Cornelius HS Instruction Manual


Karbonator HS / HK
Carbonator HS / HK

Balance Carbonator / Balance Karbonator
Manual operation / Gebrauchsanweisung
Carbonator/Karbonator HS/HK
Seite 2
Cornelius DeutschlandGmbH
Document no/ Dokumenten-Nr.: TD22022600ML
Version A, 11.05.2020, Index 0
Gebrauchsanweisung Deutsch
Manual operation English
Legal notice / Impressum
Document no. / Dokumenten-Nr.: TD1022600ML
Model range / Modellreihe
Carbonator HS / HK
Karbonator HS / HK
Version A
Date of issue / Ausgabedatum: 11.05.2020
Revision status / Änderungsstand: Index 0
Protection notices (in accordance with DIN ISO 16016:2002-5)
The reproduction, distribution and utilization of this document as well as the communication of its contents
are prohibited, unless expressly permitted. Violations shall result in an obligation to pay damages. All rights
reserved with regard to filing for/registering patents, utility models or design patents.
Schutzvermerk (gemäß DIN ISO 16016:2017-08)
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts sind
verboten, soweit nicht aus- drücklich gestattet. Zuwiderhandlungen verpflichten zu Schadenersatz. Alle
Rechte für den Fall der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten.
www.cornelius-emea.com
Cornelius Deutschland GmbH Tel.: [phone] / 79 3 –0
Carl-Leverkus-Str. 15 Fax: [phone] / 77 4 –38
40764 Langenfeld E-Mail: [e-mail]
Deutschland

Balance Carbonator / Balance Karbonator
Manual operation / Gebrauchsanweisung
Carbonator/Karbonator HS/HK
Seite 3
Cornelius DeutschlandGmbH
Document no/ Dokumenten-Nr.: TD22022600ML
Version A, 11.05.2020, Index 0
Table of Contents / Inhaltsverzeichnis
English...................................................................................................................................................................4
1.1 Safety.....................................................................................................................................................4
General Safety Regulations ..................................................................................................................4
Safety Instructions Electricity ................................................................................................................4
Safety Instructions CO2.........................................................................................................................4
Intended use..........................................................................................................................................5
Improper use .........................................................................................................................................5
Staff .......................................................................................................................................................6
1.2 Transport and packaging.......................................................................................................................7
Storage..................................................................................................................................................7
1.3 Disposal.................................................................................................................................................8
1.4 InstallationRequirements.......................................................................................................................9
Installation Sites.....................................................................................................................................9
Electrical Connections...........................................................................................................................9
1.5 Installation .............................................................................................................................................9
Water Connection..................................................................................................................................9
CO2 Connection ...................................................................................................................................9
Connecting Soda Water and Still Water................................................................................................9
Pump Control.........................................................................................................................................9
1.6 Putting into and out ofService .............................................................................................................10
Putting into Service..............................................................................................................................10
Turning On the Device.........................................................................................................................10
End of Operation .................................................................................................................................11
Daily Inspection ...................................................................................................................................11
Putting out of Service ..........................................................................................................................11
1.7 Instructions forCleaning.......................................................................................................................12
1.8 Problems andTroubleshooting ............................................................................................................13
1.9 Installation CheckList..........................................................................................................................14
Deutsch...............................................................................................................................................................15
2.1 Sicherheit.............................................................................................................................................15
SicherheitshinweiseStrom...................................................................................................................15
2.2 Sicherheitshinweise CO2 ....................................................................................................................15
Bestimmungsgemäße Verwendung ....................................................................................................16
Nicht bestimmungsgemäße Verwendung ...........................................................................................16
Personal ..............................................................................................................................................17
2.3 Entsorgung ..........................................................................................................................................17
2.4 Anforderungen an denAufstellort.........................................................................................................18
Aufstellräume.......................................................................................................................................18
Elektrische Anschlüsse........................................................................................................................18
2.5 Installation ...........................................................................................................................................18
Wasseranschluß..................................................................................................................................18
CO2-Anschluß (nur Karbonator) .........................................................................................................18
Anschluß von Sodawasser undStillwasser.........................................................................................18
Pumpensteuerung ...............................................................................................................................18
2.6 In- und Außerbetriebnahme ................................................................................................................20
Inbetriebnahme....................................................................................................................................20
Nur bei Karbonatoren:.........................................................................................................................20
Einschalten des Gerätes......................................................................................................................20
Betriebsende .......................................................................................................................................21
TäglicheKontrolle................................................................................................................................21
Außerbetriebnahme.............................................................................................................................21
2.7 Reinigung ............................................................................................................................................21
2.8 StörungenundderenBehebung...........................................................................................................22
2.9 Installationscheckliste..........................................................................................................................23
Technische Daten und Darstellung / Technical data anddiagrams.......................................................................24
3.1 Fließschema / Flow scheme................................................................................................................25
3.2 Stromlaufplan / Circuit diagram...........................................................................................................25

Balance Carbonator / Balance Karbonator
Manual operation / Gebrauchsanweisung
Carbonator/Karbonator HS/HK
Seite 4
Cornelius DeutschlandGmbH
Document no/ Dokumenten-Nr.: TD22022600ML
Version A, 11.05.2020, Index 0
English
Safety
General Safety Regulations
This device is of leading-edge design and manufacture. If used and maintained in accordance with these
operating instructions, it will be safe to operate. Please comply with the following safety instructions to
avoid hazards and damage.
The device must be in satisfactory condition whenever operated. Any modifications which detrimentally
affect the safety of the device are therefore strictly prohibited. Please contact your service company if you
wish to obtain more information about safety.
No safety equipment (such as safety valves, overload protection devices, etc.) is to be removed, modified
or put out of commission (risk of injury or death!).
Take care that only authorized persons work on the device and that the operators are trained. Make
certain that no unauthorized persons change the settings on the device or tamper with it.
You are obligated to check the device on a daily basis for externally discernible damage and defects.
Immediately report modifications which affect safety and function to the service company nearest you.
Note that only original CORNELIUS replacement parts and accessories which have been checked and
approved are to be used. IMI Cornelius Deutschland GmbH assumes no liability whatsoever for damage
resulting from the use of non-original parts and accessories or from improper handling.
Safety Instructions Electricity
An electric shock may be fatal or result in serious injury. For this reason, any unauthorized tampering is
strictly prohibited. Water and electricity are a fatal mixture.
Always pull out the mains plug before any cleaning work on or near the device. As delivered, it features a
moulded earthing-pin plug and it must be connected to a socket outlet with an earthing contact. If no
appropriate socket outlet with an earthing contact is available, the connection must be made by authorized
persons only, with the regulations applicable at the installation site (EN-standards in Germany, for
example) being observed.
Safety Instructions CO2
Place the carbon dioxide cylinder in an upright position next to the workstation and secure it against falling
over. Protect it against heat (e.g., against sunshine). Minimum distance from heater 0.5 m (TRSK).
Escaping carbon dioxide is heavier than air and may present danger of suffocation if large quantities
collect in enclosed spaces. Remember that parts of the device are at operating pressure. Do not loosen or
dismantle any components at operating pressure.

Balance Carbonator / Balance Karbonator
Manual operation / Gebrauchsanweisung
Carbonator/Karbonator HS/HK
Seite 5
Cornelius DeutschlandGmbH
Document no/ Dokumenten-Nr.: TD22022600ML
Version A, 11.05.2020, Index 0
Intended use
By using the unit as intended you will not only protect yourself, but also prevent damage occurring to the
unit and its components!
The intended use of under counter coolers from the CR R134a series (referred to as “unit” in the following)
is to refrigerate and convey non-alcoholic beverages and their basic ingredients. CO2 or electric pumps
are used as conveying equipment for the brands.
The unit is only suitable for stationary installation in a closed room. Stationary installation is to be carried
out by an expert in compliance with all of the specifications given this manual
.
The intended use means that you will carry out all activities with and on the unit to the specifications
provided in this document.
This unit is only to be operated by those who meet the requirements set out in this document.
Work on the unit and its components not included in the activities described in this document may only be
performed by experts, means authorized and skilled people.
User manual can also be down loaded at website: www.cornelius-emea.com
Improper use
Improper use of the unit and unauthorized modifications to the unit and its components may cause
personal injury and equipment damage for which Cornelius Deutschland GmbH shall assume no liability.
Improper use of the unit is prohibited.
The following in particular is regarded as improper use:
-Mobile operation of unit
-Operation of unit in areas without supervision by skilled personnel
-Operation of the unit in an area, where water jet is possible.
-Cleaning with a water jet
-Any handling as e.g. use or service by children under the age of 8 years
-Any cleaning or service by children without supervision by a skilled, authorized adult.
-Use by persons (including children) with physical, sensory or mental disabilities or those with insufficient
experience and knowledge, unless they are supervised by a person responsible for their safety, or this
person has instructed them in the use of the unit.
-Use by those under the influence of medication, alcohol, drugs or other substances which impair their
physical, sensory or mental abilities.
-The refrigeration of non-specified liquids and those above the maximum supply temperatures as this may
cause unacceptably high pressures to build up in the refrigeration circuit.
-Operating the unit below the minimum and above the maximum ambient temperatures (minimum and
maximum temperatures see chapter 3.3, page 15).
-Operating the unit with conveying media other than those defined in this document.
-Operating the unit in locations and ambient conditions which do not fully meet the requirements of this
manual
-Operation of the unit by untrained staff

Balance Carbonator / Balance Karbonator
Manual operation / Gebrauchsanweisung
Carbonator/Karbonator HS/HK
Seite 6
Cornelius DeutschlandGmbH
Document no/ Dokumenten-Nr.: TD22022600ML
Version A, 11.05.2020, Index 0
Staff
Operator
The operator is the natural or legal person who uses the unit or on whose behalf the unit is used. The operator
must ensure that the unit is only used as intended, in observance of the safety instructions set out in this
document.
The operator must ensure that all users read and understand the safety information. The operator is responsible
for the planning and proper implementation of regular safety inspections and maintenance work.
With regard to operating the unit, Cornelius Deutschland GmbH recommends observing the national regulations
of the country of use which govern the operation of drink-dispensing systems.
User
The operator specifies who will operate this unit. Cornelius recommends the following:
If this unit is only to be operated by employees, they are to be instructed in its use, demonstrate their
abilities to use it to the operator or their authorized representative, and be expressly charged with its
use. This document is to be available to staff at all times.
If this unit is openly accessible and set up so that untrained staff can use it, the operator is to provide
instructions for use directly at the unit; these must be clearly understood by this group of people,
therefore ensuring that the unit will be handled safely.
Expert
An expert in terms of this document refers to someone who has the relevant training, experience and
information and knowledge of relevant standards, laws, regulations, accident prevention regulations,
generally accepted safety-related regulations and operating conditions to be able to perform the required
activities as well as recognize potential risks and avert them.
For assignments requiring expert knowledge, e.g. in electrical engineering, mechanics or fluid technology,
only skilled workers with the right qualifications are to carry these out.
An expert must also have received technical training in the unit-specific special features of Cornelius
products. The assigned tasks are always to be carried out in compliance with this manual.

Balance Carbonator / Balance Karbonator
Manual operation / Gebrauchsanweisung
Carbonator/Karbonator HS/HK
Seite 7
Cornelius DeutschlandGmbH
Document no/ Dokumenten-Nr.: TD22022600ML
Version A, 11.05.2020, Index 0
Transport and packaging
Choose a suitable packaging when returning the unit itself or one of its components to Cornelius
Deutschland GmbH, e.g. for repairs. In particular, make sure that the unit and any components are
protected from shock/impact, moisture, dirt and electrostatic discharge (ESD). This will prevent transport
damage to the unit and to the components, for which the manufacturer shall assume no liability.
Caution!
Component damage due to freezing liquids
Ambient temperatures that are below freezing will lead to the freezing of any water or cleaning agent
residue remaining inside the unit. This will lead
to damage to internal components.
oBefore shipment, storage or relocation of the unit, the unit is to be cleaned and the cleaning solution
is to be fully drained from the unit.
Storage
Avoid excessive temperature fluctuations as condensate may form, which in turn may cause damage to
the unit or to the components.
The permissible storage temperature is -10 °C to +50 °C.
The acclimatization period is 6 hours.
Caution!
Damage due to improper storage
Dirt or moisture entering a unit, as well as certain weather conditions (e.g. condensate forming at the unit,
sunlight) will cause damage to the unit and its components.
• Protect the unit and its components by storing the unit in a clean and dry place, and by ensuring stable
ambient conditions.
• If possible, store the unit in its original packaging. Unpacked units must be covered with a dustproof
cover. No condensate must form under the cover.
Caution!
Risk of electrostatic charge!
Improper handling or storage may result in electrostatic charges.
oIf possible, store units and/or any electronic components in their original packaging.
oKeep units and/or electronic components away from charged objects, fields and insulators.
oAvoid electrostatic charges when removing packaging and/or handling electronic assemblies and
components by working at an ESD protected workstation or work area.
oWhen working at the unit or its components, wear a grounding (antistatic) wrist strap at the very least
and wear antistatic gloves if necessary.
Caution!
Component damage due to material ageing
Material can age due to long storage periods, thereby affecting the material’s properties (e.g. plastics
and seals may become brittle). The properties of lubricants may change due to long storage periods.

Balance Carbonator / Balance Karbonator
Manual operation / Gebrauchsanweisung
Carbonator/Karbonator HS/HK
Seite 8
Cornelius DeutschlandGmbH
Document no/ Dokumenten-Nr.: TD22022600ML
Version A, 11.05.2020, Index 0
oCheck the assemblies and components for damage before each use/before installing them. Do not
install assemblies or components that show visible signs of ageing.
Caution!
Component damage due to freezing liquids
Ambient temperatures that are below freezing will lead to the freezing of any water or cleaning agent
residue remaining inside the unit. This will lead to damage to internal components.
Before shipment, storage or relocation of the unit, the unit is to be cleaned and the cleaning solution is to
be fully drained from the unit.
Disposal
Disposal of the units must be carried out in compliance with the applicable local and/or national and
international regulations. Units must not be disposed of with household waste.
If the unit contains fuels or lubricants in liquid, paste-like or gaseous form, such as oil, grease, cooling
agents etc., such fuels or lubricants are to be collected using appropriate measures and disposed of in
compliance with the applicable local and/or national and international regulations. Such fuels or lubricants
must always be prevented from seeping into the ground, the sewage system and any bodies of water, and
must always be prevented from entering the atmosphere.

Balance Carbonator / Balance Karbonator
Manual operation / Gebrauchsanweisung
Carbonator/Karbonator HS/HK
Seite 9
Cornelius DeutschlandGmbH
Document no/ Dokumenten-Nr.: TD22022600ML
Version A, 11.05.2020, Index 0
InstallationRequirements
Comply with the valid national regulations for installation sites and electrical connections.
Installation Sites
Ventilation of the installation sites must be appropriate for device output. Inadequate ventilation of the
device will result in its overheating and being destroyed.
Electrical Connections
A socket outlet with an earthing contact featuring a maximum protection of 16 amps is required.Please
take care, that the socket for the unit is always accessible.
The line voltage must always be within following tolerances: 230 VAC +6%/-10% / 50 Hz
Installation
The device must be installed by a trained service technician.
Please take care, that the socket for the unit is always
accessible. There is no user serviceable items inside the
equipment.
If the power supply cable to the unit is damaged, it has to be replaced by the manufacturer, the service
partner or any other qualified person to avoid safety hazard.
Water Connection
Connecting only to drinkable water
Connect the device to a feed line with an inner diameter of min. 8 mm. We recommend using a water
filter and a water pressure regulator for the water input. Topermit flushing of the filter, a T-piece
should be mounted downstream of the water pressure regulator. The water flow pressure should be 2
bar (mount control pressure gauge on water pressure regulator). In case of falling below the unit
switches off and switches on again having reached 2 bar of water pressure.
CO2 Connection
You will require a singel-wire pressure regulator, 7 bar. Using tubing with an inner diameter of 4 mm,
connect the pressure regulator to the carbonator.
Connecting Soda Water and Still Water
Connect one tube with an inner diameter of 6 mm to each device connection. Connect the tube end to
the correct cooling coil inputs of the cooler.
Pump Control
Still Water Control at theCarbonator
For still water, one switching cable (1 x 0.75 mm2) per still water valve must run from the soda circuit
carbonator to the still water valve. The electronic control system is actuated via this cable. An addition
cable from one of the still water valves is necessery. Refer to the circuit diagram for the connection.
The flow rate of the still water has to be adjusted by the water pressure regulator and should be 170 ml
in 4 to 5 seconds.

Balance Carbonator / Balance Karbonator
Manual operation / Gebrauchsanweisung
Carbonator/Karbonator HS/HK
Seite 10
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Document no/ Dokumenten-Nr.: TD22022600ML
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Still Water Control at the pumping blocks for stillwater
The pumping block for still water includes a pressure switch. The still water pressure in the water line
decreases when the still water valve opens and switches the pump on. The flow rate is factory adjusted
at 3.2 bar and the pressure switch at 4.2 bar.
Pump Control at the pumping blocks for carbonatorbowls
For pumping block controling the three wires of the carbonator level probe have to be connected.
The commen wire has to be screwed on to point 3 of the connecting block (blue /white wire), the max.wire
has to be
screwed on to point 2 of the connecting block (orange wire) and the min. wire has to be screwed on to
point 1 of the connecting block (red wire).
Putting into and out ofService
Putting into Service
Open the cylinder globe valve on the CO2-cylinder and the globe valve on the pressure regulator.
Check the CO2- pressure at the pressure regulator. CO2 carbonization pressure aprox.5.5 bar
Set the CO2-pressure by turning the control screw:
Clockwise to increase the pressure
Counter-clockwise to reduce the pressure
Afterwards check the CO2-lines for leaks by closing the CO2-globe valve. The admission pressure
displayed at the pressure regulator should not drop. If it does, notify the service technician
immediately. Do not forget to re-open the CO2-globe valve after the check.
Open the water feed line and check the flow pressure in it. Standard
value: 2.-3 bar. Set it at the control screw on the external water pressure
regulator:
Clockwise to increase the
pressure Counter-clockwise to
reduce the pressure
Check the soda- and stillwater lines for leaks. Only a visual inspection is possible. If liquid is leaking, call a
service technician.
Close the water feed line. The pressure displayed should not drop. If it does, notify the service technician
immediately. Afterwards, re-open the water feed line.
Turning On the Device
Insert the mains plug for the carbonator into the socket outlet with an
earthing contact. Open the water feed line.
Turning On the Carbonator
Release air from the carbonator bowl by pulling the safety valve several time for
about 2 seconds. Check the flow pressure in it. Standard value: 2.-3 bar.
Fill the python and purge the installation at the valve.
The carbonator pump switches on automatically and fills the carbonator container. The carbonator
pump switches off when the water has reached its highest level in the carbonator container but after
no more than 20 minutes. Long run periods are signs of leaks or insufficient water. It is then only
possible to turn the pump back on by executing a network reset (pulling out the mains plug briefly).