Cornelius AURORA 10, 000 PLUS User Manual

Installation Manual

AURORAR10,000 PLUS
COOLING UNIT

Part No. 300614000
November 8, 1989
Revised: April 12, 1993

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment

IMI CORNELIUS INC; 1989--93Ó

PRINTED IN U.S.A

TABLE OF CONTENTS

GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT DESCRIPTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM THEORY OF OPERATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNPACKING AND INSPECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION OF LOOSE-SHIPPED PARTS 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

SELECTING LOCATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE CONDENSER COIL AND FAN ASS’Y 6. . . . . . . . . . . . . . . . . . . . . . .

INSTALLING REMOTE CONDENSER COIL AND FAN ASS’Y 6. . . . . . . . . . . . . . .

INSTALLING COOLING UNIT 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLACING COOLING UNIT IN LOCATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING REMOTE CONDENSER COIL AND FAN ASS’Y

REFRIGERATION LINES TO COOLING UNIT 6. . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING UNIT 7. . . .

CONNECTING ELECTRICAL POWER CIRCUIT TO REMOTE

CONDENSER COIL AND FAN ASS’Y 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING PLAIN WATER INLET SUPPLY LINE TO COOLING UNIT 8

CONNECTING CO2 INLET SUPPLY LINE TO COOLING UNIT 9. . . . . . . . .

CONNECTING SYRUP SOURCE LINES TO COOLING UNIT SYRUP

INLET LINES 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING COOLING UNIT SYRUP OUTLET LINES TO INSULATED

PYTHON SYRUP LINES 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING COOLING UNIT PLAIN WATER OUTLET LINES TO

INSULATED PYTHON PLAIN WATER LINES 9. . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING COOLING UNIT CARBONATED WATER OUTLET LINES TO

INSULATED PYTHON CARBONATED WATER LINES 9. . . . . . . . . . . . . . . . .

PLACING COOLING UNIT IN OPERATING POSITION 10. . . . . . . . . . . . . . . . . . . . .

PREPARING COOLING UNIT FOR OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEAK CHECK AND INSULATING COOLING UNIT OUTLET LINES 12. . . . . . . . . .

DISPENSING STATION ADJUSTMENTS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING WATER FLOW RATE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED PRODUCT 12

INSTALLING LINE IDENTIFICATION LABEL 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERA TORS INSTRUCTIONS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

OPERATING CONTROLS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT REFRIGERATION POWER SWITCH 13. . . . . . . . . . . . . . . . .

COOLING UNIT CARBONATOR MOTOR SWITCH 13. . . . . . . . . . . . . . . . . . . .

COOLING UNIT CIRCULATING MOTOR SWITCH 13. . . . . . . . . . . . . . . . . . . . .

REFRIGERATION SYSTEM TEMPERATURE SENSING DEVICE AND

HIGH-PRESSURE CUTOUT SWITCH 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY PRE-OPERATION CHECK 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i 300614000

TABLE OF CONTENTS (cont’d)

ADJUSTING CO2 REGULATORS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING DISPENSING VALVES WATER FLOW RATE 14. . . . . . . . . . . . .

ADJUSTING WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED PRODUCT 14.

ADJUSTING SIZE OF DRINK DISPENSED 14. . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING SYRUP SUPPLY 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING SYRUP SYSTEMS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT AIR INTAKE AND EXHAUST FILTERS 15. . . . . . . . . . . . . . . .

CHECKING ICE WATER BATH 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT CARBONATOR MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . .

DOUBLE LIQUID CHECK VALVE ASSEMBLIES YEARLY MAINTENANCE

(OR AFTER WATER SYSTEM DISRUPTIONS). 15. . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT CARBONATED WATER CIRCULATING PUMP MOTOR

LUBRICATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE CONDENSER COIL AND FAN ASS’Y MAINTENANCE 16. . . . . . . . . . . .

CLEANING CO2 GAS CHECK VALVES 16..................................

SERVICE AND MAINTENANCE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

COOLING UNIT MAINTENANCE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CLEANING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING COOLING UNIT AIR INTAKE AND EXHAUST FILTERS. 17. . . . .

PREPARING COOLING UNIT FOR SHIPPING, STORING, OR RELOCATING 17

PERIODIC INSPECTION 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE CONDENSER COIL AND FAN ASSEMBLY MAINTENANCE 18. . . . . . .

CHECKING ICE WATER BATH 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING ICE WATER BATH 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DOUBLE LIQUID CHECK VALVE ASSEMBLIES YEARLY MAINTENANCE

(OR AFTER WATER SYSTEM DISRUPTIONS) 19. . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMARY CO2 REGULATOR 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY CO2 REGULATORS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER FLOW RATE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED PRODUCT 22.............

CLEANING AND SANITIZING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING OF UNIT 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING POST-MIX SYRUP SYSTEMS 23. . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING SYRUP SUPPLY 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP FLAVOR CHANGE 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CO2 SYSTEM GAS CHECK VALVES 27. . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY CO2 REGULATORS AND CO2 MANIFOLD CO2 GAS

CHECK VALVES 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

300614000

ii

TABLE OF CONTENTS (cont’d)

COOLING UNIT CO2 INLET LINE CO2 GAS CHECK VALVE 27. . . . . . . . . . .

TROUBLESHOOTING 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED DRINK TOO LOW OR TOO

HIGH. 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES

NOT INCREASE TO DESIRED WATER-TO-SYRUP ‘‘RATIO”. 30. . . . . . . . . . . . . . .

ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES

NOT DECREASE TO DESIRED WATER-TO- SYRUP ‘‘RATIO’’. 31. . . . . . . . . . . . .

DISPENSED PRODUCT CARBONATION TOO LOW. 31. . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT

FOAMS IN CUP. 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT PRODUCES FOAM AS IT LEAVES DISPENSING

VALVE. 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ONLY CARBONATED WATER DISPENSED. 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ONLY SYRUP DISPENSED. 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARM PRODUCT BEING DISPENSED. 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP MOTOR WILL NOT OPERATE. 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP MOTOR WILL NOT SHUT OFF. 32. . . . . . . . . . . . . . . . . . . . . . . . . . .

ERRATIC CYCLING OF CARBONATOR. 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP

WATER. 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP CAPACITY TOO LOW. 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR DOES NOT OPERATE. 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM

SUFFICIENT ICE BANK 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSER FAN MOTOR NOT OPERATING 35. . . . . . . . . . . . . . . . . . . . . . . . . . .

AGITATOR MOTOR NOT OPERATING. 35..................................

WARRANTY 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

LIST OF FIGURES

FIGURE 1. AURORAR10,000 PLUS COOLING UNIT 1. . . . . . . . . . . . . . . . . . . . . . .

FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION) 4. . . . . . . . . . . . . . . . . . .

FIGURE 3. 240/24VAC POWER TRANSFORMER 7. . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 4. COOLING UNIT SPACE REQUIRED 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 5. PARTS IDENTIFICATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. LIQUID CHECK VALVE ASSEMBLY 22. . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 7. CO2 GAS CHECK VALVE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 8. REFRIGERATION FLOW DIAGRAM (REQUIRES CONNECTION TO

REMOTE CONDENSER COIL AND FAN ASS’Y) 28. . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 9. WIRING DIAGRAM 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF TABLES

TABLE 1. DESIGN DATA 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 2. LOOSE-SHIPPED PARTS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii 300614000

GENERAL INFORMATION

IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, and
maintaining this equipment. Refer to Table of Contents for page location of detailed information
pertaining to questions that arise during installation, operation, service and maintenance, or
troubleshooting this equipment.

GENERAL DESCRIPTION

This section gives the description, theory of operation, and design data for the AuroraR10,000 Plus Cooling
Unit, hereafter referred too as a Cooling Unit.

COOLING UNIT DESCRIPTION

The Cooling Unit is designed to provide cooled syrup, carbonated water, and plain water to the dispensing
station through an insulated python (length as ordered). The Cooling Unit refrigeration system is cooled by a
Remote Condenser Coil and Fan Assembly which is connected to the Cooling Unit.

The Cooling Unit consists of a refrigeration system with a two horsepower compressor and a Hydro BoostR
(plain water pre-cooler) which pre-cools plain water on its way to the carbonated water tank. The Cooling Unit
also consists of a plain water pump. The plain water pump pumps plain water through the Hydro BoostR ,
through the plain water cooling coils, and into the carbonated water tank. The carbonated water circulating
pump circulates cold carbonated water from the Cooling Unit to the dispensing station and back to the Cooling
Unit.

The cabinet panels are easily removed to facilitate installation and service and maintenance.
An optional Cooling Unit Stand (P/N 309309000) is available to elevate Cooling Unit up off floor. Also available

is an Aurora Service System Analyzer (P/N 30919700) that may be used to analyze and troubleshoot the
Cooling Unit refrigeration system.

CAUTION: Before shipping or relocating the Cooling Unit syrup cooling coils must be
sanitized and all sanitizing solution must be purged from the coils. All water must also be

purged from the plain and carbonated water systems. A freezing ambient environment will
cause residual sanitizing solution or water remaining inside the Cooling Unit to freeze resulting in
damage to internal components.

FIGURE 1. AURORAR10,000 PLUS COOLING UNIT

1

300614000

Table 1. Design Data

COOLING UNIT DATA

Model No. 416654

Overall Dimensions:

Height 25-inches

Width 36-1/2 inches

Depth 24-1/2 inches

NOTE: Overall dimensions if Cooling Unit is placed on optional Cooling Unit Stand (P/N 309309069).

Height (approximate) 72-5/16 inches
Width 37-1/2 inches
Depth 25-3/8 inches

Weights:

Shipping 385 pounds
Dry Weight pounds
Ice Bank Weight 40 ± pounds

Capacities:

Water Bath (no ice bank) 18 gallons

Compressor Horsepower 2 HP

Refrigeration System:

Refrigerant Type and Charge See Cooling Unit Nameplate

Ambient Operating Temp. 50° F to 100° F

Electrical Requirements:
Operating Voltage See Cooling

Nameplate

Current Draw

REMOTE CONDENSER COIL AND FAN ASS’Y DA TA (P/N 309602000)

Overall Dimensions:

Height 27 inches
Width 22-inches
Depth 38-inches

Weight:

Shipping 85 pounds

Ambient Operating Temp. -22° F to 158° F

Electrical Requirements:
Operating Voltage 208/230VAC, Single Phase,

Current Draw 2.5 Amps

Unit

60Hz

300614000

2

SYSTEM THEORY OF OPERATION

(see Figure 2)
A CO2cylinder delivers carbon dioxide gas (CO2) to primary CO2regulator assembly which deliver regulated

CO2gas to adjustable secondary CO2regulators. Secondary CO2regulators delivers regulated CO2gas to the
carbonated water tank inside the Cooling Unit and also to the soft drink tanks. Plain water enters the Cooling
Unit and is pumped through and is pre-cooled by the refrigerated Hydro Boostâ coil. Cooled water continues
through the plain water cooling coils and into the carbonated water tank. Cold plain water entering the
carbonated water tank is carbonated by regulated CO2gas pressure also entering the tank. Carbonated water
leaves the carbonated water tank and enters the inlet side of the carbonated water circulating pump.
Carbonated water passes through the carbonated water circulating pump, through the carbonated water cooling
coil, and exits the Cooling Unit through an insulated python to a turnaround inside the dispensing station.
Carbonated water returns to the Cooling Unit by passing through the insulated python, through the Cooling Unit
carbonated water cooling coils, through the carbonated water tank which makes up the carbonated water
circulating system. As carbonated water is being dispensed from the dispensing station, carbonated water
circulating system is continuously being replenished from the carbonated water tank.

Plain water enters through the Cooling Unit two plain water inlet lines, through the plain water cooling coils, and
exists the Cooling Unit out through insulated python to the dispensing station. Regulated CO2gas pressure
exerted upon the soft drinks contents forces syrup from tanks, through Cooling Unit syrup inlet lines, through
syrup cooling coils, and exists the Cooling Unit out through an insulated python to the dispensing station.

The Cooling Unit refrigeration system is cooled by a Remote Condenser Coil and Fan Assembly (P/N

309602000) that is authorized by IMI Cornelius Inc. Use of any other Remote Condenser Coil and Fan
Assembly must be authorized by IMI Cornelius Inc. Use of an unauthorized Remote Condenser Coil and Fan
Assembly will automatically void the Cooling Unit factory warranty .

3

300614000

CONTROL

*WATER TANK

WATER LEVEL

CIRCULATING PUMP

CARBONATED WATER

*SOME COOLING UNITS MAY BE

EQUIPPED WITH THE WATER

LEVEL FLOATCONTROL.

DOUBLE LIQUID

CHECK VALVE ASS’Y(2)

PLAIN

WATER PUMP

COOLING UNIT

416654

2

CO

VALVE

CHECK

COOLING UNIT MODEL:

TO

STATION

TANK ASS’Y

DISPENSING

CARBONATED WATER

VALVE

HYDRO BOOSTR

BYPASS SHUTOFF

COIL

HYDRO BOOSTR

VALVE

LIQUID

CHECK

FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION)

REGULATOR

2

DIET SYRUP

CO

REGULATOR

2

SUGAR SYRUP

ASS’Y

WATER FILTER

CO

REGULATOR

2

CARBONATOR

CO

MANIFOLD

2

CO

GAS CHECK

VALVE(10)

2

CO

SOFT DRINK TANKS(10)

VALVE

SHUTOFF

300614000

LINE LEGEND

CO2CARB WATER

PLAIN WATER

SYRUP

REGULATOR

SOURCE

WATER PRESSURE

PLAIN WATER

REGULATOR

PRIMARY

2

CO

CYLINDER

2

CO

4

INSTALLATION

This section covers unpacking and inspection, selecting location, installing the Cooling Unit and the Remote
Condenser Coil and Fan Assembly preparing for operation, and operation.

UNPACKING AND INSPECTION

NOTE: The Cooling Unit and the Remote Condenser Coil and Fan Assembly were thoroughly inspected
before leaving the factory and the carrier has accepted and signed for them. Any damage or
irregularities should be noted at time of delivery (or not later than 15 days from date of delivery) and
immediately reported to the delivering carrier. Request a written inspection report from Claims
Inspector to substantiate any necessary claim. File claim with the delivering carrier, not with IMI
Cornelius Inc.

1. After Cooling Unit has been unpacked, remove shipping tape and other packing material.

2. Unpack LOOSE-SHIPPED PAR TS. Make sure all items are present and in good condition.

Table 2. Loose-Shipped Parts

Item

No. Part No. Name Qty .

1 309852000 Tubing Clamp 24
2 770407 Barbed Connector, 1/4 by 3/8 12
3 770424 Barbed Connector, 1/2 by 1/2 2
4 311962000 Label, Line Identification 1

NOTE: The following Remote Condenser Coil and Fan Assembly and Refrigeration Line Kits are rec­ommended for use with Cooling Unit (P/N 416654000). Refrigeration Lines Kit (as ordered) is used to
connect Condenser Coil and Fan Assembly to the Cooling Unit.

5 309602000 Remote Condenser Coil and Fan Ass’y 1
6 300598025 Refrigeration Line Kit, 25-ft. long, 90 1

300598050 Refrigeration Line Kit, 50-ft. long, 90 1

IDENTIFICATION OF LOOSE-SHIPPED PARTS

1. BARBED CONNECTORS (item 2) used to connect Cooling Unit outlet lines to insulated python lines.
Connections are secured with TUBING CLAMPS (item 1).

2. BARBED CONNECTORS (item 3) are used to connect Cooling Unit outlet carbonated water lines to
insulated python lines.

3. LABEL, LINE IDENTIFICATION (item 4) to be installed on Cooling Unit and syrup flavors to be recorded in
proper spaces on label.

4. REFRIGERATION LINE KIT (items 6) is used to connect REMOTE CONDENSER COIL AND FAN ASS’Y
(item 5) to Cooling Unit.

SELECTING LOCATION

COOLING UNIT

Select location for Cooling Unit installation that will (1) Allow the shortest possible insulated python route from
the Cooling Unit to the Dispensing Station location; (2) Allow the shortest possible refrigeration lines (not to
exceed 50-ft in length) route from Remote Condenser Coil and Fan Assembly to the Cooling Unit; (3) REFER
TO THE COOLING UNIT NAMEPLATE FOR THE REQUIRED POWER CIRCUIT OPERATING VOLTAGE, HZ,
AND THE MINIMUM CIRCUIT AMPACITY OF THE COOLING UNIT. The power circuit for the Cooling Unit
must be wired through a 40-amp minimum rated disconnect switch (not provided) and the power circuit must be

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fused as indicated on the Unit nameplate. The power circuit may also be wired through an equivalent HACR
type circuit breaker rather then the disconnect switch. THE POWER CIRCUIT MUST BE MADE UP OF
COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL
CODES; (4) Close to a plain water source supply line with proper requirements; (5) Sufficient space around
Cooling Unit (see Figure4) for proper air circulation (18-inches on sides and back, front side open to room, and
top open to ceiling); (6) Be close to permanent floor drain to route Cooling Unit water tank drain and overflow
hoses to the floor drain.

REMOTE CONDENSER COIL AND FAN ASS’Y

CAUTION: Remote Condenser Coil and Fan Assemblies authorized by IMI Cornelius Inc.
(P/N 309602000)

1. An extreme warm climate installation may require extra caution in Remote Condenser Coil and Fan
Assembly location. Avoid hot sunny locations and seek shaded area if possible. The use of a structure to
shade the Unit from direct sun exposure and/or a platform extending Unit an additional 18-inches above
the rooftop is highly recommended and will improve performance. Ample space must be provided on all
sides and above Unit for proper air circulation through Unit and also access for service and maintenance.
DO NOT BLOCK AIR CIRCULATION THROUGH UNIT.

2. Remote Condenser Coil and Fan Assembly must be installed in level position and must be anchored with
adequate fastening devices.

INSTALLING REMOTE CONDENSER COIL AND F AN ASS’Y

(see Figure 6)

1. Remote Condenser Coil and Fan Assembly must be installed meeting requirements of SELECTING
LOCATION. Remote Condenser Coil and Fan Assembly must be installed in a level position and must be
anchored with adequate fastening devices.

2. Route refrigeration lines of REFRIGERATION LINE KIT (item 6) from Remote Condenser Coil and Fan
Assembly down to Cooling Unit location.

3. Connect ends of refrigeration lines to Condenser Coil and Fan Assembly refrigeration connectors.

INSTALLING COOLING UNIT

NOTE: Cooling Unit outlet lines, plain water, CO2, and syrup inlet lines, Remote Condenser Coil and
Fan Assembly refrigeration lines and power circuit cable, and Cooling Unit power circuit cable each
must be long enough when connected to Cooling Unit to allow pulling Unit out approximately
36-inches from operating position for service and maintenance. When Cooling Unit is in operating
position, excess power circuit cable, Remote Condenser Coil and Fan Assembly refrigeration lines and
power circuit cable and plain water source and CO2inlet lines may be coiled up behind Unit.

PLACING COOLING UNIT IN LOCATION

NOTE: An optional Cooling Unit Stand (P/N 309309069) is available to elevate Cooling Unit up and off
the floor.

1. Place Cooling Unit in position approximately 36-inches out from operating position to allow access all
around the Unit.

2. Remove two screws securing Cooling Unit top cover, then remove cover.

CONNECTING REMOTE CONDENSER COIL AND FAN ASS’Y REFRIGERATION LINES
TO COOLING UNIT

(see Figure 5)
Connect refrigeration lines, from Remote Condenser Coil and Fan Assembly, to refrigeration connectors on front

of Cooling Unit.

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CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING Unit

(see Figures 5 and 9)

IMPORTANT: Before 208/230VAC single-phase 60Hz electrical power circuit is connected to the cooling
unit, service power voltage entering the building must be identified. Service power voltage entering the
building will either be 208 or 230VAC and may be posted on the main service box. If not, the installer
must contact the local electrical power company for information. If these two voltage identification
attempts should fail, a voltage reading Must be performed. If service power voltage is below 218VAC,
the red electrical wire connected to the 240VAC terminal on LINE (primary) side of the 240/24VAC power
transformer inside the cooling unit switches electrical control box (see Figure 3 and 9) must be
disconnected from the 240VAC terminal and be connected to the 208VAC terminal. If voltage is above
218VAC, power transformer red electrical wire will remain connected to the 240VAC terminal. If installer
is not sure of the service power voltage entering the building, leave red electrical wire connected to the
240VAC terminal on the power transformer. If service power voltage is below 218VAC, proceed as
follows:

1. Remove four screws securing electrical control box cover, then remove cover for access to the
240/24VAC power transformer.

2. Remove red electrical wire from the 240VAC terminal on LINE (primary) side of power transformer
and connect it to the 208VAC terminal.

C

208V

240V

FIGURE 3. 240/24VAC POWER TRANSFORMER

WARNING: Make sure 40-amp minimum-rated disconnect switch (not provided) is in ‘‘OFF’’
position.

1. Remove cover from electrical handy box on back of Cooling Unit.

WARNING: The Cooling Unit must be electrically grounded to avoid possible fatal electrical
shock or serious injury to the operator. A green ground wire is provided inside electrical
box to connect power circuit ground wire which electrically grounds the Cooling Unit.

RESET BUTTON

Connect 208/230VAC Single-Phase 60Hz power circuit from 40-amp minimum rated disconnect switch (not
provided) fused at 40-amps (‘‘slow-blow’’) to electrical wires inside electrical handy box on back of Cooling Unit.
COOLING UNIT MUST BE PROPERLY GROUNDED. POWER CIRCUIT MUST BE MADE UP OF COPPER
CONDUCTORS, AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES.

DO NOT CONNECT ELECTRICAL POWER TO COOLING UNIT AT THIS TIME.

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CONNECTING ELECTRICAL POWER CIRCUIT TO REMOTE CONDENSER COIL AND
FAN ASS’Y

(see Figure 5 and 9)

CAUTION: The Cooling Unit refrigeration system is cooled by a Remote Condenser Coil
and Fan Assembly (P/N 309602000) that is authorized by IMI Cornelius Inc. Use of an
unauthorized Remote Condenser Coil and Fan Assembly will automatically void the

Cooling Unit factory warranty.

NOTE: Electrical power circuit may be connected to the Remote Condenser Coil and Fan Assembly
(P/N 309602000) in two ways. The preferred way is to draw electrical power from the cooling unit
contactor which allows the Remote Condenser Coil and Fan Assembly to operate only when the
cooling unit refrigeration system is operating. The optional way is to connect a separate electrical
power circuit (independent of the cooling unit) through an appropriately rated and fused disconnect
switch or an equivalent HACR circuit breaker which allows the Remote Condenser Coil and Fan
Assembly to operate at all times (independent of cooling unit operation).

1. Connect and route electrical power circuit cable from Remote Condenser Coil and Fan Assembly through
fuse box (not provided), fused at 15-amps (maximum) down to Cooling Unit location. REMOTE
CONDENSER COIL AND FAN ASSEMBLY MUST BE PROPERLY GROUNDED, POWER CIRCUIT
MUST BE MADE UP OF COPPER CONDUCTORS, AND ALL WIRING MUST CONFORM TO NATIONAL
AND LOCAL ELECTRICAL CODES.

2. Route Remote Condenser Coil and Fan Assembly Power cable electrical wires through electrical handy
box on back of Cooling Unit to inside of electrical control box.

3. Connect Remote Condenser Coil and Fan Assembly power cable electrical wires to T1and T2terminals on
contactor inside Cooling Unit electrical control box.

4. Install electrical control box cover and secure with four screws.

5. Install cover on electrical handy box on back of Cooling Unit.

CONNECTING PLAIN WATER INLET SUPPLY LINE TO COOLING UNIT

(see Figure 2)

NOTE: IMI Cornelius Inc. recommends that a water shutoff valve be installed in plain water inlet supply
line connected to Cooling Unit and that water supply be filtered. WATER PIPE CONNECTIONS AND
FIXTURES DIRECTLY CONNECTED TO A POTABLE WA TER SUPPLY SHALL BE SIZED, INSTALLED
AND MAINTAINED ACCORDING TO FEDERAL, STA TE, AND LOCAL LAWS.

CAUTION: Plain water inlet supply line to Cooling Unit must be 1/2-inch I.D. minimum.
Check water flow rate of water inlet supply line. MINIMUM FLOW RATE MUST BE AT LEAST

300-GALLONS PER HOUR. If flow rate is less than 300-gallons per hour, ‘‘starving’’ of
carbonator water pump will occur. Starving will allow water pump to overheat causing safety
thermostat on pump outlet to disrupt electrical power to and stop water pump motor. Carbonated
water circulating pump overheating could occur if water inlet supply line flow rate drops below
300-gallons per hour. INCOMING PLAIN WATER INLET SUPPLY LINE WATER PRESSURE MUST
REMAIN A MINIMUM OF 10-PSI BELOW THE CARBONATOR CO2OPERA TING PRESSURE.
(Example: Operating pressure is 90-psi and maximum water pressure can be no more than 80-psi,
etc.)

1. Before connecting plain water inlet supply line to Cooling Unit, open water line shutoff valve for a period of
time to flush out any metal shavings and other contaminates that may have resulted from plumbing
connections.

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2. Connect flexible plain water inlet supply line (1/2-inch I.D. min.), meeting water inlet supply line
requirements of preceding CAUTION note, to Cooling Unit 3/8-in. flare (5/8-18) bulkhead fitting on back of
Unit labeled ‘‘WATER INLET’’. DO NOT OPEN WATER INLET SUPPLY LINE SHUTOFF VALVE AT THIS
TIME.

CONNECTING CO2INLET SUPPLY LINE TO COOLING UNIT

(see Figure 2)

WARNING: CO2displaces oxygen. Strict attention must be observed in the prevention of
CO2(carbon dioxide) gas leaks in the entire CO2and soft drink system. If a CO2gas leak is

suspected, particularly in a small area, immediately ventilate the contaminated area before
attempting to repair the leak. Personnel exposed to high concentration of CO2gas will experience
tremors which are followed rapidly by loss of consciousness and suffocation.

Connect flexible CO2inlet supply line to Cooling Unit 1/4-in. flare (7/16-20) bulkhead fitting of back of Unit
labeled “CO2INLET’’. DO NOT TURN ON CO2SUPPLY TO COOLING UNIT AT THIS TIME.

CONNECTING SYRUP SOURCE LINES TO COOLING UNIT SYRUP INLET LINES

(see Figure 2)
Connect syrup source lines, from No. 1 through No. 10 soft drink tanks location, to Cooling Unit syrup inlet lines

labeled No. 1 through No. 10. DO NOT CONNECT SOFT DRINK TANKS INTO SYRUP SYSTEMS AT THIS
TIME.

CONNECTING COOLING UNIT SYRUP OUTLET LINES TO INSULATED PYTHON SYRUP
LINES

(see Figure 2)
Connect Cooling Unit syrup outlet lines labeled No. 1 through No. 10, to insulated python lines labeled No. 1

though No. 10 using BARBED CONNECTORS (item 2). Secure connections with TUBING CLAMPS (item 1).

CONNECTING COOLING UNIT PLAIN WATER OUTLET LINES TO INSULATED PYTHON
PLAIN WATER LINES

(see Figure 2)
Connect Cooling Unit plain water outlet lines to insulated python plain water lines using BARBED

CONNECTORS (item 2). Secure connections with TUBING CLAMPS (item 1).

CONNECTING COOLING UNIT CARBONATED WATER OUTLET LINES TO INSULATED
PYTHON CARBONATED WATER LINES

(see Figure 2)

NOTE: The Cooling Unit carbonated water outlet lines are used to make up the carbonated water
circulating system between the Cooling Unit and the dispensing station as explained in SYSTEM
THEORY OF OPERA TION in GENERAL INFORMATION SECTION.

Connect Cooling Unit carbonated water outlet lines to insulated python carbonated water lines using BARBED
CONNECTORS (item 3).

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