Download Cornelius ED-250 User's Manual
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www.cornelius.com Installation Manual ENDURO ICE/BEVERAGE DISPENSER Model: ED-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. 620916501INS October 19, 2005 Revised: March 10, 2006 Revision: C THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment © IMI CORNELIUS INC; 2005–2006 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 620916501INS 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 620916501INS 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 ”ENDURO” 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 ED250 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 620916501INS 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 620916501INS 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 620916501INS 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 620916501INS FAUCETS VIEWED FROM THIS SIDE FIGURE 4. FLOW DIAGRAM (UNIT WITH EIGHT FAUCETS) 620916501INS 6 S1 S2 S3 S4 W1 W2 W3 W4 S5 S6 S7 S8 W3 W4 W2 W1 COLD PLATE S8 S7 S6 S5 S4 S3 S2 S1 ITEMS INSIDE BROKEN LINE INCLUDED WITH UNIT 8 7 6 5 COLDPLATE INLET CONNECTIONS 4 3 2 1 FAUCETS 5–15 PSIG OPTIONAL FOR DIET DRINKS OR ROOT BEER S8 S7 S6 S4 S3 S2 CHECK VALVE SYRUP TANKS 15–50 PSIG S5 CO2 CARBONATOR Non–Carb Water Carb Water S1 PRESSURE REGULATORS CO2 Cylinder Carb Water INSTALL FOR NON–CARB AS REQUIRED FILTER OPTIONAL PRESSURE REGULATOR POTABLE WATER SUPPLY 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 620916501INS FIGURE 5. FLOW DIAGRAM (PNEUMATIC ICE GATE) ED250 PROGATE WIRING DIAGRAM MOTOR HEATER L INTERLOCK RELAY BLK 7 A 5 B N ICE CHUTE INTERLOCK SWITCH INCOMING POWER E TO GUSSET HINGE GROUND TERMINAL BLK TERMINAL BOARD GRN/YEL GRN/YEL BLK BLK BLK WHT WHT BLK WHT BLK YEL BLK WHT BLK WHT TO EBOX GROUND SCREW WHT DIODE BLK WHT BLK LINE WHT LINE TRANSFORMER TRANSFORMER LOAD YEL LOAD RED YEL/BLK YEL ORN/BLK ORN 1 2 3 4 5 1 2 3 4 5 WHT WHT YEL YEL RED YEL/BLK YEL BLK ORN/BLK WHT ORN BLK AGITATOR MOTOR MOTOR START CAPACITOR WHT GRN/YEL BEVERAGE VALVE BLK BEVERAGE VALVE WHT BLK BEVERAGE VALVE BLK WHT TO EBOX GROUND SCREW BEVERAGE VALVE WHT BLK BEVERAGE VALVE WHT 1 WHT 2 GRN 1 BLU 2 MANUAL OVERRIDE SOLENOID BEVERAGE VALVE (TYPICAL) (TYPICAL) BRN BLK RED BLU PNEUMATIC GATE SOLENOID RED 1 2 AGITATION RELAY 3 RED TO EBOX GROUND SCREW 4 BLK GRN/YEL BLU BRN RED ORN 1 YEL ORN 2 3 BLK 4 5 6 YEL 7 8 GRN/YEL 9 BLK BLK GRN RED 1 MANUAL/AUTO ICE TOGGLE SWITCH 2 WHT ORN 3 4 5 ORN 6 7 8 BLK RED BLU VIO WHT BLU BRN 9 YEL 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 YEL COM RED WHT NO MANUAL ICE DISPENSE SWITCH PORTION CONTROLLER/TOUCH PANEL BLK ORN BEVERAGE VALVES 25 ON/OFF SWITCH 12 YEL ORN 24 WIRE COLOR CHART 11 BLK YEL DANGER! ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SERVICING UNIT. 620913001 REV.E LEGEND BLACK WHT WHITE YEL YELLOW ORN ORANGE BRN BROWN VIO VIOLET SPLICE/QUICK CONNECT CONNECTION BLU BLUE GROUND RED RED MALE HARNESS CONNECTOR GRN GREEN FEMALE HARNESS CONNECTOR GEN/YEL GREEN W/YELLOW STRIP FIGURE 6. WIRING DIAGRAM (115 VOLT UNIT) 620916501INS 8 L ICE CHUTE INTERLOCk SWITCH 2 1 BEV VAL. 120V 24VAC START CAPACITOR AGITATOR MOTOR R S 3 2 N 620916501INS MOTOR START RELAY 4 TOUCH PANEL MANUAL OVERIDE SOLENOID VALVE MANUAL/AUTO ICE TOGGLE SWITCH BEVERAGE TRANSFORMER INTERLOCK RELAY BEV VAL. BEV VAL. 24VAC BEV VAL. BEV VAL. 24VAC PORTION CONTROLLER/ TOUCH PANEL 24VAC BEV VAL. BEV VAL. 3 4 O/L PNEUMATIC ICE GATE SOLENOID VALVE BEV VAL. BEV ON/OFF SWITCH BEVERAGE TRANSFORMER AGITATOR RELAY MANUAL ICE DISPENSE SWITCH AGITATOR MOTOR HEATER 9 FIGURE 7. WIRING SCHEMATIC (115 VOLT) THIS PAGE LEFT BLANK INTENTIONALLY 620916501INS 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 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 620916501INS Trouble NO ICE DISPENSED FROM ICE PORTION CONTROLLER (CONTINUED) NO ICE DISPENSED FROM MANUAL ICE DISPENSE PUSHBUTTON SWITCH ICE DISPENSING DURING AUTOMATIC AGITATION 620916501INS 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 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 ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644 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 OSSEO, MN (800) 238–3600 13 620916501INS IMI CORNELIUS INC.