Cornelius AURORA 10 User Manual

Installation Manual

AURORAR10,000 COOLING UNIT

Part No. 300381000 July 13, 1988 Revised: April 12, 1993

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment

IMI CORNELIUS INC; 1988--93Ó

PRINTED IN U.S.A

TABLE OF CONTENTS

GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT DESCRIPTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM THEORY OF OPERATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNPACKING AND INSPECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION OF LOOSE-SHIPPED PARTS 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

SELECTING LOCATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE CONDENSER COIL AND FAN ASS’Y 6. . . . . . . . . . . . . . . . . . . . . .

INSTALLING REMOTE CONDENSER COIL AND FAN ASS’Y 6. . . . . . . . . . . . . . .

INSTALLING COOLING UNIT 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLACING COOLING UNIT IN LOCATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING REMOTE CONDENSER COIL AND FAN ASS’Y

REFRIGERATION LINES TO COOLING UNIT 7. . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING UNIT 7. . . .

CONNECTING PLAIN WATER INLET SUPPLY LINE TO COOLING UNIT 9

CONNECTING CO2 INLET SUPPLY LINE TO COOLING UNIT 9. . . . . . . . .

CONNECTING SYRUP SOURCE LINES TO COOLING UNIT SYRUP

INLET LINES 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING COOLING UNIT SYRUP OUTLET LINES TO INSULATED

PYTHON SYRUP LINES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING COOLING UNIT PLAIN WATER OUTLET LINE TO

INSULATED PYTHON PLAIN WATER LINE 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING COOLING UNIT CARBONATED WATER OUTLET LINES TO

INSULATED PYTHON CARBONATED WATER LINES 10. . . . . . . . . . . . . . . . .

PLACING COOLING UNIT IN OPERATING POSITION 10. . . . . . . . . . . . . . . . . . . . .

PREPARING COOLING UNIT FOR OPERATION 11. . . . . . . . . . . . . . . . . . . . . .

OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING COOLING UNIT REFRIGERATION SYSTEM 12. . . . . . . . . . . . . . .

STARTING CARBONATED WATER CIRCULATING PUMP 12. . . . . . . . . . . . .

ACTIVATING SYRUP SYSTEMS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEAK CHECK AND INSULATING COOLING UNIT OUTLET LINES 13. . . . . .

DISPENSING STATION ADJUSTMENTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING LINE IDENTIFICATION LABEL 13. . . . . . . . . . . . . . . . . . . . . . . . . .

OPERA TORS INSTRUCTIONS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

OPERATING CONTROLS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT REFRIGERATION POWER SWITCH 15. . . . . . . . . . . . . . . . .

COOLING UNIT CARBONATOR MOTOR SWITCH 15. . . . . . . . . . . . . . . . . . . .

COOLING UNIT CIRCULATING MOTOR SWITCH 15. . . . . . . . . . . . . . . . . . . . .

REFRIGERATION SYSTEM TEMPERATURE SENSING DEVICE AND

HIGH-PRESSURE CUTOUT SWITCH 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY PRE-OPERATION CHECK 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING CO2 REGULATORS 16...................................

i 300381000

TABLE OF CONTENTS (cont’d)

ADJUSTING DISPENSING VALVES WATER FLOW RATE 16. . . . . . . . . . . . .

ADJUSTING WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED PRODUCT 16.

ADJUSTING SIZE OF DRINK DISPENSED 16. . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING CARBONATOR TANK LIQUID LEVEL 16....................

REPLENISHING CO2 SUPPLY 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING SYRUP SUPPLY 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING SYRUP SYSTEMS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT MAINTENANCE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT EQUIPPED WITH CONDENSER COIL AND AIR

INTAKE FILTER 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT CARBONATOR MAINTENANCE 17. . . . . . . . . . . . . . . . . . . . .

COOLING UNIT CARBONATED WATER CIRCULATING PUMP MOTOR

LUBRICATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE CONDENSER COIL AND FAN ASS’Y MAINTENANCE 18. . . . . . . . . . . .

CLEANING CO2 GAS CHECK VALVES 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND MAINTENANCE 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

PREPARING COOLING UNIT FOR SHIPPING, STORING, OR RELOCATING 19

PERIODIC INSPECTION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING UNIT MAINTENANCE 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CLEANING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CONDENSER COIL 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING ICE WATER BATH 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING ICE WATER BATH 21.....................................

WATER PUMP YEARLY MAINTENANCE (OR AFTER WATER

SYSTEM DISRUPTIONS) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATED WATER CIRCULATING PUMP MOTOR LUBRICATION 26. . . . . .

ADJUSTMENTS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMARY CO2 REGULATOR 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY CO2 REGULATORS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER FLOW RATE 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED PRODUCT 28. . . . . . . . . . . . .

ADJUSTING CARBONATORS TANKS LIQUID LEVELS 28. . . . . . . . . . . . . . . .

CLEANING AND SANITIZING 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY CLEANING OF UNIT 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING POST-MIX SYRUP SYSTEMS 29. . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING CO2 SUPPLY 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING SYRUP SUPPLY 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYRUP FLAVOR CHANGE 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING CO2 SYSTEM GAS CHECK VALVES 32. . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY CO2 REGULATORS AND CO2 MANIFOLD CO2 GAS

CHECK VALVES 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBONATORS CO2 INLET LINES CO2 GAS CHECK VALVE 32. . . . . . . . .

CONNECTING EXTERNAL CARBONATOR TO COOLING UNIT 32. . . . . . . .

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TABLE OF CONTENTS (cont’d)

TROUBLESHOOTING 39......................................................

WATER-TO-SYRUP ‘‘RATIO’’ OF DISPENSED DRINK TOO LOW OR

TOO HIGH. 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES

NOT INCREASE TO DESIRED WATER-TO-SYRUP ‘‘RATIO” 39...............

ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES

NOT DECREASE TO DESIRED WATER-TO-SYRUP ‘‘RATIO’’. 40. . . . . . . . . . . . .

DISPENSED PRODUCT CARBONATION TOO LOW. 40. . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT

FOAMS IN CUP. 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSED PRODUCT PRODUCES FOAM AS IT LEAVES DISPENSING

VALVE. 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ONLY CARBONATED WATER DISPENSED. 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ONLY SYRUP DISPENSED. 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARM PRODUCT BEING DISPENSED. 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP MOTOR WILL NOT OPERATE. 41. . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP MOTOR WILL NOT SHUT OFF. 41. . . . . . . . . . . . . . . . . . . . . . . . . . .

ERRATIC CYCLING OF CARBONATOR. 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP

WATER 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP CAPACITY TOO LOW. 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR DOES NOT OPERATE. 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM

SUFFICIENT ICE BANK. 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSER FAN MOTOR NOT OPERATING. 44. . . . . . . . . . . . . . . . . . . . . . . . . . .

AGITATOR MOTOR NOT OPERATING. 44..................................

WARRANTY 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

LIST OF FIGURES

FIGURE 1. AURORAR10,000 COOLING UNIT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION) 4. . . . . . . . . . . . . . . . . . .

FIGURE 3. 240/24VAC POWER TRANSFORMER 7. . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 4. COOLING UNIT SPACE REQUIRED 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 5. PARTS IDENTIFICATION (STANDARD COOLING UNIT W/INTERNAL

CONDENSER COIL AND FAN ASSEMBLY) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. PARTS IDENTIFICATION (COOLING UNIT REQUIRING CONNECTION

TO REMOTE CONDENSER COIL AND FAN ASSEMBLY) 23. . . . . . . . . . . . . . . . . .

FIGURE 7. CARBONATOR LIQUID LEVEL CONTROL SWITCHES 25. . . . . . . . . .

FIGURE 8. WATER STRAINER SCREEN AND LIQUID DOUBLE CHECK

VALVE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 9. LIQUID CHECK VALVE ASSEMBLY 27. . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 10. CO2 GAS CHECK VALVE 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 11. REFRIGERATION FLOW DIAGRAM (STANDARD COOLING UNIT

W/INTERNAL CONDENSER COIL AND FAN ASS’Y) 33. . . . . . . . . . . . . . . . . . . . . . .

FIGURE 12. REFRIGERATION FLOW DIAGRAM (COOLING UNIT REQUIRING

CONNECTION TO REMOTE CONDENSER COIL AND FAN ASS’Y) 34.........

FIGURE 13. WIRING DIAGRAM (LOW-VOLTAGE SYSTEM) 35. . . . . . . . . . . . . . . .

iii 300381000

TABLE OF CONTENTS (cont’d)

LIST OF FIGURES CONT’D)

FIGURE 14. WIRING DIAGRAM (LOW-VOLTAGE SYSTEM) 36. . . . . . . . . . . . . . . .

FIGURE 15. WIRING DIAGRAM (HIGH-VOLTAGE SYSTEM) 37. . . . . . . . . . . . . . .

LIST OF TABLES

TABLE 1. DESIGN DATA 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE 2. LOOSE-SHIPPED PARTS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

300381000

GENERAL INFORMATION

IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, and maintaining this equipment. Refer to Table of Contents for page location of detailed information pertaining to questions that arise during installation, operation, service and maintenance, or trouble-shooting this equipment.

GENERAL DESCRIPTION

This section gives the description, theory of operation, and design data for the AuroraR10,000 Cooling Unit, (hereafter referred to as a ‘‘Cooling Unit’’).

COOLING UNIT DESCRIPTION

The Cooling Unit is designed to provide cooled soft drink syrup, carbonated water, and plain water to dispensing station through an insulated python (length as ordered). On the standard Cooling Unit, refrigeration system is cooled by condenser coil and fan assembly located inside the Cooling Unit. Cooling Unit not provided with internal condenser coil and fan assembly is cooled by Remote Condenser Coil and Fan Assembly which is connected to Cooling Unit. The Cooling Unit consists basically of two carbonator tanks each having its own water pump to pump plain water into tanks, one carbonated water circulating pump, a Hydro Boostâ (carbonated water pre-cooler) which pre-cools carbonated water on its way to carbonated water circulating pump and a two horsepower refrigeration compressor. The cabinet panels are easily removed to facilitate installation and service and maintenance.

An optional Cooling Unit Stand (P/N 309309000) is available to elevate Cooling Unit up off floor. A System Status Display Kit (P/N 0913) is available and when installed on the Cooling Unit, allows operator or technician to monitor operation of Cooling Unit and to be aware when service is required. Also available is an Aurora Service System Analyzer (P/N 309197000) that may be used to analyze and troubleshoot the Aurora 10,000 Cooling Unit refrigeration system.

CAUTION: Before shipping or relocating Cooling Unit, syrup cooling coils must be sanitized and all sanitizing solution must be purged from coils. All water must also be

purged from plain and carbonated water systems. A freezing ambient environment will cause residual sanitizing solution or water remaining inside Cooling Unit to freeze resulting in damage to internal components.

FIGURE 1. AURORAR10,000 COOLING UNIT

300381000

Table 1. Design Data

COOLING UNIT MODEL NUMBERS: 60 HZ Unit:

Standard Cooling Unit with Internal Condenser Coil and Fan Assembly 416593

Cooling Unit Requiring Connection to Remote Condenser Coil and Fan Assembly

50 HZ Unit:

Standard Cooling Unit with Internal Condenser Coil and Fan Assembly 496593

COOLING UNIT DATA

Overall Dimensions:

Height 28-inches Width 36-1/2 inches Depth 24-1/2 inches

NOTE: Overall dimensions if Cooling Unit is placed on optional Cooling Unit Stand (P/N 309309069).

Height (approximate) 75-5/16 inches Width 37-1/2 inches Depth 25-3/8 inches

Weights: Models 416593 and 496593:

Shipping 378 pounds Dry Weight 358 pounds

416594

Model 416594:

Shipping 381 pounds Dry Weight 361 pounds

Ice Bank Weight 40 to 45 pounds

Capacities:

Water Bath (no ice bank) 18 gallons Compressor Horsepower 2 HP

Refrigeration System:

Refrigerant Type and Charge See Cooling Unit Nameplate

Ambient Operating Temp. 50° F to 100° F

Electrical Requirements:

60 HZ Cooling Unit:

Operating voltage Current Draw

50HZ Cooling Unit:

Operating Voltage Current Draw

See Cooling Unit

Nameplate

See Cooling

Nameplate

Unit

300381000 2

Table 1. Design Data (cont’d)

REMOTE CONDENSER COIL AND FAN ASS’Y DA TA (P/N 309602000)

Overall Dimensions:

Height 27 inches

Width 22-inches

Depth 38-inches

Weight:

Shipping 85 pounds

Ambient Operating Temp. -22° F to 158° F

Electrical Requirements:

Operating Voltage 208/230VAC, Single Phase,

60Hz

Current Draw 2.5 Amps

SYSTEM THEORY OF OPERATION

(see Figure 2)

A CO2cylinder delivers carbon dioxide gas (CO2) to primary CO2regulator assembly which delivers regulated CO2gas to adjustable secondary CO2regulators. Secondary CO2regulators deliver regulated CO2gas to both carbonated water tanks inside Cooling Unit and also to soft drink tanks. Plain water is pumped into carbonated water tanks by water pumps and is carbonated by regulated CO2gas pressure also entering tanks. Carbonated

water leaves carbonated water tanks and passes through the Hydro BoostR(carbonated water pre-cooler) which pre-cools carbonated water on its way to carbonated water circulating pump. Pre-cooled carbonated

water enters carbonated water circulating system through inlet side of carbonated water circulating pump. Carbonated water passes from outlet side of carbonated water circulating pump, through cooling coils inside water tank, and out through insulated line to turnaround inside dispensing station. Carbonated water returns to Cooling Unit by passing through insulated line, through cooling coils, and on to carbonated water circulating pump inlet which makes up the carbonated water circulating system. As carbonated water is being dispensed from dispensing station, carbonated water circulating system is continuously being replenished from both carbonated water tanks. Regulated CO2gas pressure, exerted upon soft drink tanks contents, forces syrup from tanks, through Cooling Unit cooling coils, and on to dispensing station through insulated lines.

Standard Cooling Unit.

The standard Cooling Unit refrigeration system is cooled by a condenser coil and fan assembly located inside Cooling Unit.

Cooling Unit Requiring Connection to Remote Condenser Coil and Fan Assembly .

The Cooling Unit refrigeration system is cooled by a Remote Condenser Coil and Fan Assembly (P/N 309602000) that is authorized by IMI Cornelius Inc. Use of any other Remote Condenser Coil and Fan Assembly must be authorized by IMI Cornelius Inc. Use of an unauthorized Remote Condenser Coil and Fan Assembly will automatically void the Cooling Unit factory warranty.

300381000

WATER

VALVE(2)

VALVE

CHECK

BYPASS VALVE

HYDRO BOOSTR

EXTERNAL

CARBONATOR

SHUTOFF

CARBONATED

LIQUID

CHECK

SINGLE

VALVE(2)

CARB WTR CARB WTR PLAIN WTR

LINES

SYRUP

HYDDRO

BOOSTR

CARBONATOR

WATER PUMP(2)

CARBONATED

WATER TANK(2)

LIQUID

CHECK

DOUBLE

VALVE(2)

TEE FITTING

PUMP

WATER

CIRCULATING

CARBONATED

GAS CHECK VALVE

PLAIN WATER

ASS’Y

WATER FILTER

VALVE

SHUTOFF

REGULATOR

WATER PRESSURE

SOURCE

LINE LEGEND

CO2PLAIN WATER

CARB WATER

PLAIN WATER

SYRUP

SHUTOFF VALVE

MANIFOLD

REGULATOR

DIET SYRUP

REGULATOR

SUGAR SYRUP

REGULATORS

CARBONATORS CO

GAS CHECK

VALVE(2)

VALVE(5)

FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION)

SOFT DRINK TANKS

CYLINDER

REGULATOR

PRIMARY CO

INSTALLATION

This section covers unpacking and inspection, selecting location, installing Cooling Unit, preparing for operation, and operation.

UNPACKING AND INSPECTION

NOTE: The Cooling Unit was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it. Any damage or irregularities should be noted at time of delivery (or not later than 15 days from date of delivery) and immediately reported to the delivering carrier. Request a written inspection report from Claims Inspector to substantiate any necessary claim. File claim with the delivering carrier, not with IMI Cornelius Inc.

1. After Cooling Unit has been unpacked, remove shipping tape and other packing material.

2. Unpack LOOSE-SHIPPED PARTS. Make sure all items are present and in good condition.

Table 2. Loose-Shipped Parts

Item

No. Part No. Name Qty .

1 110085000 Tubing Clamp 2 2 111353000 Tubing Clamp 7 3 311962000 Label, Line Identification 1

NOTE: The following Remote Condenser Coil and Fan Assembly and Refrigeration Lines Kits are recommended for use with the Cooling

Units.

4 309602000 Remote Condenser Coil and Fan Ass’y 1 5 300598025 Refrigeration Line Kit, 25-ft. long, 90° 1

300598050 Refrigeration Line Kit, 50-ft. long, 90° Straight 1

IDENTIFICATION OF LOOSE-SHIPPED PARTS

1. TUBING CLAMPS (item 1) used to secure insulated python lines to Cooling Unit carbonated water outlet lines.

2. TUBING CLAMPS (item 2) used to secure insulated python lines to Cooling Unit syrup and plain water lines.

3. REFRIGERATION LINE KITS (item 5) is used to connect the REMOTE CONDENSER COIL AND FAN ASS’Y (item 4) to the Cooling Unit.

SELECTING LOCATION

COOLING UNIT

Select location for Cooling Unit installation that will (1) Allow the shortest possible insulated python route from the Cooling Unit to the Dispensing Station location; (2) Allow the shortest possible refrigeration lines (not to exceed 50-ft in length) route from Remote Condenser Coil and Fan Assembly to the Cooling Unit; (3) REFER TO THE COOLING UNIT NAMEPLATE FOR THE REQUIRED POWER CIRCUIT OPERATING VOLTAGE, HZ, AND THE MINIMUM CIRCUIT AMPACITY OF THE COOLING UNIT. The power circuit for the Cooling Unit must be wired through a 40-amp minimum rated disconnect switch (not provided) and the power circuit must be

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fused as indicated on the Unit nameplate. The power circuit may also be wired through an equivalent HACR type circuit breaker rather then the disconnect switch. THE POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES; (4) Close to a plain water source supply line with proper requirements; (5) Allow sufficient space around Cooling Unit (see Figure 4) for proper air circulation (18-inches on sides and back, front side open to room, and top open to ceiling); (6) Be close to permanent floor drain to route Cooling Unit water tank drain and overflow hoses to the floor drain.

REMOTE CONDENSER COIL AND FAN ASS’Y (IF APPLICABLE)

1. An extreme warm climate installation may require extra caution in Remote Rooftop Condenser Coil and Fan Assembly location. Avoid hot sunny locations and seek shaded area if possible. The use of structure to shade unit from direct sun exposure and/or a platform extending unit an additional 18-inches above rooftop is highly recommended and will improve performance. Ample space must be provided on all sides and above unit for proper air circulation through unit and also access for service and maintenance. DO NOT BLOCK AIR CIRCULATION THROUGH UNIT.

2. Remote Condenser Coil and Fan Assembly must be installed in level position and must be anchored to rooftop with adequate fastening devices.

INSTALLING REMOTE CONDENSER COIL AND F AN ASS’Y (IF APPLICABLE)

see Figure 6

1. Remote Condenser Coil and Fan Assembly must be installed meeting requirements of SELECTING LOCATION. Remote Condenser Coil and Fan Assembly must be installed in level position and must be anchored to with adequate fastening devices.

2. Route REFRIGERATION LINES (item 5) from Remote Condenser Coil and Fan Assembly down to Cooling Unit location.

3. Connect ends of refrigeration lines to Remote Condenser Coil and Fan Assembly refrigeration connectors.

INSTALLING COOLING UNIT

NOTE: Cooling Unit outlet lines, plain water, CO2, and syrup inlet lines, Remote Condenser Coil and Fan Assembly refrigeration lines and power circuit cable (if applicable), and Cooling Unit power circuit cable each must be long enough when connected to Cooling Unit to allow pulling unit out approximately 36-inches from operating position for service and maintenance. When Cooling Unit is in operating position, excess power circuit cable, Remote Condenser Coil and Fan Assembly refrigeration lines and power circuit cable (if applicable) and plain water source and CO2inlet lines may be coiled up behind unit.

NOTE: An external carbonator may be connected to Cooling Unit as shown in Figure 2 for larger supply of carbonated water.

PLACING COOLING UNIT IN LOCATION

NOTE: An optional Cooling Unit Stand (P/N 309309069) is available to elevate Cooling Unit up off floor.

1. Place Cooling Unit in position approximately 36-inches out from operating position to allow access all around unit.

2. Remove two screws securing Cooling Unit top cover, then remove cover.

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CONNECTING REMOTE CONDENSER COIL AND FAN ASS’Y (IF APPLICABLE) REFRIGERATION LINES TO COOLING UNIT

(see Figure 6 ) Connect refrigeration lines, from Remote Condenser Coil and Fan Assembly, to refrigeration connectors on

back of Cooling Unit.

CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING UNIT

(see Figures 5 or 6 and 15)

IMPORTANT: Before applicable single-phase 60HZ or 50HZ electrical power circuit is connected to the Cooling Unit, service power voltage entering the building must be identified. Service power voltage entering the building will either be 208 or 230VAC and may be posted on the main service box. If not, the installer must contact the local electrical power company for information. If these two voltage identification attempts should fail, a voltage reading must be performed. If service power voltage is below 218VAC, the red electrical wire connected to the 240VAC terminal on LINE (primary) side of the 240/24VAC power transformer inside the Cooling Unit switches electrical control box (see Figure 3 and

15) must be disconnected from the 240VAC terminal and be connected to the 208VAC terminal. If voltage is above 218VAC, power transformer red electrical wire will remain connected to the 240VAC terminal. If installer is not sure of the service power voltage entering the building, leave the red electrical wire connected to the 240VAC terminal on the power transformer. If service power voltage is below 218VAC, proceed as follows:

1. Remove four screws securing switches electrical control box (see Figure 5 or 6) to Cooling Unit cabinet.

2. Pull switches electrical control box out for access to the 240/24VAC power transformer.

3. Remove red electrical wire from the 240VAC terminal on LINE (primary) side of power transformer and connect it to the 208 VAC terminal.

4. Install Cooling Unit switches electrical control box and secure with four screws.

208V

240V

RESET BUTTON

FIGURE 3. 240/24VAC POWER TRANSFORMER

WARNING: Make sure 40-amp minimum-rated disconnect switch or HACR circuit breaker (if applicable) is in ‘‘OFF’’ position.

1. Remove cover from electrical box on back of Cooling Unit.

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WARNING: The Cooling Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator. A green ground wire is provided inside electrical box to connect power circuit ground wire which electrically grounds the Cooling Unit.

2. 60HZ Cooling Unit Connect 208/230VAC Single Phase 60Hz electrical power circuit with a 40-amp minimum rated disconnect

switch (not provided) fused at 40-amps (maximum) or circuit connected through an equivalent HACR circuit breaker to electrical wires inside electrical handy box on back of cooling unit. DO NOT CONNECT ELECTRICAL POWER TO COOLING UNIT AT THIS TIME.

COOLING UNIT MUST BE PROPERLY GROUNDED, POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS, AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES.

50HZ Cooling Unit Connect 208/230VAC Single Phase 50Hz electrical power circuit with a 40-amp minimum rated disconnect

COOLING UNIT MUST BE PROPERLY GROUNDED, POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS, AND WIRING MUST CONFORM TO APPLICABLE ELECTRICAL CODES.

CONNECTING ELECTRICAL POWER CIRCUIT TO REMOTE CONDENSER COIL AND FAN ASS’Y (IF

APPLICABLE) see Figures 6 and 15)

CAUTION: The Cooling Unit refrigeration system is cooled by a Remote Condenser Coil and Fan Assembly (P/N 309602000) that is authorized by IMI Cornelius Inc. Use of an unauthorized Remote Condenser Coil and Fan Assembly will automatically void the

Cooling Unit factory warranty.

Remote Condenser Coil and Fan Assembly (P/N 309602000)

NOTE: Electrical power circuit may be connected to the Remote Condenser Coil and Fan Assembly (P/N 309602000) in two ways. The preferred way is to draw electrical power from the Cooling Unit contactor which allows the Remote Condenser Coil and Fan assembly to operate only when the Cooling Unit refrigeration system is operating. The optional way is to connect a separate electrical power circuit (independent of the cooling unit) through an appropriately rated and fused disconnect switch or an equivalent HACR circuit breaker which allows the Remote Condenser Coil and Fan Assembly to operate at all times (independent of Cooling Unit operation).

Connect and route electrical power circuit cable from Remote Condenser Coil and Fan Assembly through fuse box (not provided), fused at 15-amps (maximum) down to Cooling Unit location. REMOTE CONDENSER COIL AND FAN ASSEMBLY MUST BE PROPERLY GROUNDED, POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS, AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES.

A. Remove four screws securing electrical control box to Cooling Unit back panel, (see Figure 6) then

pull control box out for access to contactor inside box.

B. Route Remote Condenser Coil and Fan Assembly power cable electrical wires through electrical

handy box on back of Cooling Unit to inside of electrical control box.

C. Connect Remote Condenser Coil and Fan Assembly power cable electrical wires to T1and T

terminals on contactor inside Cooling Unit electrical control box.

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D. Reinstall Cooling Unit electrical control box and secure with four screws. E. Install cover on electrical handy box on back of Cooling Unit.

CONNECTING PLAIN WATER INLET SUPPLY LINE TO COOLING UNIT

(see Figure 2)

NOTE: IMI Cornelius Inc. recommends that a water shutoff valve be installed in plain water inlet supply line connected to Cooling Unit and that water supply be filtered. WATER PIPE CONNECTIONS AND FIXTURES DIRECTLY CONNECTED TO A POTABLE WA TER SUPPLY SHALL BE SIZED, INSTALLED AND MAINTAINED ACCORDING TO FEDERAL, STA TE, AND LOCAL LAWS.

CAUTION: Plain water inlet supply line to Cooling Unit must be 1/2-inch I.D. minimum. Check water flow rate of water inlet supply line. MINIMUM FLOW RATE MUST BE AT LEAST

250-GALLONS PER HOUR. If flow rate is less than 250-gallons per hour, ‘‘starving’’ of carbonator water pump will occur. Starving will allow water pump to overheat causing safety thermostat on pump outlet to disrupt electrical power to and stop water pump motor. Carbonated water circulating pump overheating could occur if water inlet supply line flow rate drops below 250-gallons per hour. INCOMING PLAIN WATER INLET SUPPLY LINE WATER PRESSURE MUST REMAIN A MINIMUM OF 10-PSI BELOW THE CARBONATOR CO2OPERA TING PRESSURE (Example: operating CO2pressure is 90-psi and maximum water pressure can be no more than 80-psi, etc.)

1. Before connecting plain water inlet supply line to Cooling Unit, open water line shutoff valve for a period of time to flush out any metal shavings and other contaminates that may have resulted from plumbing connections.

2. Connect flexible plain water inlet supply line (1/2-inch I.D. min.), meeting water inlet supply line requirements of preceding CAUTION note, to Cooling Unit 3/8-in. flare (5/8-18) bulkhead fitting on back of unit labeled ‘‘WATER INLET’’. DO NOT OPEN WATER INLET SUPPLY LINE SHUTOFF VALVE AT THIS TIME.

CONNECTING CO2INLET SUPPLY LINE TO COOLING UNIT

(see Figure 2)

WARNING: CO2displaces oxygen. Strict attention must be observed in the prevention of CO2(carbon dioxide) gas leaks in the entire CO2and soft drink system. If a CO2gas leak is

suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO2gas will experience tremors which are followed rapidly by loss of consciousness and suffocation.

Connect flexible CO2inlet supply line to Cooling Unit 1/4-in. flare (7/16-20) bulkhead fitting of back of unit labeled ‘‘CO2INLET’’. DO NOT TURN ON CO2SUPPLY TO COOLING UNIT AT THIS TIME.

CONNECTING SYRUP SOURCE LINES TO COOLING UNIT SYRUP INLET LINES

(see Figure 2 ) Connect syrup source lines, from No. 1 through No. 6 soft drink tanks location, to Cooling Unit syrup inlet lines

labeled No. 1 through No. 6. DO NOT CONNECT SOFT DRINK TANKS INTO SYRUP SYSTEMS AT THIS TIME.

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CONNECTING COOLING UNIT SYRUP OUTLET LINES TO INSULATED PYTHON SYRUP LINES

(see Figure 2) Connect Cooling Unit syrup outlet lines labeled No. 1 through No. 6, with barbed fittings on their ends, to

insulated python lines labeled No. 1 through No. 6. Secure connections with TUBING CLAMPS (item 2).

CONNECTING COOLING UNIT PLAIN WATER OUTLET LINE TO INSULATED PYTHON PLAIN WATER LINE

(see Figure 2)

NOTE: Shutoff valve in plain water line inside Cooling Unit must remain closed if plain water is not desired at dispensing valve.

Connect Cooling Unit plain water outlet line, with barbed fitting on its end, to insulated python plain water line. Secure connection with TUBING CLAMP (item 2).

CONNECTING COOLING UNIT CARBONATED WATER OUTLET LINES TO INSULATED PYTHON CARBONATED WATER LINES

(see Figure 2) Connect Cooling Unit carbonated water outlet lines, with barbed connectors on their ends, to insulated python

carbonated water lines. secure Connections with TUBING CLAMPS (item 1).

PLACING COOLING UNIT IN OPERATING POSITION

1. Very carefully, move Cooling Unit back into operating position leaving space around unit (see Figure 4) as specified in SELECTING LOCATION. MAKE SURE THERE ARE NO KINKS IN SYRUP INLET LINES, INSULATED PYTHON INTERNAL LINES, CO2AND PLAIN WATER INLET LINES, AND REMOTE CONDENSER AND FAN ASSEMBLY REFRIGERATION LINES (IF APPLICABLE).

NOTE: To comply with National Sanitation Foundation (NSF) requirements, Cooling Unit not installed on optional Cooling Unit Stand (P/N 309309069) must have its base sealed to floor with Dow-Corning RTV 731 or equivalent.

1. Tilt Cooling Unit up to expose bottom of unit base.

2. Liberally apply silastic sealant such as Dow Corning (RTV 731) or equivalent on unit base bottom edges.

NOTE: Do not move Cooling Unit after positioning or seal from unit base to floor will be broken.

18--IN.

COOLING UNIT

18--IN.

AIR FLOW

(OPEN TO ROOM)

FIGURE 4. COOLING UNIT SPACE REQUIRED

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3. Lower Cooling Unit into operating position to complete seal from unit base to floor. Apply additional sealant around bottom of base. Seal must have a minimum radius of 1/2-inch to prevent cracks and crevices and to ensure a complete seal.

4. Route Cooling Unit water tank overflow hose to permanent floor drain.

5. Seal area around overflow hose where they exit from unit using permagum sealant or equivalent.

PREPARING COOLING UNIT FOR OPERATION

1. Make sure plug in end of Cooling Unit water tank drain hose is secure.

2. Open shutoff valve in plain water inlet supply line. Due to slow water fill rate of water level float control, water tank may be hand filled until water runs out of water tank overflow hose. CLEAN LOW-MINERAL-CONTENT WATER MUST BE USED WHERE A LOCAL WATER PROBLEM EXIST.

3. Adjust primary CO2regulator (see Figure 2) on CO2cylinder to a minimum nominal setting of 120-psi or 24-psi higher than highest setting required by the secondary CO2regulators. Loosen CO2regulator adjusting screw locknut. Turn adjusting screw to the right (clockwise) until regulator gage registers nominal 120-psi, then tighten adjusting screw locknut.

4. Adjust carbonators secondary CO2regulator (see Figure 2) to a nominal 90-psi. Loosen CO2regulator adjusting screw locknut. Turn adjusting screw to the right (clockwise) until regulator gage registers nominal 90-psi, then tighten adjusting screw lock nut. CO2PRESSURE TO CARBONATORS MUST NOT EXCEED 120-PSIG.

CAUTION: Before starting refrigeration system, Hydro Boostâ coil must be completely flooded with carbonated water to prevent coil freeze-up. Proceed as follows to fill carbonated water system.

5. Make sure both carbonated water shutoff valves inside Cooling Unit (see Figure 2) are in ‘‘OPEN’’ (handles in line with tubing) positions.

6. Make sure Hydro Boostâ bypass valve inside Cooling Unit (see Figure 2) is in ‘‘CLOSED’’ (handle not in line with tubing) position.

7. Make sure Cooling Unit REFRIGERATION POWER, CARBONATOR MOTORS, and CIRCULATING MOTOR Power switches are in ‘‘OFF’’ (down) positions.

8. Connect electrical power to Cooling Unit at disconnect switch.

9. Place CARBONATOR MOTORS power switch in ‘‘ON’’ (up) position to start carbonators.

10. Dispense from dispensing station until carbonated water appears at valve indicating Hydro Boostâ and carbonated water system have been completely filled with carbonated water.

OPERATION

WARNING: Disconnect electrical power to Cooling Unit and Remote Condenser Coil and Fan Assembly (if applicable) to prevent personal injury before attempting any Cooling Unit or Remote Condenser Coil and Fan Assembly internal maintenance. Only qualified

personnel should service internal components or electrical wiring.

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Cornelius AURORA 10 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual