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Page 1: 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- - 93 Ó AURORA 10,000 COOLING UNIT PRINTED IN U.S.A... -
Page 2: Table Of Contents
........... REMOTE CONDENSER COIL AND FAN ASS’ Y INSTALLING REMOTE CONDENSER COIL AND FAN ASS’ Y INSTALLING COOLING UNIT PLACING COOLING UNIT IN LOCATION CONNECTING REMOTE CONDENSER COIL AND FAN ASS’... - Page 3 ........... . REMOTE CONDENSER COIL AND FAN ASS’ Y MAINTENANCE...
- Page 4 ............. . FIGURE 1. AURORAR10,000 COOLING UNIT FIGURE 2.
- Page 5 TABLE OF CONTENTS (cont’ d) FIGURE 14. WIRING DIAGRAM (LOW-VOLTAGE SYSTEM) FIGURE 15. WIRING DIAGRAM (HIGH-VOLTAGE SYSTEM) TABLE 1. DESIGN DATA ..........TABLE 2.
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Page 6: General Information
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. - Page 7 COOLING UNIT MODEL NUMBERS: 60 HZ Unit: Standard Cooling Unit with Internal Condenser Coil and Fan Assembly Cooling Unit Requiring Connection to Remote Condenser Coil and Fan Assembly 50 HZ Unit: Standard Cooling Unit with Internal Condenser Coil and Fan Assembly...
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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 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. -
Page 9: Figure 2. Flow Diagram (Typical Installation)
CARB CARB PLAIN 300381000... -
Page 10: Installation
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. -
Page 11: Remote Condenser Coil And Fan Ass' Y
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. -
Page 12: Connecting Remote Condenser Coil And Fan Ass' Y
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... - Page 13 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.
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Page 14: Connecting Plain Water Inlet Supply Line To 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 WATER SUPPLY SHALL BE SIZED, INSTALLED AND MAINTAINED ACCORDING TO FEDERAL, STATE, AND LOCAL LAWS. -
Page 15: Connecting Cooling Unit Syrup Outlet Lines To Insulated Python Syrup Lines
SELECTING LOCATION. MAKE SURE THERE ARE NO KINKS IN SYRUP INLET LINES, INSULATED PYTHON INTERNAL LINES, CO 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. -
Page 16: Preparing Cooling Unit For Operation
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. -
Page 17: Starting Cooling Unit Refrigeration System
Place Cooling Unit REFRIGERATION POWER switch in ‘ ‘ ON’ ’(up) position. Refrigeration compressor, condenser fan motor, and agitator motor will start and begin forming an ice bank. When full ice bank has been formed, compressor and condenser fan motor will stop but, agitator motor will continue to operate circulating ice water bath in water tank. -
Page 18: Leak Check And Insulating Cooling Unit Outlet Lines
LEAK CHECK AND INSULATING COOLING UNIT OUTLET LINES 1. Check all CO , plain and carbonated water, and syrup connections for leaks and repair if evident. 2. Make sure Cooling Unit outlet lines connections to insulated python lines are well insulated. 3. - Page 19 THIS PAGE LEFT BLANK INTENTIONALLY 300381000...
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Page 20: Operators Instructions
OPERATORS INSTRUCTIONS This section covers operating controls, daily pre-operation check, adjustments, replenishing CO supplies, cleaning and sanitizing, Cooling Unit maintenance, Remote Condenser Coil and Fan Assembly (if applicable) maintenance, lubrication, and servicing CO WARNING: Disconnect electrical power to Cooling Unit to prevent personal injury before attempting any Cooling Unit or Rooftop Condenser Coil and Fan Assembly (if applicable) internal maintenance. -
Page 21: Daily Pre-Operation Check
Remote Condenser Coil and Fan Assembly. If refrigeration system does not automatically restart itself after system has cooled down, high-pressure sensing cutout switch reset button (see Figure 6) will have to be pressed to reset switch. -
Page 22: Replenishing Syrup Supply
NOTE: When indicator on CO cylinder regulator assembly 1800-psi gage is in shaded (‘ ‘ change CO cylinder’ ’ ) portion of the dial, CO be checked daily and if necessary, replenished as instructed. REPLENISHING SYRUP SUPPLY Syrup supply should be checked daily and if necessary, replenished as instructed. CLEANING AND SANITIZING DAILY CLEANING Perform daily cleaning of dispensing station as instructed in dispensing station Installation Instructions. -
Page 23: Cooling Unit Carbonated Water Circulating Pump Motor Lubrication
FOR PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE. Area on top of and around Remote Condenser Coil and Fan Assembly must be kept free of obstructions at all times. Condenser coil must be cleaned as instructed to maintain proper cooling of coil. -
Page 24: Service And Maintenance
FOR PROLONGED PERIOD OF TIME COULD RESULT IN COMPRESSOR FAILURE. Clean Remote Condenser Coil and Fan Assembly condenser coil every 30 days, as instructed. Make sure area on top and around unit are kept free of obstructions at all times. Air must be allowed to enter and leave unit to remove heat from condenser coil. -
Page 25: Cooling Unit Maintenance
2. Clean bottom side of condenser coil using vacuum cleaner, whisk broom, or soft-bristle brush to remove any debris from coil. 3. Check and make sure fan blade moves freely and are not touching any surfaces, are not bent, or out of balance. Check and make sure wire guard is properly installed and securely fastened. -
Page 26: Changing Ice Water Bath
1. Disconnect electrical power from Cooling Unit at disconnect switch. 2. Remove two screws securing Cooling Unit top cover, then remove cover. 3. Using flashlight, inspect ice water bath and ice bank for cleanliness, ice water bath should be clear and ice bank free of foreign particles. -
Page 27: Condenser Coil And Fan Assembly)
CARBONATOR TANK(2) WATER PUMP MOTOR(2) COMPRESSOR CONDENSER COIL FIGURE 5. PARTS IDENTIFICATION (STANDARD COOLING UNIT W/INTERNAL CONDENSER COIL AND 300381000 PLAIN WATER INLET FAN ASSEMBLY) TOP COVER TOP COVER RETAINING SCREW(2) HYDRO BOOSTR CARBONATED WATER CIRCULATING PUMP CIRCULATING PUMP MOTOR... -
Page 28: Figure 6. Parts Identification (Cooling Unit Requiring Connection To Remote Condenser Coil And Fan Assembly)
CONNECTORS(2) WATER PUMP MOTOR(2) CARBONATOR TANKS(2) COMPRESSOR FIGURE 6. PARTS IDENTIFICATION (COOLING UNIT REQUIRING CONNECTION TO REMOTE CONDENSER COIL AND FAN ASSEMBLY) COIL AND FAN ASS’ Y (ITEM 4 AND 5) COMPRESSOR COOLING FAN TOP COVER RETAINING SCREW(2) CARBONATED WATER... - Page 29 4. Remove two screws securing Cooling Unit top cover,then remove cover for access to carbonators water pumps. CAUTION: Condenser Coil and Fan Assembly condenser coil must be cleaned every 30 days. Excessive accumulation of debris on condenser coil will restrict cooling air flow through coil and cause coil and refrigeration system overheat.
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Page 30: Figure 7. Carbonator Liquid Level Control Switches
13. Reassemble liquid check valve as shown in Figure 9. ALWAYS INSTALL NEW BALL SEAT (QUAD RING) P/N 312418-000. 14. Install check valve in carbonated water tank carbonated water outlet line. 15. Repeat procedures in Servicing Carbonator Water Pump Water Strainer Screen and this paragraph for servicing water strainer screen and liquid check valves on other carbonator. -
Page 31: Carbonated Water Circulating Pump Motor Lubrication
CARBONATED WATER CIRCULATING PUMP MOTOR LUBRICATION (see applicable Figure 5 or 6) Carbonated water circulating pump motor bearings must be oiled periodically. Refer to oiling instructions on motor. DO NOT OVER OIL. ADJUSTMENTS NOTE: To readjust CO regulator to a lower setting, loosen adjusting screw lock nut, then turn screw to the left (counterclockwise) until pressure gage reads 5-psi lower than new setting will be. -
Page 32: Secondary Co2 Regulators
Index Part Name 317963000 Housing 312415000 Flat Washer, Stainless Steel *312418000 Ball Seat (quad ring) 312419000 Ball 312196000 Spring 317965000 Retainer FIGURE 9. LIQUID CHECK VALVE ASSEMBLY SECONDARY CO REGULATORS (see Figure 2) Carbonator Secondary CO Regulator. Adjust carbonators secondary CO Turn adjusting screw to the right (clockwise) until regulator gage registers nominal 90-psi, then tighten adjusting screw locknut. -
Page 33: Water Flow Rate
WATER FLOW RATE Refer to Installation Instructions provided with dispensing station for dispensing valve water flow rate adjustment instructions. WATER-TO-SYRUP ‘ ‘ RATIO’ ’OF dISPENSED PRODUCT Adjust dispensing station dispensing valves for Water-to-Syrup ‘ ‘ Ratio’ ’of dispensed product as instructed in dispensing station Installation Instructions. -
Page 34: Sanitizing Post-Mix Syrup Systems
SANITIZING POST-MIX SYRUP SYSTEMS IMPORTANT: Only qualified Service Personnel should perform sanitizing procedure on the post-mix syrup systems. The post-mix syrup systems should be sanitized every 90-days using a non-scented household liquid bleach containing a 5.25 % sodium hypochlorite concentration. Proceed as follows to sanitize the post-mix syrup systems. - Page 35 Continue to activate the dispensing valve in cycles (“ ON”for 15-seconds, “ OFF” , then “ ON”for 15-seconds). Repeat “ ON”and “ OFF”cycles for 15-cycles. 10. Connect potable water source to the remaining syrup systems and flush detergent solution out of the syrup systems as instructed in step NO TAG preceding.
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Page 36: Replenishing Co2 Supply
21. Repeat steps NO TAG and NO TAG preceding to purge sanitizing solution out of the remaining syrup systems and dispensing valves. 22. Remove potable water source from the syrup system. STEP 5. PURGE WATER OUT OF SYRUP SYSTEMS (RESTORE OPERATION) 23. -
Page 37: Replenishing Syrup Supply
6. Open (counterclockwise) CO fully to back-seat valve. (Back-seating valve prevents leakage around valve shaft.) REPLENISHING SYRUP SUPPLY NOTE: The following instructions are applicable only when replenishing same flavor syrup. Refer to SYRUP FLAVOR CHANGE when changing syrup flavor. 1. Disconnect empty soft drink tank from syrup system. 2. -
Page 38: Figure 11. Refrigeration Flow Diagram (Standard Cooling Unit W/Internal Condenser Coil And Fan Ass' Y)
FIGURE 11. REFRIGERATION FLOW DIAGRAM (STANDARD COOLING UNIT W/INTERNAL CONDENSER COIL AND FAN ASS’ Y) 300381000... -
Page 39: Figure 12. Refrigeration Flow Diagram (Cooling Unit Requiring Connection To Remote Condenser Coil And Fan Ass' Y)
FIGURE 12. REFRIGERATION FLOW DIAGRAM (COOLING UNIT REQUIRING CONNECTION TO REMOTE CONDENSER COIL AND FAN ASS’ Y) 300381000... -
Page 40: Figure 13. Wiring Diagram (Low-Voltage System)
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Page 44: 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 pressure before proceeding. -
Page 45: Adjustment Of Dispensing Valve Syrup Flow Regulator Does
Trouble ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES NOT DECREASE TO DESIRED WATER-TO-SYRUP ‘ ‘ RATIO’ ’ . DISPENSED PRODUCT CARBONATION TOO LOW. DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT FOAMS IN CUP. NOTE: Crushed ice also causes dispensing problems. When finished drink hits sharp edges of ice, carbonation is released from finished drink. -
Page 46: Only Syrup Dispensed
Trouble ONLY CARBONATED WATER DISPENSED (CONT’ D) ONLY SYRUP DISPENSED. WARM PRODUCT BEING DISPENSED. Trouble TROUBLESHOOTING CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE. WATER PUMP MOTOR WILL NOT SHUT OFF. Probable Cause Dispensing valve syrup flow regulator, soft drink tank quick disconnect, or syrup lines restricted. -
Page 47: Erratic Cycling Of Carbonator
Trouble ERRATIC CYCLING OF CARBONATOR. WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP PUMP DOES NOT PUMP WATER WATER PUMP CAPACITY TOO LOW. TROUBLESHOOTING REFRIGERATION SYSTEM COMPRESSOR DOES NOT OPERATE. 300381000 Probable Cause Binding or damaged balance mechanism. Balance mechanism spring obstructed or ‘... -
Page 48: Compressor Operates Continuously But Does Not Form Sufficient Ice Bank
Repair or replace wire. Confirm which temperature sensor has failed by using the Aurora Series System Analyzer (P/N 309197-000). M. Repair or replace wire. Reduce amount of drinks drawn per given time. Relocate unit or check and if necessary, clean air filter as instructed. -
Page 49: Condenser Fan Motor Not Operating
BANK (CONT’ D) NOTE: If overload protector cuts out compressor, condenser fan motor will continue to operate otherwise; troubleshooting condenser fan motor problem is same as for ‘ ‘ COMPRESSOR DOES NOT OPERATE’ ’paragraph plus the following: CONDENSER FAN MOTOR NOT OPERATING. -
Page 50: Warranty
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 52 IMI CORNELIUS INC. CORPORATE HEADQUARTERS: One Cornelius Place Anoka, Minnesota 55303-6234 (612) 421-6120 (800) 238-3600...