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IMI CORNELIUS INC
www.cornelius.com
Telephone (800) 238–3600
Operator’s Manual
THE PROFILEtICE/DRINK DISPENSER
Model: PR150 BC
IMPORTANT:
TO THE INSTALLER.
It is the responsibility of
the Installer to ensure that
the water supply to the
dispensing equipment is
provided with protection
against backflow by an air
gap as defined in
ANSI/ASME A112.1.2-1979;
or an approved vacuum
breaker or other such
method as proved effective
by test.
Water pipe connections
and fixtures directly
connected to a potable
water supply shall be
sized, installed, and
maintained according to
Federal, State, and Local
Codes.
Part No. 620918702
October 5, 2001
Revision Date: February 27, 2007
Revision: D
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 2001–2007©
PRINTED IN U.S.A
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TABLE OF CONTENTS
SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOGNIZE SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDERSTAND SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOLLOW SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO2 (CARBON DIOXIDE) WARNING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIPPING, STORING, OR RELOCATING UNIT 1. . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PRECAUTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COUNTERTOP INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY (OR AS REQUIRED) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MONTHLY 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO2 REGULATORS ADJUSTMENTS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING DISPENSING VALVES WATER FLOW RATE 9. . . . . . . . . . . . . . . .
ADJUSTING WATER-TO-SYRUP “RATIO” (BRIX) OF DISPENSED 10. . . . . . . .
START–UP AND OPERATING INSTRUCTIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUGER ASSEMBLY BREAKDOWN 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING AND SANITIZING INSTRUCTIONS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING DISPENSER 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING DISPENSING VALVES 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZING SYRUP TANKS SYSTEM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZE B-I-B SYSTEMS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICE AUGER SPEED CONTROL 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOWN FUSE OR CIRCUIT BREAKER 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AGITATOR DOES NOT TURN, AUGER DOES NOT TURN. 19. . . . . . . . . . . . . . . . .
ICE DISPENSES CONTINUOUSLY. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SLUSHY ICE. WATER IN HOPPER. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AGITATOR TURNS, AUGER DOES NOT TURN. 19. . . . . . . . . . . . . . . . . . . . . . . . . .
AGITATOR TURNS, AUGER DOES NOT TURN (CONT’D) 20. . . . . . . . . . . . . . . . . .
AUGER TURNS, AGITATOR DOES NOT. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES DONOT DISPENSE 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES TOO SWEET. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES NOT SWEET ENOUGH 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES NOT COLD. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ILLUSTRATED PARTS LIST 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PR150BC ASSEMBLY 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PR150BC ASSEMBLY (CONT’D) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PR150BC ASSEMBLY (CONT’D) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PR150BC ASSEMBLY (CONT’D) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
FIGURE 1. MOUNTING TEMPLATE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. FLOW DIAGRAM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. UF-1 DISPENSING VALVE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. AUGER ASSEMBLY 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 5. DRIP TRAY AND REAR COVER REMOVAL 13. . . . . . . . . . . . . . . . . . . .
FIGURE 6. ICE AUGER SPEED CONTROL 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 6. WIRING DIAGRAM 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7. LADDER DIAGRAM 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SAFETY INFORMATION
Recognize Safety Information
This is the safety-alert symbol. When you see this
symbol on our machine or in this manual, be alert to
the potentially of personal injury.
Follow recommended precautions and safe operating
practices.
Understand Signal Words
A signal word - DANGER, WARNING, OR CAUTION
is used with the safety-alert symbol. DANGER identi-
fies the most serious hazards.
DANGER
Safety signs with signal word DANGER or WARNING
are typically near specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety messages in this manual.
WARNING
CAUTION
Follow Safety Instructions
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in
good condition. Replace missing or damaged safety signs. Learn how to operate the machine and how to
use the controls properly. Do not let anyone operate the machine without instructions. Keep your machine in
proper working condition. Unauthorized modifications to the machine may impair function and/or safety and
affect the machine life.
CO2 (Carbon Dioxide) Warning
CO2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO2 (carbon dioxide)
gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is suspected, particularly in a
small area, immediately ventilate the contaminated area before attempting to repair the leak.
Personnel exposed to high concentration of CO2 gas will experience tremors which are followed
rapidly by loss of consciousness and suffocation.
Maximum CO
Operating Pressure 75–PSI
2
Shipping, Storing, Or Relocating Unit
CAUTION: Before shipping, storing, or relocating this Unit, the syrup systems must be sanitized and
all sanitizing solution must be purged from the syrup systems. All water must also be purged from
the plain and carbonated water systems. A freezing ambient temperature will cause residual water
remaining inside the Unit to freeze resulting in damage to internal components of the Unit.
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SAFETY PRECAUTIONS
This dispenser has been specifically designed to provide protection against personal injury and eliminate
contamination of the ice. To ensure continued protection and sanitation , observe the following.
ALWAYS: Disconnect electrical power from the dispenser before servicing or cleaning.
NEVER: Place hands inside the hopper or gate area without disconnecting electrical power from the dispenser.
Agitator rotation occurs automatically when the dispenser is energized.
ALWAYS: Be sure the removable lid is properly installed to prevent unauthorized access to the hopper interior
and possible contamination of the ice.
ALWAYS: Be sure the upper and lower front panels are securely fastened.
ALWAYS: Keep area around the dispenser clean of ice cubes.
CAUTION: The dispenser cannot be used with crushed or flaked ice. Use of bagged ice,
which has been frozen into large chunks, can void the factory warranty. The dispenser
agitator is not designed to be an ice crusher. Use of large chunks of ice which “jam up”
inside the hopper will cause failure of the agitator motor and damage to the hopper. If bagged ice
is used, it must be carefully and completely broken into small cube sized pieces before filling into
the dispenser hopper.
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 ice cubes (up to 1–1/4 inches in size), cubelets, and hard chipped or cracked ice.
SPECIFICATIONS
Model: PR150 BC Ice Drink Dispenser (Eight–Flavor)
Dimensions 31–7/8 inches wide X 27–7/8 inches Deep X 21–1/4 inches High with
29 inches Depth Below Countertop
Electrical 120 VAC/1 Phase/60 Hz/5.2 Amps Total Current Draw
Recommended Electrical
Supply
Clearance Required 54-In. above counter front access.
Drain Base Unit is plumbed for PVC or flex plastic tubing installed to local code.
CO2 or Air Requirements CO
Flavor Selections Maximum of eight syrup flavors plus plain water and carbonated water.
Cup Selection Five Sizes (12, 16, 21, 32, and 42 0z.)
Ice Requirements Ice bin capacity is 150 pounds of ice.
Water Supply 60–PSI flowing pressure (3/4 inch supply with shutoff valve.
115 VAC/60 Hz/15.0 Amps, 3–Wire Grounded Circuit
80–100 PSI supply (preferred) or air = 70 PSI minimum supply.
2 =
Drink Draw Rate Dispenses seven 21 oz. drinks per minute at or below 40° F
continuous.
3
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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
DEPTH
(INCHES
AVAILABLE SPACE
BELOW DISPENSER
(INCHES)
USE KIT NO.
AND
629087406
AND
620517502
COUNTERT OP INSTALLATION
IMPORTANT: It is the responsibility of the installer to ensure that the drains from the dispensing
equipment is installed and maintained according to Federal, State, and local laws.
1. Locate the dispenser indoors on a level countertop.
The dispenser must be sealed to the countertop. The MOUNTING TEMPLATE (see Figure 1) indicates the
opening that must be cut in the countertop. Locate the desired position for the dispenser, then mark the
outline 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 must be wiped away immediately.
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 must continuously pitch downword and contain no “traps” or improper drainage will result.
A. Use 3/4–inch nominal plastic pipe.
B. To assure proper drainage, do not allow a “trap” to form in the drain line. Be sure drain line runs flat
with bottom of the dispenser.
IMPORTANT: This dispenser must be installed with adequate backflow protection to comply with
Federal, State, and Local Codes.
4. Clean the hopper interior (See CLEANING INSTRUCTIONS).
5. Connect dispenser power cord to 120 VAC 60 HZ 15–Amp 3–wire grounded receptacle.
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FOOT PRINT OF UNIT
ON COUNTERTOP
29 – 5/8
COUNTER CUTOUT
FOR
UNIT DROP IN
27–3/16
25–3/4
FRONT OF COUNTERTOP
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.
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FIGURE 1. MOUNTING TEMPLATE
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7
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FIGURE 2. FLOW DIAGRAM
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MAINTENANCE
The following dispenser maintenance should be performed at the intervals indicated.
DAILY (or as required)
Remove foreign material from the vending area drip tray to prevent drain blockage. Clean vending area. Check
for proper water drainage from the vending area drip tray.
MONTHLY
Clean and sanitize the hopper interior and the beverage system if applicable (see CLEANING
INSTRUCTIONS)
ADJUSTMENTS
CO2 REGULATORS ADJUSTMENTS
WARNING: CO2 displaces oxygen. Strict attention must be observed in the prevention of
CO2 (carbon dioxide) gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is
suspected, particularly in a small area, immediately ventilate the contaminated area before
attempting to repair the leak. Personnel exposed to high concentration of CO2 gas will experience
tremors which are followed rapidly by loss of consciousness and suffocation.
NOTE: To readjust CO2 regulator to a lower setting, loosen adjusting screw lock nut, then turn screw to
the left (counterclockwise) until pressure gage reads 5 psi lower than new setting will be. Turn the adjusting screw to the right (clockwise) until the gage registers new setting, then tighten the lock nut.
Adjusting Carbonator CO2 Regulator.
UNIT WITH INTEGRAL (BUILT-IN) COLD CARBONATOR
Adjust CO2 regulator for the Unit integral (built-in) carbonator at 60-psi maximum.
UNIT REQUIRING REMOTE CARBONATOR
Adjust CO2 regulator for the remote carbonator to CO
carbonator.
Adjusting Syrup Source CO2 Regulator.
SUGAR SYRUP TANKS CO2 REGULATOR
Adjust syrup tanks CO2 regulator to a minimum of 45-psi.
SYRUP PUMPS (BAG-IN-BOX SYSTEM)
pressure specified in manual provided with the
2
Adjust the syrup pumps CO2 regulator to 70-psi. DO NOT EXCEED MAXIMUM CO2 PRESSURE SPECIFIED
ON THE SYRUP PUMPS.
ADJUSTING DISPENSING VALVES WATER FLOW RATE
(see Figure 3)
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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.
WATER FLOW
REGULATOR
SYRUP FLOW
REGULATOR
INNER NOZZLE
Counterclockwise
to Decrease
Clockwise
to Increase
NOZZLE
SYRUP DIVERSION
TUBE
RATIO CUP
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.
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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.
Notice: 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.
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.
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.
CAUTION: Use caution to avoid spilling ice when filling the dispenser. Clean up
immediately any spilled ice from filling or operating the dispenser. To prevent
contamination of the ice, the lid must be installed on the dispenser at all times.
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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69
77
67
65
66
73
FIGURE 4. AUGER ASSEMBLY
CLEANING AND SANITIZING INSTRUCTIONS
WARNING: Disconnect electrical power to the dispenser before cleaning. Do not use metal
scrapers, sharp objects, or abrasives on the ice storage hopper, top cover, and the agitator
disk as damage may result. Do not use solvents or other 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 1/2–ounce of household bleach in one gallon of potable water. Preparing the sanitiz-
ing 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.
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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.
2. CLEANING INTERIOR SURFACES
CAUTION: When pouring liquid into the hopper, do not exceed the rate of 1/2–gallon per
minute.
IMPORTANT: Perform the following at least once a month.
A. Lift drip tray to expose the hopper, then 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
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 seperate 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.
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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.
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.
14620918702
system.
2
Page 18
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.
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 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
15 620918702
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FIGURE 7. WIRING DIAGRAM
Page 20
FIGURE 8. LADDER DIAGRAM
17
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THIS PAGE LEFT BLANK INTENTIONALLY
18620918702
Page 22
TROUBLESHOOTING
IMPORTANT: Only qualified Personnel should service internal components or electrical wiring.
WARNING: 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 CO
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.
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
supply, then relieve the
2
BLOWN FUSE OR CIRCUIT
BREAKER
AGITATOR DOES NOT TURN,
AUGER DOES NOT TURN.
ICE DISPENSES
CONTINUOUSLY.
A. Short circuit in electrical wiring. A. Repair electrical wiring.
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.
B. Replace transformer.
B. Replace depressor plate.
D. Replace interlocks.
F. Replace transformer.
A. Replace depressor plate.
SLUSHY ICE. WATER IN
HOPPER.
AGITATOR TURNS, AUGER
DOES NOT TURN.
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. 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.
A. Inoperative auger motor. A. Replace auger motor.
B. Inoperative or improper setting
of speed control.
19
C. Install water filter system. For
icemaker problems, consult
icemaker manual.
B. Replace speed control or
re–adjust speed control.
620918702
Page 23
Trouble RemedyProbable Cause
AGITATOR TURNS, AUGER
C. Inoperative rectifier. C. Replace rectifier.
DOES NOT TURN (CONT’D)
D. Ice jam. D. Clear ice jam.
E. Inoperative timer board. E. Replace timer board.
AUGER TURNS, AGITATOR
A. Inoperative agitator motor. A. Replace agitator motor.
DOES NOT.
B. Inoperative motor capacitor. B. Replace motor capacitor.
C. Inoperative timer board. C. Replace timer board.
BEVERAGES DONOT
DISPENSE
A. No 24 volts to dispensing
valves.
A. Make sure unit is connected to
electrical power. Check 24 VAC
transformer.
B. No CO
pressure. B. Check CO2 regulator. Check CO
2
tank pressure.
BEVERAGES TOO SWEET. A. Carbonator not operating. A. Consult carbonator manual.
B. No CO
carbonator.
C. Dispensing valve brix requires
re–adjustment.
ressure in
2 p
B. Check CO
regulator. Check CO
2
tank pressure.
C. Refer to dispensing valve
manufacturer for brix adjustment
instructions.
2
2
BEVERAGES NOT SWEET
A. Depleted syrup supply. A. Replenish syrup supply.
ENOUGH
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.
20620918702
Page 24
8
92
ILLUSTRATED PARTS LIST
35
82
93
31
16
90
117127
4142
137
80
106
105
36
103
9
35
88
93
136
53
52
132
33
141
83
115
96
99
85
95
112
31
93
40
109
114
35
36
131
98
13
110
93
93
74
75
101
33
86
134
116
121
161
160
31
16
78
146
142
35
24.
29
87
89
122
146
118
13
31
79
93
94
133
59
48
9
34
17
77
95
11
139
6
58
123412
21 620918702
Page 25
125
107
5
73
119
95
120
29
95
52
26 32
138
69 20 18 19 97
65
53
95
111
72
39
124
7
38
37
27
25
95
84
130
104
102
160 161
95
123
145
113
65
113
36
22
146
47
152
146
155
156
24
158
95
35
148
147
44
126
100
159
140
124
157
70
149
30
153
157
63
35
91
36
157
154
156 151
157
157
51
620918702
81445
22
Page 26
57
81
60
67
74
56
55
68
144
71
61
36
129
23
54
62
66
36
76
108
64
36
43
35
35
50
28
49
15
46
135
23 620918702
Page 27
PR150BC ASSEMBLY
Item
No. Part No. Name
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
8 30794
32826
9 02070 Kit Switch, includes switch, boot, and spacer
10 30995
620302901
11 31007 Boot, Switch
12 31827 Wire Harness, Dispensing Valve
13 31981 Actuator
14 620307901
32824
15 620913101
620919341
16 32953 Reed Switch Ass’y
17 32977 Switch, Key
18
19
20
21
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
42 750700502 Clip, Locking, 3/8
43 620919303 Label, Wiring Ladder
44 638009387 Switch, Bin Control
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
620918702
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Page 28
PR150BC ASSEMBLY (CONT’D)
Item
No.
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
55 620028202
56 620028204
57 620028205
58 620028209
59 620028211 Cover, Tower Top
60 620028213
61 620028214
62 620028216
63 620028218 Agitator Ass’y
64 620028222
65 620028226 Bolt, 1/4-20
66 620028227 Bracket, Leg Adapter
67 620028232 Support Bracket, Auger Motor
68 620028234
69 620028235
70 620028223 Plate, Mounting
71 620028246 Stiffener, Base
72 620028249 Plate, Syrup Lines Alignment
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
83 620044601
84 620044614 Plate, Deflector
85
86 620045301 Bracket, Reed Switch
Part No. Name
620028252
620028269
620028254
620028256
620028255
620028257
620028258
620028261
620028263
620517201
620044602
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
Plate, Pump Mounting LH
Plate, Pump Mounting RH
25 620918702
Page 29
PR150BC ASSEMBLY (CONT’D)
Item
No. Part No. Name
620918702
87 620045724
620045727
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
96
97 620711401 Insulation, Stop Ice Conduit
98 629088578 SuperSeal Kit
99
100 620314201 Connector, Power Inlet
101 629087456
629087489
102 620403001
620403002
103 620403008 Pump, Recirculating
104 629087415 Drain Tray with Elbow Kit
105 620407601
620407622
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 620506513
620506538
119 620506518 Block, Connector, Water Lines
120 620506519 Block, Connector, Syrup Lines
121 620506531 Housing, Auger
122 620517136
620517138
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
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
Hinge, Drain Trough LH
Hinge, Drain Trough RH
Drip Tray Ass’y Black, LH
Drip Tray Ass’y Black, RH
26
Page 30
PR150BC ASSEMBLY (CONT’D)
Item
No. Part No. Name
132 620704604 Fitting, 3/8 By 1/2 MPT
133 620708524 Cup Re s t
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
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
Strap, Capacitor 115V
Strap, Capacitor 230V
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 T ape
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)
Capacitor, Agitator Motor 115v
Capacitor, Agitator Motor 230v
Transformer, 120V 60HZ
Transformer, 230V 60HZ
Timer, Agitator 115V
Timer, Agitator 230V
27 620918702
Page 31
WARRANTY
IMI Cornelius Inc. Products Company warrant that all equipment and parts are free from defects in material and
workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius product, in
your country, please write, fax or telephone the IMI Cornelius office nearest you. Please provide the equipment
model number and the date of purchase.
Locate the office in your area on the Cornelius web site, www.cornelius.com, under the contacts tab.
620918702
28
Page 32
IMI CORNELIUS INC.
www.cornelius.com
(800) 238-3600
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