Cornelius IU150 BC Installation Manual

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MODEL: IU150 BC

Intraflex Ice/Beverage Dispenser

Operator’s Manual

Release Date: June 01, 2001

Publication Number: 620919519

Revision Date: April 24, 2014

Revision: F

Visit the Cornelius web site at

www.cornelius.com for all your Literature needs.

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The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and con struction requirements are being met, in addition to the information contained in this manual.

This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is subject to all of the restrictions and limitations contained in the Commercial Warranty.

Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident, (6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained persons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, operating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100% compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the product dispensed which are adversely impacted by changes in liquid scale or chemical composition.

Contact Information:

To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact:

www.cornelius.com

800-238-3600

Trademarks and Copyrights:

This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius.

Printed in U.S.A.

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TABLE OF CONTENTS

Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Qualified Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Countertop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Locate the dispenser indoors on a level countertop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cleaning and Maintenance INstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Daily Cleaning: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Daily Maintenance:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Weekly Cleaning: (In addition to daily procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Monthly Cleaning: (In addition to daily and weekly procedures) . . . . . . . . . . . . . . . . . . . . . . . . . 7

Yearly Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Start-Up and Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Auger Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cleaning and Sanitizing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Cleaning Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Cleaning Exterior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Cleaning Interior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Sanitizing Syrup Tanks System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Sanitize B-I-B Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Ice Auger Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Dispenser Section Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Intraflex Ice Drink Dispenser Operator’s Manual

DANGER:

WARNING:

CAUTION:

WARNING:

SAFETY INSTRUCTIONS

READ AND FOLLOW ALL SAFETY INSTRUCTIONS

Safety Overview

• Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or laminated cards).

• Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before operating this unit.

Recognition

Recognize Safety Alerts

This is the safety alert symbol. When you see it in this manual or on the unit,

be alert to the potential of personal injury or damage to the unit.

DIFFERENT TYPES OF ALERTS

Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment damage.

Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or equipment damage.

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or equipment damage.

SAFETY TIPS

• Carefully read and follow all safety messages in this manual and safety signs on the unit.

• Keep safety signs in good condition and replace missing or damaged items.

• Learn how to operate the unit and how to use the controls properly.

• Do not let anyone operate the unit without proper training. This appliance is not intended for use by very young children or infirm persons without supervision. Young children should be supervised to ensure that they do not play with the appliance.

• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit.

QUALIFIED SERVICE PERSONNEL

Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.

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Intraflex Ice Drink Dispenser Operator’s Manual

WARNING:

CAUTION:

DANGER:

WARNING:

SAFETY PRECAUTIONS

This unit has been specifically designed to provide protection against personal injury. To ensure continued protection observe the following:

Disconnect power to the unit before servicing following all lock out/tag out procedures established by the user. Verify all of the power is off to the unit before any work is performed.

Failure to disconnect the power could result in serious injury, death or equipment damage.

Always be sure to keep area around the unit clean and free of clutter. Failure to keep this area clean may result in injury or equipment damage.

SHIPPING AND STORAGE

Before shipping, storing, or relocating the unit, the unit must be sanitized and all sanitizing solution must be drained from the system. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the unit to freeze resulting in damage to internal components.

CO2 (CARBON DIOXIDE) WARNING

CO2 displaces oxygen. Strict attention MUST be observed in the prevention of CO2 gas leaks in the entire CO2 and soft drink system. If a CO contaminated area before attempting to repair the leak. Personnel exposed to high concentrations of CO experience tremors which are followed rapidly by loss of consciousness and DEATH.

2 gas leak is suspected, particularly in a small area, IMMEDIATELY ventilate the

2 gas

MOUNTING IN OR ON A COUNTER

When installing the unit in or on a counter top, the counter must be able to support a weight in excess of 450 lbs. to insure adequate support for the unit. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.

NOTE: Many units incorporate the use of additional equipment such as icemakers. When any addition

equipment is used you must check with the equipment manufacturer to determine the additional weight the counter will need to support to ensure a safe installation.

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Intraflex Ice Drink Dispenser Operator’s Manual

DESCRIPTION

The Intraflex ice dispenser solves your ice service needs in a sanitary, space saving, economical way.

It is designed to be manually or automatically filled with ice. The dispenser is designed to dispense ice cubes (up to 11/4 inches in size), cubelets, and hard chipped or cracked ice.

SPECIFICATIONS

Model IF150 BC Ice Drink Dispenser (Eight-Flavor)

Dimensions

Electrical 115 VAC/1 Phase/60 Hz/5.2 Amps Total Current Draw

Clearance Required 54” above counter, front access

Drain Base Unit is plumbed for PVC or flex plastic tubing installed to local code.

Flavor Selections Maximum of eight syrup flavors plus plain water and carbonated water.

Ice Requirements Ice bin capacity is 150 pounds of ice.

Full Weight 435 lbs.

31-7/8 inches wide X 27-7/8 inches Deep X 21-1/4 inches High with  29 inches Depth Below Countertop

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Intraflex Ice Drink Dispenser Operator’s Manual

WARNING:

INSTALLATION INSTRUCTIONS

COUNTER HEIGHT

(INCHES)

30 29 1 Consult Factory

31 29 2 Consult Factory

32 29 3 620517502 + 629087406

33 29 4 629087406

34 29 5 629087406

34 1/4 to 35 29 5 1/4 to 6 629087412 + 620517502

35 29 6 629087412

36 29 7 629087412

DISPENSER

DEPTH

(INCHES

AVAILABLE SPACE

BELOW DISPENSER

(INCHES)

P/N

COUNTERTOP INSTALLATION

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 and must comply with all federal, state and local codes.

Failure to comply could result in serious injury, death or damage to the equipment.

Water pipe connection and fixtures directly connected to a portable water supply must be sized, installed, and maintained according to federal, state and local laws.

Locate the dispenser indoors on a level countertop.

The dispenser that

must

the countertop using the dimensions given or use the full size template enclosed.

Apply a continuous bead of NSF International (NSF) listed silastic sealant (Dow 732 or equivalent) approximately 1/4 inch inside the dispenser outline dimensions and around all openings. Position the dispenser on the countertop within the outline dimensions. All excess sealant

1. Attach 3/4-inch elbow to drainpan outlet and orientate to floor drain. Drain line must be pitched 1-inch per

NOTE: The use of flex tubing is not recommended by the manufacturer. All lines must be insulated.

2. Clean the hopper interior (See Cleaning Instructions).

3. Connect dispenser power cord to 120 VAC 60 HZ 15-Amp 3-wire grounded receptacle.

must

be sealed to the countertop. The MOUNTING TEMPLATE (see Figure 1) indicates the opening

be cut in the countertop. Locate the desired position for the dispenser, then mark the outline dimension on

must

be wiped away immediately.

12-inch run. See mounting template (Figure 1) for unit drain location.

A. Use 3/4-inch nominal plastic pipe for entire drain installation.

B. To assure proper drainage,

do not

allow a “trap” to form in the drain line.

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COUNTER CUTOUT FOR UNIT DROP IN

FRONT OF COUNTER- TOP

FOOT PRINT OF

UNIT ON COUNTER-

27-3/16

26-1/4

31-7/8

Intraflex Ice Drink Dispenser Operator’s Manual

THE ABOVE FIGURE SHOWS THE REQUIRED CUTOUT FOR PLACING THE ICE DISPENSER INTO A COUNTERTOP. THE DASHED LINE IS THE ACTUAL CUTOUT DIMENSIONS WHILE THE SOLID LI NE SHOWS THE AMOUNT OF OVERHANG

Figure 1. Mounting Template

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Intraflex Ice Drink Dispenser Operator’s Manual

Figure 2. Flow Diagram

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Intraflex Ice Drink Dispenser Operator’s Manual

WARNING:

CAUTION:

CLEANING AND MAINTENANCE INSTRUCTIONS

These instructions are used on all Cornelius ice drink dispensers. Some models may have additional cleaning requirements. Those models will have addition procedures listed later in the manual.

Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all power is off to the unit before performing any work.

Failure to comply could result in serious injury, death or damage to the equipment.

Do not use metal scrapers, sharp objects or abrasives on the ice storage hopper, top cover, agitator disc or exterior surfaces as damage to the unit may result. Do not use solvents or other cleaning agents as they may attack the material resulting in damage to the unit.

Soap solution – Use a mixture of mild detergent and warm (100° F ) potable water.

Sanitizing Solution – Dissolve 2 packets (4 oz) of Stera Sheen Green Label into 2 gallons of warm (80 – 100° F) potable water to ensure 200 ppm of chlorine.

Daily Cleaning:

1. Remove cup rest from drip tray and clean with warm soapy water, rinse with clean water and allow to air dry.

2. Wipe down the exterior of the unit with warm soapy water, rinse with clean water and allow to air dry.

3. Remove valve nozzles and diffusers and wash in warm soapy water, rinse in clean water and allow to air dry.

4. Clean the interior of the ice chute using the brush provided with the unit with warm soapy water, rinse with clean water and allow to air dry.

5. Spray the ice chute inside and out with sanitizer and allow to air dry.

6. Pour warm soapy water down the drains to keep them clean and flowing smoothly.

7. Spray the nozzles and diffusers inside and outside with approved sanitizing solution, reinstall them on the valves and allow to air dry.

8. Reinstall the cup rest into the drip tray.

9. Pour all remaining sanitizer solution down the drains to help keep the drain clear.

Daily Maintenance:

1. Check the temperature, smell and taste of the product.

2. Check the water pressure coming to the unit using the pressure gauges on the back room package.

3. Check carbonation of the drink

4. Check level of CO

5. Check the date on all of the BIB’s (bags in boxes).

2 supply to the system.

Weekly Cleaning: (In addition to daily procedures)

Remove the ice chute cover and clean it along with the back half with warm soapy using the brush provided with the unit. Rinse with clean water and reinstall on the unit. Spray the ice chute assembly with approved sanitizer allowing it to air dry.

Monthly Cleaning: (In addition to daily and weekly procedures)

1. Flush and sanitize all syrup lines as well as all of the syrup connectors. (See the sanitize syrup lines section shown later in this manual).

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Intraflex Ice Drink Dispenser Operator’s Manual

2. Remove ice from hopper and clean and sanitize the hopper. (See the Cleaning Interior Surfaces section of this manual).

3. While cleaning the hopper use the brush provided with the unit to clean the cold plate surface. To accomplish this, the brush needs to be extended through the opening in the bottom of the hopper.

Yearly Maintenance:

Have the water pump and check valve inspected and cleaned by a qualified service technician.

Have the CO2 gas check valve inspected and cleaned by a qualified service technician.

Remove the splash and cold plate cover to clean and sanitize the cold plate surface. (See the Cleaning the Cold Plate section of this manual).

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Intraflex Ice Drink Dispenser Operator’s Manual

CAUTION:

START-UP AND OPERATING INSTRUCTIONS

Fill the hopper with ice. Dispense a large cup of ice. Repeat this procedure when ever the dispenser has run out of ice. In normal operation, pushing the ice dispenser lever will cause ice to flow from the ice chute. Ice flow will continue to flow as long as the lever is held depressed.

Avoid spilling ice when filling the dispenser. Clean up any spilled ice immediately. To prevent contamination of the

must

ice, the dispenser lid

If the dispenser fails to dispense beverage or ice, refer to the Troubleshooting Section of this manual.

AUGER ASSEMBLY BREAKDOWN

1. For cleaning, the auger assembly is constructed for simple (tools not required) breakdown. First remove the tower cap (Item 69) by removing the 3 knurled screws.

2. Once the tower cap is out of the way you will see a wire retainer (Item 77). By placing your fingers on the backside of the ice chute (Item 65) with your thumbs pointing upward, place the thumbs on the retainer wire and with a slight upward movement push the wire retainer towards the rear of the unit. The retainer should pop out of the saddle and swing backwards.

3. At this point, you should be able to pull up on the ice chute and remove it from the assembly. You will notice that the ice chute is made up of three pieces. That is the ice chute, the ice chute cover and the auger gate which is respectively (Items 65, 66, and 69). When reassembling the ice chute, the auger gate sits in slots in the ice chute with the short tang side up.

4. The auger (Item 73) can now be removed by just grasping it and pulling up. Notice that the bottom of the auger has a depression in the form of a D pattern. When replacing the auger, it is necessary to rotate the auger after insertion in the tube to engage the motor shaft.

be closed at all times

Figure 3. Auger Assembly

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Intraflex Ice Drink Dispenser Operator’s Manual

WARNING:

CAUTION:

CLEANING AND SANITIZING INSTRUCTIONS

Disconnect electrical power to the dispenser before cleaning. on the ice storage hopper, top cover, and the agitator disk as damage may result. cleaning agents as they may attack the plastic material.

Soap Solution: Use a mixture of mild detergent and warm (100° F) potable water.

Sanitizing Solution: Use 1/ solution to this ratio will create a solution of 200 PPM.

2-ounce of household bleach in one gallon of potable water. Preparing the sanitizing

Do not

use metal scrapers, sharp objects, or abrasives

Do not

use solvents or other

Cleaning Dispenser

Cleaning Exterior Surfaces

IMPORTANT: Perform the following daily.

1. Remove cup rest from the drip tray.

2. Wash the drip tray with soap solution. Rinse with potable water and allow solution to run down the drain.

3. Wash cup rest with soap solution and rinse with potable water. Install cup rest in drip tray.

4. Clean all exterior surfaces of the dispenser with soap solution and rinse with potable water.

Cleaning Interior Surfaces

When pouring liquid into the hopper,

IMPORTANT: Perform the following at least once a month.

1. Lift drip tray to expose the hopper, then remove all ice from the hopper.

2. Remove the drip tray and rear cover from the dispenser by grasping near the tower and pulling gently outward.

do not

exceed the rate of 1/2-gallon per minute.

Figure 4. Drip Tray and Rear Cover Removal

3. Remove agitator disk and agitator assembly.

4. Remove tower cover by removing two thumb screws.

5. Move the retaining bail to the rear of the tower which will allow removal of the ice chute assembly.

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Intraflex Ice Drink Dispenser Operator’s Manual

CAUTION:

6. Grasp the auger by the shaft end and lift out the auger tube. Take care not to damage either end of the auger.

7. Remove the auger tube by lifting upward. The tube will separate into two halves for easy cleaning when fully removed.

8. Open the front door of the cabinet below the hopper. This will give you access to the lower auger drive area and the passage between the hopper and the auger for cleaning.

9. Using the previously prepared detergent solution, clean the valves, the hopper covers, agitator disk, agitator assembly, interior of the hopper, both halves of the ice chute, auger, auger tubes, and the lower auger area of the auger housing. Thoroughly rinse all of the previously cleaned parts with potable water.

10. Reassemble the agitator assembly and disc into the hopper. Make certain the retaining screw is tight.

11. Using a mechanical spray bottle filled with sanitizing solution, spray the entire interior of the hopper and the agitator assembly. Go to the lower auger drive area and also spray with sanitizing solution. Allow to air dry.

12. Using the spray bottle, spray the inside of the two halves of the auger tube, the auger, the two halves of the chute assembly, and the undersides of the driptray and rear cover. Allow to air dry.

13. Reassemble the two halves of the auger tube and place back into it’s mounting. Holding the auger by the upper shaft end, insert into the auger tube. Make certain that the auger slips into it’s drive pin. The chute assembly will not assemble properly if the auger is not seated on it’s drive pin. Reassemble the chute assembly onto the auger tube and lock down by snapping the retainer onto the upper housing. Reinstall the tower cover with the thumb screws.

14. Reinstall the driptray and rear cover

NOTE: The auger tubes are different lengths and marked “TOP” and “BOTTOM” (the end with the tab

is the top). The shorter tube half is adjacent to the beverage valves. When properly assembled, the top of the two halves should be even.

Sanitizing Syrup Tanks System

Only trained and qualified persons should perform these cleaning and sanitizing procedures.

Sanitize syrup tanks system as follows:

1. Remove all the quick disconnects from all the tanks. Fill a suitable pail or bucket with soap solution.

2. Submerge all disconnects (gas and liquid) in the soap solution and then clean them using a nylon bristle brush. (Do not use a wire brush). Rinse with clean water.

3. Prepare sanitizing solution and using a mechanical spray bottle, spray the disconnects. Allow to air dry.

4. Using a clean, empty tank, prepare five (5) gallons of the sanitizing solution. Rinse the tank disconnects with approximately 9 oz. of the sanitizing solution. Close the tank.

5. Prepare cleaning tank by filling clean five (5) gallon tank with a mixture of mild detergent and potable water (120°F).

6. Connect a gas disconnect to the tank and then apply one of the product tubes to the cleaning tank. Operate the appropriate valve until liquid dispensed is free of any syrup.

7. Disconnect cleaning tank and hook up sanitizing tank to syrup line and CO

2 system.

8. Energize beverage faucet until chlorine sanitizing solution is dispensed through the faucet. Flush at least two (2) cups of liquid to ensure that the sanitizing solution has filled the entire length of the syrup tubing.

9. Allow sanitizer to remain in lines for fifteen (15) minutes.

10. Repeat the step above, applying a different product tube each time until all tubes are filled with the sanitizing solution.

11. For post-mix valves, remove the nozzle and syrup diffuser and clean them in a mild soap solution. Rinse with clean water and reassemble the nozzle and syrup diffuser on the valve.

12. For pre-mix valves, disconnect all product tubes from the tank of sanitizing solution and then open the valves to allow the pressure to be relieved. Remove the valves from the dispenser, disassemble and wash thoroughly in a mild soap solution.

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Intraflex Ice Drink Dispenser Operator’s Manual

13. Rinse the parts in clean water, reassemble the valve and reconnect it to the dispenser.

14. Discard the tank of sanitizing solution and reconnect the product (syrup or pre-mix) tanks. Operate the valves until all sanitizer has been flushed from the system and only product (syrup or pre-mix) is flowing.

Sanitize B-I-B Systems

1. Remove all the quick disconnects from all the B-I-B containers.

2. Fill a suitable pail or bucket with soap solution.

3. Submerge all disconnects (gas and liquid) in the soap solution and then clean them using a nylon bristle brush. (Do not use a wire brush). Rinse with clean water.

4. Using a plastic pail, prepare approximately five (5) gallons of sanitizing solution.

5. Rinse the B-I-B disconnects in the sanitizing solution.

6. Sanitizing fittings must be attached to each B-I-B disconnect. If these fittings are not available, the fittings from empty B-I-B bags can be cut from the bags and used. These fittings open the disconnect so the sanitizing solution can be drawn through the disconnect.

7. Place all the B-I-B disconnects into the pail of sanitizing solution. Operate all the valves until the sanitizing solution is flowing from the valve. Allow sanitizer to remain in lines for fifteen (15) minutes.

8. Remove the nozzle and syrup diffuser from each valve and clean them in a soap solution. Rinse with clean water and reassemble the nozzle and syrup diffuser to the valve.

9. Remove the sanitizing fittings from the B-I-B disconnects and connect the disconnects to the appropriate B-I-B container. Operate the valves until all sanitizer has been flushed from the system and syrup is flowing freely.

ICE AUGER SPEED CONTROL

The ice auger is a variable speed device. A potentiometer is used to control this speed. The potentiometer is located on the CB 1 control board (see Figure 5). The CB 1 control board is located inside the electrical control box which is below the counter facing towards the front of the counter expose the CB 1 Control board. By turning the potentiometer knob located on the CB1 control board CCW (counterclockwise) increases the speed of the ice delivery. Turning the potentiometer knob CW (clockwise) decreases

e speed of the ice delivery. This control is factory pre-set to the lowest speed.

. Removing the three screws and cover will

Figure 5. Ice Auger Speed Control

Page 17

Intraflex Ice Drink Dispenser Operator’s Manual

Figure 6. Wiring Diagram

Page 18

620919303 REVISION B

IF/PR150

LADDER DIAGRAM

AGIT. MTR. HTR.

RECIRC. PUMP

TRANSFORMER

COVER

SINK

LID

DISPENSE SW.

AGITATOR MTR.

CAPACITOR

BIN THERMO OPTION

AUGER LIFT MTR.

TRANSFORMER

KEY SWITCH

VA LVES 1 - 4

VA LV E S 5 - 8

WHITE

BLACK

GND

BIN STAT

PLUG

Intraflex Ice Drink Dispenser Operator’s Manual

Figure 7. Ladder Diagram

Page 19

Intraflex Ice Drink Dispenser Operator’s Manual

WARNING:

TROUBLESHOOTING

If repairs are to be made to a syrup system, disconnect syrup supply from the applicable syrup system, then relieve the system pressure before proceeding. If repairs are to be made to the CO

supply, then relieve the system pressure before proceeding. If repairs are to be made to the unit electrical

system,

make sure

electrical power is disconnected from the unit before proceeding.

IMPORTANT: Only qualified personnel should service internal components or electrical wiring.

Should the 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 to aid in locating the defect.

Trouble Probable Cause Remedy

system, stop dispensing, shut off the

BLOWN FUSE OR CIRCUIT BREAKER

AGITATOR DOES NOT TURN, AUGER DOES NOT TURN.

ICE DISPENSES CONTINUOUSLY.

SLUSHY ICE. WATER IN HOPPER.

AGITATOR TURNS, AUGER DOES NOT TURN.

AUGER TURNS, AGITATOR DOES NOT.

a Short circuit in electrical wiring.

b Inoperative 24 VAC transformer.

c Inoperative agitator motor.

d Shorted motor.

a No electrical power.

b Bent depressor plate (does not actu-

ate switch).

c Inoperative dispensing switch.

d Inoperative interlocks, lids not closed.

e Inoperative timer board.

f Inoperative 24 VAC transformer.

a Stuck or bent depressor plate (does

not release switch).

b Inoperative dispensing switch.

c Improper switch installation.

d Inoperative timer board.

a Blocked drain.

b Unit not sitting level.

c Poor ice quality due to water quality

or ice maker problems.



d Improper use of flaked ice.

a Inoperative auger motor.

b Inoperative or improper setting of

speed control.

c Inoperative rectifier.

dIce jam.

e Inoperative timer board.

a Inoperative agitator motor.

b Inoperative motor capacitor.

c Inoperative timer board.

a Repair electrical wiring.

b Replace transformer.

c Replace agitator motor.

dReplace motor.

a Restore electrical power.

b Replace depressor plate.

c Replace dispensing switch.

d Replace interlocks.

e Replace timer board.

f Replace transformer.

a Replace depressor plate.

b Replace dispensing switch.

c Correct switch installation.

d Replace timer board.

a Unplug and flush out the drain.

b Level the unit.

c Install water filter system. For ice-

maker problems, consult ice maker manual.

d Use correct ice.

a Replace auger motor.

b Replace speed control or re-adjust

speed control.

c Replace rectifier.

d Clear ice jam.

e Replace timer board.

a Replace agitator motor.

b Replace motor capacitor.

c Replace timer board.

Page 20

Intraflex Ice Drink Dispenser Operator’s Manual

Trouble Probable Cause Remedy

BEVERAGES DO NOT DISPENSE

a Beverage keyswitch in “OFF” posi-

tion.

b No 24 volts to dispensing valves.



cNo CO2 pressure.

a Beverage keyswitch is in “ON” posi-

tion

b Make sure unit is connected to elec-

trical power. Check 24 VAC transformer.

cCheck CO2 regulator. Check CO2

tank pressure.

BEVERAGES TOO SWEET.

BEVERAGES NOT SWEET ENOUGH

BEVERAGES NOT COLD.

a Carbonator not operating.

bNo CO2 pressure in carbonator.

c Dispensing valve brix requires re-

adjustment.

a Depleted syrup supply.

b Dispensing valve brix requires re-

adjustment.

a Unit standing with no ice in it’s hop-

per.

a Consult carbonator manual.

bCheck CO2 regulator. Check CO2

tank pressure.

c Refer to dispensing valve manufac-

turer for brix adjustment instructions.

a Replenish syrup supply.

b Refer to dispensing valve manufac-

turer for brix adjustment instructions.

a Replenish ice supply.

NOTE: Contact your local syrup or beverage equipment distributor for additional information and

trouble shooting of your beverage system.

Page 21

Intraflex Ice Drink Dispenser Operator’s Manual

ILLUSTRATED PARTS LIST

Figure 8. Illustrated Parts Breakdown

Page 22

Intraflex Ice Drink Dispenser Operator’s Manual

DISPENSER SECTION PARTS LIST

Item No. Part No. Name

1 15087 Retainer, Agitator

2 27107 Retainer, Lever, Ice Dispenser

3 30514 Strap, Capacitor Chiller

4 30774 Capacitor, Agitator Motor

5 30794 Heater, Agitator Motor

6 30895 Actuator Switch

7 31007 Boot, Switch

8 31107 Terminal Board

9 31981 Actuator, Magnetic

10 32498 Gear Motor, 75W, 120V 50/60HZ, 6.5RPM

11 32953 Reed Switch Ass’y

12 32977 Switch, Key

13 41333 Dispensing Valve Ass’y, LEV, Low Flow

14 50336 Pipe, PVC, .750 Dia. By 20-Feet Long

15 50458 Strain Relief

16 50573 Snap Bushing, .375 I.D.

17 50951 Fitting, Elbow, 3/4

18 51859 Seal, Shaft Motor

19 52876 Gasket, Motor Shaft

20 52998 Block, Motor

21 53219 Trim, Black

22 70015 Hex Nut, No. 10-32

23 70018 Hex Nut, 1/4-20

24 70048 Washer, .255 I.D.

25 70147 Sheet Metal Screw, Phil Rd Hd, No. 6 By 1/2-In. Long

26 70217 Sheet Metal Screw, Hex Hd, No. 8 By 1/2-In. Long

27 70260 Machine Screw, Phil Rd Hd, 1/4-20 By 1-In. Long

28 70320 Pop Rivet, 125 Dia.

29 70847 Spacer, Switch

30 70959 Hex Nut, No. 8-32

31 70992 Receptacle, 1/4 Turn

32 70993 Retainer, 1/4 Turn

33 70994 Stud, 1/4 Turn

34 71028 Bolt, 1/4-20

35 90432 Label, Warning

36 90580 Label, Electrical Data

37 91486 Medallion

38 91956 Label, Warning, Chillers

39 91975 Data Plate

40 92067 Label, Agitator Timer

41 92305 Label, Transformer

42 449999999 Transformer, 120V 60HZ--24V 80VA

43 620024701 Lever, Dispense

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Intraflex Ice Drink Dispenser Operator’s Manual

Item No. Part No. Name

44 620028201 Base, Cabinet

45 620028202 Plate, Motor Mounting

46 620028205 Wrap, Cabinet

47 620028213 Wrap, Front

48 620028214 Electrical Box

49 620028216 Panel, Base

50 620028218 Agitator Ass’y

51 620028222 Cover, Electrical Box

52 620028223 Plate, Mounting

53 620028226 Bolt, 1/4-20

54 620028227 Bracket, Leg Adapter

55 620028232 Bracket, Support, Auger Motor

56 620028204 Cover, Access

57 620028234 Bracket, Motor Mount

58 620028235 Hopper Ass’y

59 620028246 Stiffener, Base

60 620028249 Plate, Alignment, Syrup Lines

61 620028250 Plate, Alignment, Water Lines

62 620028253 Bracket, Auger Motor Mount

63 620028270 Plate, Auger Motor

64 620028282 Cover, Inlet Lines

65 620035202 Lid, Tower

66 620035203 Panel, Tower

67 620035204 Tower, Left-Hand

68 620035207 Base, Tower

69 620043101 Cap, Tower

70 620043206 Sleeve, Mounting, Ice maker Box

71 620044509 Panel, Back, Tower

72 620044614 Plate, Deflector

73 620045501 Tower, Ice

74 620709604 Hinge Bracket, Left-Hand, Cover, Back

75 620709605 Hinge Bracket, Right-Hand, Cover, Back

76 620513202 Lid, Back

77 620046017 Cover, Bin Thermostat

78 629087456 Motor, Gear, 38W, 24V

79 620311701 Timer, Agitator

80 620314201 Connector, Power Inlet

81 620403001 Cold Plate

82 620403018 Tray, Drain

83 620403021 Pipe, Drain

84 620406401 Tube, Bundle

85 620503801 Agitator Disk

86 620503802 Ice Conduit

87 620504001 Ice Chute

88 620504002 Cover, Ice Chute

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Intraflex Ice Drink Dispenser Operator’s Manual

Item No. Part No. Name

89 620504006 Seal, Hopper Conduit

90 620504011 Gate, Auger

91 620504021 Fitting, Elbow

92 620505502 Auger

93 620505703 Tube Ass’y, Auger, Front

94 620505704 Tube Ass’y, Auger, Back

95 620506503 Hopper, Generic

96 620506504 Drip Tray, Generic

97 620506506 Baffle, Hopper

98 620506513 Hinge, Drain

99 620506514 Drip Tray Ass’y, Gray

100 620506518 Block Connector, Water Lines

101 620506519 Block Connector, Syrup Lines

102 620506531 Housing, Auger

103 N/A N/A

104 620513203 Base, Tower

105 620513307 Block, Wrapper

106 620516602 Cover, Ice Maker Sleeve

107 620517501 Collar, Ice Maker Sleeve

108 620517601 Sleeve, Ice Maker

109 629087456 Seal, Motor Shaft, Auger

110 620701123 Washer

111 620704603 Fitting, Coupling

112 620704606 Cup Rest

113 620705401 Insert

114 620708907 Tube, Ice Transfer

115 620709601 Clip, Pushon

116 620906404 Label, Notice, Ice

117 620913101 Label, Wiring

118 620919303 Label, Wiring Ladder

119 620704101 Strainer, Drip Tray

120 620705201 Pushon Nut, 3/16 Dia.

121 629087430 Kit, Interlock switch bracket

122 620708908 Tube, Bin

123 620710201 Insert, Threaded, 3/8-16

124 620911202 Label, Auger Speed Control

125 620918901 Label, Plumbing

126 638009387 Switch, Bin Control

127 620704001 Retainer, Ice Chute Holdown

128 70171 Screw, No. 8-32 By 3/8-In. Long

129 70076 Nut, No. 8-32

130 620701601 Sheet Metal Screw, No. 10-16

131 70509 Nut, No. 4-40

132 620705801 Sheet Metal Screw, No. 8-18

133 70204 Screw, No. 8-32

Page 25

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