Cornelius DF 250 BCP Operator's Manual

IMI CORNELIUS REMCOR INC g 500 REGENCY DRIVE g GLENDALE HEIGHTS, IL 60139–2268

Telephone [phone] Facsimile (800) 519–4423

Operator’s 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.620919540
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

START-UP AND OPERATING INSTRUCTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ICE PORTIONING SYSTEM OPERATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NORMAL OPERATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEAN MODE 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NORMAL ICE PORTION ADJUSTMENT 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXTRA ICE PORTION ADJUSTMENT 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AGITATION REFILL TIME ADJUSTMENT 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL ICE DISPENSING OPERATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY (OR AS REQUIRED) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEEKLY (OR AS REQUIRED) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MONTHLY 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING INSTRUCTIONS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPENSER 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEVERAGE SYSTEM 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING DISPENSING VALVES 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

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 12. . . . . . . . . . . . . . . .

NO ICE DISPENSED FROM MANUAL ICE DISPENSE PUSHBUTTON

SWITCH 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ICE DISPENSING DURING AUTOMATIC AGITATION 13. . . . . . . . . . . . . . . . . . . . . .

PARTS LIST 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF FIGURES

FIGURE 1. PARTS IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 2. CUP SIZE LABEL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 3. CABINET SECTION EXPLODED VIEW 15. . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 4. ELECTRICAL BOX ASSEMBLY 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

MANUAL ICE DISPENSE

RED PUSH BUTTON SWITCH

ICE PORTION

CONTROL MODULE

BEVERAGE FAUCET

ON/OFF SWITCH

RETAINER

ICE BIN COVER

ICE AGITATOR

REMOVABLE STRAW

HOLDER PANEL

LID/STRAW

HOLDER

MANUAL/AUTO ICE

TOGGLE SWITCH

CUP REST

DRIP TRAY

LOWER ACCESS

PANEL

FIGURE 1. PARTS IDENTIFICATION

BEVERAGE FAUCETS (8)

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START-UP AND OPERATING INSTRUCTIONS

Fill the hopper with ice and replace the lid. Allow 10 to 15 minutes for the cold plate to cool down. Repeat this
procedure whenever the dispenser has been standing overnight or other long periods without ice use. Start up the
beverage system and adjust faucets to the proper brix. Contact your local syrup distributor for complete
information on the beverage system.

To dispense ice, hold cup under ice chute and press the appropriate size button on the ice portion control located
above the ice chute. An extra ice portion may be obtained by pressing the increase key before pressing the
button.

For beverage dispensing, place a cup on the cup rest against the faucet lever of the desired flavor. Beverage will
be dispensed automatically filling the cup and shutting off. A delay feature is provided in the faucet controller to
“top-off” the drink after shut off.

CAUTION: Use caution to avoid spilling ice when filling dispenser. Clean up immediately
any spilled ice from filling or operating the unit. To prevent contamination of ice, the lid
must be installed at the unit at all times.

If the dispenser fails to dispense ice or beverage, see troubleshooting guide.

ICE PORTIONING SYSTEM OPERATION

INDICATOR LIGHT

DECREASE SMALL LARGEMEDIUM X-LARGE INCREASE

FIGURE 2. CUP SIZE LABEL

The ice portioning system consists of three main components:

1. Ice Portion Control

2. Ice Gate Mechanism

3. Solenoid Operated Air Valve

When a size button on the ice portion control is pressed, the control supplies a voltage to the air valve for a brief
period of time. The air cylinder attached to the ice gate will then open the ice gate for a short time allowing ice to
be dispensed from the ice chute.

The ice portion control has five modes to allow adjustment of the ice portions and for normal operation. They are
as follows: (Refer to Figure 2)

MODE
Normal operation Green
Cleaning mode Red/Amber flashing
Normal ice portion adjustment Amber
Extra ice portion adjustment Red
Agitation refill time adjustment Amber flashing

INDICATOR STATUS

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The control will return to Normal Operation Mode (green indicator) automatically if a button has not been operated
for a period of one minute whenever one of the three adjustment modes have been accessed.

NORMAL OPERATION

To dispense ice, hold a cup directly under the ice chute, then press the appropriate size button on the ice portion
control. To obtain a full cup of ice, press the increase button followed by the appropriate size button. The ice
portion control will not dispense ice and will display a flashing green indicator light if sufficient ice is not available
in the ice chute to dispense the selected size. The indicator light will return to solid green and ice dispensing will
resume after the ice chute has been filled.

The amount of ice dispensed for each size is changed in the Normal and Extra Ice Adjustment Modes. To access
the adjustment modes, press the decrease and increase button at the same time. The control will advance to the
next mode in the sequence as shown in the table on page 3 and the indicator light will change to identify which
mode is currently active.

CLEAN MODE

Access this mode to empty all the ice in the chute. To enter clean mode, press the decrease and increase buttons
at the same time. The indicator light will alternately display red and amber. To empty the ice chute, press any of
the size buttons. The ice gate will then open to allow the ice chute to empty. The ice gate will automatically close
after the ice has been emptied.

To return to normal operation, press the increase and decrease buttons at the same time; then press both buttons
three times in sequence. The indicator light will show amber, red, amber flashing, and finally green to indicate
normal operation.

NORMAL ICE PORTION ADJUSTMENT

From the Normal Operation Mode (green indicator), press both the decrease and increase buttons at the same
time twice. The amber indicator verifies that the normal portion adjustment mode has ben accessed.

To change the amount of ice dispensed, press and hold down the size button for the desired size to be changed.
While holding the size button, press the decrease or increase button to decrease/increase the ice portion size.
When the minimum ice portion adjustment has been reached, the indicator will flash at a slow rate; at the
maximum adjustment, the indicator will flash at a fast rate. After releasing the size button, the indicator light will
flash green for five seconds. During this time period a sample can be obtained to check the portion size by
pressing the size key. The indicator light will return to amber (normal portion adjustment mode) after the sample is
dispensed.

The indicator light will flash red after dispensing a sample, if an open circuit exists in the ice gate cylinder switch
wiring to the ice portion control or if an ice gate binding condition occurred during the sample. The indicator light
will display solid red briefly after a sample is dispensed if the ice gate cylinder switch was shorted.

To return to normal operation press the decrease and increase buttons at the same time, press twice.

EXTRA ICE PORTION ADJUSTMENT

The adjustment of Extra Ice Portion is accomplished in the same manner as ice portions, except the indicator light
displays red. To access this mode press both the decrease and increase buttons simultaneously three time from
the Normal Operation Mode (green indicator). The indicator will display red.

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AGITATION REFILL TIME ADJUSTMENT

To adjust the amount of ice chute refill agitation. begin by accessing the Extra Ice Portion Adjustment Mode (red
Indicator). Next, press and hold for the decrease and increase buttons for three seconds until the indicator flashes
amber. The indicator will flash up to four times, one flash corresponds to the minimum amount of refill agitation
and four flashes corresponds to the maximum amount of refill agitation. Change the amount of refill agitation by
pressing one of the four size buttons – the small button representing the minimum amount of refill agitation.
Increase the amount of refill agitation if the ice chute does not refill properly after dispensing ice.

To return to Normal Operation Mode, press the decrease and increase buttons at the same time.

MANUAL ICE DISPENSING OPERATION

A red pushbutton switch is provided on the upper front panel (see Figure 1) to manually dispense ice. This system
can be used for dispensing ice in portions other than cup-size or in the event of a malfunction with the ice portion
controller.

For manually dispensing ice, an auto/manual toggle switch is located adjacent to the ice portioning touch panel
(cup size selector) on the upper panel. The function of this switch is to bypass the gate solenoid valve (operated
by the portion controller) and to open the gate directly. Move the toggle switch to the “manual” position which
opens the gate immediately. Ice can now be dispensed by depressing and holding the red pushbutton switch for
the desired amount of ice. To return to the ice portioning mode of operation, move the toggle switch to the “auto”
position.

CAUTION: The gate closes immediately when the toggle switch is moved to the auto
position. Do not place fingers or foreign objects into the ice chute when operating the
toggle switch.

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