Cornelius AURORA 10 User manual

Installation Manual

AURORA 10,000 PLUS

COOLINGUNIT(V2.5)

IMPORTANT:

TOTHEINSTALLER.

Itistheresponsibilityof

theInstallertoensurethat

thewatersupplytothe

dispensing equipmentis

providedwith protection

againstbackflowby anair

gapas definedin

ANSI/ASMEA112.1.2-1979;

oranapprovedvacuum

breakerorothersuch

method as provedeffective

bytest.

Waterpipe connections

and fixtures directly

connectedtoapotable

watersupply shall be

sized, installed,and

maintainedaccording to

Federal, State,and Local

Codes.CAUTION:Priortostarting theCooling Unit,thetwoser-

vice valves on therefrigeration systemreceivertank(see

applicableFIGURES 10 or11)mustbefullyopenedto

release refrigerantchargeintothe system.Operating

Cooling Unitwiththe service valves closedwill damage

the compressorwhichwill voidthefactorywarranty.

PRINTEDIN U.S.A

IMI CORNELIUS INC; 1992--93Ó

IMICORNELIUSINC gOne CorneliusPlacegAnoka,MN55303-6234

Telephone (800)238-3600 Facsimile(612)422-3246

PartNo.1593

December21,1992

Revised:April 12,1993

THISDOCUMENTCONTAINSIMPORTANTINFORMATION

ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i1593

TABLEOFCONTENTS

Page

GENERALDESCRIPTION1..................................................

COOLINGUNITDESCRIPTION1.........................................

UNITDESCRIPTION2...................................................

SYSTEMTHEORYOFOPERATION3.....................................

STANDARD COOLINGUNIT3........................................

COOLINGUNITREQUIRINGCONNECTIONTOREMOTECONDENSER

COILAND FANASSEMBLY3........................................

INSTALLATION5............................................................

UNPACKINGAND INSPECTION5........................................

IDENTIFICATIONOFLOOSE--SHIPPEDPARTS5..........................

SELECTINGLOCATION6................................................

COOLINGUNIT6...................................................

REMOTECONDENSER COILAND FANASS’Y6.......................

INSTALLINGREMOTECONDENSER COILAND FANASS’Y6...............

INSTALLINGCOOLINGUNIT6...........................................

PLACINGCOOLINGUNITINLOCATION7............................

CONNECTINGREMOTECONDENSER COILAND FANASS’Y

REFRIGERATIONLINES TOCOOLINGUNIT7........................

CONNECTINGELECTRICALPOWER CIRCUIT TOCOOLINGUNIT7....

CONNECTINGELECTRICALPOWER CIRCUIT TOREMOTECONDENSER

COILAND FANASS’Y(IFAPPLICABLE)8.............................

CONNECTINGPOTABLEWATERSOURCE SUPPLYLINES TO

COOLINGUNIT8...................................................

CONNECTINGCO2SOURCE SUPPLYLINETOCOOLINGUNIT9.......

CONNECTINGSYRUP SOURCELINES TOCOOLINGUNITSYRUP

INLETLINES 9.....................................................

CONNECTINGCOOLINGUNITSYRUPOUTLETLINES TOINSULATED

PYTHONSYRUPLINES 9...........................................

CONNECTINGCOOLINGUNITPOTABLEWATEROUTLETLINES TO

INSULATEDPYTHONPOTABLEWATERLINES 9......................

CONNECTINGCOOLINGUNITCARBONATEDWATEROUTLETLINES TO

INSULATEDPYTHON CARBONATEDWATERLINES 10.................

PLACINGCOOLINGUNITINOPERATINGPOSITION10.................

PREPARINGCOOLINGUNIT FOROPERATION10..........................

OPERATION11..........................................................

STARTINGCOOLINGUNITREFRIGERATIONSYSTEM11...............

STARTINGCARBONATEDWATER CIRCULATINGPUMP12.............

ACTIVATINGSYRUP SYSTEMS12....................................

LEAK CHECK AND INSULATINGCOOLINGUNITOUTLETLINES 12..........

DISPENSINGSTATIONADJUSTMENTS12.................................

ADJUSTINGWATERFLOWRATE12..................................

ADJUSTINGWATER--TO--SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT13.

INSTALLINGLINEIDENTIFICATIONLABEL 13..............................

OPERATORSINSTRUCTIONS15..............................................

OPERATINGCONTROLS15..............................................

1593

TABLEOFCONTENTS(cont’d)

Page

COOLINGUNITREFRIGERATIONPOWERSWITCH 15.................

COOLINGUNITCARBONATORMOTORS SWITCH 15...................

COOLINGUNITCIRCULATINGMOTORSWITCH 15.....................

REFRIGERATIONSYSTEMTEMPERATURE SENSINGDEVICE AND

HIGH--PRESSURECUTOUTSWITCH 15...................................

COOLINGUNITWITHINTERNALCONDENSER COILAND FAN

ASSEMBLY15.......................................................

COOLINGUNITCONNECTEDTOREMOTECONDENSER COILAND

FANASSEMBLY16..................................................

DAILY PRE--OPERATION CHECK16.......................................

ADJUSTMENTS16.......................................................

ADJUSTINGCO2REGULATORS16...................................

ADJUSTINGDISPENSINGVALVES WATERFLOWRATE16.............

ADJUSTINGWATER--TO--SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT16.

ADJUSTINGSIZEOFDRINKDISPENSED16...........................

REPLENISHINGCO2SUPPLY16..........................................

REPLENISHINGSYRUP SUPPLY16.......................................

CLEANINGAND SANITIZING17...........................................

DAILYCLEANING17.................................................

SANITIZINGSYRUP SYSTEMS17.....................................

COOLINGUNITMAINTENANCE17........................................

COOLINGUNITEQUIPPEDWITH CONDENSER COILAND AIR

INTAKE FILTERS17..................................................

COOLINGUNITCARBONATORMAINTENANCE17.....................

COOLINGUNITCARBONATEDWATER CIRCULATINGPUMPMOTOR

LUBRICATION17....................................................

REMOTECONDENSER COILAND FANASS’Y(IFAPPLICABLE)

MAINTENANCE18.......................................................

CLEANINGCO2GAS CHECK VALVES 18..................................

SERVICEAND MAINTENANCE19.............................................

PREPARINGCOOLINGUNIT FORSHIPPING,STORING,OR RELOCATING19

PERIODICINSPECTION19...............................................

REMOTECONDENSER COILAND FANASSEMBLYMAINTENANCE19.......

COOLINGUNITMAINTENANCE20........................................

CLEANINGCOOLINGUNITAIRINTAKE FILTERS20....................

CHECKINGICEWATERBATH20......................................

CHANGINGICEWATERBATH20.....................................

WATERPUMP YEARLYMAINTENANCE(ORAFTERWATERSYSTEM

DISRUPTIONS)23...................................................

ADJUSTMENTS24.......................................................

PRIMARYCO2REGULATOR26.......................................

SECONDARYCO2REGULATORS26..................................

WATERFLOWRATE26..............................................

WATER--TO--SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT26.............

CLEANINGAND SANITIZING26...........................................

DAILYCLEANING OFUNIT26........................................

iii 1593

TABLEOFCONTENTS(cont’d)

Page

SANITIZINGPOST-MIX SYRUP SYSTEMS27..........................

REPLENISHINGCO2SUPPLY29..........................................

REPLENISHINGSYRUP SUPPLY30.......................................

SYRUPFLAVOR CHANGE30.............................................

CLEANINGCO2SYSTEMGAS CHECK VALVES 30..........................

SECONDARYCO2REGULATORS AND CO2MANIFOLD CO2GAS

CHECK VALVES 30..................................................

CARBONATOR CO2INLETLINECO GAS CHECK VALVE 31.............

NON--CRITICALTEMPERATURE SENSORFAILURES 37....................

ICE BANKINLET TEMPERATURE SENSOR.37.........................

HYDROBOOST)WATERTEMPERATURE SENSOR37..................

CRITICALTEMPERATURE SENSORFAILURES 37..........................

ICE BANKOUTLET TEMPERATURE SENSOR.37.......................

CONDENSEROUTLET TEMPERATURE SENSOR.37...................

AURORA BUILT--IN ANALYZER37.............................................

SCANMODE37..........................................................

“HOLD”MODE”38........................................................

“WATERTEMP”MODE38.................................................

TEMPERATURE SENSORSTATUS38......................................

SHORTEDTEMPERATURE SENSOR38...................................

OPENTEMPERATURE SENSOR38........................................

TEMPERATURE SENSORISOUTOFRANGE38...........................

TROUBLESHOOTING41......................................................

WATER--TO--SYRUP‘‘RATIO’’ OFDISPENSED DRINKTOO LOWOR

TOO HIGH41............................................................

ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES

NOTINCREASE TODESIREDWATER--TO--SYRUP‘‘RATIO’’ 41..............

ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES

DECREASE TODESIREDWATER--TO--SYRUP“RATIO”41...................

DISPENSEDPRODUCTCARBONATIONTOO LOW.42......................

DISPENSEDPRODUCTCOMES OUTOFDISPENSINGVALVE CLEARBUT

FOAMSIN CUP.42.......................................................

DISPENSEDPRODUCTPRODUCES FOAMAS ITLEAVES DISPENSING

VALVE.42...............................................................

ONLYCARBONATEDWATER DISPENSED.42..............................

ONLY SYRUPDISPENSED.43............................................

WARMPRODUCTBEINGDISPENSED.43..................................

WATERPUMPMOTORWILL NOTOPERATE.43............................

WATERPUMPMOTORWILL NOTSHUTOFF.43...........................

ERRATIC CYCLING OFCARBONATOR.43.................................

WATERPUMPMOTOROPERATES BUTWATERPUMPDOES NOT

PUMPWATER44........................................................

WATERPUMPCAPACITYTOO LOW44....................................

COMPRESSOR DOES NOTOPERATE.44.................................

1593

TABLEOFCONTENTS(cont’d)

Page

COMPRESSOROPERATES CONTINUOUSLY BUTDOES NOT FORM

SUFFICIENTICE BANK45................................................

CONDENSERFANMOTOR NOTOPERATING46...........................

AGITATORMOTOR NOTOPERATING46...................................

WARRANTY47..............................................................

LISTOF FIGURES

FIGURE1.AURORA10,000R COOLINGUNIT(V2.5)1.....................

FIGURE2.FLOWDIAGRAM4............................................

FIGURE3.208 AND 240/24 VACPOWERTRANSFORMER7................

FIGURE4.COOLINGUNITSPACEREQUIRED10...........................

FIGURE5.PARTSIDENTIFICATION(STANDARD COOLINGUNITW/INTERNAL

CONDENSER COILAND FANASSEMBLY)21...............................

FIGURE6.PARTSIDENTIFICATION(COOLINGUNITREQUIRINGCONNECTION

TOREMOTE

ROOFTOPCONDENSER COILAND FANASSEMBLY)22....................

FIGURE7.WATERSTRAINERSCREENAND LIQUID DOUBLECHECK

VALVE 25................................................................

FIGURE8.LIQUID CHECK VALVE ASSEMBLY25...........................

FIGURE9.CO2GAS CHECK VALVE 30....................................

FIGURE10.REFRIGERATIONFLOWDIAGRAM(STANDARD COOLINGUNIT

WITHINTERNALCONDENSER COILAND FANASSEMBLY)32...............

FIGURE11.REFRIGERATIONFLOWDIAGRAM(COOLINGUNITREQUIRING

CONNECTIONTOREMOTEROOFTOPCONDENSER COILAND FAN

ASSEMBLY33...........................................................

FIGURE12.WIRINGDIAGRAM(MODELS1602 AND 1603)34...............

FIGURE13.WIRINGDIAGRAM(MODELS1604 AND 1605)35...............

FIGURE14.AURORA BUILT--INANALYZER39..............................

LISTOF TABLES

TABLE1.DESIGN DATA2...............................................

TABLE2.LOOSE-SHIPPEDPARTS5.....................................

GENERALDESCRIPTION

This section givesthe Unitdescription, theoryofoperation,and design dataforthe AuroraR10,000 PlusCool-

ing Unit(V2.5)hereinafter referred to asa“Cooling Unit”.

IMPORTANT:To theuserof thismanual-Thismanual isaguideforinstalling,operating,and main-

taining this equipment.RefertotheTableofContentsforpagelocation fordetailedinformation per-

taining to questionsthatarise during installation,operation,service,ormaintenance of this

equipment.

COOLINGUNITDESCRIPTION

The Cooling Unitisdesigned to provide cooled soft drink syrup,carbonated water,and potablewatertothe dis-

pensing station through an insulated python (length asordered).Onthe standardCooling Unit, refrigeration sys-

temis cooled byacondensercoil and fan assemblylocated inside the Cooling Unit. Cooling Unitnotprovided

withaninternalcondensercoil and fan assemblyis cooled byaRemoteCondenserCoil and Fan Assembly

whichis connected tothe Cooling Unit.

The Cooling Unitconsistsbasicallyofone carbonated watertankwithtwowaterpumpsto pump potablewater

intothe tank,one carbonated watercirculating pump,aHydroBoostâ(waterpre-cooler) which pre-coolswater

on itswaytothe carbonated watertank,and a two horsepower refrigeration compressor.The Cooling Unitback,

top,and side panelsare easilyremoved tofacilitateinstallation,service,and maintenance.

An optionalcooling unitstand (P/N309309069)isavailableto elevatethe Cooling Unitup off the floor.

FIGURE1.AURORA 10,000RCOOLINGUNIT(V2.5)

CAUTION:Before shipping,storing,or relocating thisUnit,the syrup systemsmustbe

sanitizedand all sanitizing solution mustbepurgedfromthe syrup systems.All watermust

also bepurgedfromtheplainand carbonatedwatersystems.Afreezing ambient

environmentwill cause residualwaterintheUnit tofreezeresulting in damagetointernal

components.

1593

UNITDESCRIPTION

Table 1.Design Data

COOLINGUNITDATA

Cooling UnitPartNumbers:

60 HZModel:

StandardCooling UnitwithInternalCondenserCoil and Fan Assembly1602

Cooling UnitRequiring 1604

Connection toRemoteCondenserCoil and Fan Assembly

50 HZModel:

StandardCooling UnitwithInternalCondenserCoil and Fan Assembly1603

Cooling UnitRequiring

Connection toRemoteCondenserCoil and Fan Assembly1605

Overall Dimensions:

Height28 inches

Width 36-1/2inches

Depth 24-1/2inches

NOTE:Overall dimensionsifCooling Unitisplaced on optionalCooling UnitStand (P/N309309069).

Height(approximate)75-5/16 inches

Width 37-1/2inches

Depth 25-3/8inches

Weights:(Approximate)

Models1602 and 1603:

Shipping 425 pounds

Models1604 and 1605:

Shipping 415 pounds

IceBank:40 to 45 pounds

Capacities:

WaterBath(no ice bank)18 gallons

CompressorHorsepower:2HP

Refrigeration System:

RefrigerantType and Charge See Cooling UnitNameplate

AmbientOperating Temp.50° Fto 100° F

ElectricalRequirements:

60 HZCooling Unit: See Cooling

Operating Voltage

CurrentDrawUnitNameplate

50 HZCooling Unit:

Operating Voltage

CurrentDraw

See Cooling Unit

Nameplate

REMOTECONDENSER COILAND FAN ASS’YDATA

ModelNumber

(50/60 HZ)309602000

Overall Dimensions:

Height27 inches

Width 22 inches

Depth 38 inches

Weight:

Shipping 85 pounds

Refrigeration System:

AmbientOperating Temp.--22° Fto 120° F

ElectricalRequirements:

(50/60 HZ)

Operating Voltage See cooling unitnameplate

CurrentDrawSee cooling unitnameplate

SYSTEMTHEORYOFOPERATION

ACO2cylinderdelivers carbon dioxide gas(CO2)to primaryCO2regulatorassemblywhich deliversregulated

CO2gasto adjustablesecondaryCO2regulators(see FIGURE2).The secondaryCO2regulatorsdeliverspres-

sureregulated CO2gastothe carbonated watertankinside the cooling unitand alsotothe soft drinktanks.Po-

tablewaterispumped intothe carbonated watertankbytwowaterpumpsand is carbonated byregulated CO2

gaspressure also entering the tank.

Carbonated waterleavesthe carbonated watertankand entersinletside of the carbonated watercirculating

pump.Carbonated waterpassesfromoutletside of the carbonated watercirculating pump,out through the

cooling unitoutletlines,and through the insulated python line toaturnaround inside the Dispensing Station.

Carbonated water returnstothe cooling unitback through the insulated python line, through the carbonated wa-

tercooling coil inside the cooling unit, and back tothe carbonated watertankwhichmakesup the carbonated

watercirculating system.As carbonated waterisbeing dispensed fromthe Dispensing Station,carbonated wa-

tercirculating systemis continuouslybeing replenished fromthe carbonated watertank.Regulated CO2gas

pressure,exerted upon soft drinktanks contents,pushes syrup fromthe syrup tanks, through the cooling unit

syrup cooling coils,and on tothe Dispensing Station through the insulated python

STANDARD COOLINGUNIT

The standardCooling Unitrefrigeration systemis cooled byacondensercoil and fan assemblylocated inside

Cooling Unit

COOLINGUNITREQUIRINGCONNECTIONTOREMOTE CONDENSER COILAND FAN

ASSEMBLY

The Cooling Unitrefrigeration systemis cooled byaRemoteCondenserCoil and Fan Assembly

(P/N309602000)thatisauthorized byIMICorneliusInc.Use ofanyotherRemoteCondenserCoil and Fan As-

semblymustbe authorized byIMICorneliusInc.Use ofan unauthorized RemoteCondenserCoil and Fan

Assemblywill automatically voidthe Cooling Unit factorywarranty.

1593

FIGURE 2. FLOW DIAGRAM

WATER PRESSURE

REGULATOR

SHUTOFF

VALVE WATER FILTER

ASS’Y

SUGAR SYRUP

CO2REGULATOR

DIET SYRUP

CO2REGULATOR

HYDRO BOOSTâ

BYPASS VALVE

CARBONATOR

CO2REGULATOR

CO2MANIFOLD

CO2GAS

CHECK VALVE

PRIMARY CO2

REGULATOR

CO2CYLINDER SOFT DRINK TANKS

CO2CHECK

VALVE

CARBONATED

WATER TANK

WATER TANK WATER

LEVEL FLOAT CONTROL

CARBONATOR

WATER

CIRCULATING

PUMP

OUTLET

LINES

CARBONATOR

WATER PUMP (2)

DOUBLE LIQUID

CHECK VALVE (2) COOLING UNIT

LINE LEGEND

CO2

PLAIN WATER

CARB WATER

SYRUP

HYDRO BOOSTâ

COIL

SYRUP

COIL (10)

COIL

RECIRC

CO2

WTR

COIL

1 2 34 5 6 7 8 9 10

P0TABLE WATER

SOURCE

INSTALLATION

This section coversunpacking and inspection,selecting location,installing Unit, preparing foroperation,and

operation.

UNPACKINGAND INSPECTION

NOTE:TheUnitwas thoroughlyinspected beforeleaving thefactory and the carrierhas acceptedand

signedforit.Anydamageorirregularities should benotedat thetimeofdelivery(ornotlaterthan15

days fromdateofdelivery)and immediatelyreportedtothedelivering carrier.Requestawritteninspec-

tion report fromClaimsInspectortosubstantiate anynecessary claim.File claimwiththedelivering

carrier,notwithIMICorneliusInc.

1.AfterCooling Unithasbeen unpacked,removeshipping tape and otherpacking material.

2.Unpack LOOSE--SHIPPEDPARTS.Makesure all itemsare presentand in good condition.

Table 2.Loose-ShippedParts

Item

No.PartNo.NameQty.

1 770407 Barbed Connector,1/4x3/8 12

2 770424 Barbed Connector,1/2x1/2 2

3 300200000 Tubing Clamps12

4 309852000 Tubing Clamps36

5 111085000 Tubing Clamps8

6 311962000 Label, Identification 1

NOTE:Refrigeration LineKit (notprovidedand as ordered)isusedtoconnectRemoteCondenser

Coil and FanAssemblytoCooling Unit.

7 309602000 RemoteRooftop CondenserCoil and Fan Ass’y(50/60 HZ)1

8 300598025 Refrigeration Line Kit, 25--ft. long,90_1

300598050 Refrigeration Line Kit, 50--ft. long,90_1

IDENTIFICATIONOF LOOSE--SHIPPEDPARTS

1.BARBED CONNECTORS(item1)are used toconnectCooling Unitsyrup and potablewateroutletlinesto

insulated python syrup and potablewaterlines.SecureconnectionswithTUBINGCLAMPS (items3 and

4).

2.BARBED CONNECTORS(item2)are used toconnectinsulated python 1/2--inchI.D.carbonated water

linestoCooling Unit1/2--inchI.D.carbonated waterlines.SealconnectionswithTUBINGCLAMPS (item

3.LABEL,LINEIDENTIFICATION(item6)tobeinstalled on Cooling Unitand syrup flavorstoberecorded in

properspaceson label.

4.REFRIGERATIONLINE KIT(items8)tobeconnected between REMOTEROOFTOPCONDENSER COIL

AND FANASS’Y(item7)and the Cooling Unit.

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