Cornelius AURORA 10,000 PLUS Installation Manual
  1. Manuals
  2. Brands
  3. Cornelius Manuals
  4. Air Conditioner
  5. AURORA 10
  6. Installation manual
Cornelius AURORA 10,000 PLUS Installation Manual

Cornelius AURORA 10,000 PLUS Installation Manual

Cooling unit
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual

Installation Manual

AURORA 10,000 PLUS
COOLING UNIT (V2.5)
IMPORTANT:
TO THE INSTALLER.
It is the responsibility of
the Installer to ensure that
the water supply to the
dispensing equipment is
provided with protection
against backflow by an air
gap as defined in
ANSI/ASME A112.1.2-1979;
or an approved vacuum
breaker or other such
method as proved effective
by test.
Water pipe connections
and fixtures directly
connected to a potable
water supply shall be
sized, installed, and
maintained according to
Federal, State, and Local
Codes.
Part No. 1593
December 21, 1992
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; 1992- - 93
Ó
IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234
Telephone (800) 238-3600
CAUTION: Prior to starting the Cooling Unit, the two ser-
vice valves on the refrigeration system receiver tank (see
applicable FIGURES 10 or 11) must be fully opened to
release refrigerant charge into the system. Operating
Cooling Unit with the service valves closed will damage
the compressor which will void the factory warranty.
Facsimile (612) 422-3246
PRINTED IN U.S.A

Advertisement

Table of Contents
loading

Related Manuals for Cornelius AURORA 10,000 PLUS

Summary of Contents for Cornelius AURORA 10,000 PLUS

  • Page 1: Installation Manual

    IMI CORNELIUS INC g One Cornelius Place g Anoka, MN 55303-6234 Telephone (800) 238-3600 Facsimile (612) 422-3246 Installation Manual AURORA 10,000 PLUS COOLING UNIT (V2.5) IMPORTANT: TO THE INSTALLER. It is the responsibility of the Installer to ensure that the water supply to the...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page GENERAL DESCRIPTION ..........COOLING UNIT DESCRIPTION .
  • Page 3 TABLE OF CONTENTS (cont’ d) Page COOLING UNIT REFRIGERATION POWER SWITCH ....COOLING UNIT CARBONATOR MOTORS SWITCH ....COOLING UNIT CIRCULATING MOTOR SWITCH .
  • Page 4 TABLE OF CONTENTS (cont’ d) Page SANITIZING POST-MIX SYRUP SYSTEMS ......REPLENISHING CO2 SUPPLY ......... . REPLENISHING SYRUP SUPPLY .
  • Page 5 TABLE OF CONTENTS (cont’ d) Page COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM SUFFICIENT ICE BANK ..........CONDENSER FAN MOTOR NOT OPERATING .

  • Page 6: General Description

    GENERAL DESCRIPTION This section gives the Unit description, theory of operation, and design data for the Aurora 10,000 Plus Cool- ing Unit (V2.5) hereinafter referred to as a “ Cooling Unit” . IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, and main- taining this equipment.

  • Page 7: Unit Description

    UNIT DESCRIPTION Table 1. Design Data COOLING UNIT DATA Cooling Unit Part Numbers: 60 HZ Model: Standard Cooling Unit with Internal Condenser Coil and Fan Assembly 1602 Cooling Unit Requiring 1604 Connection to Remote Condenser Coil and Fan Assembly 50 HZ Model: Standard Cooling Unit with Internal Condenser Coil and Fan Assembly 1603 Cooling Unit Requiring...

  • Page 8: System Theory Of Operation

    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 As- sembly 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.

  • Page 9: Figure 2. Flow Diagram

    1593...

  • Page 10: Installation

    Request a written inspec- tion report from Claims Inspector to substantiate any necessary claim. File claim with the delivering carrier, not with IMI Cornelius Inc. After Cooling Unit has been unpacked, remove shipping tape and other packing material.

  • Page 11: Selecting Location

    SELECTING LOCATION COOLING UNIT Select location for Cooling Unit installation that will (1) allow shortest possible insulated python run to dispensing station location; (2) allow shortest possible refrigeration lines (not to exceed 50-feet)) route from Remote Roof- top Condenser Coil and Fan Assembly to Cooling Unit; (3) The 60 Hz Cooling Unit is accessible to an electrical power circuit (voltage requirement is specified on the Unit nameplate).

  • Page 12: Placing Cooling Unit In Location

    PLACING COOLING UNIT IN LOCATION NOTE: An optional Cooling Unit Stand (P/N 309309069) is available to elevate Cooling Unit up and off the floor. 1. Place Cooling Unit in position approximately 36--inches out from operating position to allow access all around the Unit.

  • Page 13: Connecting Electrical Power Circuit To Remote Condenser Coil And Fan Ass' Y (If Applicable)

    CONNECTING POTABLE WATER SOURCE SUPPLY LINES TO COOLING UNIT NOTE: IMI Cornelius Inc. recommends that a water shutoff valve be installed in the potable water source supply line connected to Cooling Unit (see FIGURE 2) and that water supply be filtered. WATER PIPE CONNECTIONS AND FIXTURES DIRECTLY CONNECTED TO A POTABLE WATER SUPPLY SHALL BE SIZED, INSTALLED AND MAINTAINED ACCORDING TO FEDERAL, STATE, AND LOCAL LAWS.

  • Page 14: Connecting Co2 Source Supply Line To Cooling Unit

    CAUTION: Potable water source supply line to be connected to the Cooling Unit water inlet lines must be 1/2- -inch I.D. minimum. Check water flow rate of water inlet supply line. MINIMUM FLOW RATE MUST BE AT LEAST 300- -GALLONS PER HOUR. If flow rate is less than 300- -gallons per hour, ‘...

  • Page 15: Connecting Cooling Unit Carbonated Water Outlet Lines To Insulated Python Carbonated Water Lines

    CONNECTING COOLING UNIT CARBONATED WATER OUTLET LINES TO INSULATED PYTHON CARBONATED WATER LINES Using BARBED CONNECTORS (item 2) and TUBING CLAMPS (item 5), connect Cooling Unit 1/2--inch I.D. carbonated water outlet lines labeled “ CO WATER”to insulated python 1/2--inch I.D. carbonated water lines (see FIGURE 2).

  • Page 16: Operation

    1. Open the two service valves on the refrigeration system receiver tank fully to back--seat the valves (back-- seating the valves prevents leakage around the valve shafts). Replace caps on valves. 2. Make sure the plug in the end of the Cooling Unit water tank drain hose is secure. 3.

  • Page 17: Starting Carbonated Water Circulating Pump

    Standard Cooling Unit Utilizing Condenser Coil and Fan Assembly Place Cooling Unit REFRIGERATION POWER switch in ‘ ‘ ON’ ’position. Refrigeration compressor, condenser fan motor, and agitator motor will start and begin forming an ice bank and refrigerated Hydro Boostâ coil will also be chilling water.

  • Page 18: Adjusting Water--To--Syrup ' ' Ratio' 'Of Dispensed Product

    ADJUSTING WATER- - TO- - SYRUP ‘ ‘ RATIO’ ’OF DISPENSED PRODUCT Refer to manual provided with dispensing station for instructions to adjust dispensing valves for water--to--syrup “ Ratio”of dispensed product. INSTALLING LINE IDENTIFICATION LABEL Install LABEL, LINE IDENTIFICATION (item 6) on Cooling Unit and record syrup flavors in proper spaces. 1593...
  • Page 19 THIS PAGE LEFT BLANK INTENTIONALLY 1593...

  • Page 20: Operators Instructions

    OPERATORS INSTRUCTIONS This section covers operating controls, daily preoperation check, adjustments, replenishing CO and syrup sup- plies, cleaning and sanitizing, Cooling Unit maintenance, Remote Condenser Coil and Fan Assembly (if applica- ble) maintenance, lubrication, and servicing CO gas check valves. WARNING: Disconnect electrical power to Cooling Unit to prevent personal injury before attempting any Cooling Unit or Remote Condenser Coil and Fan Assembly (if applicable) internal maintenance.

  • Page 21: Cooling Unit Connected To Remote Condenser Coil And Fan Assembly

    COOLING UNIT CONNECTED TO REMOTE CONDENSER COIL AND FAN ASSEMBLY This Cooling Unit (see FIGURE 6) is equipped with a refrigeration system temperature sensing device and a high--pressure sensing cutout switch that will shut refrigeration system down should the system overheat due to a clogged condenser coil in Remote Condenser Coil and Fan Assembly.

  • Page 22: Cleaning And Sanitizing

    CLEANING AND SANITIZING DAILY CLEANING Perform daily cleaning of dispensing station as instructed in dispensing station Installation Instructions. Outside of Cooling Unit must be cleaned periodically. SANITIZING SYRUP SYSTEMS Syrup systems should be sanitized every 90 days as instructed following Sanitizer Manufacturer’ s recommenda- tions.

  • Page 23: Remote Condenser Coil And Fan Ass' Y (If Applicable) Maintenance

    REMOTE CONDENSER COIL AND FAN ASS’ Y (IF APPLICABLE) MAINTENANCE CAUTION: Remote Condenser Coil and Fan Assembly connected to the Cooling Unit (see FIGURE 6) is equipped with a condenser coil that must be cleaned every 30- -days. Allowing condenser coil to become clogged will cause Cooling Unit refrigeration system to overheat which will automatically shut refrigeration system down.

  • Page 24: Service And Maintenance

    This section describes Service and Maintenance procedures to be performed on Cooling Unit and the Remote Condenser Coil and Fan Assembly. Note: The Aurora 10,000 Plus Cooling Unit (V2.5) is equipped with a built in system analyzer for diag- nostic troubleshooting of the Cooling Unit. Refer to TROUBLESHOOTING section of this manual for analyzer operating instructions.

  • Page 25: Cooling Unit Maintenance

    COOLING UNIT MAINTENANCE CLEANING COOLING UNIT AIR INTAKE FILTERS CAUTION: Cooling Unit equipped with condenser coil (see FIGURE 5) is equipped with two air filters that must be cleaned every 30 days as instructed. Circulating air, required to cool the coil, is drawn in through air filters on back, and front of Unit and is exhausted out through coil on end of Unit.

  • Page 26: Figure 5. Parts Identification (Standard Cooling Unit W/Internal Condenser Coil And Fan Assembly)

    RIGHT- - SIDE TOP COVER LEFT- - SIDE TOP COVER CARBONATED WATER TANK ASS’ Y AGITATOR MOTOR HYDRO BOOSTR CONTACTOR (2) NAMEPLATE SYSTEM ANALYZER CARBONATED WATER CIRCULATING MOTOR MAIN MOTOR\PUMP CARBONATOR CIRCUIT BOARD MOTOR/PUMP (2) CIRCULATING MOTOR POWER SWITCH CARBONATORS MOTOR CONDENSER COIL POWER SWITCH REFRIGERATION...

  • Page 27: Figure 6. Parts Identification (Cooling Unit Requiring Connection To Remote Rooftop Condenser Coil And Fan Assembly)

    REMOTE CONDENSER COIL AND FAN ASS’ Y REFRIGERATION LINES (ITEM 8) RIGHT- - SIDE TOP COVER LEFT- - SIDE TOP COVER CARBONATED WATER TANK ASS’ Y AGITATOR MOTOR HYDRO BOOSTR HIGH- - PRESSURE CARBONATED WATER CUTOUT SWITCH CIRCULATING MOTOR/PUMP NAMEPLATE CONTACTOR (2) BUILT- - IN SYSTEM ANALYZER...

  • Page 28: Water Pump Yearly Maintenance (Or After Water System Disruptions)

    5. Allow ice bank to melt. Hot water may be used to speed melting. 6. Thoroughly rinse inside of water tank with clean water. 7. Install plug in end of water tank drain hose. 8. Open shutoff valve in plain water inlet supply line. Due to slow water fill rate of water level float control, tank may be hand filled until water runs out of water tank overflow tube.

  • Page 29: Adjustments

    13. Service carbonator water pump outlet liquid double check valve as instructed in next paragraph. Servicing Carbonator Water Pump Outlet Liquid Double Check Valve 1. Service water strainer screen as instructed in previous paragraph before servicing carbonator water pump outlet liquid double check valve (see FIGURES 2 and 7). 2.

  • Page 30: Figure 7. Water Strainer Screen And Liquid Double Check Valve

    WATER LINE TO TANK DOUBLE LIQUID CHECK VALVE WHITE TAPERED GASKET SAFETY THERMOSTAT ELBOW (P/N 318040- - 000) PUMP TO MOTOR COUPLING WATER PUMP WATER STRAINER SCREEN (P/N 315348- - 000) O- - RING (P/N 315349- - 000) SCREEN RETAINER FIGURE 7.

  • Page 31: Primary Co2 Regulator

    PRIMARY CO REGULATOR Adjust primary CO regulator on CO cylinder (see FIGURE 2) to a minimum nominal setting of 120--psi or 24--psi higher than highest setting required by the secondary CO regulators. Loosen CO regulator adjusting screw locknut. Turn adjusting screw to the right (clockwise) until regulator gage registers nominal 120--psi, then tighten adjusting screw locknut.

  • Page 32: Sanitizing Post-Mix Syrup Systems

    3. Wash cup rest, then rinse the cup rest with clean water. Install cup rest in the drip tray. 4. Clean all external surfaces of the Unit with a sponge. Rinse out the sponge with clean water, then wring excess water out of the sponge and wipe off all external surfaces on the Unit. Wipe Unit dry with a clean soft cloth.
  • Page 33 8. Syrup Tank Systems. Connect syrup tank containing potable water, pressurized at 60 to 80-psi, into one of the syrup systems. Bag-in-Box Syrup System. Fill five-gallon container with potable water, then place all bag-in-box syrup containers syrup outlet tubes in container containing potable water.

  • Page 34: Replenishing Co2 Supply

    19. Syrup Tank Systems. Connect syrup tank containing potable water, pressurized at 60 to 80-psi, into one of the syrup systems. Bag-in-Box Syrup System. Place all bag-in-box syrup containers syrup outlet tubes in container containing potable water. 20. Flush sanitizing solution from the syrup system and the dispensing valve as follows: Place waste container under applicable dispensing valve.

  • Page 35: Replenishing Syrup Supply

    3. Unfasten safety chain and remove empty CO cylinder. WARNING: To avoid personal injury and/or property damage, always secure CO cylinder in upright position with safety chain to prevent it from falling over. Should valve become accidentally damaged or broken off, CO cylinder can cause serious personal injury.

  • Page 36: Carbonator Co2 Inlet Line Co Gas Check Valve

    CARBONATOR CO INLET LINE CO GAS CHECK VALVE The Carbonator CO inlet line CO gas check valve, located inside the Cooling Unit (see FIGURES 2 and 9), must be inspected and serviced at least once a year under normal conditions and after any servicing or disrup- tion of the CO system.

  • Page 37: Figure 10. Refrigeration Flow Diagram (Standard Cooling Unit With Internal Condenser Coil And Fan Assembly)

    PULSE MODULATING EXPANSION VALVE ICE BANK PULSE MODULATING EXPANSION VALVE HYDRO BOOST SERVICE VALVE(2) (MUST BE OPEN FOR OPERATION) FIGURE 10. REFRIGERATION FLOW DIAGRAM (STANDARD COOLING UNIT WITH INTERNAL CON- DENSER COIL AND FAN ASSEMBLY) 1593...

  • Page 38: Figure 11. Refrigeration Flow Diagram

    REFRIGERATION LINES CONNECTED BETWEEN COOLING UNIT AND REMOTE CONDENSER COIL AND FAN ASS’ Y MUST NOT EXCEED 50- - FEET IN LENGTH. REFRIGERATION LINES VERTICAL RISE MUST NOT EXCEED 20- - FEET. REMOTE CONDENSER COIL AND FAN ASS’ Y SERVICE VALVE(2) (MUST BE OPEN FOR OPERATION)

  • Page 39: Figure 12. Wiring Diagram (Models 1602 And 1603)

    1475 REVISION A FIGURE 12. WIRING DIAGRAM (MODELS 1602 AND 1603) 1593...

  • Page 40: Figure 13. Wiring Diagram (Models 1604 And 1605)

    1769 REVSION A FIGURE 13. WIRING DIAGRAM (MODELS 1604 AND 1605) 1593...
  • Page 41 THIS PAGE LEFT BLANK INTENTIONALLY 1593...

  • Page 42: Non--Critical Temperature Sensor Failures

    Cooling Unit left- -side top cover. The Aurora 10,000 Plus Cooling Unit (V2.5) is equipped with a built--in system analyzer for diagnostic trouble- shooting and is located inside the electrical control box (see applicable FIGURES 5 or 6). Data is serially shifted out of the main circuit board microprocessor software to update the analyzer display in one of the following modes.

  • Page 43: "Hold" Mode

    STEP LEGEND DATA DISPLAYED Ice Bank Modulation Rate (in %). Ice Bank Inlet Sensor Refrigerant Temperature (in °F). Ice Bank Outlet Sensor Refrigerant Temperature (in °F). Ice Bank Delta T = Temperature Differential Between Ice Bank Sensor “ O” (ice bank outlet temperature) minus “ i”(ice bank inlet temperature). Condenser Outlet Sensor Temperature (in °F).

  • Page 44: Figure 14. Aurora Built--In Analyzer

    AURORA SYSTEM ANALYZER DIAGNOSTICS & TEMP MODE INDICATOR WATER HOLD TEMP SCAN SWITCH IN WATER TEMP POSITION: · DISPLAYS PRE- -COOLED WATER SENSOR SWITCH IN SCAN POSITION: · SCAN REFRIGERATION SENSORS MODE INDICATOR DISPLAY % MODULATION ICE BANK INLET SENSOR ICE BANK OUTLET SENSOR ICE BANK TEMP DIFFERENCE (0- -1) CONDENSER OUTLET SENSOR...
  • Page 45 THIS PAGE LEFT BLANK INTENTIONALLY 1593...

  • Page 46: Troubleshooting

    TROUBLESHOOTING IMPORTANT: Only qualified personnel should service internal components or electrical wiring. WARNING: If repairs are to be made to a product system, remove quick disconnects from the applicable product tank, then relieve the system pressure before proceeding. If repairs are to be made to the CO system, stop dispensing, shut off the CO supply, then relieve the...

  • Page 47: Dispensed Product Carbonation Too Low

    Trouble Probable Cause Remedy DISPENSED PRODUCT Carbonator CO regulator out Adjust carbonator CO regulator CARBONATION TOO LOW. of adjustment for existing as instructed. water conditions or temperature. Water, oil, or dirt in CO Remove contaminated CO supply. supply. Clean CO system (lines, regulators, etc.) using a mild detergent.

  • Page 48: Only Syrup Dispensed

    Trouble Probable Cause Remedy ONLY SYRUP DISPENSED. Plain water inlet supply line Open plain water inlet supply line shutoff valve closed. shutoff valve. CARBONATOR MOTORS Place switch in ‘ ‘ ON’ ’position. power switch in ‘ ‘ OFF’ ’ position. Water filter clogged.

  • Page 49: Water Pump Motor Operates But Water Pump Does Not Pump Water

    Trouble Probable Cause Remedy WATER PUMP MOTOR Water pump inlet water Clean or replace water strainer OPERATES BUT WATER strainer screen dirty. screen as instructed PUMP DOES NOT PUMP PUMP DOES NOT PUMP Kinked water supply line. Straighten water supply line. WATER Restriction between water Remove restriction.

  • Page 50: Valve

    Trouble Probable Cause Remedy COMPRESSOR DOES NOT No voltage to main control Check for loose or broken wiring. OPERATE. (CON’ T) board. Check 240/24 VAC power transformer for 24 VAC output. (see NOTE below) Temperature sensor is shorted Check for loose, broken, or or open circuit.

  • Page 51: Condenser Fan Motor Not Operating

    Trouble Probable Cause Remedy CONDENSER FAN MOTOR Jumper cord loose or Tighten connections or replace NOT OPERATING disconnected from condenser cord fan motor or terminals inside control box. Broken wire in cord. Fan blade obstructed Remove obstruction. Inoperative condenser fan Replace condenser fan motor.
  • Page 52 IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship un- der normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire prod- uct, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number, serial number and the date of purchase.
  • Page 53 IMI CORNELIUS INC. CORPORATE HEADQUARTERS: One Cornelius Place Anoka, Minnesota 55303-6234 (612) 421-6120 (800) 238-3600...

Table of Contents