AURORAR10,000 PLUS COOLING UNIT Installation/Service Manual (R-404A REFRIGERANT) 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.
TABLE OF CONTENTS Page SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 RECOGNIZE SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDERSTAND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 FOLLOW SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO2 (CARBON DIOXIDE) WARNING . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (cont’d) Page DISPENSING STATION ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING WATER FLOW RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 17 ADJUSTING WATER-TO-SYRUP ‘‘RATIO’’OF DISPENSED PRODUCT . INSTALLING LINE IDENTIFICATION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATORS INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (cont’d) Page DOUBLE LIQUID CHECK VALVE ASSEMBLIES YEARLY MAINTENANCE (OR AFTER WATER SYSTEM DISRUPTIONS) . . . . . . . . . . . . . . . . . . . . . . . 27 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOTE CONDENSER COIL AND FAN ASSEMBLY MAINTENANCE . . . . . . . PERIODIC CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING CONDENSER COIL . . . . . . . .
TABLE OF CONTENTS (cont’d) Page COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM SUFFICIENT ICE BANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 CONDENSER FAN MOTOR NOT OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . AGITATOR MOTOR NOT OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY INFORMATION Recognize Safety Information This is the safety-alert symbol. When you see this symbol on our machine or in this manual, be alert to the potentially of personal injury. Follow recommended precautions and safe operating practices. Understand Signal Words A signal word - DANGER, WARNING, OR CAUTION is used with the safety-alert symbol. DANGER identifies the most serious hazards. Safety signs with signal word DANGER or WARNING are typically near specific hazards.
THIS PAGE LEFT BLANK INTENTIONALLY 312022000 2
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 troubleshooting this equipment.
FIGURE 1. AURORAR 10,000 PLUS COOLING UNIT Table 1. Design Data COOLING UNIT DATA Cooling Unit Part Numbers; 60 HZ UNIT: Standard (air-cooled) Cooling Unit Equipped with Internal Condenser Coil and Fan Assembly. Cooling Unit (water-cooled) Equipped With Water-Cooled Condenser Cooling Unit Requiring Connection to a Remote Condenser Coil and Fan Assembly. 50 HZ UNIT: Standard (air-cooled) Cooling Unit with Internal Condenser Coil and Fan Assembly.
Table 1.
COOLING UNIT REQUIRING CONNECTION TO A REMOTE CONDENSER COIL AND FAN ASS’Y (see Figure 9) NOTE: The Remote Condenser Coil and Fan Assembly (P/N 4000) is a 208/230 VAC, 50/60 HZ Unit that may be used with either Cooling Units (P/N 4004, a 60 HZ Unit) or (P/N 4005, a 50 HZ Unit) which require connection to a Remote Condenser Coil and Fan Assembly. The Cooling Unit refrigeration system is cooled by a Remote Condenser Coil and Fan Assembly (P/N 4000) that is authorized by IMI Cornelius Inc.
7 312022000 FIGURE 2.
THIS PAGE LEFT BLANK INTENTIONALLY 312022000 8
INSTALLATION This section covers unpacking and inspection, selecting location, installing the 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.
Locate the Cooling Unit so the following requirements are satisfied. 1. Allow the shortest possible insulated python route from the Cooling Unit to the Dispensing Station location. 2. Cooling Unit Requiring Connection to a Remote Rooftop Condenser Coil and Fan Assembly. Allow the shortest possible refrigeration lines (not to exceed 50-feet in length) route from the Remote Condenser Coil and Fan Assembly to the Cooling Unit. 3.
NOTE: An optional Cooling Unit Stand (P/N 309309069) is available to elevate the Cooling Unit up and off the floor. 1. Place Cooling Unit in location approximately 36-inches out from operating location to allow access all around the Unit. 2. Remove four screws securing the Cooling Unit top cover, then remove the cover.
3. 50 HZ Cooling Unit. Connect (Refer to Cooling Unit nameplate for power circuit requirements) power circuit from a 40-amp minimum rated disconnect switch (not provided) fused at 40-amps (maximum) with ELCB to terminals wires inside of the Cooling Unit. COOLING UNIT MUST BE PROPERLY GROUNDED AND POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS. DO NOT CONNECT ELECTRICAL POWER TO COOLING UNIT AT THIS TIME.
1. Before connecting City plain water source line to the Cooling Unit, open the 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 the Cooling Unit 3/8-in.
CONNECTING COOLING UNIT PLAIN WATER OUTLET LINES TO INSULATED PYTHON PLAIN WATER LINES (see Figure 2) Connect Cooling Unit plain water outlet lines to insulated python plain water lines using BARBED CONNECTORS (item 2). Secure connections with TUBING CLAMPS (item 1).
5. Route Cooling Unit water tank overflow hose to a permanent floor drain. 6. Cooling Unit with Water-Cooled Refrigeration System. Route end of the Cooling Unit refrigeration cooling coil drain line to and connect to a permanent drain. 7. Seal area around drain and overflow hoses where they exit from the Unit using Dow Corning (RTV 731) or equivalent. PREPARING COOLING UNIT FOR OPERATION 1. Make sure plug in end of the Cooling Unit water tank drain hose is secure. 2.
7. Cooling Unit with Water-Cooled Refrigeration System. IMPORTANT NOTICE Water flow rate through the refrigeration cooling coil varies due to pressure change on the high side of the refrigeration compressor which influences opening and closing of the variable water regulator (see Figure 9). The variable water regulator must be adjusted to maintain 240-psi refrigeration high-side pressure.
15. Connect soft drink tanks into the syrup systems. 16. Dispense from the dispensing station dispensing valves until product is dispensed. LEAK CHECK AND INSULATING COOLING UNIT OUTLET LINES 1. Check all CO2, plain and carbonated water, and syrup connections for leaks and repair if evident. 2. Make sure the Cooling Unit outlet lines connections to the insulated python lines are well insulated. 3. Install the Cooling Unit top cover and secure with two screws.
THIS PAGE LEFT BLANK INTENTIONALLY 312022000 18
OPERATORS INSTRUCTIONS This section covers operating controls, daily pre-operation check, adjustments, replenishing CO2 and syrup supplies, cleaning and sanitizing, Cooling Unit maintenance, Remote Condenser Coil and Fan Assembly maintenance, lubrication, and servicing CO2 gas check valves. wiring. WARNING: Disconnect electrical power to the Cooling Unit and the Remote Condenser Coil and Fan Assembly to prevent personal injury before attempting any internal maintenance.
DAILY PRE-OPERATION CHECK 1. Make sure the CO2 cylinder regulator assembly 1800-psi gage indicator is not in the shaded (‘‘change CO2 cylinder’’) portion of the dial. If so, the CO2 cylinder is almost empty and must be replaced. 2. Sufficient syrup supply in all the soft drink tanks. If not, replenish the syrup supply as instructed.
COOLING UNIT MAINTENANCE COOLING UNIT WITH INTERNAL CONDENSER COIL AND FAN ASS’Y Air to cool the Cooling Unit internal condenser coil is drawn in through the end access panel on end of the Unit and is exhausted out through the front and rear access panels on the Unit. The Cooling Unit condenser coil surface area must be cleaned every 30-days as instructed in the SERVICE AND MAINTENANCE section of this manual.
Area on top of and around the Remote Condenser Coil and Fan Assembly must be kept free of obstructions at all times. The Condenser coil must be cleaned as instructed in the SERVICE AND MAINTENANCE section of this manual to maintain proper cooling of the coil.
SERVICE AND MAINTENANCE This section describes the Service and Maintenance procedures to be performed on the Cooling Unit and the Remote Condenser Coil and Fan Assembly. WARNING: Disconnect electrical power to the Cooling Unit and the Remote Condenser Coil and Fan Assembly to prevent personal injury before attempting any Cooling Unit or Remote Condenser Coil and Fan Assembly internal maintenance. Only qualified personnel should service the internal components or electrical wiring.
COOLING UNIT EQUIPPED WITH WATER-COOLED REFRIGERATION SYSTEM The Cooling Unit equipped with a water-cooled refrigeration system requires no cleanning of it’s condenser coil. COOLING UNIT MAINTENANCE PERIODIC CLEANING Periodically operate the carbonator tank relief valve. Periodically wash all external surfaces of the Cooling Unit, rinse with clean water, then wipe dry with a clean soft cloth. DO NOT USE ABRASIVE TYPE CLEANERS.
SYSTEM ANALYZER TEST PLUG *HIGH-PRESSURE SENSING CUTOUT SWITCH LOCATED INSIDE CONTROL BOX (WATER-COOLED) ELECTRICALCONTROL BOX CIRCULATING AIR OUT CIRCULATION MOTOR SWITCH CARBONATOR MOTOR SWITCH REFRIGERATION POWER SWITCH FRONT ACCESS PANEL CIRCULATING AIR IN CIRCULATING AIR OUT END ACCESS PANEL MODELS: 4002 4003 *561400006 *561400007 *Water-Cooled Refrigeration System. FIGURE 4.
AIR FLOW ROMOTE ROOFTOP CONDENSER COIL AND FAN ASSEMBLY REFRIGERATION LINES (ITEM 4) SYSTEM ANALYZER TEST PLUG ELECTRICALCONTROL BOX HIGH-PRESSURE SENSING CUTOUT SWITCH (LOCATED INSIDE CONTROL BOX) REFRIGERATION LINE CONNECTIONS (ON BACK SIDE OF COOLING UNIT) CIRCULATION MOTOR SWITCH CARBONATOR MOTOR SWITCH REFRIGERATION POWER SWITCH FRONT ACCESS PANEL CIRCULATING AIR IN CIRCULATING AIR OUT END ACCESS PANEL MODELS: 4004 4005 FIGURE 5.
3. Make sure end of the water tank drain hose is routed to the floor drain, then remove plug from end of the hose and allow water to drain from tank. CAUTION: Never use an ice pick or other instruments to remove ice from the evaporator coils. Such practice can result in punctured refrigeration circuit. 4. Allow ice bank to melt. Hot water may be used to speed melting. 5. Thoroughly rinse inside of the water tank with clean water. 6. Install plug in end of the water tank drain hose. 7.
1 3 2 6 4 5 Index Part Name No. No. 1 317963 Housing 2 312415 Flat Washer, Stainless Steel 3 *312418 Ball Seat (quad ring) 4 312419 Ball 5 312196 Spring 6 317965 Retainer * Install new ball seat at each servicing. FIGURE 6. LIQUID CHECK VALVE ASSEMBLY 10. Assemble the check valves together. DO NOT OVERTIGHTEN. 11. Install the double liquid check valve assembly in the plain water line connected between the plain water cooling coil and the carbonated water tank. 12.
CLEANING CONDENSER COIL CAUTION: Circulating air, required to pass through and cool the condenser coil, is drawn in at the bottom and is exhausted out through the top of the Unit. Failure to clean the condenser coil will cause the refrigeration system to overheat. 1. Disconnect electrical power to the Cooling Unit at the disconnect switch. 2. Clean bottom side of the condenser coil using a vacuum cleaner, whisk broom, or soft-bristle brush to remove any debris from the coil. 3.
Low-Calorie (diet) Syrup Soft Drink Tank CO2 Regulator. Adjust low-calorie (diet) soft drink tank secondary CO2 regulator for low-calorie drink at 10-psig for syrup lines up to 30-feet in length. Syrup lines longer than 30-feet in length may require a slightly higher CO2 regulator setting to 12-psig maximum. Excessive pressure may cause low-calorie syrup carbonation resulting in foam.
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. DO NOT USE ABRASIVE CLEANERS. 5. Remove nozzle and syrup diffusers from the dispensing valves. Place nozzles and syrup diffusers in sanitizing solution. 6. Wash the nozzles and syrup diffusers in sanitizing solution, then rinse them with potable water. 7.
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. 9. Flush detergent solution out of the syrup system and dispensing valve as follows: A. Place waste container under applicable dispensing valve. B. Activate the dispensing valve for one minute to purge all detergent solution and flush out the syrup system. C.
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: A. Place waste container under applicable dispensing valve. B. Activate the dispensing valve for one minute to purge all sanitizing solution out of the syrup system and the dispensing valve. C.
3. Unfasten safety chain and remove the empty CO2 cylinder WARNING: To avoid personal injury and/or property damage, always secure the CO2 cylinder in an upright position with a safety chain to prevent it from falling over. Should the valve become accidentally damaged or broken off, the CO2 cylinder can cause serious personal injury. 4. Position CO2 cylinder and secure with a safety chain. 5.
CLEANING CO2 SYSTEM GAS CHECK VALVES SECONDARY CO2 REGULATORS AND CO2 MANIFOLD CO2 GAS CHECK VALVES (see Figures 2 and 7) The secondary CO2 regulators and the CO2 manifold CO2 gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO2 system. ALWAYS REPLACE BALL SEAT (QUAD RING SEAL) EACH TIME THE GAS CHECK VALVES ARE SERVICED.
REMOTE CONDENSER COIL AND FAN ASS’Y 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. FIGURE 8.
COOLING WATER OUT (TO DRAIN) ADJUSTMENT SCREW COOLING WATER IN (CITY PLAIN WATER) *VARIABLE WATER REGULATOR *WATER FLOW RATE THROUGH COIL WATER-COOLED REFRIGERATION COOLING COIL ASS’Y VARIES DUE TO PRESURE CHANGE ON HIGH SIDE OF COMPRESSOR WHICH INFLUENCES OPENING AND CLOSING OF VARIABLE WATER REGULATOR. ADJUST VARIABLE WATER REGULATOR TO MAINTAIN 240-PSI REFRIERATION HIGH-SIDE PRESSURE. AIR-COOLED REFRIGERATION CONDENSER COIL FIGURE 9.
312022000 38 FIGURE 10.
39 312022000 FIGURE 11.
THIS PAGE LEFT BLANK INTENTIONALLY 312022000 40
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 CO2 system, stop dispensing, shut off the CO2 supply, then relieve the system pressure before proceeding.
Trouble Probable Cause Remedy DISPENSED PRODUCT CARBONATION TOO LOW (CONT’D). B. Water, oil, or dirt in CO2 supply. B. Remove contaminated CO2 supply. Clean CO2 system (lines, regulators, etc.) using a mild detergent. Replenish with a clean CO2 supply DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT FOAMS IN CUP. A. Oil film or soap scum in cups. A. Use clean cups. B. Ice used for finished drink is sub-cooled. B. Do not use ice directly from freezer.
Trouble WARM PRODUCT BEING DISPENSED. Probable Cause Remedy A. Carbonated water circulating pump CIRCULATING MOTOR power switch in ‘‘OFF’’ position. position. A. Place circulating pump CIRCULATING MOTOR power switch in ‘‘ON’’ B. Inoperable carbonated water circulating pump or motor. B. Replace pump or motor. TROUBLESHOOTING CARBONATOR WATER PUMP MOTOR WILL NOT OPERATE. WATER PUMP MOTOR WILL NOT SHUT OFF. ERRATIC CYCLING OF CARBONATOR.
Trouble WATER PUMP MOTOR OPERATES BUT WATER PUMP DOES NOT PUMP WATER (CONT’D). WATER PUMP CAPACITY TOO LOW. Probable Cause Remedy C. Restriction between water pump outlet and carbonator tank inlet. C. Remove restriction. D. Foreign object in water pump bypass. D. Clean bypass. (Note: Count number of turns bypass screw makes when removing and install same number of turns). E. Water pump worn out. E. Replace water pump. A. Water supply capacity too low. A.
Trouble COMPRESSOR DOES NOT OPERATE (CONT’D). Probable Cause Remedy M. No voltage to control board. M. Check for loose or broken wiring. Check 208/240 VAC power transformer for 24 VAC output. (see NOTE below). N. Inoperable control board or water/ice sensor PC board. N. Replace control board. O. Inoperable ICE SENSOR. O. Replace ICE SENSOR. P. EVAP IN, COND OUT, or EVAP OUT sensor is open, shorted, or out of temperature range. P. Replace inoperable sensor. Q.
Trouble COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM SUFFICIENT ICE BANK (CONT’D) Probable Cause G. Inoperative control board. No output from board to solenoids. Remedy G. Check LED’s on control board to see if they are modulating. Check for 24V output to pulse modulating expansion valve (see WIRING DIAGRAM). If control board green LED is on and yellow LED Is flashing; but no 24V output, replace board. CONDENSER FAN MOTOR NOT OPERATING AGITATOR MOTOR NOT OPERATING. 312022000 A.
WARRANTY IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius, Remcor or Wilshire product, 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. IMI Cornelius Offices AUSTRALIA D P.O.
IMI CORNELIUS INC.
