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
trouble-shooting this equipment.
GENERAL DESCRIPTION
This section gives the description, theory of operation, and design data for the AuroraR10,000 Cooling Unit,
(hereafter referred to as a ‘‘Cooling Unit’’).
COOLING UNIT DESCRIPTION
The Cooling Unit is designed to provide cooled soft drink syrup, carbonated water, and plain water to dispensing
station through an insulated python (length as ordered). On the standard Cooling Unit, refrigeration system is
cooled by condenser coil and fan assembly located inside the Cooling Unit. Cooling Unit not provided with
internal condenser coil and fan assembly is cooled by Remote Condenser Coil and Fan Assembly which is
connected to Cooling Unit. The Cooling Unit consists basically of two carbonator tanks each having its own
water pump to pump plain water into tanks, one carbonated water circulating pump, a Hydro Boostâ
(carbonated water pre-cooler) which pre-cools carbonated water on its way to carbonated water circulating
pump and a two horsepower refrigeration compressor. 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. A System
Status Display Kit (P/N 0913) is available and when installed on the Cooling Unit, allows operator or technician
to monitor operation of Cooling Unit and to be aware when service is required. Also available is an Aurora
Service System Analyzer (P/N 309197000) that may be used to analyze and troubleshoot the Aurora 10,000
Cooling Unit refrigeration system.
CAUTION: Before shipping or relocating Cooling Unit, syrup cooling coils must be
sanitized and all sanitizing solution must be purged from coils. All water must also be
purged from plain and carbonated water systems. A freezing ambient environment will
cause residual sanitizing solution or water remaining inside Cooling Unit to freeze resulting in
damage to internal components.
FIGURE 1. AURORAR10,000 COOLING UNIT
1
300381000
Table 1. Design Data
COOLING UNIT MODEL NUMBERS:
60 HZ Unit:
Standard Cooling Unit with Internal Condenser Coil and Fan Assembly416593
Cooling Unit Requiring Connection to Remote Condenser Coil and Fan
Assembly
50 HZ Unit:
Standard Cooling Unit with Internal Condenser Coil and Fan Assembly496593
Water Bath (no ice bank)18 gallons
Compressor Horsepower2 HP
Refrigeration System:
Refrigerant Type and ChargeSee Cooling Unit Nameplate
Ambient Operating Temp.50° F to 100° F
Electrical Requirements:
60 HZ Cooling Unit:
Operating voltage
Current Draw
50HZ Cooling Unit:
Operating Voltage
Current Draw
See Cooling Unit
Nameplate
See Cooling
Nameplate
Unit
3003810002
Table 1. Design Data (cont’d)
REMOTE CONDENSER COIL AND FAN ASS’Y DA TA (P/N 309602000)
Overall Dimensions:
Height27 inches
Width22-inches
Depth38-inches
Weight:
Shipping85 pounds
Ambient Operating Temp.-22° F to 158° F
Electrical Requirements:
Operating Voltage208/230VAC, Single Phase,
60Hz
Current Draw2.5 Amps
SYSTEM THEORY OF OPERATION
(see Figure 2)
A CO2cylinder delivers carbon dioxide gas (CO2) to primary CO2regulator assembly which delivers regulated
CO2gas to adjustable secondary CO2regulators. Secondary CO2regulators deliver regulated CO2gas to both
carbonated water tanks inside Cooling Unit and also to soft drink tanks. Plain water is pumped into carbonated
water tanks by water pumps and is carbonated by regulated CO2gas pressure also entering tanks. Carbonated
water leaves carbonated water tanks and passes through the Hydro BoostR(carbonated water pre-cooler)
which pre-cools carbonated water on its way to carbonated water circulating pump. Pre-cooled carbonated
water enters carbonated water circulating system through inlet side of carbonated water circulating pump.
Carbonated water passes from outlet side of carbonated water circulating pump, through cooling coils inside
water tank, and out through insulated line to turnaround inside dispensing station. Carbonated water returns to
Cooling Unit by passing through insulated line, through cooling coils, and on to carbonated water circulating
pump inlet which makes up the carbonated water circulating system. As carbonated water is being dispensed
from dispensing station, carbonated water circulating system is continuously being replenished from both
carbonated water tanks. Regulated CO2gas pressure, exerted upon soft drink tanks contents, forces syrup
from tanks, through Cooling Unit cooling coils, and on to dispensing station through insulated lines.
Standard Cooling Unit.
The standard Cooling Unit refrigeration system is cooled by a condenser coil and fan assembly located inside
Cooling Unit.
Cooling Unit Requiring Connection to Remote Condenser Coil and Fan Assembly .
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
300381000
WATER
VALVE(2)
VALVE
CHECK
BYPASS VALVE
HYDRO BOOSTR
EXTERNAL
CARBONATOR
SHUTOFF
CARBONATED
LIQUID
CHECK
SINGLE
VALVE(2)
CARB WTR
CARB WTR
PLAIN WTR
LINES
SYRUP
HYDDRO
BOOSTR
CARBONATOR
WATER PUMP(2)
CARBONATED
WATER TANK(2)
LIQUID
CHECK
DOUBLE
VALVE(2)
TEE FITTING
PUMP
WATER
CIRCULATING
CARBONATED
GAS CHECK VALVE
2
CO
PLAIN WATER
ASS’Y
WATER FILTER
VALVE
SHUTOFF
REGULATOR
WATER PRESSURE
SOURCE
LINE LEGEND
CO2PLAIN WATER
CARB WATER
PLAIN WATER
SYRUP
SHUTOFF VALVE
MANIFOLD
REGULATOR
DIET SYRUP
CO
2
REGULATOR
2
SUGAR SYRUP
CO
REGULATORS
CARBONATORS CO
2
2
GAS CHECK
GAS CHECK
CO
VALVE(2)
VALVE(5)
2
CO
2
FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION)
SOFT DRINK TANKS
CYLINDER
2
CO
REGULATOR
PRIMARY CO
4
INSTALLATION
This section covers unpacking and inspection, selecting location, installing Cooling Unit, preparing for operation,
and operation.
UNPACKING AND INSPECTION
NOTE: The Cooling Unit was thoroughly inspected before leaving the factory and the carrier has
accepted and signed for it. 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 PARTS. Make sure all items are present and in good condition.
Table 2. Loose-Shipped Parts
Item
No.Part No.NameQty .
1110085000Tubing Clamp2
2111353000Tubing Clamp7
3311962000Label, Line Identification1
NOTE: The following Remote Condenser Coil and Fan Assembly and Refrigeration Lines Kits are recommended for use with the Cooling
Units.
4309602000Remote Condenser Coil and Fan Ass’y1
5300598025Refrigeration Line Kit, 25-ft. long, 90°1
300598050Refrigeration Line Kit, 50-ft. long, 90° Straight1
IDENTIFICATION OF LOOSE-SHIPPED PARTS
1. TUBING CLAMPS (item 1) used to secure insulated python lines to Cooling Unit carbonated water outlet
lines.
2. TUBING CLAMPS (item 2) used to secure insulated python lines to Cooling Unit syrup and plain water
lines.
3. REFRIGERATION LINE KITS (item 5) is used to connect the REMOTE CONDENSER COIL AND FAN
ASS’Y (item 4) to the 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
5300381000
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) Allow sufficient space
around Cooling Unit (see Figure 4) 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 (IF APPLICABLE)
1. An extreme warm climate installation may require extra caution in Remote Rooftop Condenser Coil and
Fan Assembly location. Avoid hot sunny locations and seek shaded area if possible. The use of structure
to shade unit from direct sun exposure and/or a platform extending unit an additional 18-inches above
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 to
rooftop with adequate fastening devices.
INSTALLING REMOTE CONDENSER COIL AND F AN ASS’Y (IF
APPLICABLE)
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 level position and must be
anchored to with adequate fastening devices.
2. Route REFRIGERATION LINES (item 5) from Remote Condenser Coil and Fan Assembly down to Cooling
Unit location.
3. Connect ends of refrigeration lines to Remote 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 (if applicable), 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 (if applicable) and plain water source and CO2inlet lines may be coiled up
behind unit.
NOTE: An external carbonator may be connected to Cooling Unit as shown in Figure 2 for larger supply
of carbonated water.
PLACING COOLING UNIT IN LOCATION
NOTE: An optional Cooling Unit Stand (P/N 309309069) is available to elevate Cooling Unit up off floor.
1. Place Cooling Unit in position approximately 36-inches out from operating position to allow access all
around unit.
2. Remove two screws securing Cooling Unit top cover, then remove cover.
3003810006
CONNECTING REMOTE CONDENSER COIL AND FAN ASS’Y (IF APPLICABLE)
REFRIGERATION LINES TO COOLING UNIT
(see Figure 6 )
Connect refrigeration lines, from Remote Condenser Coil and Fan Assembly, to refrigeration connectors on
back of Cooling Unit.
CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING UNIT
(see Figures 5 or 6 and 15)
IMPORTANT: Before applicable single-phase 60HZ or 50HZ 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
15) 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 the 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 switches electrical control box (see Figure 5 or 6) to Cooling Unit cabinet.
2. Pull switches electrical control box out for access to the 240/24VAC power transformer.
3. Remove red electrical wire from the 240VAC terminal on LINE (primary) side of power transformer and
connect it to the 208 VAC terminal.
4. Install Cooling Unit switches electrical control box and secure with four screws.
C
208V
240V
RESET BUTTON
FIGURE 3. 240/24VAC POWER TRANSFORMER
WARNING: Make sure 40-amp minimum-rated disconnect switch or HACR circuit breaker (if
applicable) is in ‘‘OFF’’ position.
1. Remove cover from electrical box on back of Cooling Unit.
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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.
2. 60HZ Cooling Unit
Connect 208/230VAC Single Phase 60Hz electrical power circuit with a 40-amp minimum rated disconnect
switch (not provided) fused at 40-amps (maximum) or circuit connected through an equivalent HACR circuit
breaker to electrical wires inside electrical handy box on back of cooling unit. DO NOT CONNECT
ELECTRICAL POWER TO COOLING UNIT AT THIS TIME.
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.
50HZ Cooling Unit
Connect 208/230VAC Single Phase 50Hz electrical power circuit with a 40-amp minimum rated disconnect
switch (not provided) fused at 40-amps (maximum) or circuit connected through an equivalent HACR circuit
breaker to electrical wires inside electrical handy box on back of cooling unit. DO NOT CONNECT
ELECTRICAL POWER TO COOLING UNIT AT THIS TIME.
COOLING UNIT MUST BE PROPERLY GROUNDED, POWER CIRCUIT MUST BE MADE UP OF COPPER
CONDUCTORS, AND WIRING MUST CONFORM TO APPLICABLE ELECTRICAL CODES.
CONNECTING ELECTRICAL POWER CIRCUIT TO REMOTE CONDENSER COIL AND FAN ASS’Y (IF
APPLICABLE) see Figures 6 and 15)
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.
Remote Condenser Coil and Fan Assembly (P/N 309602000)
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).
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.
A.Remove four screws securing electrical control box to Cooling Unit back panel, (see Figure 6) then
pull control box out for access to contactor inside box.
B.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.
C.Connect Remote Condenser Coil and Fan Assembly power cable electrical wires to T1and T
2
terminals on contactor inside Cooling Unit electrical control box.
3003810008
D.Reinstall Cooling Unit electrical control box and secure with four screws.
E.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
250-GALLONS PER HOUR. If flow rate is less than 250-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
250-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 CO2pressure 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.
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. 6 soft drink tanks location, to Cooling Unit syrup inlet lines
labeled No. 1 through No. 6. DO NOT CONNECT SOFT DRINK TANKS INTO SYRUP SYSTEMS AT THIS
TIME.
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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. 6, with barbed fittings on their ends, to
insulated python lines labeled No. 1 through No. 6. Secure connections with TUBING CLAMPS (item 2).
CONNECTING COOLING UNIT PLAIN WATER OUTLET LINE TO INSULATED PYTHON
PLAIN WATER LINE
(see Figure 2)
NOTE: Shutoff valve in plain water line inside Cooling Unit must remain closed if plain water is not
desired at dispensing valve.
Connect Cooling Unit plain water outlet line, with barbed fitting on its end, to insulated python plain water line.
Secure connection with TUBING CLAMP (item 2).
CONNECTING COOLING UNIT CARBONATED WATER OUTLET LINES TO INSULATED
PYTHON CARBONATED WATER LINES
(see Figure 2)
Connect Cooling Unit carbonated water outlet lines, with barbed connectors on their ends, to insulated python
carbonated water lines. secure Connections with TUBING CLAMPS (item 1).
PLACING COOLING UNIT IN OPERATING POSITION
1. Very carefully, move Cooling Unit back into operating position leaving space around unit (see Figure 4) as
specified in SELECTING LOCATION. MAKE SURE THERE ARE NO KINKS IN SYRUP INLET LINES,
INSULATED PYTHON INTERNAL LINES, CO2AND PLAIN WATER INLET LINES, AND REMOTE
CONDENSER AND FAN ASSEMBLY REFRIGERATION LINES (IF APPLICABLE).
NOTE: To comply with National Sanitation Foundation (NSF) requirements, Cooling Unit not installed
on optional Cooling Unit Stand (P/N 309309069) must have its base sealed to floor with Dow-Corning
RTV 731 or equivalent.
1. Tilt Cooling Unit up to expose bottom of unit base.
2. Liberally apply silastic sealant such as Dow Corning (RTV 731) or equivalent on unit base bottom edges.
NOTE: Do not move Cooling Unit after positioning or seal from unit base to floor will be broken.
18--IN.
18--IN.
COOLING UNIT
18--IN.
AIR FLOW
(OPEN TO ROOM)
FIGURE 4. COOLING UNIT SPACE REQUIRED
30038100010
3. Lower Cooling Unit into operating position to complete seal from unit base to floor. Apply additional sealant
around bottom of base. Seal must have a minimum radius of 1/2-inch to prevent cracks and crevices and
to ensure a complete seal.
4. Route Cooling Unit water tank overflow hose to permanent floor drain.
5. Seal area around overflow hose where they exit from unit using permagum sealant or equivalent.
PREPARING COOLING UNIT FOR OPERATION
1. Make sure plug in end of Cooling Unit water tank drain hose is secure.
2. Open shutoff valve in plain water inlet supply line. Due to slow water fill rate of water level float control,
water tank may be hand filled until water runs out of water tank overflow hose. CLEAN
LOW-MINERAL-CONTENT WATER MUST BE USED WHERE A LOCAL WATER PROBLEM EXIST.
3. Adjust primary CO2regulator (see Figure 2) on CO2cylinder to a minimum nominal setting of 120-psi or
24-psi higher than highest setting required by the secondary CO2regulators. Loosen CO2regulator
adjusting screw locknut. Turn adjusting screw to the right (clockwise) until regulator gage registers nominal
120-psi, then tighten adjusting screw locknut.
4. Adjust carbonators secondary CO2regulator (see Figure 2) to a nominal 90-psi. Loosen CO2regulator
adjusting screw locknut. Turn adjusting screw to the right (clockwise) until regulator gage registers nominal
90-psi, then tighten adjusting screw lock nut. CO2PRESSURE TO CARBONATORS MUST NOT EXCEED
120-PSIG.
CAUTION: Before starting refrigeration system, Hydro Boostâ coil must be completely
flooded with carbonated water to prevent coil freeze-up. Proceed as follows to fill
carbonated water system.
5. Make sure both carbonated water shutoff valves inside Cooling Unit (see Figure 2) are in ‘‘OPEN’’ (handles
in line with tubing) positions.
6. Make sure Hydro Boostâ bypass valve inside Cooling Unit (see Figure 2) is in ‘‘CLOSED’’ (handle not in
line with tubing) position.
7. Make sure Cooling Unit REFRIGERATION POWER, CARBONATOR MOTORS, and CIRCULATING
MOTOR Power switches are in ‘‘OFF’’ (down) positions.
8. Connect electrical power to Cooling Unit at disconnect switch.
9. Place CARBONATOR MOTORS power switch in ‘‘ON’’ (up) position to start carbonators.
10. Dispense from dispensing station until carbonated water appears at valve indicating Hydro Boostâ and
carbonated water system have been completely filled with carbonated water.
OPERATION
WARNING: Disconnect electrical power to Cooling Unit and Remote Condenser Coil and
Fan Assembly (if applicable) to prevent personal injury before attempting any Cooling Unit
or Remote Condenser Coil and Fan Assembly internal maintenance. Only qualified
personnel should service internal components or electrical wiring.
11300381000
STARTING COOLING UNIT REFRIGERATION SYSTEM
NOTE: As ice bank forms in water tank, water expansion will take place and excess water will escape
through water tank overflow hose to permanent floor drain.
Cooling Unit Connected To Remote Condenser Coil and Fan Assembly. (P/N 309602000).
Place Cooling Unit REFRIGERATION POWER switch in ‘‘ON’’ (up) position. Refrigeration compressor,
compressor cooling fan, agitator motor, and Remote Condenser Coil and Fan Assembly will start. Cooling Unit
will begin forming an ice bank and refrigerated Hydro Boostâ coil will also be chilling water. When full ice bank
has been formed, Remote Condenser oil and Fan Assembly, Cooling Unit compressor, and compressor cooling
fan will stop but agitator motor will continue to operate circulating ice water bath in water tank.
Standard Cooling Unit Utilizing Condenser Coil and Fan Assembly .
Place Cooling Unit REFRIGERATION POWER switch in ‘‘ON’’ (up) position. Refrigeration compressor,
condenser fan motor, and agitator motor will start and begin forming an ice bank. When full ice bank has been
formed, compressor and condenser fan motor will stop but, agitator motor will continue to operate circulating ice
water bath in water tank.
STARTING CARBONATED WATER CIRCULATING PUMP
1. Place CIRCULATING MOTOR power switch in ‘‘ON’’ (up) position. Circulating pump will start and begin
circulating carbonated water in system.
2. Dispense carbonated water from dispensing valve to make sure all air has been purged from system.
3. If Cooling Unit plain water outlet line is connected to dispensing system, open plain water shutoff valve
inside unit. Dispense from valve until all air is purged from plain water system.
ACTIVATING SYRUP SYSTEMS
1. Adjust soft drink tanks secondary CO2regulators (see Figure 2) as follows:
Sugar Syrup Soft Drink Tanks CO2Regulator.
Adjust sugar syrup soft drink tanks secondary CO2regulator at 40-psig for syrup lines up to 10-feet in
length plus one pound for each additional length of 10-feet, plus one pound for each 2-feet of vertical lift.
For example: if syrup line total length is 30-feet and total vertical lift is 6-feet, then 40-psig + 2-psig
(1-pound for every 10-feet of length over 10-feet which is 20-feet) + 3-psig (1-pound for every 2-feet of
vertical lift which is 6-feet); total equals 40 + 2 + 3 = 45-psig CO2regulator setting.
Low-Calorie (diet) Syrup Soft Drink Tank CO2Regulator.
Adjust low-calorie (diet) soft drink tank secondary CO2regulator for low-calorie drink at 10-psig for syrup
lines up to 30-feet in length. Syrup lines longer than 30-feet in length may require a slightly higher CO
regulator setting to 12-psig maximum. Excessive CO2pressure may cause low-calorie syrup carbonation
resulting in foam.
2
IMPORTANT: Syrup systems must be sanitized as instructed before syrup is connected into syrup
systems.
2. Connect soft drink tanks into syrup systems.
3. Dispense from all dispensing stations dispensing valves until product is dispensed.
30038100012
LEAK CHECK AND INSULATING COOLING UNIT OUTLET LINES
1. Check all CO2, plain and carbonated water, and syrup connections for leaks and repair if evident.
2. Make sure Cooling Unit outlet lines connections to insulated python lines are well insulated.
3. Install Cooling Unit top cover and secure with two screws.
DISPENSING STATION ADJUSTMENTS
ADJUSTING WATER FLOW RATE
Refer to Installation Instructions provided with dispensing station for dispensing valve water flow rate adjustment
instructions.
ADJUSTING WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED PRODUCT
Adjust dispensing station dispensing valves for Water- to-Syrup ‘‘Ratio’’ of dispensed product as instructed in
dispensing station Installation Instructions.
INSTALLING LINE IDENTIFICATION LABEL
Install LABEL, LINE IDENTIFICATION (item 3) on Cooling Unit and record syrup flavors in proper spaces.
13300381000
THIS PAGE LEFT BLANK INTENTIONALLY
30038100014
OPERATORS INSTRUCTIONS
This section covers operating controls, daily pre-operation check, adjustments, replenishing CO2and syrup
supplies, cleaning and sanitizing, Cooling Unit maintenance, Remote Condenser Coil and Fan Assembly (if
applicable) maintenance, lubrication, and servicing CO2gas check valves.
WARNING: Disconnect electrical power to Cooling Unit to prevent personal injury before
attempting any Cooling Unit or Rooftop Condenser Coil and Fan Assembly (if applicable)
internal maintenance. Only qualified personnel should service internal components or
electrical wiring.
OPERATING CONTROLS
COOLING UNIT REFRIGERATION POWER SWITCH
(see Figure 5 or 6)
REFRIGERATION POWER switch, located on front of Cooling Unit, placed in ‘‘OFF’’ position will interrupt
electrical power to refrigeration compressor, agitator motor, condenser fan motor (if applicable), and carbonated
water circulating pump. Switch must be in ‘‘ON’’ (up) position for operation. REFRIGERATION POWER
SWITCH DOES NOT DISRUPT ELECTRICAL POWER TO CARBONATORS PUMPS MOTORS.
COOLING UNIT CARBONATOR MOTOR SWITCH
(see Figure 5 or 6)
CARBONATOR MOTORS power switch, located on front of Cooling Unit, placed in ‘‘OFF’’ (down) position will
interrupt electrical power to both carbonators pumps motors. Switch must be placed in ‘‘ON’’ (up) position before
carbonators will operate.
COOLING UNIT CIRCULATING MOTOR SWITCH
(see Figure 5 or 6)
CIRCULATING MOTOR power switch, located on front of Cooling Unit, placed in ‘‘OFF’’ (down) position will
interrupt electrical power to carbonated water circulating pump. Switch must be placed in ‘‘ON’’ (up) position
before circulating pump will operate.
REFRIGERATION SYSTEM TEMPERATURE SENSING DEVICE AND HIGH-PRESSURE
CUTOUT SWITCH
Cooling Unit with Internal Condenser Coil and Fan Assembly .
(see Figure 5)
The Cooling Unit is equipped with a refrigeration system temperature sensor which will automatically initiate
shutdown if the temperature of the liquid return line from the condenser exceeds 155° F. Temperature rise may
be caused by a clogged condenser coil air intake filter, or refrigeration components problem. After cool down,
the refrigeration system will restart as required.
CAUTION: If the refrigeration system continues to ‘‘short cycle’’ following restart,
immediate attention is required to avoid compressor failure.
15
300381000
Cooling Unit Connected to Remote Condenser Coil and Fan Assembly.
(see Figure 6)
This Cooling Unit is equipped with a refrigeration system temperature sensing device and a high-pressure
sensing cutout switch that will shut refrigeration system down should the system overheat due to a clogged
condenser coil in the Remote Condenser Coil and Fan Assembly. If refrigeration system does not automatically
restart itself after system has cooled down, high-pressure sensing cutout switch reset button (see Figure 6) will
have to be pressed to reset switch. MAKE SURE REFRIGERATION SYSTEM PROBLEM IS CORRECTED.
OPERATING REFRIGERATION SYSTEM IN THIS MANNER FOR PROLONGED PERIOD OF TIME COULD
RESULT IN COMPRESSOR FAILURE.
DAILY PRE-OPERATION CHECK
1. Make sure CO2cylinder regulator assembly 1800-psi gage indicator is not in shaded (‘‘change CO
cylinder’’) portion of dial. If so, CO2cylinder is almost empty and must be replaced.
2. Sufficient syrup supply in all soft drink tanks. If not, replenish syrup supply as instructed.
2
ADJUSTMENTS
ADJUSTING CO2REGULATORS
CO2regulators should be periodically checked for proper pressure settings and if necessary, adjusted as
instructed.
ADJUSTING DISPENSING VALVES WATER FLOW RATE
If adjustment of dispensing valves water flow rate should be necessary, adjust as instructed in dispensing
station Installation Instructions.
ADJUSTING WATER-TO-SYRUP ‘‘RA TIO’’ OF DISPENSED PRODUCT
Water-To-Syrup ‘‘Ratio’’ of dispensed product should be checked and if necessary , adjusted as instructed in
dispensing station Installation Instructions.
ADJUSTING SIZE OF DRINK DISPENSED
Adjust drink size of dispensed product as instructed in dispensing station Installation Instructions.
ADJUSTING CARBONATOR TANK LIQUID LEVEL
The carbonator tank liquid level (40 to 60-ounces) pump cut-in and cut-out were adjusted at the factory and
should require no further adjustment. If incorrect adjustment is suspected, adjust as instructed.
REPLENISHING CO2SUPPLY
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.
30038100016
NOTE: When indicator on CO2cylinder regulator assembly 1800-psi gage is in shaded (‘‘change CO
cylinder’’) portion of the dial, CO2cylinder is almost empty and should be changed. CO2supply should
be checked daily and if necessary, replenished as instructed.
2
REPLENISHING SYRUP SUPPLY
Syrup supply should be checked daily and if necessary , replenished as instructed.
CLEANING AND SANITIZING
DAILY CLEANING
Perform daily cleaning of dispensing station as instructed in dispensing station Installation Instructions. Outside
of Cooling Unit must be cleaned periodically.
SANITIZING SYRUP SYSTEMS
Syrup systems should be sanitized every 90 days as instructed following Sanitizer Manufacturer’s
recommendations.
COOLING UNIT MAINTENANCE
COOLING UNIT EQUIPPED WITH CONDENSER COIL AND AIR INTAKE FILTER
CAUTION: Cooling Unit equipped with condenser coil is equipped with an air filter that
must be cleaned every 30 days as instructed. Circulating air, required to cool the coil, is
drawn in through air filter on back, and is exhausted out through coil on front of Unit.
Failure to clean and allowing air filter to become clogged, will cause refrigeration system to
overheat which will automatically shut refrigeration system down. After refrigeration system has
cooled down, system will automatically restart and operate until overheated and shut down again.
OPERA TING COOLING UNIT IN THIS MANNER FOR PROLONGED PERIOD OF TIME COULD
RESULT IN COMPRESSOR FAILURE.
Area around Cooling Unit must be kept free of obstructions at all times for proper air circulation through the Unit.
Air filter must be cleaned every 30 days as instructed.
COOLING UNIT CARBONATOR MAINTENANCE
Lubrication
Carbonator water pump motor bearings must be oiled periodically as instructed.
Water Pump Yearly Maintenance (or After Water System Disruptions).
Carbonator water pump water strainer screen and liquid double check valve must be inspected and cleaned at
least once a year under normal circumstances and after any water system disruption (plumbing work,
earthquake, etc.). Inspect and clean water strainer screen and liquid double check valve as instructed.
17
300381000
COOLING UNIT CARBONATED WATER CIRCULATING PUMP MOTOR LUBRICATION
Carbonated water circulating pump motor bearings must be oiled periodically as instructed.
REMOTE CONDENSER COIL AND F AN ASS’Y (IF APPLICABLE)
MAINTENANCE
(see Figure 6)
CAUTION: Remote Condenser Coil and Fan Assembly connected to this Cooling Unit is
equipped with a condenser coil that must be cleaned every 30-days. Allowing condenser
coil to become clogged will cause refrigeration system to overheat which will automatically
shut refrigeration system down. After condenser coil has been cleaned, high-pressure cutout
switch reset button on top of switches electrical control box under Cooling Unit top cover will
have to be pressed to restart refrigeration system. OPERA TING COOLING UNIT IN THIS MANNER
FOR PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE.
Area on top of and around Remote Condenser Coil and Fan Assembly must be kept free of obstructions at all
times. Condenser coil must be cleaned as instructed to maintain proper cooling of coil.
CLEANING CO2GAS CHECK VALVES
(see Figure 2 )
The CO2gas check valves must be inspected and serviced at least once a year under normal conditions and
after any CO2system servicing or disruption as instructed.
30038100018
SERVICE AND MAINTENANCE
This section describes Service and Maintenance procedures to be performed on the Cooling Unit and the
Remote Condenser Coil and Fan Assembly.
WARNING: Disconnect electrical power to Cooling Unit to prevent personal injury before
attempting any Cooling Unit or Remote Rooftop Condenser Coil and Fan Assembly (if
applicable) internal maintenance. Only qualified personnel should service internal
components or electrical wiring.
PREPARING COOLING UNIT FOR SHIPPING, STORING, OR RELOCATING
CAUTION: Before shipping, storing, or relocating Cooling Unit, syrup systems must be
sanitized and all sanitizing solution must be purged from syrup systems. All water must be
purged from plain and carbonated water systems and ice bank must be melted and all
water drained from water tank. A freezing ambient environment will cause residual water remaining
inside unit to freeze resulting in damage to internal components.
PERIODIC INSPECTION
Cooling Unit Equipped With Condenser Coil and Air Intake Filter.( see Figure 5 )
CAUTION: Cooling Unit equipped with condenser coil is equipped with an air filter that
must be cleaned every 30 days as instructed. Circulating air, required to cool the coil, is
drawn in through air filter on back, and is exhausted out through coil on front of Unit.
Failure to clean and allowing the air filter to become clogged, will cause refrigeration system to
overheat which will automatically shut refrigeration system down. After refrigeration system has
cooled down, system will automatically restart and operate until overheated and shut down again.
OPERA TING COOLING UNIT IN THIS MANNER FOR PROLONGED PERIOD OF TIME COULD
RESULT IN COMPRESSOR FAILURE.
Clean air filter every 30 days as instructed. Area around Cooling Unit must be kept free of obstructions at all
times for proper air circulation through the unit.
Cooling Unit Utilizing a Remote Condenser Coil and Fan Assembly.
CAUTION: Remote Condenser Coil and Fan assembly connected to this Cooling Unit is
equipped with a condenser coil that must be cleaned every 30-days. Allowing condenser
coil to become clogged will cause refrigeration system to overheat which will automatically
shut refrigeration system down. After condenser coil has been cleaned, high-pressure cutout
switch reset button on top of switches electrical control box under Cooling Unit top cover will
have to be pressed to restart refrigeration system. OPERA TING COOLING UNIT IN THIS MANNER
FOR PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE.
Clean Remote Condenser Coil and Fan Assembly condenser coil every 30 days, as instructed. Make sure area
on top and around unit are kept free of obstructions at all times. Air must be allowed to enter and leave unit to
remove heat from condenser coil. Restricting air through condenser coil will cause Cooling Unit refrigeration
system to overheat.
3. Check entire system for leaks or damaged components. Repair as necessary.
19300381000
COOLING UNIT MAINTENANCE
PERIODIC CLEANING
Periodically wash all external surfaces of Cooling Unit, rinse with clean water, then wipe dry with a clean soft
cloth. DO NOT USE ABRASIVE TYPE CLEANERS.
CLEANING CONDENSER COIL
Cooling Unit Equipped With Condenser Coil and Air Filter.
(see Figure 5)
CAUTION: Air filter on back of Cooling Unit must be removed and cleaned every 30 days.
Excessive accumulation of dust, lint, and grease on air filter will restrict air flow through
the Unit and cause refrigeration system to overheat
Condenser coil air intake filter on back of Cooling Unit may either be removed and washed out with detergent
solution or may be vacuumed in place on Unit.
Remote Condenser Coil and Fan Assembly (If applicable).
see Figure 6
CAUTION: The Remote Condenser Coil and Fan Assembly condenser coil must be cleaned
every 30 days. Circulating air, required to cool the coil, is drawn in at bottom and is
exhausted out through top of unit. Failure to clean condenser coil will cause refrigeration
system to overheat.
1. Disconnect electrical power to Cooling Unit at disconnect switch.
2. Clean bottom side of condenser coil using vacuum cleaner, whisk broom, or soft-bristle brush to remove
any debris from coil.
3. Check and make sure fan blade moves freely and are not touching any surfaces, are not bent, or out of
balance. Check and make sure wire guard is properly installed and securely fastened.
4. Check and make sure roof area immediately surrounding unit is free and clear of any debris that may have
collected such as leaves, paper, trash, etc.
5. Restore electrical power to Cooling Unit at disconnect switch.
CHECKING ICE WATER BATH
(see applicable Figure 5 or 6)
A gurgle heard from Cooling Unit indicates water level in water tank is low . This indicates the water tank water
level float control is not operating properly and must be repaired or replaced. If a continuous trickle of water is
coming out of the water tank overflow tube, this indicates the water level float control is not shutting off properly
and must be repaired or replaced. Ice water bath and ice bank should be checked for cleanliness and water
tank coils and the water level float control should be checked for excessive mineral deposit build-up as follows:
30038100020
1. Disconnect electrical power from Cooling Unit at disconnect switch.
2. Remove two screws securing Cooling Unit top cover, then remove cover.
3. Using flashlight, inspect ice water bath and ice bank for cleanliness, ice water bath should be clear and ice
bank free of foreign particles.
4. If cleaning of water tank is necessary, refer to CHANGING ICE WATER BATH in this section.
5. Fill water tank with clean water until water starts flowing from water tank overflow hose. USE LOW
MINERAL CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS.
6. Install Cooling Unit top cover and secure with two screws.
7. Restore electrical power to Cooling Unit at disconnect switch.
CHANGING ICE WATER BATH
(see Figures 5 or 6)
1. Disconnect electrical power from Cooling Unit at disconnect switch.
2. Close shutoff valve in plain water inlet supply line.
3. Remove two screws securing the Cooling Unit top cover, then remove the cover.
4. Make sure end of water tank drain hose is routed to the floor drain, then remove plug from end of hose and
allow water to drain from water tank.
CAUTION: Never use an ice pick or other instrument to remove ice from evaporator coils.
Such practice can result in punctured refrigeration circuit.
5. Allow ice bank to melt. Hot water may be used to speed melting.
6. Thoroughly rinse inside of water tank with clean water.
7. Install plug in end of water tank drain hose.
8. Open shutoff valve in plain water inlet supply line. Due to slow water fill rate of the water level float control,
the water tank may be hand filled until water runs out of the overflow tube. USE LOW MINERAL
CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS.
9. Install Cooling Unit top cover and secure with two screws.
10. Connect electrical power to Cooling Unit at disconnect switch.
WATER PUMP YEARLY MAINTENANCE (OR AFTER WATER SYSTEM DISRUPTIONS)
WARNING: The carbonators water inlet strainer screens, double liquid check valves, and
carbonated water tanks water outlet lines single check valves, must be inspected and
serviced at least once a year under normal circumstances, and after any disruptions
(plumbing work, earthquake, etc.) to the water supply system that might cause turbulent (erratic)
flow of water through system. Water pump with no screen or defective screen in the strainer would
allow foreign particles to foul the liquid double check valve. CO2gas could then back flow into
water system and create a health hazard in water system.
21300381000
ELECTRICAL
CONTROL BOX
TOP COVER
TOP COVER
RETAINING SCREW(2)
AIR FILTER
RETAINING SCREW(4)
FILTER
BRACKET
AIR FILTER
CO2INLET
CO2INLET
CHECK VALVE
LIQUID DOUBLE
CHECK VALVE(2)
CARBONAT OR
WATER PUMP(2)
LEFT--SIDE
PANEL
CARBONAT OR
TANK(2)
PLAIN WATER
INLET
HYDRO BOOSTR
CARBONATED WATER
CIRCULATING PUMP
CIRCULATING
PUMP MOTOR
SWITCHES ELECTRICAL
CONTROL BOX
CIRCULATING MOT OR
POWER SWITCH
CARBONAT ORSMOTOR
POWER SWITCH
REFRIGERATION
POWER SWITCH
SYSTEM ANAL YZER
TEST PLUG
WATER PUMP MOTOR(2)
COMPRESSOR
CONDENSER COIL
FIGURE 5. PARTS IDENTIFICATION (STANDARD COOLING UNIT W/INTERNAL CONDENSER COIL AND
FAN ASSEMBLY)
30038100022
REMOTE ROOFTOP CONDENSER
COIL AND FAN ASS’Y
REFRIGERATION LINES
(ITEM 4 AND 5)
TOP COVER
HYDRO BOOSTR
PLAIN WATER INLET
ELECTRICAL
CONTROL BOX
CO2INLET
CHECK VALVE
CO2INLET
LIQUID DOUBLE
CHECK VALVE(2)
CARBONAT OR
WATER PUMP(2)
REFRIGERATION
LINES
CONNECTORS(2)
TOP COVER
RETAINING SCREW(2)
CARBONATED WATER
CIRCULATING PUMP
CIRCULATING
PUMP MOTOR
AGITATOR MOTOR
SWITCHES ELECTRICAL
CONTROL BOX
CIRCULATING MOT OR
POWER SWITCH
CARBONAT ORSMOTOR
POWER SWITCH
REFRIGERATION
POWER SWITCH
RESET BUTTON
WATER PUMP
MOTOR(2)
CARBONAT OR
TANKS(2)
COMPRESSOR
COMPRESSOR COOLING FAN
SYSTEM ANAL YZER
TEST PLUG
ACCESS GRILLE
REFRIGERATION
SYSTEM SIGHT GLASS
FIGURE 6. PARTS IDENTIFICATION (COOLING UNIT REQUIRING CONNECTION TO REMOTE
CONDENSER COIL AND FAN ASSEMBLY)
23300381000
Servicing Carbonator Water Pump Water Strainer Screen. (see applicable Figure 5 or 6 and 8)
1. Disconnect electrical power from Cooling Unit at disconnect switch.
2. Close shutoff valve in plain water inlet supply line.
3. Note pressure setting on carbonator CO2regulator, then turn regulator adjusting screw to the left
(counterclockwise) until regulator gage reads 0-psi.
4. Remove two screws securing Cooling Unit top cover,then remove cover for access to carbonators water
pumps.
CAUTION: Condenser Coil and Fan Assembly condenser coil must be cleaned every 30
days. Excessive accumulation of debris on condenser coil will restrict cooling air flow
through coil and cause coil and refrigeration system overheat. Operating refrigeration
system in overheated condition will eventually result in Cooling Unit compressor failure.
5. If left-side (facing front switch side) of Cooling Unit is obstructed, unit will have to be pulled out for removal
of left-side panel for access to carbonator tanks and tanks carbonated water outlet lines liquid single check
valves.
6. Remove Cooling Unit left-side panel.
7. Loosen carbonator water pump screen retainer, then pull screen retainer and strainer screen from water
pump.
8. Pull strainer screen from screen retainer. Clean any sediment from screen retainer and pump screen
retainer port.
9. Inspect strainer screen for holes, restrictions, corrosion and other damage. Discard damaged strainer
screen.
10. Check O-Ring on screen retainer. Replace worn or damaged O-Ring (P/N 315349000). NOTE: A strainer
screen should always be used, otherwise particles could foul liquid double check valve.
11. Install good or new strainer screen (P/N 315348000) in screen retainer, then screw retainer into water
pump and tighten securely.
12. Service other carbonator water pump water strainer screen by repeating preceding steps 7 through 11.
13. Service carbonator water inlet liquid double check valve and carbonated water tank water outlet line single
check valve. Refer to next paragraph, Servicing Carbonator Plain Water Inlet Liquid Double Check Valve
and Carbonated Water Tank Carbonated Water Outlet Line Liquid Single Check Valve.
Servicing Carbonator Plain Water Inlet Liquid Double Check Valve and Carbonated Water Tank Carbonated
Water Outlet Line Single Liquid Check Valve. (see Figures 2, 8, and 9)
1. Service water strainer screen as instructed in previous paragraph before servicing liquid double and single
check valves.
2. Pull up on carbonator tanks relief valves to release CO2pressure from tanks.
3. Disconnect carbonator tank water inlet line from liquid double check valve outlet, then remove double
check valve from elbow in water pump outlet.
4. Remove one check valve from the other, then disassemble each check valve as shown in Figure 9.
5. Wipe each part with clean lint-free cloth. Inspect each part, especially the ball, for burrs, nicks, corrosion,
deterioration, and other damage. Discard ball seat and any damaged or suspicious parts and replace with
new parts during reassemble.
30038100024
6. Reassemble check valves as shown in Figure 9. ALWAYS INSTALL NEW BALL SEAT (QUAD RING) P/N
312418000.
NOTE: Make sure when assembling check valves together, check valve female end with white tapered
gasket inside, is on inlet side of liquid double check valve assembly.
7. Assemble check valves together as shown in Figure 8 . DO NOT OVERTIGHTEN.
8. Make sure white tapered gasket is in place inside female end of liquid double check valve, then install
double check valve on elbow in water pump outlet port.
9. Connect carbonator tank water inlet line to liquid double check valve outlet.
10. Remove liquid single check valve from carbonated water tank carbonated water outlet line.
11. Disassemble check valve as shown in Figure 9.
12. Wipe each part with clean lint-free cloth. Inspect each part, especially the ball, for burrs, nicks, corrosion,
deterioration, and other damage. Discard ball seat and any damaged or suspicious parts and replace with
new parts during reassemble.
13. Reassemble liquid check valve as shown in Figure 9. ALWAYS INSTALL NEW BALL SEAT (QUAD RING)
P/N 312418-000.
14. Install check valve in carbonated water tank carbonated water outlet line.
15. Repeat procedures in Servicing Carbonator Water Pump Water Strainer Screen and this paragraph for
servicing water strainer screen and liquid check valves on other carbonator.
16. Turn carbonator CO2regulator adjusting screw to the right (clockwise) until its gage indicates pressure
setting observed in step 3 of Servicing Carbonator Water Pump Water Strainer Screen.
17. Open shutoff valve in plain water inlet supply line.
18. Restore electrical power to Cooling Unit at disconnect switch.
19. Dispense carbonated water at dispensing station and allow carbonators to cycle on and off. Check for
water leaks and repair if evident.
20. Disconnect electrical power from Cooling Unit at disconnect switch.
21. Install Cooling Unit left-side panel and top cover. Place unit back in operating position if moved out for
panel removal.
22. Restore electrical power to Cooling Unit at disconnect switch.
TANK BRACKET
SWITCH ADJUSTMENT
BRACKET
LEVEL CONTROL
SWITCH(2)
SWITCH ACTUAT OR(2)
FIGURE 7. CARBONATOR LIQUID LEVEL CONTROL SWITCHES
25300381000
CARBONATED WATER CIRCULATING PUMP MOTOR LUBRICATION
(see applicable Figure 5 or 6)
Carbonated water circulating pump motor bearings must be oiled periodically. Refer to oiling instructions on
motor. DO NOT OVER OIL.
ADJUSTMENTS
NOTE: To readjust CO2regulator to a lower setting, loosen adjusting screw lock nut, then turn screw to
the left (counterclockwise) until pressure gage reads 5-psi lower than new setting will be. Turn
adjusting screw to the right (clockwise) until gage registers new setting, then tighten lock nut.
PRIMARY CO2REGULATOR
(see Figure 2)
Adjust primary CO2regulator on CO2cylinder to a minimum nominal setting of 120-psi or 24-psi higher than
highest setting required by the secondary CO2regulators. Loosen CO2regulator adjusting screw locknut. Turn
adjusting screw to the right (clockwise) until regulator gage registers nominal 120-psi, then tighten adjusting
screw locknut.
PUMPTOMOTORCOUPLING
WATERPUMP
WATER
STRAINERSCREEN
(P/N315348000)
O--RING(P/N315349000)
ELBOW
WATER LINE TO T ANK
DOUBLELIQUID
CHECKVALVE
WHITETAPERED GASKET
SAFETY THERMOSTAT
(P/N 318040000)
SCREENRETAINER
FIGURE 8. WA TER STRAINER SCREEN AND LIQUID DOUBLE CHECK VALVE
Adjust carbonators secondary CO2regulator to a nominal 90-psi. Loosen CO2regulator adjusting screw locknut.
Turn adjusting screw to the right (clockwise) until regulator gage registers nominal 90-psi, then tighten adjusting
screw locknut. CO2PRESSURE TO CARBONATORS MUST NOT EXCEED 125-PSIG.
Sugar Syrup Soft Drink Tanks CO2Regulator.
Adjust sugar syrup soft drink tanks secondary CO2regulator at 40-psig for syrup lines up to10-feet in length plus
one pound for each additional length of 10-feet, plus one pound for each 2-feet of vertical lift. For example: if
syrup line total length is 30-feet and total vertical lift is 6-feet, then 40-psig+ 2-psig (1-pound for every10-feet of
length over10-feet which is 20-feet)+3-psig (1-pound for every 2-feet of vertical lift which is 6-feet); total equals
40+2+3=45-psig CO2regulator setting.
Low-Calorie (diet) Syrup Soft Drink Tank CO2Regulator.
Adjust low-calorie (diet) soft drink tank secondary CO2regulator for low-calorie drink at 10-psig for syrup lines
up to 30-feet in length. Syrup lines longer than 30-feet in length may require a slightly higher CO2regulator
setting to 12-psig maximum. Excessive CO2pressure may cause low-calorie syrup carbonation resulting in
foam.
27300381000
WATER FLOW RATE
Refer to Installation Instructions provided with dispensing station for dispensing valve water flow rate adjustment
instructions.
WATER-TO-SYRUP ‘‘RATIO’’ OF dISPENSED PRODUCT
Adjust dispensing station dispensing valves for Water-to-Syrup ‘‘Ratio’’ of dispensed product as instructed in
dispensing station Installation Instructions.
ADJUSTING CARBONATORS TANKS LIQUID LEVELS
(see Figure 7)
NOTE: The carbonator tanks liquid levels (40 to 60-ounces) pump cut-in and cut-out were adjusted at
the factory and should require no further adjustment. If incorrect adjustment is suspected, check and
make necessary adjustment as follows:
Under 40-ounces of carbonated water dispensed.
If total amount of carbonated water dispensed is under 40-ounces, loosen screw securing switch adjustment
bracket and move bracket up slightly. Moving bracket up allows weight of more water in tank to push tank
further down before activating liquid level control switches which shuts off water pump. Tighten screw after
adjustment.
Over 60-ounces of carbonated water dispensed.
If total measurement of carbonated water dispensed is over 60-ounces, loosen screw securing switch
adjustment bracket and move bracket down slightly. Moving bracket down allows weight of less water in tank o
activate liquid level control switches which shuts off water pump motor. Tighten screw after adjustment.
CLEANING AND SANITIZING
DAILY CLEANING OF UNIT
1. Remove cup rest from the drip tray.
2. Wash drip tray in place on the Unit, then rinse drip tray with hot water allowing water to drain out through
the drain hose.
3. Wash cup rest, then rinse the cup rest with clean water. Install cup rest in the drip tray.
4. Clean all external surfaces of the Unit with a sponge. Rinse out the sponge with clean water, then wring
excess water out of the sponge and wipe off all external surfaces on the Unit. Wipe Unit dry with a clean
soft cloth. DO NOT USE ABRASIVE CLEANERS.
5. Remove nozzle and syrup diffusers from the dispensing valves. Place nozzles and syrup diffusers in
sanitizing solution.
6. Wash the nozzles and syrup diffusers in sanitizing solution, then rinse them with potable water.
7. Re-install nozzles and syrup diffusers back on the dispensing valves.
30038100028
SANITIZING POST-MIX SYRUP SYSTEMS
IMPORTANT: Only qualified Service Personnel should perform sanitizing procedure on the post-mix
syrup systems.
The post-mix syrup systems should be sanitized every 90-days using a non-scented household liquid bleach
containing a 5.25 % sodium hypochlorite concentration. Proceed as follows to sanitize the post-mix syrup
systems.
1. Disconnect syrup supplies from syrup systems.
2. Rinse quick disconnects (syrup tanks systems) or bag-in-box connectors (syrup bag-in-box systems) in
warm potable water.
STEP 1. WASH SYRUP SYSTEMS
3. Using a clean syrup tank (syrup tank system) or a five-gallon container (bag-in-box system), prepare a full
tank or container of liquid dishwasher detergent by using 70_ F (21_ C) to 100_ F (38_ C) potable water
and 0.5 oz. (15 ml) of liquid dishwasher detergent to one gallon of potable water. Stir detergent solution to
thoroughly mix the solution.
4. Syrup Tank Systems.
A.Observe and note CO2pressure setting on the syrup tanks CO2regulator, then re-adjust CO
2
regulator to 60 to 80-psi. Pressurize syrup tank containing detergent solution to 60 to 80-psi.
B.Connect detergent solution tank, pressurized at 60 to 80-psi, into one of the syrup systems.
Bag-in Box Syrup Systems.
C.Install bag valves, cut from empty bag-in-box syrup containers, on ends of syrup containers syrup
outlet tubes connectors.
D.Place all syrup outlet tubes, with bag valves on their ends, in container containing detergent solution.
5. Flush the syrup system and dispensing valve as follows:
A.Place waste container under applicable dispensing valve.
B.Activate the dispensing valve for one minute to purge all syrup and flush out the syrup system.
C.Continue to activate the dispensing valve in cycles (“ON” for 15-seconds, “OFF”, then “ON” for
15-seconds). Repeat “ON” and “OFF” cycles for 15-cycles.
6. Connect detergent solution to the remaining syrup systems and flush syrup out of the syrup systems as
instructed in step NO TAG preceding.
7. Remove detergent solution source from the syrup system.
STEP 2. FLUSH SYRUP SYSTEMS
8. Syrup Tank Systems.
Connect syrup tank containing potable water, pressurized at 60 to 80-psi, into one of the syrup systems.
Bag-in-Box Syrup System.
Fill five-gallon container with potable water, then place all bag-in-box syrup containers syrup outlet tubes in
container containing potable water.
9. Flush detergent solution out of the syrup system and dispensing valve as follows:
A.Place waste container under applicable dispensing valve.
B.Activate the dispensing valve for one minute to purge all detergent solution and flush out the syrup
system.
29300381000
C.Continue to activate the dispensing valve in cycles (“ON” for 15-seconds, “OFF”, then “ON” for
15-seconds). Repeat “ON” and “OFF” cycles for 15-cycles.
10. Connect potable water source to the remaining syrup systems and flush detergent solution out of the syrup
systems as instructed in step NO TAG preceding.
11. Remove potable water source from the syrup system.
STEP 3. SANITIZE SYRUP SYSTEMS
12. Using a clean syrup tank (syrup tanks system) or a five-gallon container (bag-in-box system), prepare
sanitizing solution using 70_ F (21_ C) to100_ F (38_ C) potable water and 0.5 oz. (15 ml) of non-scented
household liquid bleach that contains a 5.25 % sodium hypochlorite concentration to one gallon of potable
water. This mixture must not exceed 200 PPM of chlorine. Stir sanitizing solution to thoroughly mix.
13. Syrup Tank Systems.
Connect sanitizing solution tank, pressurized at 60 to 80-psi, into one of the syrup systems.
Bag-in-Box Syrup System.
Place all bag-in-box syrup containers syrup outlet tubes in container containing sanitizing solution.
14. Sanitize the syrup system and dispensing valve as follows:
A.Place waste container under applicable dispensing valve.
B.Activate the dispensing valve for one minute to purge all water from and install sanitizing solution in
the syrup system and dispensing valve.
C.Continue to activate the dispensing valve in cycles (“ON” for 15-seconds, “OFF”, then “ON” for
15-seconds). Repeat “ON” and “OFF” cycles for 15-cycles.
15. Repeat stepsNO TAG and NO TAG to flush water out of and install sanitizing solution in the remaining
syrup systems and dispensing valves.
16. Remove sanitizing solution source from the syrup system.
17. Allow sanitizing solution to remain in the syrup systems for not less than 10 or no more than 15-minutes
(max.) contact time.
STEP 4. WATER FLUSH SYRUP SYSTEMS
WARNING: Flush sanitizing solution from the syrup systems as instructed. Residual
sanitizing solution left in the syrup systems could create a health hazard.
18. Fill syrup tank (syrup tank system) or a five-gallon container (bag-in-box system) with potable water.
19. Syrup Tank Systems.
Connect syrup tank containing potable water, pressurized at 60 to 80-psi, into one of the syrup systems.
Bag-in-Box Syrup System.
Place all bag-in-box syrup containers syrup outlet tubes in container containing potable water.
20. Flush sanitizing solution from the syrup system and the dispensing valve as follows:
A.Place waste container under applicable dispensing valve.
B.Activate the dispensing valve for one minute to purge all sanitizing solution out of the syrup system
and the dispensing valve.
C.Continue to activate the dispensing valve in cycles (“ON” for 15-seconds, “OFF”, then “ON” for
15-seconds). Repeat “ON” and “OFF” cycles for 15-cycles.
30038100030
21. Repeat steps NO TAG and NO TAG preceding to purge sanitizing solution out of the remaining syrup
systems and
dispensing valves.
22. Remove potable water source from the syrup system.
STEP 5. PURGE WATER OUT OF SYRUP SYSTEMS (RESTORE OPERATION)
23. Syrup Tank Systems.
A.Noting syrup tanks CO2regulator pressure setting observed in step 4 preceding, readjust CO
2
regulator to the observed pressure setting,
B.Connect tanks containing syrup into syrup systems.
Bag-in-Box Syrup System.
C.Remove all bag valves from bag-in-box syrup containers outlet tubes connectors.
D.Connect bag-in-box syrup containers into the syrup systems.
24. Place waste container under dispensing valves. Dispense from all dispensing valves to permit syrup to
purge all potable water from the syrup systems and the dispensing valves. Continue to dispense from the
dispensing valves until only syrup is dispensed from the syrup systems and valves.
WARNING: To avoid possible personal injury or property damage, do not attempt to
remove the syrup tank cover until CO2pressure has been released from the tank.
25. Dispose of waste sanitizing solution in a sanitary sewer, not in a storm drain, then thoroughly rinse the
inside and the outside of the container that was used for sanitizing solution to remove all sanitizing solution
residue.
REPLENISHING CO2SUPPLY
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.
NOTE: When indicator on CO2cylinder primary CO2regulator assembly 1800-psi gage is in shaded
(‘‘change CO2cylinder’’) portion of dial, CO2cylinder is almost empty and should be changed.
1. Fully close (clockwise) CO2cylinder valve.
2. Slowly loosen primary CO2regulator assembly coupling nut allowing CO2pressure to escape, then remove
regulator assembly from empty CO2cylinder.
3. Unfasten safety chain and remove empty CO2cylinder.
WARNING: To avoid personal injury and/or property damage, always secure CO2cylinder in
upright position with safety chain to prevent it from falling over. Should valve become
accidentally damaged or broken off, CO2cylinder can cause serious personal injury.
4. Position CO2cylinder and secure with safety chain.
5. Make sure gasket is in place inside primary CO2regulator coupling nut, then install regulator on CO
2
cylinder.
31300381000
6. Open (counterclockwise) CO2cylinder valve slightly to allow lines to slowly fill with gas, then open valve
fully to back-seat valve. (Back-seating valve prevents leakage around valve shaft.)
REPLENISHING SYRUP SUPPLY
NOTE: The following instructions are applicable only when replenishing same flavor syrup. Refer to
SYRUP FLAVOR CHANGE when changing syrup flavor.
1. Disconnect empty soft drink tank from syrup system.
2. Check soft drink tank quick disconnects for sticky or restricted operation. Wash disconnects in warm water.
3. Connect full tank of syrup into syrup system.
SYRUP FLAVOR CHANGE
1. Perform sanitizing procedure on syrup system syrup flavor change will be made on.
2. Check soft drink tank quick disconnects for sticky or restricted operation. Wash disconnects in warm water.
3. Connect full tank of new flavor syrup into syrup system.
FIGURE 10. CO2GAS CHECK VALVE
CLEANING CO2SYSTEM GAS CHECK VALVES
SECONDARY CO2REGULATORS AND CO2MANIFOLD CO2GAS CHECK VALVES
(see Figures 2 and 10)
The secondary CO2regulators and CO2manifold CO2gas check valves must be inspected and serviced at
least once a year under normal conditions and after any servicing or disruption of the CO2system.
ALWAYS REPLACE QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED.
CARBONATORS CO2INLET LINES CO2GAS CHECK VALVE
(see Figures 2 and 10)
Carbonators CO2inlet lines CO2gas check valve, located inside Cooling Unit, must be inspected and serviced
at least once a year under normal conditions and after any servicing or disruption of the CO2system. ALWAYS
INSTALL NEW BALL SEAT (QUAD RING) P/N 312418000 EACH TIME CHECK VALVE IS SERVICED.
CONNECTING EXTERNAL CARBONATOR TO COOLING UNIT
An external carbonator may be connected to the Cooling Unit (see Figure 2) for a larger supply of carbonated
water.
FIGURE 12. REFRIGERATION FLOW DIAGRAM (COOLING UNIT REQUIRING CONNECTION TO
REMOTE CONDENSER COIL AND FAN ASS’Y)
30038100034
30--9340--001
REVISION B
MODEL NUMBERS:
416593
496593
35
FIGURE 13. WIRING DIAGRAM (LOW-VOLTAGE SYSTEM)
300381000
1054
REVISION A
MODEL NUMBER
416594
300381000
FIGURE 14. WIRING DIAGRAM (LOW-VOLTAGE SYSTEM)
36
30--9356--000
REVISION H
MODEL NUMBERS:
416593
416594
496593
37
FIGURE 15. WIRING DIAGRAM (HIGH-VOLTAGE SYSTEM)
300381000
THIS PAGE LEFT BLANK INTENTIONALLY
38300381000
TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
COregulatorouto
f
COregulatorasinstructed
.
C
O2regulatorouto
f
D.Dispensingvalvesyrupflo
w
C
O2regulatorasinstructed
.
instructed.
D.Dispensingvalvesyrupflo
w
restricted.
instructed.restricted
.
tubeswivelnutconnection
washerseatsproperlyinswivel
WARNING: If repairs are to be made to a product system, remove quick disconnects from
the applicable product tank, then relieve the system pressure before proceeding. If repairs
are to be made to the CO2system, stop dispensing, shut off the CO2supply , then relieve the
system pressure before proceeding. If repairs are to be made to the refrigeration system, make sure
electrical power is disconnected from the unit.
TROUBLESHOOTING POST-MIX SYSTEM
TroubleProbable CauseRemedy
WATER-TO-SYRUP ‘‘RATIO’’
OF DISPENSED DRINK TOO
LOW OR TOO HIGH.
ADJUSTMENT OF
DISPENSING VALVE SYRUP
FLOW REGULATOR DOES
NOT INCREASE TO DESIRED
WATER-TO-SYRUP ‘‘RATIO”
A.Dispensing valve syrup flow
regulator not properly
adjusted.
B.CO2gas pressure to soft drink
tanks insufficient to push syrup
out of tanks.
A.No syrup supply.
B.Soft drink tank quick
disconnects not secure.
C.Soft drink tanks secondary
adjustment.
regulator, soft drink tank quick
disconnect, or syrup line
E.Tapered nylon washer inside
tube swivel nut connection
distorted from being
overtightened restricting syrup
flow.
A.Adjust Water-To-Syrup ‘’Ratio’’
(refer to dispensing station
installation Instructions).
rotate pump or motor shaft 180
degrees, then recouple pump to
motor.
instructed.
WATER PUMP MOTOR WILL
NOT SHUT OFF.
A.Foreign object restricting tank
A.Remove foreign object.
movement.
B.Dirty balance mechanism.B.Clean balance mechanism.
C.Leak in carbonated water line.C.Tighten or replace line.
D.Inoperative level control
D.Replace level control switches.
switches.
41300381000
TroubleRemedyProbable Cause
PUMPDOESNOTPUMP
ERRATIC CYCLING OF
CARBONATOR.
WATER PUMP MOTOR
OPERATES BUT WATER
WATER
WATER PUMP CAPACITY
TOO LOW.
E.Binding or damaged balance
mechanism.
A.Balance mechanism spring
obstructed or ‘‘cocked’’.
E.Repair or replace balance
mechanism.
A.Remove obstruction. Make sure
spring is perpendicular to spring
release and is not twisted.
B.Dirty balance mechanism.B.Clean balance mechanism.
A.Water pump inlet water strain
screen dirty.
A.Clean or replace water strainer
screen as instructed.
B.Kinked water supply line.B.Straighten water supply line.
C.Restriction between water
C.Remove restriction.
pump outlet and carbonator
tank inlet.
D.Foreign object in water pump
bypass.
D.Clean bypass. (Note: Count
number of turns bypass screw
makes when removing and install
same number of turns.)
E.Water pump worn out.E.Replace water pump.
A.Water pump inlet water
strainer screen dirty.
A.Clean or replace water strainer
screen as instructed.
B.Water supply capacity too low.B.Inlet water supply must be at a
minimum of 250-gallons per hour
with a maximum water pressure
of 80-psi
C.Water filter clogged.C.Replace water filter cartridge as
D.Inoperative water pump.D.Replace water pump.
TROUBLESHOOTING REFRIGERATION SYSTEM
COMPRESSOR DOES NOT
A.Ice bank sufficient.A.Refrigeration not called for.
OPERATE.
B.REFRIGERATION POWER
switch in ‘‘OFF’’ position.
C.Electrical power to Cooling
Unit turned off.
D.No Cooling Unit power source.
Blown fuse or tripped circuit
breaker.
E.Low voltage.E.Voltage must be at least 208 volts
F.Loose, disconnected, or
broken wiring.
G.Inoperable contactor.G.Replace contactor.
H.Inoperable control board.H.Replace control board.
instructed.
B.Place REFRIGERATION POWER
switch in ‘‘ON’’ position.
C.Turn on electrical power to
Cooling Unit.
D.Replace fuse or reset circuit
breaker.
at compressor terminals when
compressor is trying to start.
F.Tighten connections or replace
broken wiring.
42300381000
TroubleRemedyProbable Cause
COMPRESSOR DOES NOT
OPERATE (CONT’D)
I.Hi-pressure cutout tripped
(remote Cooling Unit only).
J.No voltage to control board.J.Check for loose or broken wiring.
K.Inoperative compressor.K.Replace compressor.
L.Temperature sensor is shorted
or open circuit.
M.Loose or broken wire to
satellite board from ice sensor
probe on main control board
(see low-voltage system wiring
diagram).
I.Reset pressure switch (see
REFRIGERATION SYSTEM
TEMPERATURE SENSING
DEVICE AND HIGH-PRESSURE
CUTOUT SWITCH in
OPERATORS INSTRUCTIONS
SECTION.
Check 240/24 VAC power
transformer for 24 VAC output.
(see NOTE below)
L.Check for loose, broken, or
disconnected wire or plug at
pre-cool coil. Repair or replace
wire. Confirm which temperature
sensor has failed by using the
Aurora Series
System Analyzer (P/N
309197-000).
M.Repair or replace wire.
NOTE: The 240/24 VAC power transformer has an overload reset button located on its 24 VAC output
side (see Figure 3). An overload on the transformer will cause its reset button to pop out disrupting
the 24 VAC output to the main control board. Overload reset button must be pressed in to restore 24
VAC output.
COMPRESSOR OPERATES
CONTINUOUSLY BUT DOES
NOT FORM SUFFICIENT ICE
BANK.
A.Cooling capacity is exceeded
by overdrawing.
B.Standard Cooling Unit with
condenser coil and fan
assembly-- Cooling Unit
located in excessively hot area
or air circulation through
condenser coil is restricted.
C.Remote Rooftop Condenser
Coil and Fan Assembly-- Air
circulation through condenser
coil is restricted.
D.Insufficient refrigerant charge.D.Check refrigeration system with
A.Reduce amount of drinks drawn
per given time.
B.Relocate unit or check and if
necessary , clean air filter as
instructed.
C.Check and if necessary, clean
condenser coil as instructed.
gage set and Aurora
Series System Analyzer
(P/N 309197000). Find and repair
refrigeration leak, then replenish
refrigerant charge.
43300381000
TroubleRemedyProbable Cause
COMMPRESSOR OPERATES
CONTINUOUSLS BUT DOES
NOT FORM SUFFICIENT ICE
BANK (CONT’D)
E.Inoperative or disconnected
pulse-modulating expansion
valve (see applicable
REFRIGERATION FLOW
DIAGRAM).
E.Check that expansion valve is
operating by touch (should be
able to feel valve pulse).Check for
loose or disconnected wire to
solenoid coil. If necessary,
troubleshoot expansion valve with
a gage set to see if it is opening.
If expansion valve is not opening,
suction pressure will be in a
vacuum.
F.Inoperative control board. No
output from board to
solenoids.
F.Check LED’s on control board to
see if they are modulating. Check
for 24V output to pulse
modulating expansion valve (see
WIRING DIAGRAM). If control
board green LED is on and yellow
LED Is flashing; but no 24V
output, replace board.
NOTE: If overload protector cuts out compressor, condenser fan motor will continue to operate
otherwise; troubleshooting condenser fan motor problem is same as for ‘‘COMPRESSOR DOES NOT
OPERA TE’’ paragraph plus the following:
CONDENSER FAN MOTOR
NOT OPERATING.
Standard Cooling Unit with
Condenser Coil and Fan
Assembly
AGITATOR MOTOR NOT
OPERATING.
A.Jumper cord loose or
disconnected from condenser
A.Tighten connections or replace
cord.
fan motor or terminals inside
control box. Broken wire in
cord.
B.Fan blade obstructed.B.Remove obstruction.
C.Inoperative condenser fan
C.Replace condenser fan motor.
motor.
Remote Condenser Coil and Fan
assembly .
A.Blown power circuit fuse.A.Replace power circuit fuse.
B.Fan blade obstructed.B.Remove obstruction.
C.Inoperative condenser fan
C.Replace condenser fan motor.
motor.
D.Cooling unit contactor
D.Replace Cooling Unit contactor.
inoperable.
A.Agitator motor propeller
A.Remove obstruction.
obstructed.
B.Low voltage.B.Voltage must be at least 208 volts
IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or W ilshireproduct, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the
equipment model number, serial number and the date of purchase.
IMI Cornelius Offices
AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166
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GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438
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HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222
ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814
NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361
SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604
SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379
USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (612) 421-6120 D FAX (612) 422-3255
LD004
4/21/98
45300381000
IMI CORNELIUS INC.
CORPORATE HEADQUARTERS:
One Cornelius Place
Anoka, Minnesota 55303-6234
(612) 421-6120
(800) 238-3600
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