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 [phone] 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..............................................

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1593
TABLEOFCONTENTS(cont’d)
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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........................................

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TABLEOFCONTENTS(cont’d)
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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.................................

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TABLEOFCONTENTS(cont’d)
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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.....................................