Cornelius NITROPRO MINI Service And Preventative Maintenance Manual

SPECIALTY BEVERAGE DISPENSER

NITROPRO MINI

Service and Preventative Maintenance Manual

Release Date: 2/15/19

Publication Number: 548000106SER

Revision Date: 2/15/19

Revision: Rev. 2.0 Model: CNB Mini

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The products, technical information, and instructions contained in this manual are subject to change without notice. These

RECYCLE

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 equip ment 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 construction requirements are being met, in addition to the information contained in this manual.

This Product is warranted only as provided in Cornelius’ Commercial Warranty 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.

‐

This document contains the original instructions for the unit described.

CORNELIUS INC

101 Regency Drive

Glendale Heights, IL

Tel: + 1 800‐238‐3600

Printed in U.S.A.

Correct Disposal of this Product

This marking indicates that this product should not be disposed with other household wastes throughout the EU. To prevent possible harm to the environment or human health from uncontrolled waste disposal, recycle it responsibly to promote the sustainable reuse of material resources. To return your used device, please use the return and collection systems or contact the retailer where the product was purchased. They can take this product for environmental safe recycling.

Table of Contents

1.0 SAFETY 1

2.0 OVERVIEW AND REQUIRED TOOLS 3

2.1 Nitropro Functions & Specifications 3

2.2 Key Components 4

2.3 Required Tools 6

3.0 SYSTEM OPERATION 7

3.1 Facility Supplies 7

3.2 Operating Processes 8

3.3 Component Functions

3.3.1 Tap Handles 10

3.3.2 Product Concentrate Pump 10

3.3.3 Water Inlet Solenoid 11

3.3.4 Air Compressor & Storage 11

3.3.5 Mixing-Infusion Manifold & Check Valves 11

3.3.6 Dispense Manifold 12

3.3.8 Mixing-Dispensing Assembly 12

3.3.9 Ice Bank Chilling System 13

3.3.10 Front-Door Control Switches 14

4.0 PREVENTATIVE MAINTENANCE 15

4.1 Overview 15

4.2 Maintenance Schedule 15

4.3 Annual Maintenance 15

4.3.1 Refrigeration Condenser & Cabinet Fan Cleaning 15

4.3.2 Ice Bank Level Check 15

4.3.3 Product Pump Mix-Ratio Verification 16

4.3.3.1 Measuring TDS (Total Dissolved Solids) 16

4.3.4 Components Visual Inspection 18

4.3.5 Ice-Bank Sensor & Agitator Check 18

4.3.6 Concentrate-Pump Hose Replacement 19

Table of Contents

5.0 TROUBLESHOOTING 20

Table 5-1 - Systems-Level Troubleshooting 20

Table 5-2 - Drink-Quality Troubleshooting 21

Table 5-3 - Compressed Air & Infusion Troubleshooting 22

Table 5-4 - Dispensing-Function Troubleshooting 23

5.1 Air-Compressor Pressure Verification 24

6.0 COMPONENT REPLACEMENT 25

6.1 Safety Precautions 25

6.3 Access Panel Removal 25

6.3 Main PCB 27

6.4 Mixing-Dispensing Assembly Components 28

6.4.1 Air Pressure Regulator 28

6.4.2 Mixing - Infusion Manifold 29

6.4.3 Dispense Manifold 29

6.4.4 Concentrate Pump 30

6.5 Air Compressor 30

6.5.1 Compressor Air Filter Replacement 30

6.6 Water Inlet Solenoid 31

6.7 Power Supply (24Vdc) 31

6.8 Merchandiser LED Back-Lighting Panel 32

6.9 Ice Bank 32

6.9.1 Ice Sensor Probe 32

6.9.2 Agitator Motor 33

6.9.3 Ice Bank Controller 34

6.9.4 Refrigeration Components 35

6.10 Tap Microswitches 35

APPENDIX A - SYSTEM DRAWINGS 37

Nitropro Mini Service Manual

1.0 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.

Types of Alerts

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

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

CAUTION: 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 labels on the unit.

• Keep safety labels in good condition and replace missing or damaged ones.

• Do not let anyone operate the unit without proper training. This appliance is not intended for use

by untrained or unauthorized persons without supervision.

• Maintain the unit in proper working condition and do not allow any unauthorized modifications.

NOTE: The dispenser is not designed for a wash-down environment and MUST NOT be placed in an area where a water jet could be used.

QUALIFIED SERVICE PERSONNEL



WARNING:

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 COMPLYCOULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE. IF THE SUPPLY CORD IS DAMAGED, IT MUST BE REPLACED BY THE MANUFACTURER, ITS SERVICE AGENT OR SIMILARLY QUALIFIED PERSONS IN ORDER TO AVOID A HAZARD.

Nitropro Mini Service Manual

1.0 SAFETY INSTRUCTIONS (CONT.)

SAFETY PRECAUTIONS

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



DANGER:

Disconnect power to the unit before servicing while following all lock out/tag out procedures established by the user. Verify 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.



CAUTION:

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.

DO NOT STORE EXPLOSIVE SUBSTANCES SUCH AS AEROSOL CANS WITH A FLAMMABLE PROPELLANT IN THIS APPLIANCE.

UNTRAINED AND UNAUTHORIZED INDIVIDUALS SHALL NOT OPERATE THE APPLIANCE OR PERFORM  ANY CLEANING OR USER-MAINTENANCE PROCEDURES.

SHIPPING AND STORAGE



CAUTION:

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.

MOUNTING IN OR ON A COUNTER



DANGER:

When installing the unit in or on a counter top, the counter must be able to support a weight in excess of 140 lbs. (63.5 kg.) to insure adequate support for the unit.

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.

THE APPLIANCE MUST BE ORIENTED IN A VERTICAL POSITION.

2.0 OVERVIEW AND REQUIRED TOOLS

2.1 Nitropro Functions & Specifications

The Nitropro Mini dispenses still or air-injected, chilled Nitro coffee at the pull of a tap handle. Opening a tap automatically engages the product mixing pump (as well as the air pump for the injected-coffee selection). The dispensing unit requires facility electrical and water inputs; Nitro infusion gas is generated within the unit.

• Coffee syrup from a product container is automatically mixed with water at the selected ratio (with mix ratios user-selectable via a DIP switch on the main control PCB)

• Nitro coffee is created via its dispensing circuit including a gas-infusion (air-injection) manifold prior to the tap (dispensing) valve

• Metering of the product concentrate is performed by a servo-driven, peristaltic pump

• Water inlet rate is fixed and controlled by an inlet solenoid valve assembly that also provides pressure limiting and flow control

• Chilling of the product cabinet and mix water is performed by an automatically-controlled ice bank at the base of the enclosure

Water Supply Pressure

Water Supply Flow Rate

Water Temperature 40 - 90° F. (4.4 - 32.2° C)

Water Inlet Size

Table 2-5 - General | Dimensions | Weight

Unit Height 34.05 in. (86.5 cm)

Unit Width 10.44 in. (26.5 cm)

Unit Depth 24.47 in. (62.2 cm)

Clearance Requirements

Unit Weight (Dry) 120 lbs (54.4 kg)

Operating Weight 185 lbs (84.0 kg)

Ambient Operating Temperature

Nitropro Mini Service Manual

Table 2-4 - Water Requirements

35 psig (241 kPa) Min. 90 psig (621 kPa) Max. (if >90 psi, install external pressure regulator, set @ 50 psi)

3 fl. oz. (88.7 ml) per second, minimum

3/8 in. (0.95 cm) SAE male flare fitting on dispenser

Back: 4” (10.16 cm) Top: 12” (30.48 cm) Sides: 4” (10.16 cm)

50 to 90 °F (10 to 32 °C)

Table 2-1 - Electrical Specifications

Models

Mini 115 5 1 60

CNB

Mini 230 2 1 50

VAC Amps Ph Hz

Ice Bank Capacity 7-8 lbs. (3.2-3.6 kg.)

Temp. Pull Down Time 3 hours at 75 °F (24 °C)

Table 2-6 - Ice Bank Specifications

Table 2-2 - Refrigerant Type

Refrigerant

Oz Grams Type

5.64 160 R-134a

Table 2-3 - Refrigeration Nameplate Values

Pressure psi (kPa) [bar]

High

side Low side

315 (2171.9) [21.7

] 140 (965.3) [9.7]

Nitropro Mini Service Manual

Figure 2-1 - Front LED-Backed Merchandiser Removal

2.0 BREWER OVERVIEW AND REQUIRED TOOLS (Cont.)

2.2 Key Components

The Nitropro Mini consists of these main controls and components (refer to Figs. 2-1 and 2.2).

Dispensing Taps (for Still & Nitro Coffee)

Allow coffee dispensing. Pulling of tap handle triggers switch that activates outlet solenoid valve (in dispense manifold); also turns on water inlet solenoid valve and concentrate pump to initiate flow.

Ice Bank (Water Reservoir and Refrig. Unit)

Water/ice-filled reservoir for chiller lines. Includes controller to manage refrigeration compressor, bath agitator, circulation pump and temperature/ice sensor.

Air Compressor & Storage Chamber

Provides air to the gas-infusion manifold. Stores compressed air to support high drink volumes. The compressor is independent and is activated by the storage-chamber pressure switch. Storage outlet routes to a pressure regulator prior to entering the infusion manifold.

System Controller Board (Main PCB)

Manages system events and device interactions. Includes adjustable DIP switch for concentrate-pump ratio selection. Also includes PCB switches for fine-tuning the ratio selection.

24Vdc Power Supply

Provides power to Main PCB and the air compressor.

Concentrate Pump

Meters input of coffee product from BIB (Bag In Box) to mixing manifold. Peristaltic pump, servo-motor driven.

Product-Mixing & Gas-Infusion Manifold

Interconnected plastic blocks with check valves and a mixing chamber for mixing, airinjecting and routing of coffee concentrate, water and air to the dispense manifolds. Three check valves control flow routing by preventing backflow.

Dispense Manifolds

Tap-handle activated, outlet solenoid valve. Outlet valve allows product dispensing.

Water-Inlet Solenoid Valve/Regulator

Solenoid valve allows water inlet. Regulator limits inlet pressure & flow rate.

Nitropro Mini Service Manual

2.0 BREWER OVERVIEW AND REQUIRED TOOLS (Cont.)

2.2 Key Components (Cont.)

Figure 2-2 - Main Components

Nitropro Mini Service Manual

2.0 BREWER OVERVIEW AND REQUIRED TOOLS (Cont.)

2.3 Required Tools

These tools are required for conducting the various procedures in this manual. You may find it helpful to review the Troubleshooting and Component Replacement sections to determine what additional tools you might prefer to include.

HAND TOOLS

ELECTRICAL TOOLS

Multimeter - Digital VOM

1000V/10A ac/dc, milliohm to megohm, millivolt, auto-ranging, ±2.5% +1 digit accuracy

Wrenches - SAE Open-end or Combination

(1/4” through 7/8”)

Wrenches - Adjustable

(2” x 6”- 8” Length, Crescent)

Nut Driver Set - SAE

Pliers - Adjustable

Channel-Lock/Knipex-style

Pliers - Needlenose

Flat Screwdriver

3/16”

Phillips Screwdrivers

#2 & #0 (6” Length) #2 Stubby or Flex-shaft

Diagonal Cutting Pliers

Pick Set - Dental Type

Magnetic Pickup Wand

Temp erat ure Mete r & P rob e

±2.5% +1 digit accuracy

Cordless Drill or Screwdriver

With Screwdriver Bits / Nut Drivers

Flashlight

Portable Vacuum Cleaner

With hose and crevice tool

SUPPLIES

O-Ring Lubricant/Sealant Food-Grade Silicone

Dow Corning Molykote 111 or equiv.

Solvent - Nonflammable

Tefl on T hre ad- sea lin g Ta pe

Lint-free Cloth Rags

Cleaning Brushes

Bristle and Wire

Air Pressure Gauge

Capable of 100 psi (689 kPa) with high-pressure hose and 1/4”push-connect fitting

Hose-Clamp Crimping/Cutting Tool

Oetiker HIP 2800 Es

3.0 SYSTEM OPERATION

Figure 3-1 - Power Input Figure 3-2 - Water Input

This section describes how the Nitropro Mini dispenser operates. By grasping the details of the operating process for still and Nitro coffee dispensing, you will have the knowledge to detect many of the common malfunctions.

3.1 Facility Supplies

Electrical: Depending on model and application,

the unit operates from either 115Vac or 230Vac that enters the unit through a back-panel cord socket, as shown in Fig 3-1. Input AC power is supplied to the ice bank controller (which manages the refrigeration compressor and the ice-bath agitator motor). AC power is also routed to the 24Vdc power supply which provides power to the Main PCB and the air pump. The Main PCB then provides 24V power to the remainder of the DC components.

Nitropro Mini Service Manual

Water: Store water enters the unit through a rear inlet solenoid valve within the pressure range indicated in Figure 3-2. The inlet solenoid valve activates when a dispensing tap is pulled. The inlet solenoid assembly also provides input pressure control [29 psi (200 kPa) - fixed] and flow-rate limiting within the range of 1 to 1.25 fluid ounces (29.6 to 37 ml) per second.

Inlet water is first routed to the ice bank for chilling and then is supplied to the mixing-infusion manifold.

Nitropro Mini Service Manual

Left Tap Handle - Still Coffee Dispensing

Figure 3-3 - Still Coffee Dispense Process

Step 1) Left tap handle is pulled. Step 2) Left Dispense switch is depressed, activating (via Main PCB):

Dispense Manifold Solenoid Valve (allows front dispensing) Concentrate Pump (delivers coffee concentrate to Mixing Manifold) Inlet Solenoid (delivers water to Mixing Manifold)

Action: Water and coffee concentrate combine in the mixing manifold and then flow to the dispense manifold and into the serving cup. NOTE: There is no flow in the Nitro-coffee circuit and infusion manifold since its dispense valve is closed. The low-pressure path is to the still-coffee dispense manifold in which the dispense solenoid valve is open.

3.0 SYSTEM OPERATION (Cont.)

3.2 Operating Processes

3.0 SYSTEM OPERATION (Cont.)

Right Tap Handle - Nitro Coffee DispensingRight Tap Handle - Nitro Coffee Dispensing

Figure 3-4 - Nitro Coffee Dispense Process

Step 1) Right tap handle is pulled. Step 2) Right Dispense switch is depressed, activating (via Main PCB):

Dispense Manifold Solenoid Valve (allows front dispensing) Concentrate Pump (delivers coffee concentrate to Mixing Manifold) Inlet Solenoid (delivers water to Mixing Manifold)

Action: Water and coffee concentrate combine in the mixing manifold, are then infused with air in the gas infusion manifold and then flow to the Nitro dispense manifold and into the serving cup. NOTE: There is no flow in the still-coffee circuit since its dispense valve is closed. The low-pressure path is to the Nitro-coffee dispense manifold in which the dispense solenoid valve is open.

3.2 Operating Processes (Cont.)

Nitropro Mini Service Manual

Figure 3-5 - Tap Handles / Microswitch Assemblies

Figure 3-6 - Microswitch Assembly

Figure 3-7 - Concentrate Pump

Figure 3-8 - Ratio Select Switch & Tuning Buttons

3.0 SYSTEM OPERATION (Cont.)

3.3 Component Functions

3.3.1 Tap Handles

The dispensing tap handles (Fig.3-5), when pulled, activate microswitches (Fig. 3-6) that signal the Main PCB to activate specific components, as described previously in section 3.2.

3.3.2 Coffee Concentrate Pump

This pump (Fig.3-7) draws coffee concentrate from the chilled Bag In Box (BIB) and meters it to the mixing manifold at a specific, user-selected ratio to the input water (which is supplied at a fixed pressure and flow rate).

Mixing ratios are adjusted by changing the DIP switch settings on the Main PCB mounted beneath the cabinet, as shown in Figure 3-8. Adjustment of these settings changes the speed of the peristaltic pump to provide more or less concentrate per unit time.

The selectable ratios provide, from one gallon of concentrate, the coffee yields shown in Table 3-1. (NOTE: Select one ratio - one switch ON.)

Table 3-1 - Concentrate Pump Ratios

Ratio

3:1 Switch 1 ON 1 4

4:1 Switch 2 ON 1 5

5:1 Switch 3 ON 1 6

7:1 Switch 4 ON 1 8

Main PCB

Switch Setting

Concentrate

Gallons

Coffee Yield

Gallons

Ratio Tuning Buttons: One press of a button changes the pump motor speed by 5 RPMs (or by

0.02 - 0.08 of the average TDS value).

The peristaltic pump is driven by a 24V DC servo motor. A maintenance kit for the pump includes a replacement pump hose with nipple ends.

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Cornelius NITROPRO MINI Service And Preventative Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual