Cornelius COR6519UBCSD Service Manual

®

BOTTLE COOLERS

COR6519UBCSD

Service Manual

Release Date: May, 2004
Publication Number: 630460278SER
Revision Date: NA
Revision: A
Visit the IMI Cornelius web site at www.cornelius.com

for all your Literature needs.

SERVICE MANUAL

The products, technical information, and instructions contained in this manual are subject
to change without notice. These instructions are not intended to cover all details or varia­tions of the equipment, nor to provide for every possible contingency in the installation,
operation or maintenance of this equipment. This manual assumes that the person(s)
working on the equipment have been trained and are skilled in working with electrical,
plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety
precautions are taken and that all local safety and construction requirements are being
met, in addition to the information contained in this manual.

To inquire about current revisions of this and other documentation or for assistance with
any Cornelius product contact:

www.cornelius.com

800-238-3600

Trademarks and copyrights:
Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olympus,

and Vista are registered trademarks of IMI Cornelius Inc.
Optifill trademark is pending.

This document contains proprietary information and it may not be

reproduced in any way without permission from Cornelius.

Printed in U.S.A.

Copyright © 2004, All Rights Reserved, IMI Cornelius, Inc.

COR6519UBCSD Service Manual

TABLE OF CONTENTS

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Features of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description of its components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

The Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cleaning and Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Condensate Disposal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Possible causes and solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Español . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Caracteristicas del equipo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Sistema de Refrigeracion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Explicación de los componentes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

El Ciclo de Refrigeracion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Diagrama eléctrico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Limpieza y Mantenimiento Preventivo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Sistema de Recolección de Condensado . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Principales Problemas del Refrigerador . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Posibles causas y soluciones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

© 2004, IMI Cornelius Inc. - i - Publication Number: 630460278SER

COR6519UBCSD Service Manual

Publication Number: 630460278SER - ii - © 2004, IMI Cornelius Inc.

FEATURES OF THE UNIT

Sturdy, stainless steel top

Strong body with thick walls,
injected with CFC-free
polyurethane foam

Exterior cabinet and lining
made of galvanized, pre­painted steel, with baked
polyester paint

Reinforced, heavy-duty,
adjustable dividers

Interior lining made of
acrylic-coated galvanized
steel for extra corrosion
resistance

Heavy-duty R-134a
condensing unit with easy
access for maintenance

COR6519UBCSD Service Manual

ENGLISH

Rubber pull handle for easy
sliding of lids

Forced-air evaporator for
quick temperature pull­down

Reinforced, 16 gauge
galvanized steel base

Forced-air condenser made
of copper and aluminum,
resistant to rust and saline
environments

FIGURE 1

R

EFRIGERATION SYSTEM

Description of its components

Compressor:

The compressor is a factory-sealed unit located underneath (outside) the cooling cabinet. This pump is
activated by a motor which draws low-pressure vapor (refrigerant) from the evaporator. It then
compresses the gas and forces it into the condenser at a high pressure.

Starter relay:

The starter relay is attached on one side of the compressor box. The compressor motor has two
windings: one for starting and another for running. In order to provide for necessary additional torque
when the motor is first ignited, the starter relay connects the additional start-up windings. After the motor
reaches its correct operating speed, the relay opens the ignition windings and the motor carries on with
the operation windings.

Thermal protector:

This protector is a thermo-sensible device attached to one side of the compressor’s box. In any given
situation, if the compressor overheats or the voltage source varies drastically, the thermal protector
opens, turning off the compressor. After the compressor cools down to a normal and safe working
temperature, the thermal protector turns on the compressor.

Condenser:

The condenser is located underneath (outside) the cooling cabinet in front of the compressor. It receives
hot, high-pressure refrigerant gas from the compressor and cools it down until it returns to liquid state.

© 2004, IMI Cornelius Inc. - 1 - Publication Number: 630460278SER

COR6519UBCSD Service Manual

Condenser fan motor:

The condenser fan motor is located underneath the cooling cabinet. It is a ventilation device which forces
the ambient air to flow over the condenser in order to cool down the refrigerant flowing inside it. The fan
motor works only if the compressor is on.

Evaporator:

The evaporator is located inside the cooling cabinet. As the gas flows at a low pressure through the
evaporator, it absorbs heat through the copper coil from inside the cabinet.

Evaporator fan motor:

This device provides the required circulation of air through the cooling cabinet as well as over the surface
of the evaporator’s serpentine thermal exchange area. This fan motor runs continuously.

The evaporator and condenser serpentines have aluminum fins that help increase the surfaces for the
thermal exchange in an efficient way.

Capillary tube:

It consists of several feet of tubing having a small inside diameter. It is a device used to control the
amount of refrigerant that flows into the evaporator.

Drier:

The drier is located in between the condenser and the evaporator. It traps and removes moisture in the
refrigeration system while allowing oil and refrigerant to flow freely.

Accumulator:

The accumulator is located in between the evaporator and the compressor. It is a storage tank which
receives refrigerant liquid from the evaporator and prevents it from flowing into the compressor.

Temperature control:

The adjustable temperature control is responsible for detecting temperature changes inside the cooling
cabinet. It also starts the compressor motor whenever the cabinet rises above the desired temperature.

The temperature control consists of a switch which is mechanically activated by a diaphragm. This
diaphragm is connected to a thermo-sensible bulb (located inside the cabinet) through a small diameter
tube. All three components (the diaphragm, the thermo-sensible bulb, and the small diameter tube) are
filled with refrigerant gas which reacts to temperature changes.

When the cabinet temperature rises, the refrigerant in the bulb heats up and expands, expanding the
diaphragm. The diaphragm’s expanding closes the temperature control’s interrupting device and then
starts the compressor and condenser motors.

The drop in temperature inside the cooling compartment is caused by the refrigerant’s continuous
circulation through the system. When the temperature drops, the refrigerant inside the temperature
control’s bulb contracts, allowing the diaphragm to open the interrupting device, which consequently
shuts down the compressor and condenser motors.

Cooling cabinet:

This is the area where the goods are stored. It has been designed to allow for constant cold air circulation
to flow through the goods.

THE REFRIGERATION CYCLE

1. Depending on the increase in temperature inside the cooling compartment, the refrigerant gas
inside the temperature control's bulb heats up and expands, expanding the diaphragm. The
diaphragm's expansion closes the temperature control's interrupting device.

2. The temperature control's interrupting device turns on the compressor and condenser motors.

3. The compressor recirculates the refrigerant throughout the system by drawing the refrigerant gas
as low vapor pressure from the evaporator. Then it compresses the refrigerant and forces it into the
condenser.

Publication Number: 630460278SER - 2 - © 2004, IMI Cornelius Inc.

COR6519UBCSD Service Manual

4. The condenser, with the help of its fan motor, removes the refrigerant's heat as it flows through the
condenser. The heat is then released to the outside environment. Consequently, the decrease in
temperature will change the refrigerant from a gaseous to a liquid state.

5. The capillary tube regulates the amount of refrigerant that is discharged into the evaporator.

6. The evaporator's serpentine allows the refrigerant to absorb and remove heat from the cooling
compartment.

7. The drop in temperature inside the cooling compartment is caused by the refrigerant's continuous
circulation through the system. This gas continuously absorbs the heat that exists inside the cooling
compartment and expels it to the outside environment. When the temperature drops, the refrigerant
inside the temperature control's bulb contracts, allowing the diaphragm to open the interrupting
device, which consequently shuts down the compressor and condenser motors.

FIGURE 2

© 2004, IMI Cornelius Inc. - 3 - Publication Number: 630460278SER