Cornelius UC-40 Manual

REMOTE COOLING UNIT

UC-40 and UCC-40

Installation and Service Manual

Release Date:September 28, 2004

Publication Number: 710160089

Revision Date: N/A

Revision: N/A

Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

INSTALLATION AND 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 varia-

tions 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, Olym-

pus, 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.

Installation and Service Manual

IMPORTANT INFORMATION AND SAFETY NOTES. PLEASE READ BEFORE

INSTALLING DISPENSER.

• Always transport equipment in an upright position and never drag over rough floors or down steps.

• A trained person, who is qualified to make connections to water, electrical and/or compressed gas

supplies must only carry out installation and maintenance. Local by-laws/regulations must be

followed.

• Switch off and unplug electrical power to unit during maintenance operations. Do not attempt to

remove any protective covers.

• Locate equipment on a firm, level surface and protect from physical damage. Mounting surface must

be able to support 500 lbs. (227kg) weight. Never allow air vents/louvers to become blocked and do

not place any non-specified items on top. Regularly clean condensers and louvers with a soft brush or

vacuum.

• This dispenser is for indoor use only. Do not expose equipment to extremes of temperature, water

spillage, spray, steam, or high humidity or clean with water jet into dispenser components because

this could cause damage to electrical components and shock to personnel. Do not place or store

objects on top of unit.

• This dispenser must be connected to correctly rated electrical power outlet, preferably protected by a

safety cutout and is easily accessible for isolation of the equipment. The equipment must be earth

grounded.

• Use and ELCB (earth leakage circuit breaker)/GFCI (ground fault interrupt) for electrical power

protection.

• Use an HVAC circuit breaker to the power outlet circuit supplying the dispenser.

• Each module or accessory requires a 120 VAC 15 Amp 60 HZ grounded outlet. If 230 VAC 50/

60 HZ, use a minimum of 10 Amp outlet for each module or accessory.

• Ambient temperature must not exceed 90oF (32.3oC) on units with merchandisers.

WATERSYSTEM

• Insufficient water supply to carbonator will cause pump damage.

WARNING: If the installation is idle and exposed to freezing temperatures, disconnect water

supply lines and blow out all water from pump, carbonator tank, and dispensing system.

WARNING: UNDETECTED CO2 LEAKS MAY CAUSE HARM OR DEATH DUE TO ASPHYXIATION.

CO2 tank must be located next to a solid wall and chained to the wall. CO2 cylinders must be

secured in a vertical position and only connected to dispensing equipment via a suitable

pressure regulator. Check connections for leaks.

WARNING: DO NOT lift dispenser modules by valve housing assemblies. Lifting by the valve

housing assemblies will cause damage to the housing.

WARNING: System must be sanitized in accordance with the procedures found in this manual

under the cleaning and maintenance section.

WARNING: Before attempting to remove the refrigeration deck, disconnect all electrical power.

Melt the ice bank and thoroughly drain the water bath. See additional notes in Water Bath

Cleaning Section in the manual.

Installation and Service Manual

SPECIFICATIONS

DIMENSIONS

See Illustration Below

SHIPPINGWEIGHT

135 lbs. (61.4 kg)

OPERATINGWEIGHT

241 lbs. (109.5 kg)

ELECTRICALRATING

115 VAC/60HZ/14.6 AMPS; 220VAC/50-60HZ/7.3 AMPS

Transformer: (Built In) 24VAC Secondary

REFRIGERATION

1/3 HP (Lift Out Type)

Condenser: Air Cooled

Refrigerant: R134a

APPROVAL

U.L., C.S.A., N.S.F.

Installation and Service Manual

MECHANICAL SERVICE REQUIREMENTS

LOCATION

The dispenser will tolerate a surface +/- 1/2oor +/- 1/8” per foot or +/- 10.4mm per meter maximum slope

without affecting refrigeration capacity or cause water spillage from water bath.

Do not install dispenser next to any heat producing equipment such as furnaces, ovens, deep-fat fryers.

Never store items on top of dispenser which will restrict the air flow through the air-cooled condenser coil.

Clearance: The space above the dispenser must have a minimum of 16 inches (406mm). Of clearance

to allow for the removal of the top cover and refrigeration chassis and to provide adequate ventilation.

There should be at least 1 inch (25.4mm) of clearance on each side and to the rear of the dispenser for

servicing and ventilation.

ELECTRICAL

The electrical power supply should conform with that printed on dispenser name plate.

All other electrical connections are to comply with local codes.

A wiring diagram can be found in Section 7.0 of this instruction manual.

A separate electrical circuit with a minimum rating equal to the electrical ratings shown on the dispenser

nameplate (amperage and voltage) is recommended for satisfactory operation.

WATERSUPPLY& DRAINAGE

A water supply having a 1/2” O.D. (12.7mm) copper water tube, minimum is required with a minimum 20

PSIG (1.4 bar) line pressure.

A shut-off valve within three feet (1 meter) of the unit is recommended.

A suitable water filter is recommended to ensure top quality drinks.

A water pressure regulator or reducing valve should be installed in line to the main water supply and set

at 30 to 40 psi (2.1 to 2.8 bar). By limiting the incoming water pressure, a 15 psi (1.05 bar) pressure

differential (water pressure versus higher carbonator CO2 gas pressure) will ensure that flooding of the

carbonator tank does not occur.

Teflon pipe tape should be used (as required) on any fittings used in the water system.

Any contaminants such as dirt, cutting oil, pipe dope left in the system may affect the quality of the

finished drink. Therefore, flush water lines prior to start up.

CARBONDIOXIDE(CO2) GASSUPPLYTOCARBONATOR

For the product tank supply line use a CO2 regulator capable of 0 psig to 100 psig (6.8 bar) normal

working pressure. Recommended setting 75 psi (5.17 bar).

A minimum CO2 gas supply pressure 15 psi (1.05 bar) greater than the incoming water pressure will

ensure that flooding of the carbonator tank will not occur.

Installation and Service Manual

SYRUPCOMPONENTS

Syrup containers, sold as an accessory, are stainless steel with a capacity of five gallons (18.9 liters).

They are equipped with a CO2 gas quick disconnect fitting and syrup quick disconnect fitting.

The dispenser’s syrup outlets are 1/4” (6.4mm) barb fittings, and are located at the front wall, mid-height,

of the dispenser.

Each syrup inlet in labeled with the valve number that it services.

If the “syrup in” lines need replacement or extension, a .265 I.D. (6.7 mm I.D.) polytube is recommended.

Avoid using soft or easily collapsible tubing on the “syrup in” lines.

Only stainless steel or plastic, barb or compression type fittings should be used on any syrup or soda

water connections.

Optional bag-in-box system is also suitable for use with this beverage cooler.

Installation and Service Manual

INSTALLATION AND START UP PROCEDURE

1. Remove dispenser and related parts from the corrugated shipping carton.

2. Locate dispenser at point of operation.

3. Connect the building’s electrical supply to the dispenser’s main power box (see wiring diagram).

4. It is recommended that the unit’s drain be permanently plumbed to the building drain and conform

to all plumbing codes and regulations.

5. Remove the dispenser’s top cover by removing two screws found on the top surface of cover.

6. Remove the filler cap found on the refrigeration platform. Pour clean cool water through the filler

hole until water is seen flowing from the overflow tube which is connected to the building’s plumbing

system. Replace filler cap and top cover.

7. Now start the refrigeration system by plugging the system’s main power cord into the outlet

provided in the cabinet’s main electrical box.

8. It is normal to see a small amount of water being displaced from the water bath through the

overflow tube as the ice bank is built.

9. A generalized fluid/gas diagram is provided at the end of this manual.

10. Position the CO2 gas tank in a secure location. Assemble high pressure regulator to CO2 gas

cylinder and run jumper line to low pressure regulator.

11. Position the syrup tanks or bag-in-box components in the desired location. Attach the CO2 gas

lines leading from the low pressure regulator to these tanks, or B.I.B. manifold.

12. Connect syrup lines from tanks or bag-in-box system to the appropriate inlets at the front of the unit.

The syrup outlet lines from the cooling unit to the dispensing tower(s) are now connected using

(normally .265” I.D.) insulated polytubing conduit.

13. The low pressure gas regulator which controls the flow of syrup to each dispensing valve is

normally set at 25 psig to 35 psig (1.75 to 2.45 bar) or as required for proper operation of the valve.

For diet type syrup, the tank pressures should be set at from 3 to 8 psi (.21 to .56 bar) or as

recommended by the syrup supplier. Additional pressure may be necessary depending on the

distance from the syrup tank to the unit.

14. Mount the water filter assembly (if used) and water regulator in a convenient location.

15. Connect water inlet line to water regulator, set at 30 to 40 psig (2.1 to 2.8 bar), to water filter, and

then to the 3/8” (9.5mm) barbed water inlet of the UCC-40.

16. Connect a (.265” I.D.) (6.7mm I.D.) CO2 gas line from the high pressure CO2 regulator to the 1/4”

(6.4mm) barbed “CO2 Supply Connection” fitting at the UCC-40. This fitting supplies CO2 gas to

the built-in carbonator tank. The normal setting range of the high pressure CO2 gas regulator is 55

to 80 psi (3.85 to 5.6 bar), but may be set as high as 100 psi (7 bar).

17. The soda water outlet fitting of the UCC-40 (a pump with tag) is connected to the dispensing

tower(s) using the 3/8” I.D. (9.5mm I.D.) line of an insulated polytubing conduit.

18. The recirculating (return) soda water from the dispensing tower(s) is connected to the 3/8” (9.5mm)

barb fitting (tag) of the UCC-40 using a 3/8” I.D. (9.5mm) line of an insulated polytubing conduit.

19. After all connections to water, CO2 gas, electrical power and syrup containers are made, check for

leaks.

20. Be sure syrup tanks or BIB boxes contain syrup.

21. Turn on water. Open the pressure relief valve on the carbonator tank by lifting the wire ring, and

hold it open until water flows from the relief valve. Close the relief valve and turn on the CO2 gas

and electrical power in that order. DO NOT operate carbonator pump with water supply shut off.

22. To fill all lines with carbonated water, cycle the carbonator several times by operating the

dispensing valves. If valves do not operate check that the valve switch it “ON”.

23. The recirculating soda water “pump/motor” is controlled by the rocker switch at the unit’s electrical

box identified as “RECIRC. PUMP SWITCH”. This switch is now turned “ON”.

24. The dispensing valves should be adjusted in accordance to the instructions of the dispensing tower

or valve manufacturer.

Installation and Service Manual

ICE BANK CONTROL REPLACEMENT

1. Disconnect power to dispenser.

2. Remove cap from drain tube and position the drain tube in the drain pan and drain the water bath.

3. Refill water bath with warm water at a temperature of 120oF (49oC). Let stand for ten (10) minutes

to melt ice bank. If ice remains, repeat Steps 2 and 3 until all ice is melted. Failure to melt all ice

may cause the dispenser to freeze-up after the new ice bank control is installed.

4. Remove two screws from dispenser top and remove top.

5. Remove old ice bank control.

6. Install new ice bank control by pushing probe down into the 3/4” tube until it stops on the bottom of

the tube. Secure probe with tape.

7. Fill water bath with fresh water. Replace dispenser top and secure with two screws.

8. Connect dispenser to power source and turn ON.

Installation and Service Manual

CLEANING AND MAINTENANCE

NOTE: The dispenser must be cleaned and sanitized after installation and, thereafter, as required

by state and local health departments, or every three months minimum.

Continuous maintenance of this unit is a basic requirement for proper operation and sanitation, including

all support equipment utilized in the daily operation of this equipment.

1. On a daily basis, clean the external cabinet (splash areas) with mild soap and warm water. Wash

the cup rest and drip pan in cleaning solution and rinse with warm tap water. DO NOT use strong

bleach or detergents or they may discolor and corrode the cabinet materials. DO NOT use steel

wool or other abrasive scouring pads.

2. DO NOT use excessively hot water which may cause damage to plastic components.

3. The water bath should be cleaned two to four times annually, depending upon local water

conditions and in accordance with state and local health departments.

4. Cleaning of the refrigeration components should be performed by a qualified service person.

Disconnect power before removing the dispenser top. The dispenser top grilles should be cleaned

periodically to maintain efficient refrigeration. Condenser fins should be combed, if needed, to

maintain adequate circulation. Clogged condensers can lead to premature compressor failure.

SANITIZING, CLEANING, & MAINTENANCE

This section details the following:

A. Sanitizing of System

B. Daily Cleaning

C. Ice Water Bath Maintenance

It will be necessary to periodically check and correct the water level of the water bath.

The frequency of filling will depend on the environment within which the dispenser is operating and

consequently, the degree of evaporation of water.

Noisy operation and/or reduced cooling capacity can be caused by insufficient water in the water bath.

The condenser coil will require periodical cleaning to ensure correct air flow and cooling at the

condenser. The frequency of cleaning will depend on the environment within which the dispenser

operates.

All refrigeration components have been factory lubricated for life-time service and will require no further

lubrication.

CLEANINGAND SANITIZINGPROCEDURE

Water Circuits: Cleaning and sanitizing is not required for potable water circuits. Potable water lines

should remain connected and operational during the cleaning and sanitizing procedures for syrup

circuits.

NOTE: Carbonated Water Lines must remain connected and operational during cleaning and

sanitizing of the syrup circuits. Sanitizing of the valve without the carbonated water side

operational, may leave bacteria in the nozzle, diffuser, and syrup tube.

CLEANINGEQUIPMENTAND SUPPLIES

• Recommended cleaner: A.C. Fergusson Company #3391 or any caustic-base (low sudsing, non-

perfumed, easily rinsed) detergent solution which provides a minimum 2% sodium hydroxide. The

solution should be prepared in accordance with the manufacturer’s instructions. Solution should be

room temperature.

• Recommended sanitizer: A.C. Fergusson Company SuperChlor (1 ounce in 5 gallons of water) or

any sanitizer which provides a minimum of 200 parts per million of available chlorine. Solution should

be room temperature.

Installation and Service Manual

• Three five (5) gallon figals (syrup tanks) and fittings, cleaned and sanitized (one for water; one for

cleaner; one for sanitizer)

• Containers for cleaner and sanitizer solutions

• Clean, nonabrasive cloths

• Bucket

• Small brush

• Extra nozzles

• Extra jumpers

CLEANINGPROCEDURES

1. Disconnect each syrup container from its product line. Fill a figal with clean water, pressurize to 40

to 60 psig and connect the pressurized figal to the syrup product line. Remove syrup from the lines

by activating the dispensing valve. Continuously activate the dispensing valve until all syrup has

been purged from the product lines and valves as noted by the flow of clean water from the valves.

All product lines should be sequentially purged of syrup using this procedure.

2. Clean all lines and fittings with cleaning solution and rinse with clean, room temperature water to

remove all traces of residual product.

3. Clean each valve product line as follows: Fill a figal with dissolved cleaning solution, pressurize to

40 to 60 psig and connect the pressurized figal to the syrup product line. Activate the dispensing

valve continuously for one (1) minute to remove all air bubbles. Pressurize the lines by pulsing the

valves, 15 seconds ON, OFF, then immediately ON again for fifteen (15) cycles, then allow the

valve to remain flowing for three (3) minutes. Repeat pulsing and flowing the valves again until all

cleaning solution has been used.

WARNING: DO NOT allow cleaning and sanitizing solutions to remain in syrup systems longer

than is necessary to complete these procedures. Exceeding contact time will result in damage to

valve components.

4. Wait three (3) minutes and then flush the cleaning solution from the lines with clean water by

connecting a pressurized figal with clean water. Pressurized and flush the valves by pulsing the

valve for (15) cycles and then flushing three (3) minutes as described in the previous paragraph.

Continue pulsing and flushing until testing with phenolphthalein shows the rinse water is free of

residual detergent.

5. Sanitize each valve product line as follows: Be sure all connections are cleaned and sanitized

before connecting to each product line. Fill a figal with dissolved sanitizing solution, pressurize to

40 to 60 psig and connect the pressurized figal to the syrup product line. Activate the dispensing

valve continuously for one (1) minute to remove all air bubbles. Allow the sanitizing solution to flow

through each valve while activating the valves for fifteen (15) cycles, then leave valves OFF and

allow to stand pressurized for thirty (30) minutes. Activate the valves for fifteen (15) cycles, then

flush remaining sanitizer continuously through the valves.

6. Remove the nozzles and the diffuser assemblies from the valves, disengage diffuser assembly

components and clean with cleaning solution. Agitate the assemblies to assure assemblies are

clean. Place them in a container of sanitizing solution for fifteen (15) minutes. Wearing sanitary

gloves, remove the nozzles and diffuser assemblies from the sanitizing solution, drain dry, then

reassemble them to the valves.

7. Reconnect the syrup containers to their respective circuits and ready the unit for operation.

8. Draw drinks to refill lines and flush the sanitizing solution from the dispenser. Taste the beverage to

verify that there is no off-taste (chlorine).

WATERBATHCLEANING

It is recommended that the water bath be cleaned two to four times annually, depending upon local

conditions and/or required by state and local health departments. The water bath should be clean to

obtain maximum cooling efficiency.

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