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

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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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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........................................

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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.................................

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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.....................................

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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.

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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

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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.

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c
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)
PW
COIL
RECIRC
CO2
WTR
COIL
PW
COIL
1
2
3
4
5 6
7 8
9
10
1 2 34 5 6 7 8 9 10
P0TABLE WATER
SOURCE

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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
5)
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.