Download Cornelius SID851A/250S Installation manual

IMI CORNELIUS REMCOR INC g 500 REGENCY DRIVE g GLENDALE HEIGHTS, IL 60139–2268
Telephone (800) 551–4423
Facsimile (800) 519–4423
Installation Manual
DURAFLEX ICE/BEVERAGE DISPENSER
Model: DF-250 BCP
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. 620919541
Revised: July, 2001
Revision A
Control Code A
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
 IMI CORNELIUS INC; 2001
PRINTED IN U.S.A
TABLE OF CONTENTS
Page
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
BLOWN FUSE OR CIRCUIT BREAKER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
SLUSHY ICE. WATER IN HOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
BEVERAGES DO NOT DISPENSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
BEVERAGES TOO SWEET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
BEVERAGES NOT SWEET ENOUGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
BEVERAGES NOT COLD (UNITS WITH BUILD-IN COLD PLATE). . . . . . . . . . .
11
NO ICE DISPENSED FROM ICE PORTION CONTROLLER . . . . . . . . . . . . . . . .
11
NO ICE DISPENSED FROM ICE PORTION CONTROLLER (CONTINUED) . . .
12
NO ICE DISPENSED FROM MANUAL ICE DISPENSE PUSHBUTTON SWITCH 12
ICE DISPENSING DURING AUTOMATIC AGITATION . . . . . . . . . . . . . . . . . . . . . .
12
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
LIST OF FIGURES
Page
FIGURE 1. PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
FIGURE 2. DRIP TRAY DRAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
FIGURE 3. MOUNTING TEMPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
FIGURE 4. FLOW DIAGRAM (BEVERAGE VALVE MANIFOLD R TO L 3.1.2.2)
6
FIGURE 5. FLOW DIAGRAM (PNEUMATIC ICE GATE) . . . . . . . . . . . . . . . . . . . .
7
FIGURE 6. WIRING DIAGRAM (115 VOLT UNIT) . . . . . . . . . . . . . . . . . . . . . . . . . .
8
FIGURE 7. WIRING SCHEMATIC (115 VOLT UNIT) . . . . . . . . . . . . . . . . . . . . . . . .
9
i
RETAINER
ICE BIN COVER
ICE AGITATOR
MANUAL ICE DISPENSE
RED PUSH BUTTON SWITCH
ICE PORTION
CONTROL MODULE
BEVERAGE FAUCET
ON/OFF SWITCH
REMOVABLE STRAW
HOLDER PANEL
MANUAL/AUTO ICE
TOGGLE SWITCH
LID/STRAW
HOLDER
CUP REST
DRIP TRAY
BEVERAGE FAUCETS (8)
LOWER ACCESS
PANEL
FIGURE 1. PARTS IDENTIFICATION
1
620919541
SAFETY PRECAUTIONS
Always: Disconnect power to the dispenser before servicing or cleaning.
Never: Place hands inside of hopper or gate area without disconnecting power to the dispenser. Agitator rotation
occurs automatically when dispenser is energized!
This ice dispenser has been specifically designed to provide protection against personal injury and eliminates
contamination of ice.To insure continued protection and sanitation, observe the following:
ALWAYS: Be sure the removable lid is properly installed to prevent unauthorized access to the hopper interior
and possible contamination of the ice.
ALWAYS: Be sure the upper and lower front panels are securely fastened.
ALWAYS: Keep area around the dispenser clean of ice cubes.
Dispenser cannot be used with crushed or flaked ice.
Use of bagged ice which has frozen into large chunks can void warranty. The
dispenser agitator is not designed to be an ice crusher. Use of large chunks of
ice which ”jam up” inside the hopper will cause failure of the agitator motor and
damage to the hopper. If bagged ice is used, it must be carefully and completely
broken into small, cube-sized pieces before filling into the dispenser hopper.
CAUTION:
DESCRIPTION
The “DURAFLEX” series of ice dispensers solves your ice and beverage service needs in a sanitary, space saving, economical way. Designed to be manually filled with ice from any remote ice making source, these dispensers
will dispense cubes (up to 1-1/4 in. in size), cubelets, and hard-chipped or cracked ice; and in addition, several
flavors of post–mix beverages. The unit includes beverage faucets and a cold plate and is designed to be supplied direct from syrup tanks and a carbonator, with no additional cooling required.
SPECIFICATIONS
Model
DF250 BCP
B (Beverage Faucets)
C (Cold Plate)
P (Pneumatic ice portioning system)
Ice storage
250 pounds
Maximum No. of
8
Beverage Faucets
Available
Cold Plate (Built–In)
Yes
Electrical
120/1/60, 3.5 Amps
Dimensions
30 in. Wide X 30-11/16 in. Deep X 39-5/8
in. High
620919541
2
INSTALLATION INSTRUCTIONS
1. Locate the dispenser indoors on a level counter top.
The ice dispenser must be sealed to the counter. The MOUNTING TEMPLATE (see Figure 3)
indicates where openings can be cut in the counter. Locate the desired position for the dispenser, then
mark the outline dimensions on the counter using the MOUNTING TEMPLATE. Cut openings in the
counter.
Rotate the line support bracket, located under base, to the up position and route all the lines below the
bracket.
Apply a continuous bead of National Sanitation Foundation (NSF) listed silastic sealant (Dow 732 or
equal) approximately 1/4” inside of the unit outline dimensions and around all openings. Then, position
the unit on the counter within the outline dimensions. All excess sealant must be wiped away
immediately.
2. The beverage tubes, drain tube and power cord are routed through the large opening in the bottom of the
unit. See the MOUNTING TEMPLATE (see Figure 3), for locating the required clearance hole in the counter
for these utility lines.
3. DRIP TRAY DRAIN ASSEMBLY (see Figure 2). Route the drain tube to an open drain with the end of the
tube above the “flood” level of the drain. Use the tubing, fittings, clamps, and insulation provided with the Dispenser to assemble the drain. The completed drain line must pitch continuously downward and contain no
“traps” or improper drainage will result.
NOTE: This equipment must be installed with adequate backflow protection to comply with federal, state,
and local codes.
4. Connect the beverage system product tubes as indicated in the Flow Diagram. This work should be done by
a qualified Service Person. Any non-carbonated water tubing must be connected to the outlet of the check
valve.
Note: See the Flow Diagram (see Figure 4) or decal on lower front panel of the unit for the location of syrup and water connections.
Note: 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.
5. ICE PORTION CONTROLLER: Regulated CO2 gas pressure is required to operate the portion control dispensing system. Proceed as follows to connect the CO2 gas pressure source line to the dispenser.
A.
Connect and route the CO2 line from outlet side of the source regulator assembly up to the dispenser.
NOTE: That the minimum source-regulated pressure is 40 psig.
B.
Connect the CO2 source line to dispenser inlet line labeled “CO2“.
C.
The dispenser regulator outlet pressure is factory preset to 34 psig ± 2 psig DO NOT ADJUST.
IMPORTANT: Maximim CO2 operating pressure is 50 psig.
6. Clean the hopper interior (see Owner’s Manual P/N 620916502 for cleaning instructions).
7. Connect the power cord to a 120 volt, 60 cycle, 3–wire grounded receptacle.
3
620919541
SOLVENT BOND
HOSE CLAMP
DRIP TRAY DRAIN
FITTING
COUPLING
3/4 SOCKET X 3/4 FPT
BARB ADAPTER
1 BARB X 3/4 MPT
DRAIN LINE
1-IN. I.D. PLASTIC TUBING
(6 FT) WITH INSULATION
FIGURE 2. DRIP TRAY DRAIN ASSEMBLY
620919541
4
30
26–7/16
1–13/16
1–5/16
23
7/16
12
21–1/4
9
18–5/8
23–1/16
21–1/4
OPENING
29
30–11/16
3–1/2
REMOVABLE DRIP TRAY
Z STYLE
9–3/16
11–5/8
RECOMMENDED COUNTER OPENING SIZE
9.00 X 12.00 FOR UTILITIES AND
BEVERAGE TUBING. OPENING CAN BE LOCATED
ANYWHERE WITHIN THE SHADED AREA.
TO FRONT OF DRIP TRAY
ON COUNTERTOP
TO FRONT TOP OF
DRIP TRAY
FIGURE 3. MOUNTING TEMPLATE
5
620919541
NON–CARB WATER
620919541
CARB WATER
FAUCETS
CHECK
VALVE
WATER
WATER
OPTIONAL
PRESSURE
REGULATOR
POTABLE
WATER
SUPPLY
FILTER
WATER
CARBONATOR
WATER
INSTALL FOR
NON–CARB AS
REQUIRED
CO2
CARB WATER
6
FAUCETS VIEWED FROM FRONT OF UNIT
COLDPLATE
INLET
CONNECTIONS
OPTIONAL FOR
DIET DRINKS
OR ROOT BEER
WATER
5–15
PSIG
WATER
COLD PLATE
WATER
WATER
SYRUP TANKS
15–50 PSIG
PRESSURE
REGULATORS
ITEMS INSIDE BROKEN LINE INCLUDED WITH UNIT
NOTE: Refer to plumbing schematic located behind
lower splash panel.
FIGURE 4. FLOW DIAGRAM (BEVERAGE VALVE MANIFOLD R TO L 3.1.2.2)
CO2
CYLINDER
PNEUMATIC GATE SOLENOID VALVE
3-WAY NORMALLY CLOSED
FILTER–REGULATOR
(FACTORY-SET OUTLET
PRESSURE TO 32-36 PSIG)
CO2 SUPPLY
50 PSIG MAX.
7
ICE GATE CYLINDER REVERSE
SINGLE ACTING-SPRING EXTENDED
MANUAL OVERIDE SOLENOID VALVE
3-WAY NORMALLY CLOSED
620919541
FIGURE 5. FLOW DIAGRAM (PNEUMATIC ICE GATE)
INTERLOCK ICE CHUTE INTERRELAY
LOCK SWITCH
MOTOR
HEATER
5
BLK
BLK
TERMINAL
BOARD
A
7
L
N INCOMING POWER
E
GRN/YEL
B
GRN/YEL
TO GUSSET
HINGE GROUND
TERMINAL
BLK
BLK
WHT
WHT
BLK
BLK
WHT
BLK
WHT
BLK
WHT
TO EBOX
GROUND
SCREW
YEL
3
VIO
2
4
STARTING
RELAY
WHT
BLK
WHT
WHT
MOTOR START
CAPACITOR
DIODE
BLK
WHT
BLK
WHT
LINE
LINE
TRANSFORMER
TRANSFORMER
LOAD
LOAD
YEL
YEL/BLK
YEL
RED BLK
ORN/BLK ORN
WHT
WHT
YEL
YEL/BLK YEL
1 2
3 4 5
1 2
3 4 5
YEL
RED BLK
ORN/BLK ORN
BLK WHT
AGITATOR
MOTOR
BLK WHT
GRN/YEL
BEVERAGE
BEVERAGE
VALVE
VALVE
BLK WHT
TO EBOX
GROUND
SCREW
BLK WHT
BEVERAGE
BEVERAGE
VALVE
VALVE
BLK WHT
1
RED
WHT
BLK WHT
MANUAL
OVERRIDE
SOLENOID
2
TO EBOX
BEVERAGE
BEVERAGE
VALVE TYP.
VALVE TYP.
GROUND
SCREW
BRN
BLU
RED
BLK
ORN
1
BLU
2
PNEUNATIC
GATE SOLENOID
TO EBOX
GROUND
SCREW
1
2
TO EBOX
GROUND
SCREW
AGITATION
RELAY
3
RED
4
BLK
BLU GRN/YEL
BRN
ORN
RED
YEL
YEL
BLK
ORN
BLK BLK GRN
1 2 3 4 5 6 7 8 9
RED WHT BLU
1 2 3 4 5 6 7 8 9
MANUAL/AUTO ICE
TOGGLE SWITCH
WHT
ORN
ORN
BLK
YEL
RED
YEL
VIO
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
RED
WHT
ORN ORN
WIRE COLOR CHART
24
11
YEL YEL
LEGEND
DANGER!
ELECTRIC SHOCK HAZARD. DISCONNECT
POWER BEFORE SERVICING UNIT
SPLICE/QUICK CONNECT CONNECTION
GROUND
MALE HARNESS CONNECTOR
FEMALE HARNESS CONNECTOR
620919541
COM NO
PORTION CONTROLLER/
TOUCH PANEL
BLK
BEVERAGE VALVES 25
ON/OFF SWITCH 12
GRN/YEL
BLU
BRN
8
BLK
WHT
YEL
ORN
BRN
VIO
BLU
RED
GRN
GEN/YEL
BLACK
WHITE
YELLOW
ORANGE
BROWN
VIOLET
BLUE
RED
GREEN
GREEN W/YELLOW STRIP
MANUAL ICE
DISPENSE
SWITCH
FIGURE 6. WIRING DIAGRAM (115 VOLT UNIT)
BLK
L
N
120V
ICE CHUTE INTERLOCk
SWITCH
INTERLOCK RELAY
BEVERAGE
TRANSFORMER
BEVERAGE
TRANSFORMER
24VAC
24VAC
24VAC
BEV ON/OFF
SWITCH
BEV
VAL.
BEV
VAL.
BEV
VAL.
BEV
VAL.
BEV
VAL.
BEV
VAL.
BEV
VAL.
BEV
VAL.
FIGURE 7. WIRING SCHEMATIC (115 VOLT)
MANUAL OVERIDE
SOLENOID VALVE
MANUAL/AUTO ICE
TOGGLE SWITCH
24VAC
AGITATOR
RELAY
1
3
2
4
PORTION CONTROLLER/
TOUCH PANEL
TOUCH
PANEL
PNEUMATIC ICE GATE
SOLENOID VALVE
AGITATOR MOTOR
MANUAL ICE DISPENSE
SWITCH
O/L
3
R
2
S
4
START CAPACITOR
AGITATOR MOTOR
HEATER
9
MOTOR
START RELAY
620919541
THIS PAGE LEFT BLANK INTENTIONALLY
620919541
10
TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
WARNING: If repairs are to be made to the beverage 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. If repairs are to be made to the ice dispensing
system, make sure electrical power is disconnected from the unit.
Trouble
NOTE:
Probable Cause
Remedy
should your unit fail to operate properly, check that there is power to the unit and that the
hopper contains ice. If the unit does not dispense, check the following chart under the
appropriate symptoms(s) to aid in locating the defect.
BLOWN FUSE OR CIRCUIT
BREAKER.
A.
Short circuit in wiring (115V
circuit).
A.
Replace defective wiring.
B.
Defective agitator motor.
B.
Replace agitator motor.
A.
Blocked drain.
A.
Open–up/flush out drain.
B.
Unit not level.
B.
Level unit.
C.
Poor ice quality due to water
quality or ice maker problems.
C.
Install water filter system. For
Icemaker problems, consult
icemaker manual.
D.
Improper use of flaked ice.
D.
Replaced flaked ice with “cube
style ice (see page 2, Unit
Description).
A.
No 24 volt power to faucets.
A.
Check that beverage switch is
“on”. Check 24V transformers.
B.
No CO2 pressure.
B.
Check CO2 regulator. Check CO2
tank pressure.
A.
Carbonator not working.
A.
Check carbonator.
B.
No CO2 pressure in
carbonator.
B.
Check CO2 regulator. Check CO2
tank pressure.
C.
Faucet brix requires adjusting.
C.
Brix Faucet.
BEVERAGES NOT SWEET
ENOUGH.
A.
Empty syrup tank.
A.
Refill syrup tank.
B.
Faucet Brix requires adjusting.
B.
Brix Faucet.
BEVERAGES NOT COLD
(UNITS WITH BUILD-IN COLD
PLATE).
A.
Unit standing with no ice in
hopper - no ice in cold plate
cabinet.
A.
Refill hopper with ice.
SLUSHY ICE. WATER IN
HOPPER
BEVERAGES DO NOT
DISPENSE.
BEVERAGES TOO SWEET.
NOTE: Contact your local syrup or beverage equipment distributor for additional information and
trouble shooting of beverage system.
NO ICE DISPENSED FROM
ICE PORTION CONTROLLER
A.
Insufficient ice supply in ice
bin.
A.
Replenish ice supply as required.
B.
Ice in ice bin bridged (stuck
together).
B.
Gently tap on ice to break it loose.
C.
No electrical power to
dispenser.
C.
Plug in dispenser power cord, or
check fuse or circuit breaker.
11
620919541
Trouble
NO ICE DISPENSED FROM
ICE PORTION CONTROLLER
(CONTINUED)
NO ICE DISPENSED FROM
MANUAL ICE DISPENSE
PUSHBUTTON SWITCH
ICE DISPENSING DURING
AUTOMATIC AGITATION
620919541
Probable Cause
Remedy
D.
Insufficient or no CO2 supply
to dispenser.
D.
Restore CO2 supply to dispenser.
E.
Ice chute cover not properly
Installed.
E.
Make sure that cover is “snapped”
into place.
F.
Defective ice chute interlock
switch.
F.
Replace interlock switch.
G.
Defective interlock relay.
G.
Replace relay.
H.
Defective 24V transformer.
H.
Replace transformer.
I.
Defective portion controller.
I.
Replace controller.
J.
Defective ice gate cylinder.
J.
Replace cylinder.
K.
Defective ice gate solenoid
valve.
K.
Replace solenoid valve.
L.
Agitation relay wiring incorrect.
L.
Red wire should be connected to
“+” terminal (no. 3) of relay coil.
M.
Defective agitation relay.
M.
Replace relay.
N.
Defective agitator motor or
start capacitor or start relay.
N.
Replace defective component.
A.
Manual/Auto toggle switch in
“Auto” position.
A.
Move toggle switch to “Manual”
position.
B.
Insufficient or no CO2 supply to
dispenser.
B.
Restore CO2 supply to dispenser.
C.
Defective 24V transformer.
C.
Replace transformer.
D.
Defective manual override
solenoid valve.
D.
Replace valve.
E.
Defective manual ice dispense
pushbutton switch.
E.
Replace switch.
F.
Defective agitator motor or
start capacitor or start relay.
F.
Replace defective component.
G.
Defective ice gate cylinder.
G.
Replace cylinder
A.
Manual/Auto toggle switch in
“manual” position.
A.
Move toggle switch to “auto”
position.
B.
Defective ice gate cylinder.
B.
Replace cylinder.
C.
Defective ice gate solenoid
valve.
C.
Replace valve.
D.
Defective portion controller.
D.
Replace controller.
12
IMI CORNELIUS INC.
ONE CORNELIUS PLACE
ANOKA, MN. 55303–6234
TELEPHONE (800) 238–3600
FACSIMILE (763) 422–3232
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 product, in your country,
please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment model number
and the date of purchase.
IMI Cornelius Offices
AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166
AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930
BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307
BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829
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FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201
GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, WEST GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438
GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491
HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222
ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814
NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361
SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604
SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379
USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (763) 421-6120 D FAX (763) 422-3255
13
620919541
IMI CORNELIUS INC.
Corporate Headquarters:
One Cornelius Place
Anoka, Minnesota 55303-6234
(763) 421-6120
(800) 238-3600