maxi cooler user manual (maxi 210, 310, 410)

17
® MAXI RANGE PRODUCT MANUAL PM R11, R12, R13 Issue 2 1/00

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user manual for the cornelius maxi coolers, 210, 310, 410. setup and maintenance for cornelius 2, 3 and 4 line beer coolers

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Page 1: Maxi Cooler User Manual (Maxi 210, 310, 410)

®

MAXI RANGEPRODUCT MANUAL

PM R11, R12, R13 Issue 2 1/00

Page 2: Maxi Cooler User Manual (Maxi 210, 310, 410)

® MAXI RANGE

1

CONTENTS

1. Introduction ......................................................1

2. Specification .....................................................2

3. Installation ........................................................2

4. Service Information ..........................................4

5. User Maintenance .............................................4

6. Fault Finding ....................................................5

7. Exploded View Maxi 110.................................8

8. Spare Parts List Maxi 110 ................................9

9. Exploded View Maxi 210...............................10

10.Spare Parts List Maxi 210 ..............................11

11.Exploded View Maxi 310...............................12

12.Spare Parts List Maxi 310 ..............................13

13.Wiring Diagrams ............................................14

1. INTRODUCTION

The IMI Cornelius Maxi Range are the UK’s number1 shelf coolers. The Maxi range are small to mediumcapacity beer coolers, compact enough to be sited ona shelf beneath a bar. The range can dispense up to 4products and are available with a number of optionsto maximise account flexibility. They are designedfor ease of installation, maintenance and operation.The redesigned range now gives improved reliabilitywith failures down to 0.5%. The consistent layoutsimplifies servicing, training and assembly to givemore repeatable quality and quicker repair. Commonparts reduce spares stock holding.

Their functions, dependant on model, include:-

Product temperature control

Still water recirculation

Python only cooling with user adjustabletemperature control

Page 3: Maxi Cooler User Manual (Maxi 210, 310, 410)

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3. INSTALLATION

Please follow these instructions carefully. Only if thebeverage cooler is properly installed will trouble freeoperation and customer satisfaction be achieved.

NOTE The cooler is fully automatic, therefore theelectrical supply must not be interrupted (unlessaccess for maintenance is required), otherwise reducedperformance and reliability will occur.

HANDLING AND TRANSPORTATION

Keep the unit in an upright position and do not dragover rough floors or down steps.

On receipt, unpack the unit carefully and inspect forany superficial damage which the unit may havesustained in transit. Record the nature of damage onthe Courier’s Delivery Note and at the same timeinform your supplier.

Do not move once the unit is in position, and filledwith water.

INSTALLATION AND OPERATION

1. General

Installation must only be carried out by a suitablytrained person and comply with national and localcodes for connection to electrical supplies.

It is recommended that the mains electrical supply isprotected by an RCCB.

2. Siting

The cooler is designed for indoor use only, in ambientsbetween 5°C and 35°C and should not be exposed towater spillage, spray, steam or high humidity (inexcess of 90% rh).

Allow 80mm clearance around the unit to aid aircirculation and keep the front of the unit clear to allowan unimpeded fresh air supply to enter the cooler.

Air vents and louvres should never be obstructed orblocked, also access should be possible to the unit lidfor ease of service.

Site the cooler on a firm level support, protect fromphysical damage and do not place items on the cooler.Locate the cooler within 2 metres of an earthed,switched socket of correct rating (indicated on ratingplate) which should be accessible for isolation of theequipment. The socket should be installed to currentIEE regulations.

Locate the cooler as near to the dispense point aspossible to reduce heat pick up by the product after ithas left the unit.

2. SPECIFICATION

DIMENSIONS

Maxi 110 Maxi 210 Maxi 310

Height 255mm 260mm 260mm

Width 360mm 480mm 600mm

Depth 425mm 480mm 480mm

Weight (empty) 17kg 25kg 27kg

Weight (service) 22kg 34kg 42kg

Compressor Size 5cc 7.5cc 7.5cc

Page 4: Maxi Cooler User Manual (Maxi 210, 310, 410)

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3. InstallationThe appliance must be earthed.With the unit unpacked and in position, remove allcoil caps.Ensure all panels are secured in position.3.1 Filling the water bathRemove the overflow bung from the tube sited on thefront of the unit. The overflow position is indicatedon the front label.Rotate the filler disc cover, situated on the unit lid,until the hole is aligned with the filler tube, allowingwater to be poured into the unit.Do not use de-ionized water or add any substance tothe water.Do not leave hose pipes unattended while filling thewater bath as the unit may become flooded.Fill the bath, through the filler funnel, with cool,clean water until the water flows from the overflow.When the water has stopped flowing from theoverflow, replace the bung and rotate the filler discuntil the filler tube is covered.3.2a) Units fitted with agitator only (productthermostat and no still water recirculation)The cooler may now be switched ON, allowing an icereserve to be made.3.2b) Units fitted with a still water recirculationpumpThe connections are sited on the front of the cooler.To allow the cooler to operate during installation andform an ice reserve, any pump connections for stillwater recirculation must be looped together withpipe. This will prevent water being pumped from thewater bath. The cooler can now be switched ON.Time to create an ice reserve is between 2 to 5 hoursdepending on unit type and ambient temperature.3.3a) Plumbing connections (excluding still waterrecirculation)Follow the label instructions sited on the front of thecooler.The product supply is connected to the product coilinlets, marked IN.The outlets from the product coils, marked OUT,should be connected to dispensing point(s).3.3b) For coolers fitted with a still waterrecirculation pumpSwitch the cooler OFF and disconnect the looppreviously fitted.The connections are to be made to the python waterrecirculation lines. The other end of the python musthave these two python tubes connected to allow the

water to recirculate from the cooler water bath throughthe python, enabling the product in the python toremain cool.

3.4 PrimingOnce the connections are made, the cooler can beswitched ON. This will allow the python to primewith water. The cooler must then be switched OFFand the water bath ‘topped up’ following the procedureindicated earlier. Never allow the water pump to rundry – caused by priming a large python with waterfrom the unit. This is to ensure the correct water levelis maintained in the cooler.

Insulate the cooled product outlet tubes to reduce heatpick up between the cooler and dispense tap.

4. OperationUnits have one or more of the following functions,dependent on the model.

4.1 Product temperature controlThis allows thermostatically controlled producttemperature adjustment according to customerpreference. The coldest setting is fully clockwise atposition 7 and the warmest setting at position 1. Thefrequency of the product thermostat operation dependson beer inlet temperature, dispense rate and ambientconditions. Never adjust the thermostat beforeallowing time for the previous setting to stabilize.The water bath agitator motor will rotate at a reducedspeed when the product is at the desired temperature,otherwise it will rotate at full speed agitating thewater bath and aiding cooling of the product coils.

4.2 Still water recirculation controlWater is pumped from the water bath to the dispensepoint and back into the water bath to maintain producttemperature in the python.

4.3 Python cooling only (no product coils fitted)These models are fitted with a thermostat sited on thefront of the cooler which provides water bathtemperature control by automatically switching therefrigeration system on and off. The coldest setting isfully clockwise at position 7 and the warmest settingat position 1. Never adjust the thermostat beforeallowing time for the previous setting to stabilize.

Page 5: Maxi Cooler User Manual (Maxi 210, 310, 410)

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5. USER MAINTENANCE

Switch off and unplug the unit during maintenanceoperations.

Do not switch the unit ‘off’ and ‘on’ within fiveminutes.

Do not attempt to remove any protective covers.

Ensure grilles and condenser fins remain unobstructedand free from particles at all times to ensure reliableand consistent operation. A soft brush or vacuumcleaner may be used for cleaning.

If the cooler makes a ‘gurgling’ sound, this is due tovortexing in the water bath caused by a low waterlevel and will result in reduced cooling of the beverage.To remedy, follow the procedure below:-

1. If the unit is fitted with a still water recirculationpump check the python and connections for leaks.

2. If leaks are found call the service engineer.

3. If no leaks are found/unit not fitted with a waterrecirculation facility, follow the instructions forfilling the water bath illustrated in Section 3 –Installation.

Sanitise the pipelines by flushing with water, followedby a chlorinated alkaline sanitizing agent and finallypotable water flush when product tainting is evidentor when advised by the equipment installer or beveragesupplier. This can be at the same time as the ordinaryservice lines are cleaned, therefore no dismantling ofthe cooler is required. It is important that the sanitizingagent manufacturer’s procedure and safetyprecautions are followed. Under no circumstancesshould boiling water or steam be used with this unitas it may result in permanent damage to the thermostatand plastic product tubing. The maximum watertemperature permissible is 40°C.

Ensure that objects are not placed on top of the unitand vents or grilles are never obstructed as this mayaffect the unit’s function.

The 1989 Electricity at Work Regulations requireperiodic testing of electrical equipment and this shouldonly be carried out by a competent person.

4. SERVICE INFORMATION

There are no user serviceable items inside theequipment. Maintenance and repairs must only becarried out by a properly qualified and trained person.

Switch off the mains electrical supply and unplug theequipment if it malfunctions, suffers spillage, orphysical damage. Do not switch the unit ‘off’ and‘on’ within five minutes.

In the event of component failure, SWITCH OFFAND UNPLUG the unit.

Remove the cooler lid to gain access to:-

Icebank Thermostat

Product Thermostat

Agitator/Recirculation Pump

Condenser Fan

Remove the cooler lid and left rear panel to gainaccess to:-

Compressor

Compressor Electrics

To remove the recirculation pump undo pumpfasteners, allowing removal from lid. Lift from lidrotating the pump assembly to allow attached flowtube to unwind. Remove clip (if fitted) which securesthe flow tube to the pump body. To refit therecirculation pump rotate the assembly to take upexcess pipe length. Ensure the assembly locatescorrectly.

Page 6: Maxi Cooler User Manual (Maxi 210, 310, 410)

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6. FAULT FINDING

Maintenance and repairs must only be carried out by a properly qualified and trained person.Always switch off and unplug the equipment before servicing or repairing the unit.

6.1 Totally Inoperative Possible Cause Remedy

Variation in supply.

Isline voltage

within 10% ofnameplatevoltage?

Isline voltagehigh or low

Isother equipment

on the samecircuit?

a) Loose or corroded connectionin supply wiring.

b)Supply wiring undersized.c) Incorrect supply.

1. Remove all otherequipment from circuit

2. Install new dedicatedcircuit

No

Yes

No

Yes

Yes

No

High

Low

No

Yes

Issupply fuse

blown or hascircuit breaker

tripped?

Is fuse orcircuit breakersize correct?

Loose connection or broken wirein supply wiring to unit.

Incorrect size device.

Short circuit inside unit and/orgrounded wiring.

Replace or reconnect wire.

Install correctly sized device.

Replace or reconnect wire.

Install a voltage reducingtransformer.

a) Replace or reconnect wire.

b)Increase wire size.c) Install a voltage increasing

inverter.

Page 7: Maxi Cooler User Manual (Maxi 210, 310, 410)

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6. FAULT FINDING

Maintenance and repairs must only be carried out by a properly qualified and trained person.Always switch off and unplug the equipment before servicing or repairing the unit.

6.2 No Cooling

No

Yes

Isline voltage

within 10% ofnameplatevoltage?

Go to 6.1 (Page 5)

Possible Cause Remedy

Iscompressor

cold?

Yes

No

a) Faulty ice bank thermostat.

b)Overload protector is open (faulty).c) Improper or loose wiring, no power

to compressor.d)Faulty start relay or capacitor.

Go to 6.1 (Page 5)

a) Check ice bank thermostat.Replace if necessary.

b)Short circuit or overload in unit.c) Replace or reconnect wiring.

d)Examine connections. Replacefaulty components.

a) Start capacitor shorted or blown.

b)Start relay will not close or is burnedout.

c) Compressor motor has opened orshorted out windings.

d)Compressor stuck.

a) Check connections. Replacecapacitor if necessary.

b) Check connections. Replace relayif necessary.

c) Replace compressor.

d)Replace compressor.

Yes

No

Compressordoes not start

hums & trips onoverload

a) Improper wiring.b)Relay failing to open.c) Excessively high discharge pressure.d)Open or shorted windings in

compressor motor.e) Tight compressor (binding internally).

Yes

No

Compressorstarts but does not

switch off startwinding

a) Defective overload protector.b)Excessively high discharge pressure

– Check for restricted air flowthrough condenser or inoperativecondenser fan motor.

c) Compressor running too hot– Suction gas is too hot, check for

refrigerant leak.

Compressorstarts and runs but short

cycles on overloadprotector

Yes

a) Replace & reconnect wiring.b)Replace relay.c) Clean condenser or replace fan motor.d)Replace compressor.

e) Replace compressor.

a) Replace overload protector.b)Clean condenser or replace fan

motor.

c) Repair leak and rechargerefrigerant.

Page 8: Maxi Cooler User Manual (Maxi 210, 310, 410)

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6. FAULT FINDING

Maintenance and repairs must only be carried out by a properly qualified and trained person.Always switch off and unplug the equipment before servicing or repairing the unit.

6.3 Warm Drinks

NoIs

compressorrunning?

Yes

Ice bankbuild?

Yes

No

YesLeaks.

Lowwater bath

level?

No

Possible Cause Remedy

Go to 6.2 (Page 6)

a) Defective agitator thermostat.

b)Defective agitator motor orrecirculation pump motor.

c) Control knob setting incorrect.

Go to 6.2 (Page 6)

Check for leaks and fill to overflow.

a) Activate override switch. Ifagitator still does not run checkconnections first, then replacethermostat.

b)Replace agitator motor orrecirculation pump motor.

c) Increase control knob settingtowards ‘7’ until the agitatorruns.

a) Faulty ice bank thermostat.

b)Condenser blocked.

c) Defective condenser fan motorassembly.

d)Loss of refrigerant charge.

e) Incorrectly specified cooler.

a) Check ice bank thermostat.Replace if necessary.

b)Clean condenser grille, orremove objects in front of thecondenser which are restrictingair flow into the unit.

c) Replace condenser fan motorassembly.

d)Check for leaks, repair andrecharge.

e) Leave for an hour. If ice bank stilldoes not reform, checkspecification against accountrequirement.

Page 9: Maxi Cooler User Manual (Maxi 210, 310, 410)

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7. EXPLODED VIEW MAXI 110

1

2

3

5

4

7

6

9

8

Page 10: Maxi Cooler User Manual (Maxi 210, 310, 410)

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8. PARTS LIST MAXI 110

ITEMNo.

DESCRIPTIONPART No.

1 44 0000 212 Compressor Set 5cc LST

2a 06 9 010101 Agit Motor Assy - 1/2" Stack

2b 06 9 010303 Pump Assy No. 2

3 58 1174 007 Thermostat Icebank

4 58 1730 207 Condenser

5 06 0 011107 Grille Condenser

6 58 0475 060 Control Knob

7 58 0400 075 Thermostat Agitator

8 58 1731 206 Bracket Fan Motor

9 58 0410 059 Fan Motor - 5"

Page 11: Maxi Cooler User Manual (Maxi 210, 310, 410)

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9. EXPLODED VIEW MAXI 210

1

2

34

7

5

6

Page 12: Maxi Cooler User Manual (Maxi 210, 310, 410)

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10. PARTS LIST MAXI 210

ITEMNo.

DESCRIPTIONPART No.

1a 06 9 010101 Agitator Motor Assy

1b 06 9 010303 Pump Assy No. 2

2 58 1174 007 Thermostat Icebank

3 58 0400 075 Thermostat Agitator

4 58 0475 060 Control Knob

5 58 0431 011 Fan Blade OD 7"

6 2MR387A Fan Motor 5W

7 44 0000 229 Comp. Set 7.5cc LST

Page 13: Maxi Cooler User Manual (Maxi 210, 310, 410)

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11. EXPLODED VIEW MAXI 310

1

2

3

4

5

6 7

Page 14: Maxi Cooler User Manual (Maxi 210, 310, 410)

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12. PARTS LIST MAXI 310

ITEMNo.

DESCRIPTIONPART No.

1a 06 9 010101 Agitator Motor Assy

1b 06 9 010303 Pump Assy No. 2

1c 06 9 010313 Pump Assy No. 6

2 58 1174 007 Thermostat Icebank

3 58 0400 075 Thermostat Agitator

4 58 0475 060 Control Knob

5 2MP153A Fan Blade 8" x 31° 5B CCW

6 2MR387A 5 Watt Fan Motor

7a 44 0000 229 Comp. Set 7.5cc GL80PB (Electrolux)

7b 44 0000 204 Comp. Set FR 7.5cc LST (Danfoss)

Page 15: Maxi Cooler User Manual (Maxi 210, 310, 410)

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13. WIRING DIAGRAMS

13.1 Agitator Only

13.2 Recirculation Pump

Page 16: Maxi Cooler User Manual (Maxi 210, 310, 410)

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®

Part Number Part Description Qty Required Price per Unit Cost

OFFICE USE ONLY

Total Cost

Delivery

VAT @ 17.5%

Total Order ValueIMI Cornelius standard terms & conditions of sale apply.

2.

3.

Please complete fully all parts 1-4

Name:--------------------------------------------------------------- Company Name:----------------------------------------------------------

Day Time Phone Number:---------------------------------------- Fax Number:---------------------------------------------------------------

Invoice Address:-------------------------------------------------- Delivery Address:-------------------------------------------------

----------------------------------------------------------------------- -----------------------------------------------------------------------

---------------------------------------- Post Code:----------------- ---------------------------------------- Post Code:-----------------

Special Instructions:-------------------------------------------------------------------------------------------------------------------------------

OFFICE USE ONLY

Cornelius Account No.Customer Order Number:1.

ORDER FORM/PROFORMA INVOICE

Please indicate payment method: Account Cheque Postal Order Access/Visa

Cheques or Postal Orders should be made payable to IMI Cornelius (UK) Ltd.

For Access or Visa Payments, please indicate your card number.

Expiry Date:---------------------------

Signature:------------------------------------------------ Name:-------------------------------------------------- Date:--------------------

Address:------------------------------------------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------Post Code:------------------------------------

4.

☎ORDER8.30 am

HOTLINE5.15 pmTEL: 0114 285 5886 FAX: 0114 232 1070

Please return to: IMI CORNELIUS (UK) LTD Rawson Spring Way Riverdale Industrial Estate Sheffield S6 1PG

OFFICE USE ONLY

Acknowledgement No. Cheque Clearance Date Due Date Request Date

Page 17: Maxi Cooler User Manual (Maxi 210, 310, 410)

®

IMI CORNELIUS (UK) LTD

Tything Road

Alcester

Warwickshire

England B49 6EU

Telephone: 01789 763101

Facsimile: 01789 400595

®