Cornelius 620073775 Service Manual
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Cornelius 620073775 Service Manual

Cornelius 620073775 Service Manual

Abs 2.0 pre-chiller
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ABS 2.0 PRE-CHILLER
Service Manual
620073775 – ABS Pre-Chiller, 115V, 60Hz, R290
620073774 – ABS Pre-chiller, 230V, 50Hz, R290
Release Date: March 6, 2023
Publication Number: 620073775MNL
Revision Date: March 6, 2023
Revision: A
Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

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  • Page 1 620073775 – ABS Pre-Chiller, 115V, 60Hz, R290 620073774 – ABS Pre-chiller, 230V, 50Hz, R290 Release Date: March 6, 2023 Publication Number: 620073775MNL Revision Date: March 6, 2023 Revision: A Visit the Cornelius web site at www.cornelius.com for all your Literature needs.
  • Page 2 This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is subject to all of the restrictions and limitations contained in the Commercial Warranty.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Safety Instructions ................1 Unit Dimensions .

  • Page 4: Safety Instructions

    ABS 2.0 Pre-Chiller Service Manual SAFETY INSTRUCTIONS OLLOW AFETY NSTRUCTIONS Safety Overview ALL SAFETY INSTRUCTIONS • Read and follow in this manual and any warning/caution labels on the unit (decals, labels or laminated cards). • Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before operating this unit.
  • Page 5 ABS 2.0 Pre-Chiller Service Manual UALIFIED ERVICE ERSONNEL WARNING: Only trained and certified electrical and refrigeration technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE. IF THE SUPPLY CORD IS DAMAGED, IT MUST BE REPLACED BY THE MANUFACTURER, ITS SERVICE AGENT OR SIMILARLY QUALIFIED PERSONS IN ORDER TO AVOID A HAZARD.
  • Page 6 ABS 2.0 Pre-Chiller Service Manual R290 R EFRIGERANT RECAUTIONS WARNING! R290 Refrigerant used in this dispenser is flammable. Follow the Warnings listed below to avoid hazards. DANGER: Risk Of Fire or Explosion. Flammable Refrigerant Used. Do Not Use Mechanical Devices To Defrost Refrigerator. Do Not Puncture Refrigerant Tubing.
  • Page 7 ABS 2.0 Pre-Chiller Service Manual WARNING: Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer. The appliance shall be stored in a room without continuously operating ignition sources (for example: open flames, an operating gas appliance or an operating electric heater.

  • Page 8: Unit Dimensions

    ABS 2.0 Pre-Chiller Service Manual UNIT DIMENSIONS Figure 1 © 2023, Marmon Foodservice Technologies Inc. - 5 - Publication Number: 620073775MNL...

  • Page 9: Installation Details & Reference Information

    INSTALLATION DETAILS & REFERENCE INFORMATION Nameplate Data  Refrigerant Test Pressure PSI (kPa) (Bar) Pre-Chiller Pre-Chiller Shipping Weight Grams Type High Side Low Side 620073775 115V 4.23 R-290 425 (2930.3) (29.3) 170 (1172.1) (11.7) 189 lbs (85.7kg) 620073774 230V 5.29 R-290  DANGER: Only trained and certified electrical/HVAC technicians should service the electrical components and wiring connections in the pre-chiller unit.
  • Page 10 ABS 2.0 Pre-Chiller Service Manual INSTALLATION Assembly Instructions Table 2 Step Action Place the glide strips on the frame of the cabinet (rails must be clean and dry). Figure 3 Place the “L” nut on one of the carbonated water lines and clamp.
  • Page 11 ABS 2.0 Pre-Chiller Service Manual INSTALLATION ABS 2.0 P COOLER NSTALLATION Table 3 Step Action Remove nozzle housing bracket by remov- ing 2 screws. Nozzle Housing Screws Figure 6 A. Place the Pre-Cooler unit in the ABS 2.0 lower cabinet. If the electrical outlets are behind the ABS, plug the power cords in before the Pre-cooler is installed.
  • Page 12 ABS 2.0 Pre-Chiller Service Manual Table 3 Step Action Route and connect the three labeled 1/2- inch [12.7 mm] I.D. carbonated and plain water tubing from the ABS 2.0 unit to the Pre-cooler. The tubing is individually insu- lated and labeled as being WATER and CAR- BONATED WATER, the connections on the Pre-cooler are also marked as being WATER and CARBONATED WATER...
  • Page 13 ABS 2.0 Pre-Chiller Service Manual AC Electrical Connections (cont.) Electrical schematics are shown below (Figs. 11 & 12) detailing the component interconnections. Figure 11 Publication Number: 620073775MNL - 10 - © 2023, Marmon Foodservice Technologies Inc.
  • Page 14 ABS 2.0 Pre-Chiller Service Manual AC Electrical Connections (cont.) Figure 12 © 2023, Marmon Foodservice Technologies Inc. - 11 - Publication Number: 620073775MNL...
  • Page 15 ABS 2.0 Pre-Chiller Service Manual Refrigeration System Diagram 115V and 230V Pre-Chiller Figure 13 Publication Number: 620073775MNL - 12 - © 2023, Marmon Foodservice Technologies Inc.
  • Page 16 ABS 2.0 Pre-Chiller Service Manual External Water Connections Four (4) water lines from the ABS 2.0 unit extend to the pre-chiller unit in the left-side location indicated below. These water lines support the cooling capacity of the external devices. Accessories to connect external devices are not included. Connections should be performed by a certified installer.
  • Page 17 ABS 2.0 Pre-Chiller Service Manual WATER (SUPPLY) INPUT AND (CHILLED) OUTPUT COIL LINES. Figure 16 Publication Number: 620073775MNL - 14 - © 2023, Marmon Foodservice Technologies Inc.

  • Page 18: Component Locations

    ABS 2.0 Pre-Chiller Service Manual COMPONENT LOCATIONS Refer to the following figures for system component locations. Figure 17 1) Refrigeration Compressor 2) Start Tower (115V Compressor only) (Capacitor/Relay on back of bracket) 3) Global Ice Bank Controller 4) Electrical Box 5) Condenser 6) Condenser Fan 7) TXV (Expansion) Valve...
  • Page 19 ABS 2.0 Pre-Chiller Service Manual Figure 18 1) Electrical Box 6) Ice Bank (Water Reservoir & Coils) 2) Condenser & Debris Filter 7) Agitator Motor 3) Refrigeration Compressor 8) Ice Bank Overflow Hose 4) TXV (Expansion) Valve 9) Drier Canister 5) Expansion Valve Sensor Bulb (230V Units) Figure 19...
  • Page 20 ABS 2.0 Pre-Chiller Service Manual Agitator Motor Condenser Fan Drier Canister Tank Manual Drain (Underside) Pressure-Limit Switch Drain Hose Fitting Ice-Bank Overflow-Drain Hose (from Standpipe) Figure 20 © 2023, Marmon Foodservice Technologies Inc. - 17 - Publication Number: 620073775MNL...

  • Page 21: Component Details & Guidelines

    ABS 2.0 Pre-Chiller Service Manual Component Details & Guidelines Note details of component locations and orientation. NOTICE: Sensor Bulb must be installed at approx. 2 O’clock (or 45°) on the line. Figure 21 1) TXV (Expansion) Valve) 2) Expansion Valve Sensor Bulb Sensor Bulb Refrig.
  • Page 22 ABS 2.0 Pre-Chiller Service Manual Agitator Motor (Motor) Heat Transfer Brackets Impeller Refrigeration Coils (copper) Manual Drain Overflow Drain (Standpipe) Water  Cooling Coils (Stainless Steel) Ice Bank Interior Ice Bank Sensor Probe (blue) Figure 22 © 2023, Marmon Foodservice Technologies Inc. - 19 - Publication Number: 620073775MNL...
  • Page 23 ABS 2.0 Pre-Chiller Service Manual Compressor Details and Start-Device Wiring - 115V Units 115V Compressor & Start Tower Tower Junction Tower Rear Covers Relay & Removed Capacitor Start Tower Wiring Schematic Figure 23 Publication Number: 620073775MNL - 20 - © 2023, Marmon Foodservice Technologies Inc.
  • Page 24 ABS 2.0 Pre-Chiller Service Manual Compressor Details and Start-Device Wiring - 115V Units 115V Units Figure 24 © 2023, Marmon Foodservice Technologies Inc. - 21 - Publication Number: 620073775MNL...
  • Page 25 ABS 2.0 Pre-Chiller Service Manual Compressor Details and Start-Device Wiring - 115V Units Figure 25 Publication Number: 620073775MNL - 22 - © 2023, Marmon Foodservice Technologies Inc.
  • Page 26 ABS 2.0 Pre-Chiller Service Manual Compressor Details and Start Device Wiring - 230V Units Capacitor 230V Compressor Figure 26 © 2023, Marmon Foodservice Technologies Inc. - 23 - Publication Number: 620073775MNL...
  • Page 27 ABS 2.0 Pre-Chiller Service Manual Compressor Details and Start Device Wiring - 230V Units 230V Units Figure 27 Publication Number: 620073775MNL - 24 - © 2023, Marmon Foodservice Technologies Inc.
  • Page 28 ABS 2.0 Pre-Chiller Service Manual Compressor Details and Start Device Wiring - 230V Units Figure 28 © 2023, Marmon Foodservice Technologies Inc. - 25 - Publication Number: 620073775MNL...

  • Page 29: Pre-Chiller Access And Removal

    ABS 2.0 Pre-Chiller Service Manual PRE-CHILLER ACCESS AND REMOVAL The Pre-chiller is located in the lower-right compartment of the ABS 2.0 Dispenser unit. Its components are mounted on a steel pan (refrigeration base) that slides out of the unit to allow access. For major maintenance or repairs, the entire chiller system may be lifted and removed using an hydraulic hand-truck.

  • Page 30: Maintenance

    ABS 2.0 Pre-Chiller Service Manual MAINTENANCE Perform these procedures to ensure that the ice bank has the proper water level and that the condenser debris filter is not impeding air flow. Frequency: Every Three Months Table 4 Step Action Disconnect electrical power from the pre-chiller. Remove the two screws securing the access cover atop the ice bank.

  • Page 31: Troubleshooting

    ABS 2.0 Pre-Chiller Service Manual TROUBLESHOOTING The guide below provides Causes and Corrective Actions with respect to malfunctions related to a reduction or loss of water- cooling capacity. NOTE: Since troubleshooting and repair/replacement procedures to be performed on the pre-chiller must be conducted by a qualified/certified, HVAC repair technician (or in some cases an MFT Field Service Engineer), already trained in applicable diagnostic and corrective procedures, this manual provides only general procedural and safety guidelines relevant to them.
  • Page 32 ABS 2.0 Pre-Chiller Service Manual TROUBLESHOOTING Perform the following checks to evaluate refrigeration system operation. WARNING: Only trained and certified electrical, plumbing and refrigeration technicians should diagnose and service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
  • Page 33 ABS 2.0 Pre-Chiller Service Manual TROUBLESHOOTING Refrigeration Compressor Check DANGER: Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all power is off to the unit before performing any work. Failure to comply could result in serious injury, death or damage to the equipment.
  • Page 34 ABS 2.0 Pre-Chiller Service Manual TROUBLESHOOTING Expansion Valve Check A thermostatic expansion valve is used to control the amount of refrigerant flowing through the evaporator (ice bank refrigeration coils). Improperly installed or defective expansion valves may cause deficient cooling. By using general refrigeration system troubleshooting along with the pressure charts you can easily determine whether or not the expansion valve is working properly.

  • Page 35: Component Replacement

    ABS 2.0 Pre-Chiller Service Manual COMPONENT REPLACEMENT Follow these instructions to replace selected components. For refrigeration-system components, only essential guidelines are provided. WARNING: Only trained and certified electrical, plumbing and refrigeration technicians should diagnose and service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
  • Page 36 ABS 2.0 Pre-Chiller Service Manual COMPONENT REPLACEMENT When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct number of cylinders for holding the total system charge is available. All cylinders to be used are designated for the recovered refrigerant and labeled for that refrigerant (i.e.
  • Page 37 Discharge capacitors in a way that won’t cause any spark, using a Supco CapDis tool. Refrigerant Test Pressure PSI (kPa) (Bar) Pre-Chiller Pre-Chiller Shipping Weight Grams Type High Side Low Side 620073775 115V 4.23 R-290 425 (2930.3) (29.3) 170 (1172.1) (11.7) 189 lbs (85.7kg) 620073774 230V 5.29 R-290 When BRAZING is required, the following procedures shall be carried out in the order indicated: A) Remove the refrigerant.

  • Page 38: Pressure Switch Replacement

    ABS 2.0 Pre-Chiller Service Manual COMPONENT REPLACEMENT Disposal Ensure sufficient ventilation in the work area. Remove the refrigerant. Where controlled, refrigerant-recovery is required, follow all local regulatory guidelines and requirements. Where refrigerant recovery is not required by local/national regulations, drain the refrigerant to the outside. Take care that the drained refrigerant will not cause any danger.
  • Page 39 ABS 2.0 Pre-Chiller Service Manual COMPONENT REPLACEMENT Figure 38 Publication Number: 620073775MNL - 36 - © 2023, Marmon Foodservice Technologies Inc.
  • Page 40 ABS 2.0 Pre-Chiller Service Manual COMPONENT REPLACEMENT Figure 39 © 2023, Marmon Foodservice Technologies Inc. - 37 - Publication Number: 620073775MNL...

  • Page 41: Ice Bank Controller Replacement

    ABS 2.0 Pre-Chiller Service Manual COMPONENT REPLACEMENT Ice Bank Controller Replacement Table 7 Step Action Disconnect electrical power from the pre-chiller. Mounting bracket NOTE: Four (4) is slotted left to sockets for wiring right.(Note harness connector  bracket in Fig. 43). plug-in.

  • Page 42: Ice Probe Replacement

    ABS 2.0 Pre-Chiller Service Manual COMPONENT REPLACEMENT Ice Probe Replacement Table 8 Step Action Disconnect electrical power from the pre-chiller. Drain the pre-chiller reservoir water using the manual drain on the underside of the unit (or pump it out). Disconnect the chiller electrical and plumbing lines. (Refer to PRE-CHILLER ACCESS AND REMOVAL section.) Unlock and slide out and remove the chiller from the ABS 2.0 compartment using an hydraulic lift-truck.

  • Page 43: Agitator Motor Replacement

    ABS 2.0 Pre-Chiller Service Manual COMPONENT REPLACEMENT Agitator Motor Replacement Table 9 Step Action Disconnect electrical power from the pre-chiller. Drain or partially drain the reservoir to reduce weight. Disconnect the chiller electrical & plumbing lines. (Refer to PRE-CHILLER ACCESS AND REMOVAL section.) Unlock and slide the pre-chiller out enough to allow access to the Agitator motor shown below.

  • Page 44: Condenser Fan Replacement

    ABS 2.0 Pre-Chiller Service Manual COMPONENT REPLACEMENT Condenser Fan Replacement Table 10 Step Action Disconnect electrical power from the pre-chiller. Drain or partially drain the reservoir to reduce weight. Disconnect the chiller electrical & plumbing lines. (Refer to PRE-CHILLER ACCESS AND REMOVAL section.) Unlock and slide the pre-chiller out enough to allow access to the Agitator motor shown below.

  • Page 45: Start Capacitor Replacement

    ABS 2.0 Pre-Chiller Service Manual COMPONENT REPLACEMENT Start Capacitor (230V) / Start Tower (115V) Replacement NOTE: The start capacitor in 230V units may be replaced individually; but for 115V units, capacitor replacement entails replacing the Start Tower assembly as a unit Table 11 Step Action...
  • Page 46 ABS 2.0 Pre-Chiller Service Manual Table 11 Step Action Start Tower Junction Boxes 115V units (from here onward) Open the Tower junction boxes as shown at right. Safely discharge the capacitor using a Supco CapDis tool across the applicable junction box terminals 1, 2 and 4 as shown in the junction-box cover diagram at right (or Blue/...
  • Page 47 Marmon Foodservice Technologies Inc. www.marmonfoodservice.com www.cornelius.com...

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