Cornelius PR150 BC Installation Manual

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Operator’s Manual

THE PROFILE™ ICE/DRINK DISPENSER

Model: PR150 BC

Release Date: October 5, 2001

Publication Number: 620918702

Revision Date: March 27, 2014

Revision: G

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 possi ble 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 construction 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 per sons 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-usa.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.

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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

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). . . . . . . . . . . . . . . . . . 8

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

Unit Requiring Remote Carbonator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Adjusting Syrup Source Co2 Regulator.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Adjusting Dispensing Valves Water Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Adjusting Water-to-syrup “ratio” (Brix) Of Dispensed Product . . . . . . . . . . . . . . . . . . . . . . . 10

Start-up And Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Auger Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Cleaning And Sanitizing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cleaning Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1. Cleaning Exterior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. Cleaning Interior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cleaning Dispensing Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Sanitizing Syrup Tanks System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Sanitize B–I–B Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Ice Auger Speed Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Blown Fuse Or Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Agitator Does Not Turn, Auger Does Not Turn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Ice Dispenses Continuously. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Slushy Ice. Water In Hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Agitator Turns, Auger Does Not Turn.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Agitator Turns, Auger Does Not Turn (Cont’d) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Auger Turns, Agitator Does Not. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Beverages Donot Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Beverages Too Sweet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Beverages Not Sweet Enough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Beverages Not Cold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

PR 150 BC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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PR150 BC 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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PR150 BC 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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PR150 BC Ice Drink Dispenser Operator’s Manual

DESCRIPTION

The Undercounter ice dispenser solves your ice service needs in a sanitary, space saving, economical way. Designed to be manually filled with ice this dispenser will dispense cubes (up to 1-1/4” in size), cubelets and hard chipped or cracked ice.

SPECIFICATIONS

Model:

Dimensions

Electrical

Recommended Electrical

Supply

Clearance Required

Drain

or Air Requirements

Flavor Selections

Cup Selection

Ice Requirements

Water Supply

Drink Draw Rate

PR150 BC Ice Drink Dispenser (Eight-Flavor)

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

120 VAC/1 Phase/60 Hz/5.2 Amps Total Current Draw

115 VAC/60 Hz/15.0 Amps, 3-Wire Grounded Circuit

54–In. above counter front access.

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

80-100 PSI supply (preferred) or air = 70 PSI minimum supply.

2 =

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

Five Sizes (12, 16, 21, 32, and 42 0z.)

Ice bin capacity is 150 pounds of ice.

60-PSI flowing pressure (3/4 inch supply with shutoff valve)

Dispenses seven 21 oz. drinks per minute at or below 40° F continuous.

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PR150 BC 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

33 29 4 629087406

34 29 5 629087406

34-1/2 29 5-1/2 629087412

35 29 6 629087412

36 29 7 629087412

DISPENSER

(INCHES

COUNTERTOP INSTALLATION

DEPTH

AVAILABLE SPACE

BELOW DISPENSER

(INCHES)

USE KIT NO.

AND

629087406

AND

620517502

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. 1.2-1976; 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 connections and fixtures directly connected to a potable water supply shall be sized, installed, and maintained according to federal, state and local laws.

1. Locate the dispenser indoors on a level countertop.



must

The dispenser opening that dimension on 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

2. The drain tube is routed through the large opening in the bottom of the dispenser. See the MOUNTING TEMPLATE (see Figure 1) for locating the required clearance hole in the countertop for these utility lines. The power cord is routed through hole in the side of the dispenser electrical control box.

3. SINK DRAIN ASSEMBLY: Connect the drain tube to an open drain. Additional drain tubing is provided with the Dispenser. The drain tube result.

A. Use 3/4-inch nominal plastic pipe. B. To assure proper drainage,

must

bottom of the dispenser.

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

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

must

be wiped away immediately.

must

continuously pitch downward and contain no “traps” or improper drainage will

do not

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

Be sure

drain line runs flat with

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PR150 BC Ice Drink Dispenser Operator’s Manual

COUNTER CUTOUT FOR UNIT DROP IN

FRONT OF COUNTERTOP

FOOT PRINT OF UNIT ON COUNTERTOP

29 - 5/8

27-3/16

25-3/4

31-7/8

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 LINE SHOWS THE AMOUNT OF OVERHANG FOR THE DISPENSER.

4. Clean the hopper interior (See CLEANING INSTRUCTIONS).

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

Figure 1. Mounting Template

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PR150 BC Ice Drink Dispenser Operator’s Manual

Figure 2. Flow Diagram

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PR150 BC 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 cleaning or servicing following all lock out / tag out procedures established by the user. Verify all of the 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 CO2 supply to the system.

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

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.

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PR150 BC Ice Drink Dispenser Operator’s Manual

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).

2. Remove ice from hopper and clean and sanitize the hopper. (See the Cleaning the interior surfaces section shown later in 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 unit’s splash and cold plate cover to clean and sanitize the cold plate surface. (See the cleaning the cold plate section shown later in this manual).

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PR150 BC Ice Drink Dispenser Operator’s Manual

Unit Requiring Remote Carbonator

Adjust CO2 regulator for the remote carbonator to CO

pressure specified in manual provided with the carbonator.

Adjusting Syrup Source CO2 Regulator.

SUGAR SYRUP TANKS CO2 REGULATOR



Adjust syrup tanks CO

SYRUP PUMPS (BAG–IN–BOX SYSTEM)



Adjust the syrup pumps CO

regulator to a minimum of 45–psi.

regulator to 70–psi.

DO NOT EXCEED MAXIMUM CO2 PRESSURE SPECIFIED ON

THE SYRUP PUMPS.

ADJUSTING DISPENSING VALVES WATER FLOW RATE

(see Figure 3)

1. Remove cover from the dispensing valve by lifting the front cover up 1/4 inch and pulling forward.

2. Install syrup diversion tube assembly on the dispensing valve by pushing rubber end of the syrup diversion

tube onto the syrup outlet of the inner nozzle.

3. Measure the water flow rate by dispensing water into a graduated cup for a set period of time.

NOTE: Adjusting screw stops are built into the valve to prevent leakage when the screws are adjusted too far clockwise. Stop adjusting clockwise when turning resistance increases. Turn the screw counterclockwise 1-1/2 turns after the stop are contacted.

4. Turn the water flow regulator adjusting screw to the left (counterclockwise) to decrease the water flow rate or

turn the adjusting screw to the right (clockwise) to increase the water flow rate, then recheck the flow rate. Adjustments should be no more than 1/4 turn at a time.

5. Remove syrup diversion tube from the dispensing valve, then install cover on the dispensing valve.

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PR150 BC Ice Drink Dispenser Operator’s Manual

WATER FLOW

REGULATOR

SYRUP FLOW

REGULATOR

INNER NOZZLE

NOZZLE

SYRUP DIVERSION

TUBE

RATIO CUP

Counterclockwise

to Decrease

Clockwise

to Increase

Figure 3. UF–1 Dispensing valve

ADJUSTING WATER-TO-SYRUP “RATIO” (BRIX) OF DISPENSED PRODUCT

(see Figure 3)

NOTE: Make sure the dispensing valve water flow rate is as desired before adjusting the valve for Water– to–Syrup ‘‘Ratio’’ (Brix) of the dispensed product.

Adjust Water-to-Syrup “Ratio” (Brix) of the dispensed product by using ratio cup (P/N 311100000) and syrup diversion tube assembly (P/N 319540000) as follows:

1. Remove cover from the dispensing valve by lifting front cover up 1/4 inch and pulling forward.

2. Install syrup diversion tube assembly on the dispensing valve by pushing the rubber end of the syrup diversion

tube onto the syrup outlet of the inner nozzle.

NOTE: Refer to syrup manufacturer’s recommendations on syrup package for water–to–syrup ratio.

3. Dispense enough to fill syrup diversion tube with syrup.

4. Hold large chamber of the ratio cup under the dispensing valve nozzle. Place free end of the syrup diversion

tube into the syrup chamber marked for the proper ratio. Dispense approximately 6 ounces of water into the ratio cup. Water and syrup levels should be even in cup.

NOTE: Adjusting screw stops are built into the valve to prevent leakage when the screws are adjusted clockwise too much. Stop adjusting clockwise when turning resistance increases. Turn the screw counterclockwise 1-1/2 turns after the stop are contacted.

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PR150 BC Ice Drink Dispenser Operator’s Manual

5. Adjusting Syrup Flow Regulator - If water and syrup levels are uneven in the ratio cup, adjust by  turning the dispensing valve syrup flow regulator adjusting screw labeled SYRUP as follows.

A. For less syrup, turn the adjusting screw counterclockwise no more than 1/4 turn at a time.

B. For more syrup, turn the adjusting screw clockwise no more than 1/4 turn at a time.

6. Repeat water–to–syrup ratio test and adjust syrup flow regulator as many times as necessary until proper ratio of dispensed drink is achieved.

7. Remove syrup diversion tube assembly from dispensing valve.

8. Install dispensing valve front cover.

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PR150 BC Ice Drink Dispenser Operator’s Manual

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.

If the dispenser fails to dispense beverage or ice, refer to TROUBLESHOOTING in back of the manual.

AUGER ASSEMBLY BREAKDOWN

1. For cleaning, the auger assembly is constructed for simple (tools not required) breakdown. First remove the tower cover (item 69) by removing the 2 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 67). Take not so that when reassembling the ice chute, the auger gate cradles 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 will be necessary to rotate the auger after insertion in the tube to engage the motor shaft.

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PR150 BC Ice Drink Dispenser Operator’s Manual

Figure 4. Auger Assembly

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PR150 BC Ice Drink Dispenser Operator’s Manual

CAUTION:

CLEANING AND SANITIZING INSTRUCTIONS

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

Sanitizing Solution solution to this ratio will create a solution of 200 PPM.

Cleaning Dispenser

1. CLEANING EXTERIOR SURFACES

IMPORTANT: Perform the following daily.

A. Remove cup rest from the drip tray.

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

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

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

- Use 1/2-ounce of household bleach in one gallon of potable water. Preparing the sanitizing

2. CLEANING INTERIOR SURFACES

When pouring liquid into the hopper, do not exceed the rate of 1/2-gallan per minute.

IMPORTANT: Perform the following at least once a month.

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

B. The drip tray can be removed from the dispenser by grasping at rear side panels and pulling gently

outward.

Figure 5. Drip Tray and Rear Cover Removal

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PR150 BC Ice Drink Dispenser Operator’s Manual

C. Remove agitator disk and agitator assembly.

D. Remove tower cover by removing two thumb screws.

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

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

auger.

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

fully removed.

H. 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.

I. 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.

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

K. 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.

L. 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 right and left covers. Allow to air dry.

M. 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 guide 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 upper auger and chute assembly onto the auger and lock down by snapping the ball onto the upper housing. Reinstall the tower cover with the thumb screws.

N. Reinstall the covers. Put the right cover on first before you close the left cover.

3. Last are the auger housings (Items 74 and 75). They are dislodged by pulling upward. Check their orientation and the fact that the longer tube is on the front side. When positioning the housings back in the dispenser, the longer tube should be placed first so as to seat in the lower housing to set up the orientation (top and bottom are marked on end of the tube tab at the top), otherwise the ice chute spout will not point towards the front of the dispenser.

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PR150 BC Ice Drink Dispenser Operator’s Manual

CLEANING DISPENSING VALVES

Refer to addendum supplied with the unit that is applicable to the manufacturer of the valves installed  on the unit.

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

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.

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

system.

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.

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PR150 BC Ice Drink Dispenser Operator’s Manual

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 4). The CB 1 control board is located inside the electrical control box which is below the counter facing towards the front of the counter. Removing the three screws and cover will expose the CB 1 Control board. By turning the potentiometer knob located on the CB1 control board CCW (counterclockwise) will increase the speed of the ice delivery. Turning the potentiometer knob CW (clockwise) will decrease the speed of the ice delivery.

Figure 6. Ice Auger Speed Control

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PR150 BC Ice Drink Dispenser Operator’s Manual

Figure 7. Wiring Diagram

Page 23

PR150 BC Ice Drink Dispenser Operator’s Manual

Figure 8. Ladder Diagram

Page 24

PR150 BC 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 CO2 system, stop dispensing, shut off the CO2 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 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 to aid in locating the defect.

Trouble Probable Cause Remedy

BLOWN FUSE OR CIRCUIT BREAKER

A. Short circuit in electrical wiring. A. Repair electrical wiring.

AGITATOR DOES NOT TURN, AUGER DOES NOT TURN.

ICE DISPENSES CONTINUOUSLY.

SLUSHY ICE. WATER IN HOPPER.

B. Inoperative 24 VAC

transformer.

C. Inoperative agitator motor. C. Replace agitator motor.

D. Shorted motor. D. Replace Agitator Auger motor.

A. No electrical power. A. Restore electrical power.

B. Bent depressor plate (does not

actuate switch).

C. Inoperative dispensing switch. C. Replace dispensing switch.

D. Inoperative interlocks, lids not

closed.

E. Inoperative timer board. E. Replace timer board.

F. Inoperative 24 VAC

transformer.

A. Stuck or bent depressor plate

(does not release switch).

B. Inoperative dispensing switch. B. Replace dispensing switch.

C. Improper switch installation. C. Correct switch installation.

D. Inoperative timer board. D. Replace timer board.

A. Blocked drain. A. Unplug and flush out the drain.

B. Replace transformer.

B. Replace depressor plate.

D. Replace interlocks.

F. Replace transformer.

A. Replace depressor plate.

B. Unit not sitting level. B. Level the unit.

C. Poor ice quality due to water

quality or icemaker problems.

D. Improper use of flaked ice. D. Use correct ice.

AGITATOR TURNS, AUGER DOES NOT TURN.

A. Inoperative auger motor. A. Replace auger motor.

B. Inoperative or improper setting

of speed control.

C. Inoperative rectifier. C. Replace rectifier.

C. Install water filter system. For

icemaker problems, consult icemaker manual.

B. Replace speed control or re-adjust

speed control.

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PR150 BC Ice Drink Dispenser Operator’s Manual

AGITATOR TURNS, AUGER DOES NOT TURN (CONT’D)

AUGER TURNS, AGITATOR DOES NOT.

BEVERAGES DONOT DISPENSE

BEVERAGES TOO SWEET.

BEVERAGES NOT SWEET ENOUGH

D. Ice jam. D. Clear ice jam.

E. Inoperative timer board. E. Replace timer board.

A. Inoperative agitator motor. A. Replace agitator motor.

B. Inoperative motor capacitor. B. Replace motor capacitor.

C. Inoperative timer board. C. Replace timer board.

A. No 24 volts to dispensing

valves.

A. Make sure unit is connected to

electrical power. Check 24 VAC transformer.

B. No CO2 pressure. B. Check CO2 regulator. Check CO

tank pressure.

A. Carbonator not operating. A. Consult carbonator manual.

B. No CO2 Pressure in carbonator. B. Check CO2 regulator. Check CO

tank pressure.

C. Dispensing valve brix requires

re-adjustment.

C. Refer to dispensing valve

manufacturer for brix adjustment instructions.

A. Depleted syrup supply. A. Replenish syrup supply.

B. Dispensing valve brix requires

re-adjustment.

B. Refer to dispensing valve

manufacturer for brix adjustment instructions.

BEVERAGES NOT COLD.

A. Unit standing with no ice in it’s

A. Replenish ice supply.

hopper.

NOTE: Contact your local syrup or beverage equipment distributor for additional information and trouble shooting of your beverage system.

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PR150 BC Ice Drink Dispenser Operator’s Manual

1234

139

122

133

118

114

142

141

134

115

116

121

24.

136

105

110

112

109

117127

103

4142

137

131

106

132

146

160

161

ILLUSTRATED PARTS LIST

101

Page 27

145

140

124

126

125

124

138

120

119

104

113

111

26 32

102

123

100

130

69 20 18 19 97

146

148

147

157

152

155

158

156

149

157

159

157

154

156 151

157

153

160 161

PR150 BC Ice Drink Dispenser Operator’s Manual

107

81445

Page 28

PR150 BC Ice Drink Dispenser Operator’s Manual

108

135

144

129

Page 29

PR150 BC Ice Drink Dispenser Operator’s Manual

PR150BC ASSEMBLY

Item

Part No. Name

No.

1 1919 Mounting Block Ass’y, UF–1

2 1950 Cover, Valve, Back

3 1951 Cover, Valve, Front

4 1966 Dispensing Valve

5 15087 Retainer, Agitatotr

6 27107 Retainer, Ice Lever

7 29303R Plate, Motor Mount

9 02070 Kit Switch, includes switch, boot, and spacer

11 31007 Boot, Switch

12 31827 Wire Harness, Dispensing Valve

13 31981 Actuator

16 32953 Reed Switch Ass’y

17 32977 Switch, Key

22 50458 Strain Relief

23 50573 Snap Bushing, .375 I.D.

24 50951 Fitting, Elbow

25 51859 Seal, Motor Shaft

26 52132 Adhesive, Locktite

27 52876 Gasket, Motor Shaft

28 620911202 Label, Operate Auger Speed

29 70018 Hex Nut, 1/4–20 Keps

30 70023 Hex Nut, No. 4–40 STCA Keps

31 70048 Washer, .449 I.D.

32 70260 Machine Screw, Phil Rd Hd, 1/4–20 By 1–In. Long

33 70320 Pop Rivet, 125 Dia.

34 70847 Spacer, Switch

35 70894 Machine Screw, Phil Truss Hd, No. 8–32 By 3/4–In. Long

36 70959 Nut, No. 8–32

37 70992 Receptacle, 1/4 Turn

38 70993 Retainer, 1/4 Turn

39 70994 Stud, Wing Hd, 1/4 Turn

40 71028 Bolt, 1/4–20

41 720509208 Fitting, Push Connector, 3/8 By 3/8–NPTF

30794 32826

30995 620302901

620307901 32824

620913101 620919341

Heater, Agitator Motor, 115v Heater, Agitator Motor, 230v

Cord Ass’y, 115v Cord Ass’y, 230v

Gear Motor Kit, 115/120V 50/60HZ, includes motor, seal gasket, and hardware Gear Motor, 230v 50/60HZ

Label, Wiring 115v Label, Wiring 230v

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PR150 BC Ice Drink Dispenser Operator’s Manual

PR150BC ASSEMBLY (CONT’D)

Item

Part No.

No.

42 750700502 Clip, Locking, 3/8

43 620919303 Label, Wiring Ladder

44 638009387 Switch, Bin Control

45 90432 Label, Warning, Disconnect

46 90580 Label, Identification Data

47 90629 Label, Clean Hopper

48 91486 Medallion, Cornelius Logo

49 91956 Label, Warning Chiller Disconnect

50 92067 Label, Operation, Agitation Timer

51 92305 Label, Notice Transformer

52 31525003 O–Ring, .239 I.D. By .070 CS

53 31525017 O–Ring, .426 I.D. By .070 CS

54 620028201 Base, Cabinet

59 620028211 Cover, Tower Top

63 620028218 Agitator Ass’y

65 620028226 Bolt, 1/4–20

66 620028227 Bracket, Leg Adapter

67 620028232 Support Bracket, Auger Motor

70 620028223 Plate, Mounting

71 620028246 Stiffener, Base

72 620028249 Plate, Syrup Lines Alignment

620028202 620028252

620028204 620028269

620028205 620028254

620028209 620028256

620028213 620028255

620028214 620028257

620028216 620028258

620028222 620028261

620028234 620028263

620028235 620517201

Name

Plate, Motor Mount LH Plate, Motor Mount RH

Cover, Access LH Cover, Access RH

Wrap, Cabinet LH Wrap, Cabinet RH

Tower, Valve Mounting LH Tower, Valve Mounting RH

Wrap, Cabinet, Front LH Wrap, Cabinet, Front RH

Electrical Box LH Electrical Box RH

Panel, Base LH Panel, Base RH

Cover, Electrical Box LH Cover, Electrical Box RH

Bracket, Lower Motor Mount LH Bracket, Lower Motor Mount RH

Hopper Ass’y LH Hopper Ass’y RH

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PR150 BC Ice Drink Dispenser Operator’s Manual

PR150BC ASSEMBLY (CONT’D)

Item No.

Part No.

73 620028250 Plate, Water Lines Alignmen

74 620028253 Bracket, Auger Motor Mount, Right–Hand

75 620028270 Plate, Auger Motor Spacing

76 620028282 Cover, Inlet Lines

77 620906404 Label, Ice Notice

78 620043104 End Cap, Hinge, Left–Hand

79 620043105 End Cap, Hinge, Right–Hand

80 620043201 Insulation Box Foamed

81 620043206 Icemaker Sleeve Mounting Box

82 620043507 Lid, Ice Fill, Back

84 620044614 Plate, Deflector

86 620045301 Bracket, Reed Switch

88 620045904 Bracket, Dispense Switch

89 620045958 Bracket Ass’y, Interlock Switch

90 620046005 Cover, Reservoir

91 620046017 Cover, Bin Thermostat

92 620048102 Panel, Tower, Back

93 70076 Hex Nut, Keps, No. 8–32

94 70188 Screw, Knurled Hd, No. 8–32

95 70204 Screw, Self–Tapping, No. 8–32

97 620711401 Insulation, Stop Ice Conduit

98 629088578 SuperSeal Kit

100 620314201 Connector, Power Inlet

101

102

103 620403008 Pump, Recirculating

104 629087415 Drain Tray with Elbow Kit

105

620044601 620044602

620045724 620045727

629087456



629087489

620403001 620403002

620407601 620407622

Name

Plate, Pump Mounting LH Plate, Pump Mounting RH

Base, Tower LH Base, Tower RH

SuperSeal Upgrade Kit - units built before 2/02/2001 (Includes Motor, Seals, and Motor Housing) Motor and SuperSeal Asy Kit - units built after 2/01/2001 (Includes Motor and Seals)

Cold Plate LH Cold Plate RH

Coil Pack Ass’y LH Coil Pack Ass’y RH

Page 32

PR150 BC Ice Drink Dispenser Operator’s Manual

PR150BC ASSEMBLY (CONT’D)

Item

Part No.

No.

106 620407801 Fitting, Nipple, 1/2 By 1/2 NPTF

107 620503801 Agitator, Disk

108 620918901 Label, Plumbing

109 620504001 Ice Chute

110 620504002 Cover, Ice Chute

111 620504006 Seal, Hopper Conduit

112 620504011 Gate, Auger

113 620504021 Fitting, Elbow

114 620505502 Auger

115 620505703 Tube Ass’y, Auger, Front

116 620505704 Tube Ass’y, Auger, Back

117 620506512 Reservoir, Recirculating

118

119 620506518 Block, Connector, Water Lines

120 620506519 Block, Connector, Syrup Lines

121 620506531 Housing, Auger

122 620517136

123

124 620516602 Cover, Icemaker Sleeve

125 620517501 Collar, Icemaker Sleeve

126 620517601 Sleeve, Icemaker

127 620202849 Propylene Glycol

128 620700602 Sheet Metal Screw, Phil Rd Hd, No. 10–16 By 1–In. Long

129 620701123 Washer, 9/16 I.D.

130 620718101 Strainer, Drip Tray

131 620704603 Coupling

132 620704604 Fitting, 3/8 By 1/2 MPT

133 620708524 Cup Rest

134 620705201 Pushon Nut, 3/16

135 620705401 Insert Nut, 1/2–13

136 620705501 Retainer, Ice Chute Holddown

137 620708202 Plug

138 620708908 Tube, Bin Stat

139 620709301 Lever, Ice

140 620709601 Clip, Pushon

141 620709604 Clip, Back Lid, Left–Hand

620506513 620506538

620517138

Name

Hinge, Drain Trough LH Hinge, Drain Trough RH

Drip Tray Ass’y Black, LH Drip Tray Ass’y Black, RH

Page 33

PR150 BC Ice Drink Dispenser Operator’s Manual

PR150BC ASSEMBLY (CONT’D)

Item

Part No.

No.

142 620707605 Clip, Back Lid, Right–Hand

143 620709901 Pop Rivet, 125 Dia.

144 620710201 Insert, 3/8–16

145 620710301 Stop, Insulation Foam Inlets

146 50336 PVC Pipe, 3/4

147 30514

620045302

148 30774

620314301

149 31107 Terminal Board

150 33617 Wire Harness, Agitator Motor

151 449999999

560002114

152 70223 Screw, No. 10–32 By 3/4–In. Long

153 33082 Relay

154 620311701

620311702

155 70015 Hex Nut, No. 10–32

156 70147 Sheet Metal Screw, Phil Rd Hd, No. 6 By 1/2–In. Long

157 70217 Sheet Metal Screw, No. 8 By 1/2–In. Long

158 32244 Terminal Board, 230V only

159 620307301 Filter

160 50158R Armaflex

161 50326 Armaflex Tape

162 620307301 Filter RFI 230v only

163 620304601 Varistor Ass’y 230v only

164 629087412 6” Leg Kit (Not Shown)

165 629087430 Interlock Switch Bracket Kit (Not Shown)

166 70739 Key, Keyswitch Replacement (Not Shown)

Name

Strap, Capacitor 115V Strap, Capacitor 230V

Capacitor, Agitator Motor 115v Capacitor, Agitator Motor 230v

Transformer, 120V 60HZ Transformer, 230V 60HZ

Timer, Agitator 115V Timer, Agitator 230V

Page 34

PR150 BC Ice Drink Dispenser Operator’s Manual

Page 35

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Cornelius Inc.

www.cornelius.com