Cornelius 0 User manual

AURORAR10,000
COOLINGUNIT
Installation Manual
PRINTEDIN U.S.A
IMI CORNELIUS INC; 1988--93Ó
PartNo.300381000
July13,1988
Revised:April 12,1993
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i300381000
TABLEOFCONTENTS
Page
GENERALINFORMATION1..................................................
GENERALDESCRIPTION1..............................................
COOLINGUNITDESCRIPTION1.........................................
SYSTEMTHEORYOFOPERATION3.....................................
INSTALLATION5............................................................
UNPACKINGAND INSPECTION5........................................
IDENTIFICATIONOFLOOSE-SHIPPEDPARTS5...........................
SELECTINGLOCATION5................................................
COOLINGUNIT5...................................................
REMOTECONDENSER COILAND FANASS’Y6......................
INSTALLINGREMOTECONDENSER COILAND FANASS’Y6...............
INSTALLINGCOOLINGUNIT6...........................................
PLACINGCOOLINGUNITINLOCATION6............................
CONNECTINGREMOTECONDENSER COILAND FANASS’Y
REFRIGERATIONLINES TOCOOLINGUNIT7........................
CONNECTINGELECTRICALPOWER CIRCUIT TOCOOLINGUNIT7....
CONNECTINGPLAINWATERINLETSUPPLYLINETOCOOLINGUNIT9
CONNECTINGCO2INLETSUPPLYLINETOCOOLINGUNIT9.........
CONNECTINGSYRUP SOURCELINES TOCOOLINGUNITSYRUP
INLETLINES 9.....................................................
CONNECTINGCOOLINGUNITSYRUPOUTLETLINES TOINSULATED
PYTHONSYRUPLINES 10...........................................
CONNECTINGCOOLINGUNITPLAINWATEROUTLETLINETO
INSULATEDPYTHONPLAINWATERLINE10...........................
CONNECTINGCOOLINGUNITCARBONATEDWATEROUTLETLINES TO
INSULATEDPYTHON CARBONATEDWATERLINES 10.................
PLACINGCOOLINGUNITINOPERATINGPOSITION10.....................
PREPARINGCOOLINGUNIT FOROPERATION11......................
OPERATION11......................................................
STARTINGCOOLINGUNITREFRIGERATIONSYSTEM12...............
STARTINGCARBONATEDWATER CIRCULATINGPUMP12.............
ACTIVATINGSYRUP SYSTEMS12....................................
LEAK CHECK AND INSULATINGCOOLINGUNITOUTLETLINES 13......
DISPENSINGSTATIONADJUSTMENTS13.............................
INSTALLINGLINEIDENTIFICATIONLABEL 13..........................
OPERATORSINSTRUCTIONS15..............................................
OPERATINGCONTROLS15..............................................
COOLINGUNITREFRIGERATIONPOWERSWITCH 15.................
COOLINGUNITCARBONATORMOTORSWITCH 15....................
COOLINGUNITCIRCULATINGMOTORSWITCH 15.....................
REFRIGERATIONSYSTEMTEMPERATURE SENSINGDEVICE AND
HIGH-PRESSURECUTOUTSWITCH 15...............................
DAILY PRE-OPERATION CHECK16...................................
ADJUSTMENTS16.......................................................
ADJUSTINGCO2REGULATORS16...................................

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300381000
TABLEOFCONTENTS(cont’d)
Page
ADJUSTINGDISPENSINGVALVES WATERFLOWRATE16.............
ADJUSTINGWATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT16.
ADJUSTINGSIZEOFDRINKDISPENSED16...........................
ADJUSTINGCARBONATORTANKLIQUIDLEVEL 16....................
REPLENISHINGCO2SUPPLY16......................................
REPLENISHINGSYRUP SUPPLY17...................................
CLEANINGAND SANITIZING17...........................................
DAILYCLEANING17.................................................
SANITIZINGSYRUP SYSTEMS17.....................................
COOLINGUNITMAINTENANCE17........................................
COOLINGUNITEQUIPPEDWITH CONDENSER COILAND AIR
INTAKE FILTER17...................................................
COOLINGUNITCARBONATORMAINTENANCE17.....................
COOLINGUNITCARBONATEDWATER CIRCULATINGPUMPMOTOR
LUBRICATION18....................................................
REMOTECONDENSER COILAND FANASS’YMAINTENANCE18............
CLEANINGCO2GAS CHECK VALVES 18..................................
SERVICEAND MAINTENANCE19.............................................
PREPARINGCOOLINGUNIT FORSHIPPING,STORING,OR RELOCATING19
PERIODICINSPECTION19...............................................
COOLINGUNITMAINTENANCE20........................................
PERIODIC CLEANING20.............................................
CLEANINGCONDENSER COIL 20.....................................
CHECKINGICEWATERBATH20......................................
CHANGINGICEWATERBATH21.....................................
WATERPUMP YEARLYMAINTENANCE(ORAFTERWATER
SYSTEMDISRUPTIONS)21..........................................
CARBONATEDWATER CIRCULATINGPUMPMOTORLUBRICATION26......
ADJUSTMENTS26.......................................................
PRIMARYCO2REGULATOR26.......................................
SECONDARYCO2REGULATORS27..................................
WATERFLOWRATE28..............................................
WATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT28.............
ADJUSTINGCARBONATORSTANKS LIQUIDLEVELS28................
CLEANINGAND SANITIZING28...........................................
DAILYCLEANING OFUNIT28........................................
SANITIZINGPOST-MIX SYRUP SYSTEMS29..........................
REPLENISHINGCO2SUPPLY31......................................
REPLENISHINGSYRUP SUPPLY32...................................
SYRUPFLAVOR CHANGE32.........................................
CLEANINGCO2SYSTEMGAS CHECK VALVES 32..........................
SECONDARYCO2REGULATORS AND CO2MANIFOLD CO2GAS
CHECK VALVES 32..................................................
CARBONATORSCO2INLETLINES CO2GAS CHECK VALVE 32.........
CONNECTINGEXTERNALCARBONATORTOCOOLINGUNIT32........

iii 300381000
TABLEOFCONTENTS(cont’d)
Page
TROUBLESHOOTING39......................................................
WATER-TO-SYRUP‘‘RATIO’’ OFDISPENSED DRINKTOO LOWOR
TOO HIGH.39...........................................................
ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES
NOTINCREASE TODESIREDWATER-TO-SYRUP‘‘RATIO”39...............
ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES
NOTDECREASE TODESIREDWATER-TO-SYRUP‘‘RATIO’’.40.............
DISPENSEDPRODUCTCARBONATIONTOO LOW.40......................
DISPENSEDPRODUCTCOMES OUTOFDISPENSINGVALVE CLEARBUT
FOAMSIN CUP.40.......................................................
DISPENSEDPRODUCTPRODUCES FOAMAS ITLEAVES DISPENSING
VALVE.40...............................................................
ONLYCARBONATEDWATER DISPENSED.40..............................
ONLY SYRUPDISPENSED.41............................................
WARMPRODUCTBEINGDISPENSED.41..................................
WATERPUMPMOTORWILL NOTOPERATE.41............................
WATERPUMPMOTORWILL NOTSHUTOFF.41...........................
ERRATIC CYCLING OFCARBONATOR.42.................................
WATERPUMPMOTOROPERATES BUTWATERPUMPDOES NOTPUMP
WATER42...............................................................
WATERPUMPCAPACITYTOO LOW.42...................................
COMPRESSOR DOES NOTOPERATE.42..................................
COMPRESSOROPERATES CONTINUOUSLY BUTDOES NOT FORM
SUFFICIENTICE BANK.43...............................................
CONDENSERFANMOTOR NOTOPERATING.44...........................
AGITATORMOTOR NOTOPERATING.44..................................
WARRANTY45..............................................................
LISTOF FIGURES
FIGURE1.AURORAR10,000 COOLINGUNIT1............................
FIGURE2.FLOWDIAGRAM(TYPICALINSTALLATION)4...................
FIGURE3.240/24VACPOWERTRANSFORMER7.........................
FIGURE4.COOLINGUNITSPACEREQUIRED10...........................
FIGURE5.PARTSIDENTIFICATION(STANDARD COOLINGUNITW/INTERNAL
CONDENSER COILAND FANASSEMBLY)22...............................
FIGURE6.PARTSIDENTIFICATION(COOLINGUNITREQUIRINGCONNECTION
TOREMOTECONDENSER COILAND FANASSEMBLY)23..................
FIGURE7.CARBONATORLIQUIDLEVELCONTROLSWITCHES 25..........
FIGURE8.WATERSTRAINERSCREENAND LIQUID DOUBLECHECK
VALVE 26................................................................
FIGURE9.LIQUID CHECK VALVE ASSEMBLY27...........................
FIGURE10.CO2GAS CHECK VALVE 32...................................
FIGURE11.REFRIGERATIONFLOWDIAGRAM(STANDARD COOLINGUNIT
W/INTERNALCONDENSER COILAND FANASS’Y)33.......................
FIGURE12.REFRIGERATIONFLOWDIAGRAM(COOLINGUNITREQUIRING
CONNECTIONTOREMOTECONDENSER COILAND FANASS’Y)34.........
FIGURE13.WIRINGDIAGRAM(LOW-VOLTAGE SYSTEM)35................

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TABLEOFCONTENTS(cont’d)
Page
LISTOF FIGURES CONT’D)
FIGURE14.WIRINGDIAGRAM(LOW-VOLTAGE SYSTEM)36................
FIGURE15.WIRINGDIAGRAM(HIGH-VOLTAGE SYSTEM)37...............
LISTOF TABLES
TABLE1.DESIGN DATA2...............................................
TABLE2.LOOSE-SHIPPEDPARTS5.....................................

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GENERALINFORMATION
IMPORTANT:To theuserof thismanual-Thismanual isaguideforinstalling,operating,and
maintaining this equipment.Referto TableofContentsforpagelocation ofdetailedinformation
pertaining to questionsthatarise during installation,operation,service and maintenance,or
trouble-shooting this equipment.
GENERALDESCRIPTION
This section givesthe description, theoryofoperation,and design dataforthe AuroraR10,000 Cooling Unit,
(hereafter referred to asa‘‘Cooling Unit’’).
COOLINGUNITDESCRIPTION
The Cooling Unitisdesigned to provide cooled soft drink syrup,carbonated water,and plainwaterto dispensing
station through an insulated python (length asordered).Onthe standardCooling Unit, refrigeration systemis
cooled by condensercoil and fan assemblylocated inside the Cooling Unit. Cooling Unitnotprovided with
internalcondensercoil and fan assemblyis cooled byRemoteCondenserCoil and Fan Assemblywhichis
connected toCooling Unit. The Cooling Unitconsistsbasicallyof twocarbonatortanks each having itsown
waterpumpto pump plainwaterintotanks,one carbonated watercirculating pump,aHydroBoostâ
(carbonated waterpre-cooler) which pre-cools carbonated wateron itswaytocarbonated watercirculating
pumpandatwo horsepower refrigeration compressor.The cabinetpanelsare easilyremoved tofacilitate
installation and service and maintenance.
An optionalCooling UnitStand (P/N309309000)isavailableto elevateCooling Unitup off floor.A System
StatusDisplayKit(P/N0913)isavailable and when installed on the Cooling Unit, allowsoperatorortechnician
tomonitoroperation ofCooling Unitand to be awarewhen serviceisrequired.Also availableisan Aurora
ServiceSystemAnalyzer (P/N309197000)thatmaybe used to analyze and troubleshoot the Aurora 10,000
Cooling Unitrefrigeration system.
CAUTION:Before shipping or relocating Cooling Unit,syrup cooling coilsmustbe
sanitizedand all sanitizing solution mustbepurgedfromcoils.All watermustalso be
purgedfromplainand carbonatedwatersystems.Afreezing ambientenvironmentwill
cause residualsanitizing solution orwater remaining insideCooling Unit tofreezeresulting in
damagetointernalcomponents.
FIGURE1.AURORAR10,000 COOLINGUNIT

300381000 2
Table 1.Design Data
COOLINGUNITMODELNUMBERS:
60 HZUnit:
StandardCooling UnitwithInternalCondenserCoil and Fan Assembly416593
Cooling UnitRequiring Connection toRemoteCondenserCoil and Fan
Assembly416594
50 HZUnit:
StandardCooling UnitwithInternalCondenserCoil and Fan Assembly496593
COOLINGUNITDATA
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:
Models416593 and 496593:
Shipping 378 pounds
DryWeight358 pounds
Model416594:
Shipping 381 pounds
DryWeight361 pounds
IceBankWeight40 to 45 pounds
Capacities:
WaterBath(no ice bank)18 gallons
CompressorHorsepower2HP
Refrigeration System:
RefrigerantType and Charge See Cooling UnitNameplate
AmbientOperating Temp.50° Fto 100° F
ElectricalRequirements:
60 HZCooling Unit:
Operating voltage
CurrentDrawSee Cooling Unit Nameplate
50HZCooling Unit:
Operating Voltage
CurrentDrawSee Cooling Unit
Nameplate

3300381000
Table 1.Design Data(cont’d)
REMOTECONDENSER COILAND FAN ASS’YDATA(P/N309602000)
Overall Dimensions:
Height27 inches
Width 22-inches
Depth 38-inches
Weight:
Shipping 85 pounds
AmbientOperating Temp.-22° Fto 158° F
ElectricalRequirements:
Operating Voltage 208/230VAC,SinglePhase,
60Hz
CurrentDraw2.5Amps
SYSTEMTHEORYOFOPERATION
(see Figure 2)
ACO2cylinderdelivers carbon dioxide gas(CO2)to primaryCO2regulatorassemblywhich deliversregulated
CO2gasto adjustablesecondaryCO2regulators.SecondaryCO2regulatorsdeliver regulated CO2gasto both
carbonated watertanks inside Cooling Unitand alsotosoft drinktanks.Plainwaterispumped intocarbonated
watertanks bywaterpumpsand is carbonated byregulated CO2gaspressure also entering tanks.Carbonated
waterleaves carbonated watertanks and passesthrough the HydroBoostR(carbonated waterpre-cooler)
which pre-cools carbonated wateron itswaytocarbonated watercirculating pump.Pre-cooled carbonated
waterenters carbonated watercirculating systemthrough inletside ofcarbonated watercirculating pump.
Carbonated waterpassesfromoutletside ofcarbonated watercirculating pump, through cooling coilsinside
watertank,and out through insulated line toturnaround inside dispensing station.Carbonated water returnsto
Cooling Unitbypassing through insulated line, through cooling coils,and on tocarbonated watercirculating
pumpinletwhichmakesup the carbonated watercirculating system.As carbonated waterisbeing dispensed
fromdispensing station,carbonated watercirculating systemis continuouslybeing replenished fromboth
carbonated watertanks.Regulated CO2gaspressure,exerted upon soft drinktanks contents, forces syrup
fromtanks, through Cooling Unitcooling coils,and on to dispensing station through insulated lines.
StandardCooling Unit.
The standardCooling Unitrefrigeration systemis cooled byacondensercoil and fan assemblylocated inside
Cooling Unit.
Cooling UnitRequiring Connection toRemoteCondenserCoil and Fan Assembly.
The Cooling Unitrefrigeration systemis cooled byaRemoteCondenserCoil and Fan Assembly
(P/N309602000)thatisauthorized byIMICorneliusInc.Use ofanyotherRemoteCondenserCoil and Fan
Assemblymustbe authorized byIMICorneliusInc.Use ofan unauthorized RemoteCondenserCoil and Fan
Assemblywill automatically voidthe Cooling Unit factorywarranty.

4
3
0
0
3
8
1
0
0
0
LINE LEGEND CO2 PLAIN WATER CARB WATER SYRUP
SHUTOFF
VALVE
WATER PRESSURE
REGULATOR
WATER FILTER
ASS’Y
PLAIN WATER
SOURCE
PLAIN WATER
SHUTOFF VALVE
SUGAR SYRUP
CO2REGULATOR
DIET SYRUP
CO2REGULATOR
CO2GAS CHECK
VALVE(5)
CARBONATORS CO2
REGULATORS
GAS CHECK
VALVE(2) CO2MANIFOLD
PRIMARY CO2
REGULATOR
CO2CYLINDER SOFT DRINK TANKS
SYRUP
LINES
PLAINWTR
CARB WTR
CARB WTR
HYDRO BOOSTR
BYPASS VALVE
CHECK
VALVE
TEE FITTING
HYDDRO
BOOSTR
CARBONATED
WATER
CIRCULATING
PUMP
CARBONATOR
WATER PUMP(2)
DOUBLE
LIQUID
CHECK
VALVE(2)
EXTERNAL
CARBONATOR
CARBONATED
WATER
SHUTOFF
VALVE(2)
SINGLE
LIQUID
CHECK
VALVE(2)
CO2GAS CHECK VALVE
CARBONATED
WATER TANK(2)
FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION)

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INSTALLATION
This section coversunpacking and inspection,selecting location,installing Cooling Unit, preparing foroperation,
and operation.
UNPACKINGAND INSPECTION
NOTE:TheCooling Unitwas thoroughlyinspected beforeleaving thefactory and the carrierhas
acceptedand signedforit.Anydamageorirregularities should benotedat timeofdelivery(ornotlater
than15 days fromdateofdelivery)and immediatelyreportedtothedelivering carrier.Requestawritten
inspection report fromClaimsInspectortosubstantiate anynecessary claim.File claimwiththe
delivering 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 110085000 Tubing Clamp 2
2 111353000 Tubing Clamp 7
3 311962000 Label,Line Identification 1
NOTE:Thefollowing RemoteCondenserCoil and FanAssembly and Refrigeration Lines Kits arerec-
ommendedforuse withtheCooling
Units.
4 309602000 RemoteCondenserCoil and Fan Ass’y1
5 300598025 Refrigeration Line Kit, 25-ft. long,90°1
300598050 Refrigeration Line Kit, 50-ft. long,90°Straight1
IDENTIFICATIONOF LOOSE-SHIPPEDPARTS
1.TUBINGCLAMPS (item1)used tosecureinsulated python linestoCooling Unitcarbonated wateroutlet
lines.
2.TUBINGCLAMPS (item2)used tosecureinsulated python linestoCooling Unitsyrup and plainwater
lines.
3.REFRIGERATIONLINE KITS(item5)isused toconnect the REMOTECONDENSER COILAND FAN
ASS’Y(item4)tothe Cooling Unit.
SELECTINGLOCATION
COOLINGUNIT
Selectlocation forCooling Unitinstallation thatwill (1)Allowthe shortestpossibleinsulated python routefrom
the Cooling Unit tothe Dispensing Station location;(2)Allowthe shortestpossiblerefrigeration lines(not to
exceed 50-ft inlength) routefromRemoteCondenserCoil and Fan Assemblytothe Cooling Unit; (3)REFER
TOTHECOOLINGUNITNAMEPLATEFORTHEREQUIREDPOWER CIRCUITOPERATINGVOLTAGE,HZ,
AND THEMINIMUMCIRCUITAMPACITYOF THECOOLINGUNIT.The powercircuit forthe Cooling Unit
mustbe wired through a 40-ampminimumrated disconnectswitch(notprovided)and the powercircuitmustbe