Cornelius 000 PLUS User manual

AURORAR10,000 PLUS
COOLINGUNIT
Installation Manual
PRINTEDIN U.S.A
IMI CORNELIUS INC; 1989--93Ó
PartNo.300614000
November8,1989
Revised:April 12,1993
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i300614000
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 TOCOOLINGUNIT6........................
CONNECTINGELECTRICALPOWER CIRCUIT TOCOOLINGUNIT7....
CONNECTINGELECTRICALPOWER CIRCUIT TOREMOTE
CONDENSER COILAND FANASS’Y8................................
CONNECTINGPLAINWATERINLETSUPPLYLINETOCOOLINGUNIT8
CONNECTINGCO2INLETSUPPLYLINETOCOOLINGUNIT9.........
CONNECTINGSYRUP SOURCELINES TOCOOLINGUNITSYRUP
INLETLINES 9.....................................................
CONNECTINGCOOLINGUNITSYRUPOUTLETLINES TOINSULATED
PYTHONSYRUPLINES 9...........................................
CONNECTINGCOOLINGUNITPLAINWATEROUTLETLINES TO
INSULATEDPYTHONPLAINWATERLINES 9.........................
CONNECTINGCOOLINGUNITCARBONATEDWATEROUTLETLINES TO
INSULATEDPYTHON CARBONATEDWATERLINES 9.................
PLACINGCOOLINGUNITINOPERATINGPOSITION10.....................
PREPARINGCOOLINGUNIT FOROPERATION10..........................
OPERATION11..........................................................
LEAK CHECK AND INSULATINGCOOLINGUNITOUTLETLINES 12..........
DISPENSINGSTATIONADJUSTMENTS12.................................
ADJUSTINGWATERFLOWRATE12..................................
ADJUSTINGWATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT12
INSTALLINGLINEIDENTIFICATIONLABEL 12..............................
OPERATORSINSTRUCTIONS13..............................................
OPERATINGCONTROLS13..............................................
COOLINGUNITREFRIGERATIONPOWERSWITCH 13.................
COOLINGUNITCARBONATORMOTORSWITCH 13....................
COOLINGUNITCIRCULATINGMOTORSWITCH 13.....................
REFRIGERATIONSYSTEMTEMPERATURE SENSINGDEVICE AND
HIGH-PRESSURECUTOUTSWITCH 13...............................
DAILY PRE-OPERATION CHECK14........................................
ADJUSTMENTS14.......................................................

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TABLEOFCONTENTS(cont’d)
Page
ADJUSTINGCO2REGULATORS14...................................
ADJUSTINGDISPENSINGVALVES WATERFLOWRATE14.............
ADJUSTINGWATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT14.
ADJUSTINGSIZEOFDRINKDISPENSED14...........................
REPLENISHINGCO2SUPPLY14..........................................
REPLENISHINGSYRUP SUPPLY14...................................
CLEANINGAND SANITIZING14...........................................
DAILYCLEANING14.................................................
SANITIZINGSYRUP SYSTEMS15.....................................
COOLINGUNITMAINTENANCE15........................................
COOLINGUNITAIRINTAKE AND EXHAUST FILTERS15................
CHECKINGICEWATERBATH15......................................
COOLINGUNITCARBONATORMAINTENANCE15.....................
DOUBLELIQUID CHECK VALVE ASSEMBLIES YEARLYMAINTENANCE
(ORAFTERWATERSYSTEMDISRUPTIONS).15.......................
COOLINGUNITCARBONATEDWATER CIRCULATINGPUMPMOTOR
LUBRICATION15....................................................
REMOTECONDENSER COILAND FANASS’YMAINTENANCE16............
CLEANINGCO2GAS CHECK VALVES 16..................................
SERVICEAND MAINTENANCE17.............................................
COOLINGUNITMAINTENANCE17........................................
PERIODIC CLEANING17.............................................
CLEANINGCOOLINGUNITAIRINTAKE AND EXHAUST FILTERS.17.....
PREPARINGCOOLINGUNIT FORSHIPPING,STORING,OR RELOCATING17
PERIODICINSPECTION17...............................................
REMOTECONDENSER COILAND FANASSEMBLYMAINTENANCE18.......
CHECKINGICEWATERBATH18......................................
CHANGINGICEWATERBATH18.....................................
DOUBLELIQUID CHECK VALVE ASSEMBLIES YEARLYMAINTENANCE
(ORAFTERWATERSYSTEMDISRUPTIONS)19.......................
LUBRICATION21........................................................
ADJUSTMENTS21.......................................................
PRIMARYCO2REGULATOR21.......................................
SECONDARYCO2REGULATORS21..................................
WATERFLOWRATE22..............................................
WATER-TO-SYRUP‘‘RATIO’’ OFDISPENSEDPRODUCT22.............
CLEANINGAND SANITIZING22...........................................
DAILYCLEANING OFUNIT22........................................
SANITIZINGPOST-MIX SYRUP SYSTEMS23..........................
REPLENISHINGCO2SUPPLY26..........................................
REPLENISHINGSYRUP SUPPLY26.......................................
SYRUPFLAVOR CHANGE27.............................................
CLEANINGCO2SYSTEMGAS CHECK VALVES 27..........................
SECONDARYCO2REGULATORS AND CO2MANIFOLD CO2GAS
CHECK VALVES 27..................................................

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TABLEOFCONTENTS(cont’d)
Page
COOLINGUNITCO2INLETLINECO2GAS CHECK VALVE 27...........
TROUBLESHOOTING30......................................................
WATER-TO-SYRUP‘‘RATIO’’ OFDISPENSED DRINKTOO LOWORTOO
HIGH.30................................................................
ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES
NOTINCREASE TODESIREDWATER-TO-SYRUP‘‘RATIO”.30...............
ADJUSTMENTOFDISPENSINGVALVE SYRUPFLOWREGULATOR DOES
NOTDECREASE TODESIREDWATER-TO-SYRUP‘‘RATIO’’.31.............
DISPENSEDPRODUCTCARBONATIONTOO LOW.31......................
DISPENSEDPRODUCTCOMES OUTOFDISPENSINGVALVE CLEARBUT
FOAMSIN CUP.31.......................................................
DISPENSEDPRODUCTPRODUCES FOAMAS ITLEAVES DISPENSING
VALVE.31...............................................................
ONLYCARBONATEDWATER DISPENSED.31..............................
ONLY SYRUPDISPENSED.32............................................
WARMPRODUCTBEINGDISPENSED.32..................................
WATERPUMPMOTORWILL NOTOPERATE.32............................
WATERPUMPMOTORWILL NOTSHUTOFF.32...........................
ERRATIC CYCLING OFCARBONATOR.32.................................
WATERPUMPMOTOROPERATES BUTWATERPUMPDOES NOTPUMP
WATER.33..............................................................
WATERPUMPCAPACITYTOO LOW.33...................................
COMPRESSOR DOES NOTOPERATE.33..................................
COMPRESSOROPERATES CONTINUOUSLY BUTDOES NOT FORM
SUFFICIENTICE BANK34................................................
CONDENSERFANMOTOR NOTOPERATING35...........................
AGITATORMOTOR NOTOPERATING.35..................................
WARRANTY36..............................................................
LISTOF FIGURES
FIGURE1.AURORAR10,000 PLUSCOOLINGUNIT1.......................
FIGURE2.FLOWDIAGRAM(TYPICALINSTALLATION)4...................
FIGURE3.240/24VACPOWERTRANSFORMER7.........................
FIGURE4.COOLINGUNITSPACEREQUIRED10...........................
FIGURE5.PARTSIDENTIFICATION20....................................
FIGURE6.LIQUID CHECK VALVE ASSEMBLY22...........................
FIGURE7.CO2GAS CHECK VALVE 26....................................
FIGURE8.REFRIGERATIONFLOWDIAGRAM(REQUIRES CONNECTIONTO
REMOTECONDENSER COILAND FANASS’Y)28..........................
FIGURE9.WIRINGDIAGRAM29..........................................
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
troubleshooting this equipment.
GENERALDESCRIPTION
This section givesthe description, theoryofoperation,and design dataforthe AuroraR10,000 PlusCooling
Unit, hereafter referred too asaCooling Unit.
COOLINGUNITDESCRIPTION
The Cooling Unitisdesigned to provide cooled syrup,carbonated water,and plainwatertothe dispensing
station through an insulated python (length asordered).The Cooling Unitrefrigeration systemis cooled bya
RemoteCondenserCoil and Fan Assemblywhichis connected tothe Cooling Unit.
The Cooling Unitconsistsofarefrigeration systemwithatwo horsepowercompressorand a HydroBoostR
(plainwaterpre-cooler) which pre-coolsplainwateron itswaytothe carbonated watertank.The Cooling Unit
alsoconsistsofa plainwaterpump.The plainwaterpump pumpsplainwaterthrough the HydroBoostR,
through the plainwatercooling coils,and intothe carbonated watertank.The carbonated watercirculating
pumpcirculates coldcarbonated waterfromthe Cooling Unit tothe dispensing station and back tothe Cooling
Unit.
The cabinetpanelsare easilyremoved tofacilitateinstallation and service and maintenance.
An optionalCooling UnitStand (P/N309309000)isavailableto elevateCooling Unitup off floor.Also available
isan AuroraServiceSystemAnalyzer (P/N30919700)thatmaybe used to analyze and troubleshoot the
Cooling Unitrefrigeration system.
CAUTION:Before shipping or relocating theCooling Unitsyrup cooling coilsmustbe
sanitizedand all sanitizing solution mustbepurgedfromthe coils.All watermustalso be
purgedfromtheplainand carbonatedwatersystems.Afreezing ambientenvironmentwill
cause residualsanitizing solution orwater remaining insidetheCooling Unit tofreezeresulting in
damagetointernalcomponents.
FIGURE1.AURORAR10,000 PLUSCOOLINGUNIT

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Table 1.Design Data
COOLINGUNITDATA
ModelNo.416654
Overall Dimensions:
Height25-inches
Width 36-1/2inches
Depth 24-1/2inches
NOTE:Overall dimensionsifCooling Unitisplaced on optionalCooling UnitStand (P/N309309069).
Height(approximate)72-5/16 inches
Width 37-1/2inches
Depth 25-3/8inches
Weights:
Shipping 385 pounds
DryWeightpounds
IceBankWeight40 ±pounds
Capacities:
WaterBath(no ice bank)18 gallons
CompressorHorsepower2HP
Refrigeration System:
RefrigerantType and Charge See Cooling UnitNameplate
AmbientOperating Temp.50° Fto 100° F
ElectricalRequirements:
Operating Voltage See Cooling
Unit
Nameplate
CurrentDraw
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

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SYSTEMTHEORYOFOPERATION
(see Figure 2)
ACO2cylinderdelivers carbon dioxide gas(CO2)to primaryCO2regulatorassemblywhich deliver regulated
CO2gasto adjustablesecondaryCO2regulators.SecondaryCO2regulatorsdeliversregulated CO2gastothe
carbonated watertankinside the Cooling Unitand alsotothe soft drinktanks.Plainwaterentersthe Cooling
Unitand ispumped through and ispre-cooled bythe refrigerated HydroBoostâcoil.Cooled watercontinues
through the plainwatercooling coilsand intothe carbonated watertank.Cold plainwaterentering the
carbonated watertankis carbonated byregulated CO2gaspressure also entering the tank.Carbonated water
leavesthe carbonated watertankand entersthe inletside of the carbonated watercirculating pump.
Carbonated waterpassesthrough the carbonated watercirculating pump, through the carbonated watercooling
coil,and exitsthe Cooling Unit through an insulated python toaturnaround inside the dispensing station.
Carbonated water returnstothe Cooling Unitbypassing through the insulated python, through the Cooling Unit
carbonated watercooling coils, through the carbonated watertankwhichmakesup the carbonated water
circulating system.As carbonated waterisbeing dispensed fromthe dispensing station,carbonated water
circulating systemis continuouslybeing replenished fromthe carbonated watertank.
Plainwaterentersthrough the Cooling Unit two plainwaterinletlines, through the plainwatercooling coils,and
existsthe Cooling Unitout through insulated python tothe dispensing station.Regulated CO2gaspressure
exerted upon the soft drinks contentsforces syrup fromtanks, through Cooling Unitsyrup inletlines, through
syrup cooling coils,and existsthe Cooling Unitout through an insulated python tothe dispensing station.
The Cooling Unitrefrigeration systemis cooled byaRemoteCondenserCoil and Fan Assembly(P/N
309602000)thatisauthorized byIMICorneliusInc.Use ofanyotherRemoteCondenserCoil and Fan
Assemblymustbe authorized byIMICorneliusInc.Use ofan unauthorized RemoteCondenserCoil and Fan
Assemblywill automatically voidthe Cooling Unit factorywarranty.

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PLAIN WATER
SOURCE
SHUTOFF
VALVE
WATER PRESSURE
REGULATOR
WATER FILTER
ASS’Y
DIET SYRUP
CO2REGULATOR
SUGAR SYRUP
CO2REGULATOR
CARBONATOR
CO2REGULATOR
CO2MANIFOLD
CO2GAS CHECK
VALVE(10)
PRIMARY
CO2REGULATOR
CO2CYLINDER SOFT DRINK TANKS(10)
CARBONATED WATER
TANK ASS’Y
TO
DISPENSING
STATION
HYDRO BOOSTR
BYPASS SHUTOFF
VALVE
HYDRO BOOSTR
COIL
LIQUID
CHECK
VALVE
CO2
CHECK
VALVE
PLAIN
WATER PUMP
*WATER TANK
WATER LEVEL
CONTROL
CARBONATED WATER
CIRCULATING PUMP
*SOME COOLING UNITS MAY BE EQUIPPED WITH THE WATER LEVEL FLOAT CONTROL.
COOLING UNIT MODEL:
416654
COOLING UNIT DOUBLE LIQUID
CHECK VALVE ASS’Y(2)
LINE LEGEND CO2 CARB WATER PLAIN WATER SYRUP
FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION)

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INSTALLATION
This section coversunpacking and inspection,selecting location,installing the Cooling Unitand the Remote
CondenserCoil and Fan Assemblypreparing foroperation,and operation.
UNPACKINGAND INSPECTION
NOTE:TheCooling Unitand theRemoteCondenserCoil and FanAssemblywerethoroughlyinspected
beforeleaving thefactory and the carrierhas acceptedand signedforthem.Anydamageor
irregularities should benotedat timeofdelivery(ornotlaterthan15 days fromdateofdelivery)and
immediatelyreportedtothedelivering carrier.Requestawritteninspection report fromClaims
Inspectortosubstantiate anynecessary claim.File claimwiththedelivering carrier,notwithIMI
CorneliusInc.
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 309852000 Tubing Clamp 24
2 770407 Barbed Connector,1/4 by3/8 12
3 770424 Barbed Connector,1/2 by1/2 2
4 311962000 Label,Line Identification 1
NOTE:Thefollowing RemoteCondenserCoil and FanAssembly and Refrigeration LineKits arerec-
ommendedforuse withCooling Unit (P/N416654000).Refrigeration Lines Kit (as ordered)isusedto
connectCondenserCoil and FanAssemblytotheCooling Unit.
5 309602000 RemoteCondenserCoil and Fan Ass’y1
6 300598025 Refrigeration Line Kit, 25-ft. long,90 1
300598050 Refrigeration Line Kit, 50-ft. long,90 1
IDENTIFICATIONOF LOOSE-SHIPPEDPARTS
1.BARBED CONNECTORS(item2)used toconnectCooling Unitoutletlinestoinsulated python lines.
Connectionsaresecured withTUBINGCLAMPS (item1).
2.BARBED CONNECTORS(item3)are used toconnectCooling Unitoutletcarbonated waterlinesto
insulated python lines.
3.LABEL,LINEIDENTIFICATION(item4)tobeinstalled on Cooling Unitand syrup flavorstoberecorded in
properspaceson label.
4.REFRIGERATIONLINE KIT(items6)isused toconnectREMOTECONDENSER COILAND FANASS’Y
(item5)toCooling 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

6300614000
fused asindicated on the Unitnameplate.The powercircuitmayalsobewired through an equivalentHACR
type circuitbreaker ratherthen the disconnectswitch.THE POWER CIRCUITMUSTBE MADEUPOF
COPPER CONDUCTORS AND ALL WIRINGMUSTCONFORMTONATIONALAND LOCALELECTRICAL
CODES;(4)Closetoaplainwatersourcesupplyline with proper requirements;(5)Sufficientspace around
Cooling Unit(see Figure4)forproperaircirculation (18-incheson sidesand back, frontside open toroom,and
top open toceiling);(6)Becloseto permanent floordraintorouteCooling Unitwatertankdrain and overflow
hosestothe floordrain.
REMOTE CONDENSER COILAND FAN ASS’Y
CAUTION:RemoteCondenserCoil and FanAssemblies authorized byIMICorneliusInc.
(P/N309602000)
1.An extremewarmclimateinstallation mayrequire extracaution inRemoteCondenserCoil and Fan
Assemblylocation.Avoid hotsunnylocationsand seek shaded area ifpossible.The use ofastructureto
shade the Unit fromdirectsun exposure and/ora platformextending Unitan additional18-inchesabove
the rooftop ishighlyrecommended and will improve performance.Amplespacemustbe provided on all
sidesand aboveUnit forproperaircirculation through Unitand also access forservice and maintenance.
DONOTBLOCK AIR CIRCULATIONTHROUGH UNIT.
2.RemoteCondenserCoil and Fan Assemblymustbe installed inlevelposition and mustbe anchored with
adequatefastening devices.
INSTALLINGREMOTECONDENSER COILAND FAN ASS’Y
(see Figure 6)
1.RemoteCondenserCoil and Fan Assemblymustbe installed meeting requirementsofSELECTING
LOCATION.RemoteCondenserCoil and Fan Assemblymustbe installed inalevelposition and mustbe
anchored with adequatefastening devices.
2.Routerefrigeration linesofREFRIGERATIONLINE KIT(item6)fromRemoteCondenserCoil and Fan
AssemblydowntoCooling Unitlocation.
3.Connectendsofrefrigeration linestoCondenserCoil and Fan Assemblyrefrigeration connectors.
INSTALLINGCOOLINGUNIT
NOTE:Cooling Unitoutletlines,plainwater,CO2,and syrup inletlines,RemoteCondenserCoil and
FanAssemblyrefrigeration lines and powercircuitcable,and Cooling Unitpowercircuitcable each
mustbelong enough whenconnectedtoCooling Unit toallowpulling Unitoutapproximately
36-inches fromoperating position forservice and maintenance.WhenCooling Unitisin operating
position,excess powercircuitcable,RemoteCondenserCoil and FanAssemblyrefrigeration lines and
powercircuitcable and plainwatersource and CO2inletlines may be coiled up behind Unit.
PLACINGCOOLINGUNITINLOCATION
NOTE:An optionalCooling UnitStand (P/N309309069)is availabletoelevateCooling Unitup and off
thefloor.
1.PlaceCooling Unitin position approximately36-inchesout fromoperating position to allowaccess all
around the Unit.
2.Removetwoscrews securing Cooling Unit top cover, then removecover.
CONNECTINGREMOTE CONDENSER COILAND FAN ASS’Y REFRIGERATIONLINES
TOCOOLINGUNIT
(see Figure 5)
Connectrefrigeration lines, fromRemoteCondenserCoil and Fan Assembly, torefrigeration connectorson front
ofCooling Unit.