”
and “W2”.
CONNECTINGCO2SOURCE SUPPLYLINE TOCOOLINGUNIT
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 flexibleCO2sourcesupplyline toCooling UnitCO2inletsupplyline labeled “CO2INLET”
(see FIGURE2).
CONNECTINGSYRUP SOURCE LINES TOCOOLINGUNITSYRUP INLET LINES
Connectsyrup sourcelinestoCooling Unitsyrup inletlineslabeled No.1through No.10 (see FIGURE2).
CONNECTINGCOOLINGUNITSYRUP OUTLET LINES TOINSULATED PYTHON SYRUP
LINES
Using BARBED CONNECTORS(item1)and TUBINGCLAMPS (items3 and 4),connectCooling Unitsyrup
outletlinestoinsulated python syrup lines(see FIGURE2).
CONNECTINGCOOLINGUNITPOTABLEWATER OUTLET LINES TOINSULATED
PYTHON POTABLEWATER LINES
Using BARBED CONNECTOR(item1)and TUBINGCLAMPS ((items3 and 4),connectCooling Unitpotable
wateroutletlineslabeled “W1”and “W2”toinsulated python potablewaterline (see FIGURE2).

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CONNECTINGCOOLINGUNITCARBONATED WATER OUTLET LINES TOINSULATED
PYTHON CARBONATED WATER LINES
Using BARBED CONNECTORS(item2)and TUBINGCLAMPS (item5),connectCooling Unit1/2--inchI.D.
carbonated wateroutletlineslabeled “CO2WATER”toinsulated python 1/2--inchI.D.carbonated waterlines
(see FIGURE2).
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)REMOTEROOFTOPCONDENSERAND FANASSEMBLYREFRIGERA-
TIONLINES.
18--IN.18--IN.
18--IN.
COOLINGUNIT
ELECTRICAL
CONTROLBOXAIRFLOW
(OPENTOROOM)
FIGURE4.COOLINGUNITSPACEREQUIRED
NOTE:To complywithNationalSanitation Foundation (NSF)requirements,Cooling Unitnotinstalled
on optionalCooling UnitStand (P/N309309069)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 permagumsealantorequiva-
lent.
PREPARINGCOOLINGUNIT FOROPERATION
CAUTION:Priortostarting theCooling Unit,thetwoservice valves on therefrigeration
systemreceivertank(see applicableFIGURES 10 or11)mustbefullyopenedtorelease
refrigerantchargeintothe system.Operating theCooling Unitwiththe service valves
closedwill damagethe compressorwhichwill voidthefactorywarranty.

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1.Open the twoservicevalveson the refrigeration systemreceivertankfullyto back--seat the valves(back--
seating the valvespreventsleakage around the valveshafts).Replacecapson valves.
2.Makesurethe plug inthe end of the Cooling Unitwatertankdrain hoseis secure.
3.Open shutoff valvein potablewaterinletsupplyline.Due toslow waterfill rate ofwaterlevelfloatcontrol,
tankmaybe hand filled until water runsoutofwatertankoverflowhose.CLEANLOW--MINERAL--CON-
TENTWATERMUSTBE USEDWHEREALOCALWATERPROBLEMS EXISTS.
4.AdjustprimaryCO2regulator (see Figure2)on CO2cylindertoaminimumnominalsetting of120--psior
24--psihigherthan highestsetting required bythe secondaryCO2regulators.Loosen CO2regulatoradjust-
ing screwlocknut. Turn adjusting screwtothe right(clockwise)until regulatorgage registersnominal
120--psi, then tighten adjusting screwlocknut.
5.AdjustcarbonatorsecondaryCO2regulator (see Figure 2)to a nominal90--psi.Loosen CO2regulatorad-
justing screwlocknut. Turn adjusting screwtothe right(clockwise)until regulatorgage registersnominal
90--psi, then tighten adjusting screwlock nut. CO2PRESSURETOCARBONATORMUSTNOTEXCEED
120--PSIG.
CAUTION:Before starting refrigeration system,HydroBoostâcoil mustbe completely
floodedwithcarbonatedwaterto preventcoil freeze--up.Proceedas followstofill
carbonatedwatersystem.
6.MakesureHydroBoostâbypass shutoff valveinside Cooling Unit(see FIGURE2)isin“CLOSED”(han-
dle notinline withtubing)position.
7.MakesureCooling UnitREFRIGERATIONPOWER,CARBONATORMOTORS,and CIRCULATINGPow-
erswitchesarein‘‘OFF’’ positions.
8.ConnectelectricalpowertoCooling Unitatdisconnectswitch.
9.PlaceCARBONATORMOTORSpowerswitchin‘‘ON’’ position tostartcarbonator.
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.
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’’ position.Refrigeration compressor,compressor
cooling fan,agitatormotor,and RemoteCondenserCoil and Fan Assemblywill start. Cooling Unitwill begin
forming an ice bankand refrigerated HydroBoostâcoil will alsobechilling water.When ice bankhasbeen
formed,RemoteCondenserCoil and Fan Assembly,Cooling Unitcompressor,and compressorcooling fan will
stop butagitatormotorwill continue to operatecirculating icewaterbathinwatertank.

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StandardCooling UnitUtilizing CondenserCoil and Fan Assembly
PlaceCooling UnitREFRIGERATIONPOWERswitchin‘‘ON’’ position.Refrigeration compressor,condenser
fan motor,and agitatormotorwill startand beginforming an ice bankand refrigerated HydroBoostâcoil will
alsobechilling water.When full ice bankhasbeen formed,compressorand condenserfan motorwill stop but,
agitatormotorwill continue to operatecirculating icewaterbathinwatertank.
STARTINGCARBONATED WATER CIRCULATINGPUMP
1.PlaceCIRCULATINGMOTORpowerswitchin‘‘ON’’ position.Circulating pumpwill startand begincirculat-
ing carbonated waterinsystem.
2.Dispensecarbonated waterfromall dispensing valvestomakesure all airhasbeen purged fromsystem.
ACTIVATINGSYRUP SYSTEMS
1.Adjustsoft drinktanks secondaryCO2regulators(see Figure 2)asfollows:
SugarSyrup Soft DrinkTanks CO2Regulator.
Adjustsugarsyrup soft drinktanks secondaryCO2regulatorat40--psigforsyrup linesup to 10--feetinlength
plusone pound foreach additional length of10--feet, plusone pound foreach 2--feetofvertical lift. Forexam-
ple:ifsyrup line total lengthis30--feetand totalvertical lift is6--feet, then 40--psig+2--psig(1--pound forevery
10--feetoflength over10--feetwhichis20--feet)+3--psig(1--pound forevery2--feetofvertical lift whichis
6--feet); totalequals40 +2+3=45--psigCO2regulatorsetting.
Low--Calorie(diet)Syrup Soft DrinkTankCO2Regulator.
Adjustlow--calorie(diet)soft drinktank secondaryCO2regulatorforlow--calorie drinkat10--psigforsyrup lines
up to 30--feetinlength.Syrup lineslongerthan 30--feetinlengthmayrequireaslightlyhigherCO2regulatorset-
ting 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.
LEAK CHECK AND INSULATINGCOOLINGUNITOUTLET LINES
1.Check all CO2,potable and carbonated water,and syrup connectionsforleaks and repairifevident.
2.MakesureCooling Unitoutletlines connectionstoinsulated python linesarewell insulated.
3. Install bothCooling Unit top covers.
DISPENSINGSTATION ADJUSTMENTS
ADJUSTINGWATER FLOWRATE
Refertomanualprovided with dispensing station fordispensing valvewaterflowrate adjustmentinstructions.

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ADJUSTINGWATER--TO--SYRUP ‘‘RATIO’’ OFDISPENSED PRODUCT
Refertomanualprovided with dispensing station forinstructionsto adjustdispensing valvesforwater--to--syrup
“Ratio”ofdispensed product.
INSTALLINGLINEIDENTIFICATIONLABEL
Install LABEL,LINEIDENTIFICATION(item6)on Cooling Unitand recordsyrup flavorsin properspaces.

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OPERATORSINSTRUCTIONS
This section coversoperating controls,dailypreoperation check,adjustments,replenishing CO2and syrup sup-
plies,cleaning and sanitizing,Cooling Unitmaintenance,RemoteCondenserCoil and Fan Assembly(ifapplica-
ble)maintenance,lubrication,and servicing CO2gas check valves.
WARNING:DisconnectelectricalpowertoCooling Unit to preventpersonal injurybefore
attempting anyCooling UnitorRemoteCondenserCoil and FanAssembly(ifapplicable)
internalmaintenance.Onlyqualified personnelshouldservice internalcomponentsor
electricalwiring.
OPERATINGCONTROLS
COOLINGUNITREFRIGERATION POWER SWITCH
REFRIGERATIONPOWERswitch,located on frontofCooling Unit(see FIGURE5 or6),placed in‘‘OFF’’ posi-
tion will interruptelectricalpowertorefrigeration compressor,agitatormotor,condenserfan motor (ifapplicable),
and carbonated watercirculating pump.Switchmustbe in‘‘ON’’ position foroperation.REFRIGERATION
POWERSWITCH DOES NOTDISRUPTELECTRICALPOWERTOCARBONATORWATERPUMPS
MOTORS.
COOLINGUNITCARBONATORMOTORS SWITCH
CARBONATORMOTORSpowerswitch(see FIGURE5 or6),located on frontofCooling Unitplaced in‘‘OFF’’
position,will interruptelectricalpowertothe twocarbonatorwaterpumpsmotors.Switchmustbe placed in
‘‘ON’’ position beforecarbonatorwill operate.
COOLINGUNITCIRCULATINGMOTOR SWITCH
CIRCULATINGMOTORpowerswitch,located on frontofCooling Unit(see FIGURE5 or6)placed in‘‘OFF’’
position,will interruptelectricalpowertocarbonated watercirculating pump.Switchmustbe placed in‘‘ON’’
position beforecirculating pumpwill operate.
REFRIGERATIONSYSTEMTEMPERATURE SENSINGDEVICEAND
HIGH--PRESSURECUTOUTSWITCH
COOLINGUNITWITHINTERNALCONDENSER COILAND FAN ASSEMBLY
The Cooling Unit(see FIGURE5)isequipped witharefrigeration systemtemperaturesensorwhichwill auto-
maticallyinitiateashutdownif the temperature of the liquidreturnline fromthe condenserexceeds155_ F.
Temperaturerisemaybe caused byaclogged condensercoil airintakefilter,or refrigeration componentsprob-
lem.Aftercooldown, the refrigeration systemwill restartasrequired.
CAUTION:If therefrigeration systemcontinues to‘‘shortcycle’’ following restart,
immediate attention isrequiredtoavoidcompressorfailure.